Power Tool Crimping Status Detection Using Force and Travel
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Solution Overview
Problem
Existing power tools lack efficient methods to determine the status of actions, such as crimping, in real-time, especially regarding the type of accessory, force applied, and distance traveled, which affects the accuracy and completeness of the crimping process.
Innovation Solution
A power tool system comprising a housing, an accessory with an identifier, and an electronic processor that receives signals to determine the accessory type, initiate actions, calculate force and distance, and assess the crimping status based on these parameters, using sensors and wireless communication for data exchange.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If real-time monitoring of crimping action status is implemented, then the accuracy and completeness of crimping process is improved, but the device complexity increases due to multiple sensors and electronic processors
Solution Approach 1:
The electronic processor is designed to perform multiple functions: receiving signals from sensors, determining accessory type, calculating force applied, measuring distance traveled, and determining crimping status. This multi-functionality consolidates what could be separate systems into a single integrated processor, improving measurement precision while limiting the increase in device complexity.
Solution Approach 2:
Sensors act as intermediaries between the physical crimping process and the electronic processor. These sensors convert physical quantities (force, distance) into electrical signals that the processor can analyze, enabling accurate real-time monitoring without requiring direct complex mechanical measurement systems within the processor itself.
2Reliability
If multiple parameters (force, distance, accessory type) are monitored simultaneously, then the reliability of crimping action status determination is improved, but the loss of information increases due to the complexity of data integration
Solution Approach 1:
The system implements feedback by continuously monitoring multiple parameters (force, distance, accessory type) and using this information to determine and verify the crimping status. The electronic processor integrates data from all sensors and compares it against expected crimping patterns, providing real-time feedback on whether the crimping action is proceeding correctly. This feedback mechanism ensures that no critical information is lost and that the determination of crimping status is reliable.
3Productivity
If real-time feedback through indicators and external devices is provided, then the productivity of crimping operations is improved, but the use of energy increases due to continuous monitoring and communication
Solution Approach 1:
The electronic processor performs monitoring and data processing at periodic intervals rather than continuously. The system collects data from sensors during the crimping action and processes this information at key moments to determine status and provide feedback. This periodic operation maintains high productivity through timely feedback while reducing energy consumption compared to truly continuous monitoring and communication.
Data Source
AI summary
Systems and methods for determining a status of an action performed by a power tool. For example, the power tool includes a power tool housing, an accessory, and an electronic processor. The housing includes a recess and an input device. The accessory is configured to be received by the recess. The accessory includes an identifier. The electronic processor is connected to the input device. The electronic processor is configured to receive a first signal from the identifier, determine an accessory type based on the first signal, receive a second signal from the input device, initiate an action based on the second signal, determine an outer diameter of the workpiece, calculate a force applied by the power tool, determine a distance traveled by the accessory during the action, and determine a status of the action based on the force applied to the workpiece and the distance.