Power Tool Nut Removal Control Using Torque-Based Speed Switching
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Solution Overview
Problem
Conventional power tools reduce motor speed after nut removal, which can decrease productivity in applications where quick nut removal is important, such as in iron or utility work and heavy-duty maintenance.
Innovation Solution
Implement an adaptive nut removal mode that increases motor speed after tension is eliminated to quickly remove the nut, then reduces speed to maintain control, using dynamic field weakening and motor configuration switching.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If motor speed is reduced after nut removal to maintain control, then control over the nut is improved, but productivity decreases
Solution Approach 1:
The motor speed is made dynamic rather than static, automatically adjusting between high speed mode during loosening and controlled speed mode during removal based on real-time torque monitoring. This resolves the contradiction by allowing the system to optimize for productivity when needed and for control when needed, rather than being locked into one speed setting
Solution Approach 2:
The system continuously monitors motor torque and uses this feedback to determine when the nut has been sufficiently loosened. When torque drops below a threshold indicating tension elimination, the system transitions from high-speed loosening mode to controlled removal mode, automatically adapting its behavior based on the actual state of the fastener
2Force
If motor operates at high torque for loosening, then loosening capability is improved, but speed decreases
Solution Approach 1:
The motor operates in periodic cycles, alternating between high-torque loosening phases and high-speed removal phases. During the loosening phase, high torque is applied to break the joint; once loosening is detected via torque monitoring, the system transitions to a removal phase where speed is increased. This periodic switching resolves the contradiction by applying high torque only when necessary for loosening, then prioritizing speed for removal
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
Enhances productivity while maintaining control over nut removal, allowing faster completion of tasks in applications with long threaded stud sections.
Implementation Method 1
operate, when the torque of the motor is greater than the threshold torque value, the motor in a loosening mode
Implementation Method 2
increase, when the torque of the motor is equal to or less than the threshold torque value, a speed of the motor
Data Source
AI summary
Systems and methods for providing an adaptive nut removal mode in a power tool. The power tool includes a housing and a motor. The motor includes a rotor and a stator. The stator includes a plurality of stator windings. A power switching circuit is configured to provide a supply of power from a power source to the motor. An electronic controller is configured to control the power tool to remove a fastener from a joint. The electronic controller is configured to monitor a torque of the motor, determine whether the torque of the motor is equal to or less than a threshold torque value, operate, when the torque is greater than the threshold torque value, the motor in an loosening mode while the torque of the motor decreases, and increase, when the torque is equal to or less than the threshold torque value, a speed of the motor.