Compression Drive Nailer Soft-Stop Control With Dual Controllers
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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 be mitigated by incorporating an on-board air compressor and advanced motor control systems.
Innovation Solution
A powered fastener driver with an on-board air compressor and a dual-controller system that performs load tests, determines control schemes based on operation cycles, and electrically brakes the motor to optimize energy use and ensure precise fastener driving.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If an on-board air compressor is incorporated to eliminate external air pressure sources, then the power and independence of the fastener driver is improved, but the tool size and weight increase
Solution Approach 1:
The patent combines the air compressor, motor, battery, and control systems into a single integrated power tool unit. This merging eliminates the need for external air pressure sources while consolidating the overall system size, resolving the contradiction between power independence and tool weight.
Solution Approach 2:
The patent uses a pneumatic system with an on-board compressor to generate compressed air for driving the fastener. This pneumatic approach replaces external air sources, providing power independence while the compact compressor design minimizes weight increase.
2Power
If an on-board air compressor is incorporated to eliminate external air pressure sources, then the power and independence of the fastener driver is improved, but the tool size increases
Solution Approach 1:
The patent combines the air compressor, motor, battery, and control systems into a single integrated power tool unit. This merging eliminates the need for external air pressure sources while consolidating the overall system size, resolving the contradiction between power independence and tool size.
Solution Approach 2:
The patent employs a nested arrangement where the drive piston is positioned within the compression cylinder, and various components are housed within each other. This nesting minimizes the overall tool volume while accommodating the on-board compressor and other subsystems.
3Manufacturing precision
If a dual-controller system with load tests and operation cycle monitoring is implemented, then the precision and reliability of fastener driving is improved, but the device complexity increases
Solution Approach 1:
The patent divides the control system into two separate controllers: a first controller that monitors operation cycles, piston positions, and performs load tests, and a second controller that executes driving commands. This segmentation manages complexity while maintaining precise control over the fastening process.
Solution Approach 2:
The patent implements feedback mechanisms where sensors monitor piston position, motor operation, and load conditions, and this data is fed back to the controllers. The first controller uses this feedback to determine operation cycle completion and battery load, enabling precise control despite the increased system complexity.
4Reliability
If electrical braking and operation cycle control are implemented, then the consistency and reliability of fastener driving performance is improved, but the energy consumption increases
Solution Approach 1:
The patent employs periodic operation cycles with defined phases: motor driving, electrical braking, and reset. The first controller monitors these periodic cycles and determines completion based on piston position and timing, ensuring consistent performance while managing energy consumption through controlled cycling rather than continuous operation.
Solution Approach 2:
The patent converts the harmful effect of motor inertia and residual energy into beneficial electrical braking. The motor's kinetic energy is dissipated through electrical resistance during braking, providing controlled stopping and consistent cycle completion while recovering some energy as heat, thereby improving reliability without excessive energy waste.
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 system reduces tool size and weight while enhancing handling and manufacturability, and ensures consistent fastener driving performance by controlling the motor's operation cycles and positions.
Implementation Method 1
a motor operably coupled to the crank arm assembly
Implementation Method 2
The control system may electrically brake the motor, via a command from the first controller
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.