Power Tool Angle Sensing for Precise Handheld Angled Cuts
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Solution Overview
Problem
Users face challenges when attempting to make angled cuts or bores with power tools, as they often rely on manual alignment and setup, which can be time-consuming and require significant user skill, especially when using handheld tools like drills.
Innovation Solution
A power tool system equipped with distance sensors, a gyroscope, and an electronic controller that measures distances to a workpiece, calculates the angle, and provides feedback through an angle output indicator, allowing for precise alignment and automatic adjustment to maintain the desired angle during operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual alignment and setup are used for angled cuts, then the power tool can be operated without additional sensors or electronics, but the operation becomes time-consuming and requires significant user skill
Solution Approach 1:
The patent replaces manual mechanical alignment methods with an automated optical sensing system. Distance sensors electronically measure positions and calculate angles, substituting the mechanical skill-based alignment process with an automated measurement and computation system that provides real-time feedback.
Solution Approach 2:
The patent implements a feedback mechanism where distance sensors continuously measure the position of the workpiece, the controller calculates the current angle, and an indicator provides real-time feedback to the user. This allows the user to adjust the tool until the desired angle is achieved and maintain it during operation.
2Measurement precision
If manual alignment methods are used, then the device remains simple without sensors or controllers, but the measurement precision and manufacturing precision of angled cuts deteriorate
Solution Approach 1:
The patent replaces simple mechanical alignment aids with an electronic measurement system comprising distance sensors and a controller. This substitution enables precise digital measurement of angles through mathematical calculation based on sensor data, significantly improving measurement precision despite increased device complexity.
Solution Approach 2:
The system performs self-measurement and self-calculation of angles using the distance sensors and controller. The tool automatically measures distances, computes the angle through mathematical algorithms, and provides feedback without requiring external measurement devices or complex manual procedures.
3Ease of operation
If handheld tools are used for angled operations, then the tool maintains portability and ease of handling, but the stability and precision of maintaining the desired angle during operation deteriorates
Solution Approach 1:
The patent implements continuous feedback during operation where the distance sensors monitor the angle in real-time and the indicator alerts the user to any deviation from the desired angle. This allows the user to make immediate corrections while maintaining the handheld, portable nature of the tool.
Solution Approach 2:
The system dynamically adjusts to changes in tool orientation by continuously measuring distances and recalculating the angle. The real-time feedback mechanism adapts to the user's movements and provides guidance to maintain the desired angle throughout the cutting operation.
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.