Power Tool Bind-Up Detection With Dynamic Motion Thresholds
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Solution Overview
Problem
Existing power tools lack effective mechanisms to detect and respond to bind-up conditions, which can cause damage to the tool and user safety due to uncontrolled rotational motion when the tool is braced against an object.
Innovation Solution
A power tool system with a controller that monitors rotational motion using sensors, adjusts thresholds based on detected conditions, and initiates protective operations such as braking or throttling to prevent bind-up, incorporating machine learning algorithms for enhanced detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a fixed rotational motion threshold is used to detect bind-up conditions, then the detection simplicity is maintained, but the accuracy of bind-up detection deteriorates when operating conditions change (e.g., battery fetting events or bracing)
Solution Approach 1:
The patent implements dynamic threshold adjustment by modifying the rotational motion threshold based on detected operating conditions such as battery fetting events and bracing events. The controller automatically adapts the threshold value during operation to maintain accurate bind-up detection across varying conditions, transitioning from a static to a dynamic detection parameter.
Solution Approach 2:
The patent changes the parameter (rotational motion threshold) based on detected conditions. When a battery fetting event or bracing event is detected, the controller adjusts the threshold parameter to compensate for the changed operating conditions, ensuring continued accurate bind-up detection without requiring complex additional sensors.
2Measurement precision
If the rotational motion threshold is lowered to improve bind-up detection sensitivity, then detection sensitivity improves, but false bind-up detection increases during normal operation
Solution Approach 1:
The patent dynamically adjusts the rotational motion threshold parameter based on detected conditions. During battery fetting events or bracing events, the threshold is temporarily modified to allow for reduced rotational motion while preventing false bind-up detection. This conditional parameter adjustment maintains high sensitivity only when appropriate, reducing false positives during normal operation.
3Object-affected harmful factors
If protective operations are initiated frequently to ensure safety, then user safety is improved, but tool productivity deteriorates due to frequent interruptions
Solution Approach 1:
The patent implements a feedback-based protective operation system that continuously monitors rotational motion and compares it against dynamically adjusted thresholds. Protective operations are initiated only when bind-up conditions are confidently detected, avoiding unnecessary interruptions during normal operation. The system provides feedback to the user through indicators, allowing informed continuation or cessation of 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 system effectively prevents tool damage and user injury by dynamically adjusting to bind-up conditions, ensuring safe and controlled operation.
Implementation Method 1
a motion sensor configured to sense a rotational motion of the housing
Data Source
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AI summary
Systems and methods for detecting and acting on bind-up conditions of a power tool. The power tool includes a housing, a motor, a battery pack, and a motion sensor configured to sense rotational motion of the housing. An electronic controller is connected to the motor, the battery pack, and the motion sensor. The electronic controller is configured to determine whether a battery fetting event is occurring and adjust a rotational motion threshold used to determine a bind-up event based on the battery fetting event. The electronic controller is further configured to receive, from the motion sensor, a first signal associated with a rotational motion of the housing, compare a value based on the signal to the rotational motion threshold, and initiate, in response to the value being greater than or equal to the rotational motion threshold, a protective operation.