Power Tool Position Feedback for Precise Screw Driving Depth
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Solution Overview
Problem
Conventional power tools require manual throttling to achieve precise screw driving depth, leading to challenges such as overdriving or underdriving, which can result in damage to screws or workpieces due to imprecise control.
Innovation Solution
A power tool equipped with position feedback control using sensors and a controller that determines operating angles and drive depth, allowing for automatic adjustment and mode selection to ensure accurate screw driving, including blind hole and auto flush modes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual throttling is used to control screw driving depth, then the user can operate the power tool, but the precision of depth control deteriorates leading to overdriving or underdriving
Solution Approach 1:
The patent employs position feedback control where a sensor detects the position of the power tool relative to the workpiece and feeds this information back to a controller. The controller automatically adjusts the motor operation based on the detected position, eliminating the need for manual throttling while achieving precise depth control. This resolves the contradiction by replacing manual control with automated feedback-based control.
Solution Approach 2:
The patent replaces the mechanical manual throttling system with an electronic control system comprising a sensor, controller, and motor. The sensor detects position, the controller processes the information, and the motor executes automatic depth control, substituting the mechanical manual operation with an electronic automation system to achieve precise depth control.
2Manufacturing precision
If the trigger is released at precisely the correct moment for manual throttling, then accurate depth control can be achieved, but the operation becomes difficult and time-consuming
Solution Approach 1:
The power tool performs depth control automatically without requiring user intervention. The sensor continuously monitors position and the controller autonomously adjusts motor operation to achieve the target depth, allowing the system to serve itself rather than relying on manual throttling. This enables both high precision and maintained productivity.
Solution Approach 2:
The automated feedback control system maintains continuous monitoring and adjustment throughout the screw driving process, ensuring precise depth control without interrupting the operation. The controller continuously adjusts motor operation based on real-time position feedback, eliminating the need to release the trigger while maintaining both accuracy and speed.
3Ease of operation
If imprecise throttling occurs resulting in overdriving or underdriving, then manual operation is simple, but damage to screws and workpieces occurs
Solution Approach 1:
The position feedback control system preemptively prevents damage by continuously monitoring position and automatically stopping the motor at the precise target depth. The controller anticipates the end of the driving process and halts operation before overdriving can occur, eliminating the harmful effects of imprecise manual throttling while maintaining operational simplicity.
Solution Approach 2:
The sensor provides continuous position feedback to the controller, which adjusts motor operation in real-time to achieve precise depth control. This feedback mechanism prevents both overdriving and underdriving by maintaining accurate position information, thereby preventing damage to screws and workpieces while keeping the operation simple for the user.
Data Source
AI summary
Various embodiments of power tool and method of operating same are described. The power tool may include a first position sensor, a second position sensor, a third position sensor, and a controller. The first, second, and third position sensors may each generate a signal indicative of a distance between the respective position sensor and a workpiece. The controller may determine one or more angles of the power tool with respect to the workpiece based on the first, second, and third signal and present an indication as to whether the one or more angles are within a predetermined range. The controller may further obtain a depth measurement based on the first signal, the second signal, and the third signal and generate, based on the obtained depth measurement, one or more control signals that control operation of the power tool.