PEX Crimping Tool Ball Screw Control for Consistent Torque
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Solution Overview
Problem
Existing PEX crimping tools lack efficient and controlled mechanisms for crimping operations, often resulting in inconsistent crimping quality and potential tool damage due to lack of precise torque control and sensor feedback.
Innovation Solution
A power tool with a ball screw mechanism, motor-driven output shaft, and sensor assembly that includes Hall-effect sensors to detect position and rotational speed, enabling precise axial displacement and torque application to prevent inner housing rotation, ensuring consistent crimping and preventing tool damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a motor-driven ball screw mechanism is used for crimping, then crimping precision and consistency are improved, but device complexity increases due to added sensors and control systems
Solution Approach 1:
The patent implements feedback through Hall-effect sensors that detect the position and rotational speed of the output shaft. This feedback enables the control system to precisely control the axial displacement of the screw and the torque applied, ensuring consistent crimping quality while managing the increased device complexity through electronic control.
Solution Approach 2:
The patent replaces manual mechanical crimping with an automated motor-driven ball screw mechanism. This substitution introduces precision control through electronic systems while eliminating the need for manual operation, thereby improving crimping precision despite the increase in device complexity.
2Manufacturing precision
If torque control mechanisms are added to prevent inner housing rotation, then crimping consistency is improved, but device complexity increases
Solution Approach 1:
The Hall-effect sensor detects the rotational position and speed of the output shaft, providing feedback to the control system. This enables precise torque control that prevents inner housing rotation during crimping, ensuring consistency while managing the added complexity through electronic control mechanisms.
3Reliability
If sensor assembly with Hall-effect sensors is implemented, then operational safety and torque management are improved, but device complexity and cost increase
Solution Approach 1:
The sensor assembly with Hall-effect sensors provides real-time feedback on output shaft position and rotational speed. This enables the control system to manage torque effectively and detect potential overloading conditions, improving operational safety despite the increased device complexity.
Solution Approach 2:
The patent replaces mechanical torque control mechanisms with an electronic control system driven by motor and sensor feedback. This substitution improves torque management precision and operational safety while managing complexity through electronic rather than mechanical means.
4Reliability
If electronic control system is added to manage torque and detect overloading, then tool stress reduction and safety are improved, but device complexity increases
Solution Approach 1:
The electronic control system uses feedback from Hall-effect sensors to monitor output shaft position and rotational speed. This enables real-time torque management and detection of potential overloading conditions, reducing tool stress and improving reliability despite the added device complexity.
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 provides consistent crimping quality, reduces tool stress, and enhances operational safety by using electronic control to manage torque and detect potential overloading, improving the reliability and precision of the crimping process.
Implementation Method 1
sensor assembly for detecting a position of the roller carriage relative to the inner housing... The sensor assembly may include a magnet coupled to one of the roller carriage and the inner housing, and a Hall-effect sensor coupled to the other of the roller carriage and the inner housing
Implementation Method 2
a ball screw mechanism including a nut supported at least partially within the inner housing, and a screw coupled to the nut for relative axial displacement therewith in response to relative rotation between the screw and the nut
Data Source
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AI summary
A power tool includes an outer housing (14) having a drive unit support portion (26) and a handle portion (34), an inner housing (42) positioned at least partially within the handle, and a drive unit (30) positioned in the drive unit support portion (26). The drive unit (30) includes an output shaft (70) extending at least partially through the handle portion. The power tool also includes a ball screw mechanism (38) having a nut (102) supported at least partially within the inner housing and a screw (98) coupled to the nut (102) for relative axial displacement therewith in response to relative rotation between the screw (98) and the nut (102). Torque from the output shaft (70) is applied to one of the nut (102) and the screw (98) to cause the relative rotation. The handle portion (34) exerts a reaction torque on the inner housing (42) in response to the relative rotation between the nut (102) and screw (98) to prevent the inner housing (14) from rotating relative to the outer housing.