Hand-held Power Tool Torque Clutch Detection via Acceleration Sensor
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Solution Overview
Problem
Existing hand-held power tools with torque clutches face inaccuracies due to hysteresis in magnetic measuring circuits and require a wear-prone mechanical component, leading to design complexities and larger dimensions.
Innovation Solution
Incorporating an acceleration sensor to detect torque clutch activation contact-free, wear-free, and robustly, which allows for rapid and reliable detection of torque clutch engagement, enabling motor control and minimizing wear through power reduction and haptic feedback.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a magnetic measuring circuit with a magnetically conductive sleeve is used to detect torque clutch activation, then the activation can be detected, but hysteresis in the magnetic measuring circuit results in imprecise response characteristics and the magnetically conductive sleeve adds mechanical wear and design complexity
Solution Approach 1:
The patent replaces the magnetic measuring circuit with an acceleration sensor that detects mechanical vibrations caused by torque clutch activation. This substitution eliminates the magnetically conductive sleeve and its associated hysteresis problems, providing more precise response characteristics without the mechanical wear and design complexity of the magnetic system.
Solution Approach 2:
The patent changes the detection parameter from magnetic field changes to acceleration/vibration signals. By monitoring the acceleration signals generated during torque clutch activation, the system achieves precise detection without the hysteresis effects that plague magnetic measuring circuits, thereby improving measurement precision while reducing device complexity.
2Reliability
If a magnetically conductive sleeve is used in the torque clutch detection system, then torque clutch activation can be detected, but an additional mechanical component subject to wear is required which complicates design and increases dimensions
Solution Approach 1:
The patent replaces the mechanical magnetically conductive sleeve with an electronic acceleration sensor. This substitution maintains reliable detection of torque clutch activation through vibration sensing while eliminating the wear-prone mechanical component, thereby reducing structural complexity and improving overall system reliability.
Solution Approach 2:
The acceleration sensor acts as an intermediary that indirectly detects torque clutch activation through the vibrations it generates, rather than directly measuring magnetic field changes. This intermediary approach provides reliable detection without requiring the complex mechanical structure of a magnetically conductive sleeve.
3Loss of time
If traditional torque clutch detection methods are used, then activation can be detected, but friction times and number of friction actions increase causing unnecessary wear
Solution Approach 1:
The patent implements a feedback mechanism where the acceleration sensor continuously monitors vibrations and provides real-time information about torque clutch activation to the control unit. This feedback enables the control unit to immediately respond by reducing motor power, thereby minimizing friction time and the number of friction actions, which extends torque clutch longevity.
Solution Approach 2:
The system uses the acceleration sensor to automatically detect and respond to torque clutch activation without requiring external intervention. The control unit autonomously adjusts motor power based on the sensor signals, reducing friction wear and extending the torque clutch's service life through self-regulating operation.
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 precise and reliable detection of torque clutch activation, reduces unnecessary wear, and simplifies the tool's design by using an acceleration sensor to control motor power and provide haptic feedback, enhancing user experience and tool longevity.
Implementation Method 1
the acceleration signal represents vibrations which are transmitted during operation of the hand-held power tool to the tool housing
Data Source
AI summary
A hand-held power tool has a tool housing in which a gear unit which is drivable by a drive motor for driving a drive shaft is situated and to which a torque clutch is assigned. On the hand-held power tool, the drive shaft is provided with a tool holder for holding an assigned insertion tool, and an acceleration sensor is provided which is designed for enabling detection of an activation of the torque clutch.