Compression Drive Nailer Soft Stop With Isolated Motor Control
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Solution Overview
Problem
Existing fastener drivers face power, size, and cost constraints due to reliance on external air pressure sources, which can limit their efficiency and versatility in various fastening applications.
Innovation Solution
A powered fastener driver with an on-board air compressor and control system that includes a first controller for isolating motor control during operation cycles, sensing piston positions, and implementing mechanism control schemes to optimize motor braking and driving, allowing for efficient and adaptable fastener driving without external air pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If an on-board air compressor is integrated into the fastener driver, then the tool becomes self-contained and eliminates external air pressure dependencies, but the tool size and weight increase
Solution Approach 1:
The patent combines the air compressor, battery pack, motor, and fastener driver functions into a single integrated power tool unit. This merging eliminates the need for external air compressors and hoses, making the tool self-contained while managing the weight through unified design
Solution Approach 2:
The fastener driver is designed as a multi-functional tool that integrates air compression, motor-driven piston operation, and fastener driving capabilities in one device. This universal design allows the tool to operate independently without external air pressure sources
2Manufacturing precision
If a dual-controller system with isolation during operation cycles is implemented, then motor control precision and mechanism optimization are improved, but device complexity increases
Solution Approach 1:
The control system is divided into two separate controllers: a first controller that manages motor control during operation cycles, and a second controller that handles sensor data processing. This segmentation allows each controller to specialize in specific functions, improving control precision while managing complexity through functional separation
Solution Approach 2:
The patent introduces a communication interface as an intermediary between the first and second controllers. This intermediary enables data exchange and coordination between the two controllers, allowing precise motor control and sensor integration without requiring a single complex controller
3Productivity
If electrical braking and motor driving control are implemented during operation cycles, then mechanism efficiency and fastener driving precision are improved, but energy consumption increases
Solution Approach 1:
The motor operates in periodic cycles of driving and braking, rather than continuous operation. The motor drives the piston during the power stroke to drive the fastener, then electrically brakes during the return stroke. This periodic action improves efficiency by applying power only when needed while managing energy consumption through controlled braking phases
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables reduced tool size and weight, improved handling, and versatility in driving different fastener sizes with adjustable back-pressure, enhancing the tool's suitability for various fastening tasks.
Implementation Method 1
The control system may electrically brake the motor, via a command from a first controller, based on a first mechanism control scheme
Data Source
AI summary
A method for controlling a motor of a power tool including performing a load test on a battery pack of the power tool, determining, via a first controller, a first mechanism control scheme based on the load test, receiving, via the first controller, a user input indicative of beginning an operation cycle of the power tool, and isolating the first controller from a second controller. The method further including controlling, via the first controller, the motor based on the first mechanism control scheme, sensing a dataset indicative of a result of the operation cycle based on the first mechanism control scheme, receiving, via the second controller, the dataset, connecting the first controller to the second controller upon completion of the operation cycle, transmitting, via the second controller, the dataset to the first controller, and determining, via the first controller, a second mechanism control scheme based on the dataset.