Power Tool Angle Alignment Using Dual Distance Sensors
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Solution Overview
Problem
Existing power tools lack an efficient system for assisting users in making angled cuts or boreholes in workpieces, relying on manual alignment and setup which can be time-consuming and prone to errors.
Innovation Solution
The power tool system incorporates a controller with distance sensors and a gyroscope, allowing it to measure distances to a workpiece, calculate the angle between the tool and the workpiece, and indicate this angle to the user, thereby facilitating precise angled operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual alignment methods are used for angled cuts, then device complexity is reduced, but manufacturing precision and measurement precision deteriorate
Solution Approach 1:
The patent replaces manual mechanical alignment methods with an electronic measurement and control system. Distance sensors electronically measure positions to calculate angles, substituting the mechanical protractor or square-based manual alignment process. This electronic substitution achieves higher precision while accepting increased device complexity through integration of sensors, processors, and display components.
2Productivity
If manual alignment procedures are used, then device complexity is minimized, but productivity and time efficiency worsen
Solution Approach 1:
The alignment system performs self-measurement and self-indication functions. The distance sensors automatically measure positions, the processor calculates angles without user intervention, and the display automatically shows results. This automated self-service approach eliminates time-consuming manual measurement steps, significantly improving productivity despite the added complexity of the electronic system.
3Measurement precision
If automated angle measurement systems are implemented, then measurement precision and productivity improve, but device complexity increases
Solution Approach 1:
The controller serves multiple functions: it processes distance sensor data, calculates angles, controls the display output, and potentially coordinates with other tool functions. By making the controller universal and multi-functional, the patent reduces the need for separate dedicated components for each function, thereby managing device complexity better while maintaining high measurement precision through integrated electronic processing.
Data Source
AI summary
Power tool methods and systems are provided for aligning a power tool to implement an angled cut in a workpiece. The power tool includes a first distance sensor and a second distance sensor. The power tool measures a first distance to the workpiece with the first distance sensor and a second distance to the workpiece with the second distance sensor. The power tool calculates an angle between the power tool and the workpiece based on the first and second distances, and indicates the angle via an angle output indicator of the power tool. The power tool may measure an angle between the power tool and the workpiece using a proximate edge and a distal edge of the workpiece, and indicate whether the power tool maintains a correct angle as it traverses a cut through the workpiece from the proximate edge to the distal edge.