Motor Current Control for Powered Dispensing Tool
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Solution Overview
Problem
Existing power dispensing tools lack effective control mechanisms for motor current monitoring and management, leading to inefficiencies and potential tool damage during material dispensing, as well as issues with power conservation and preventing material excretion after operation.
Innovation Solution
A method and system that utilize a motor controller and microcontroller to monitor and control motor current by comparing it to thresholds, adjusting based on demand rates, and implementing features like soft start, auto-reverse, and battery conservation techniques to manage power efficiently and prevent material excretion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If motor current is increased to improve dispensing performance, then material dispensing capability is improved, but risk of tool damage and power consumption increases
Solution Approach 1:
The patent implements a feedback control system that continuously monitors motor current during dispensing operations. When the motor current exceeds a predetermined threshold, the system automatically reduces the drive signal to the motor, preventing excessive current from causing tool damage while maintaining optimal dispensing performance during normal operation
Solution Approach 2:
The system dynamically adjusts motor current based on real-time operating conditions rather than using a fixed current level. The motor controller modifies the drive signal in response to feedback about actual motor current, allowing the system to adapt current levels to match the specific demands of different dispensing tasks while preventing harmful current levels
2Reliability
If motor current is monitored and controlled continuously, then tool reliability is improved, but device complexity increases
Solution Approach 1:
The control system is designed to be relatively self-contained, with the microcontroller and motor controller working together to automatically monitor and regulate motor current without requiring complex external control systems. The system uses built-in feedback mechanisms and predetermined thresholds to automatically adjust operation, reducing the need for additional complex control hardware or software
3Use of energy by moving object
If power conservation measures are implemented, then energy efficiency is improved, but responsiveness to operation demand may worsen
Solution Approach 1:
The system dynamically adjusts power consumption based on operational state. During active dispensing, the motor controller provides full power to meet demand. When dispensing stops or slows, the system automatically reduces power consumption by lowering motor current, thus conserving energy without compromising responsiveness when material needs to be dispensed
4Productivity
If motor demand is increased to improve dispensing speed, then productivity is improved, but material excretion at end of operation increases
Solution Approach 1:
The system applies a preliminary reverse action before material excretion becomes problematic. When dispensing operation ceases, the control system automatically reverses the motor drive signal to create a reverse motion that prevents material from excreting at the end of the dispensing operation, thus counteracting the harmful effect before it occurs
Data Source
AI summary
An apparatus and method for monitoring and controlling motor current during a dispensing of material from a dispensing tool (10) is provided, including a method for measuring the motor current of the dispensing tool during operation through a motor controller (U2). The method further includes sending a feedback signal from the motor controller (U2) relating to the measured motor current to an input of a microcontroller (U1) that is adapted to a dispensing tool (10). The feedback signal is compared to a prescribed threshold and the motor current is conditioned based on the comparing of the feedback signal to the prescribed threshold.