Power Tool Angle Guidance for Accurate Sensor-Based Angled Cuts
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Solution Overview
Problem
Users face challenges when attempting to make angled cuts or bore into workpieces with power tools, as existing methods require manual alignment and setup, which can be time-consuming and dependent on user skill and precision.
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
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 optically measure the distance to the workpiece surface, and an electronic controller calculates the angle, substituting the mechanical trial-and-error alignment process with precision electronic measurement and computation.
Solution Approach 2:
The system provides real-time feedback through an angle indicator that displays the measured angle to the user. This feedback loop allows the user to adjust the tool orientation and immediately see the effect, enabling precise angle achievement without complex mechanical alignment fixtures.
2Productivity
If manual alignment methods are used, then device complexity is reduced, but alignment time increases
Solution Approach 1:
The patent replaces time-consuming manual alignment procedures with rapid electronic distance measurement. The distance sensors quickly optically measure the workpiece surface position, and the controller immediately calculates and displays the angle, dramatically reducing alignment time compared to manual methods.
Solution Approach 2:
The system performs preliminary measurement and calculation of the angle before the cutting operation begins. By measuring the distance to the workpiece surface in advance and calculating the angle beforehand, the system prepares the alignment information ready for immediate use, eliminating setup time during the actual operation.
3Measurement precision
If user skill-dependent manual alignment is used, then device complexity is reduced, but measurement precision deteriorates
Solution Approach 1:
The patent replaces subjective user skill-based alignment with objective electronic measurement. Distance sensors provide precise optical measurement of the workpiece surface position, and the controller objectively calculates the angle based on mathematical computation, eliminating the variability and limitations of human skill and perception.
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.