Power Tool Sensor Arrays for Workpiece Contact Stability
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Solution Overview
Problem
Power tools often experience undesirable relative motion between the workpiece and the workpiece support, leading to potential damage or kickback conditions, necessitating improved detection and response mechanisms to maintain a stable orientation during operations.
Innovation Solution
Incorporating a sensor array and controller in power tools to detect physical contact and orientation of the workpiece, allowing for controlled operation and prevention of unwanted motion, thereby maintaining a fixed orientation and reducing the risk of damage or kickback.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a sensor array and controller are added to detect workpiece orientation and prevent unwanted motion, then safety and operational stability are improved, but device complexity increases
Solution Approach 1:
The sensor array detects workpiece orientation and position before the cutting operation begins, allowing the controller to verify proper setup and prevent operation until the workpiece is correctly positioned. This preliminary detection prevents unsafe conditions from developing during operation.
Solution Approach 2:
The sensor array continuously monitors workpiece orientation and provides real-time feedback to the controller, which can then adjust or stop operation if the workpiece moves into an unsafe position. This closed-loop control maintains safety throughout the cutting process.
2Measurement precision
If sensor arrays are integrated into the workpiece support to detect physical contact, then measurement precision of workpiece position is improved, but device complexity increases
Solution Approach 1:
The sensor array is integrated directly into the workpiece support structure, combining the support function with the detection function. This merging eliminates the need for separate detection apparatus and reduces overall system complexity while maintaining high measurement precision.
Solution Approach 2:
The workpiece support structure serves dual purposes: it physically supports the workpiece during cutting and simultaneously detects the workpiece's position and orientation through integrated sensors. This self-service approach reduces the need for additional components.
Data Source
AI summary
Power tools with sensor arrays and methods of operating power tools are disclosed herein. In addition to the sensor arrays, the power tools include an implement holder, a motor, a workpiece support, and a controller. The implement holder is configured to hold an implement. The motor is configured to receive an electric current and to actuate the implement holder to move the implement. The workpiece support includes a support surface configured to support the workpiece and is configured to maintain an at least substantially fixed orientation relative to the workpiece while the implement performs an operation on the workpiece. The sensor array is configured to detect physical contact between the workpiece support and the workpiece and to generate a sensor output. The controller is programmed to receive the sensor output and to control the operation of the power tool based, at least in part, on the sensor output.