Power Tool Hammer Position Sensing for Magnetic Impact Timing
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Solution Overview
Problem
Existing power tools lack precise control over the position, speed, and acceleration of components such as hammers and anvils, leading to inefficiencies, increased vibrations, and reduced durability due to improper timing of impacts.
Innovation Solution
Incorporating sensors to detect the rotational and axial positions of components like hammers and anvils, allowing a controller to optimize the impact timing and adjust motor operation based on sensed data, thereby enhancing energy transfer and reducing vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If impact timing is not precisely controlled, then the power tool operation is simple and reliable, but the durability of hammer and anvil decreases and vibrations increase
Solution Approach 1:
The patent replaces complex mechanical position sensing mechanisms with magnetic sensing technology. Magnetic sensors detect the position of the hammer by sensing changes in magnetic field caused by magnetic features attached to or embedded in the hammer, eliminating the need for complex mechanical encoders or potentiometers while achieving precise position control for optimized impact timing
Solution Approach 2:
The patent introduces magnetic features as an intermediary between the hammer and the magnetic sensor. These magnetic features serve as a mediator that translates hammer position into detectable magnetic field changes, enabling non-contact position sensing without requiring direct mechanical connection between the sensor and moving components
2Productivity
If impact timing is optimized using position sensing, then energy transfer and efficiency increase, but device complexity increases
Solution Approach 1:
The patent replaces complex mechanical position measurement systems with magnetic sensing technology. The magnetic sensor detects hammer position through magnetic field interactions, providing the necessary position data for optimized impact timing without requiring complex mechanical encoders, potentiometers, or other traditional position sensing mechanisms
Solution Approach 2:
The magnetic features attached to or embedded in the hammer serve a dual purpose: they are integral parts of the hammer structure and simultaneously function as the sensing target for position detection. This eliminates the need for separate sensing components on the hammer, reducing overall system complexity while enabling precise position measurement for efficiency optimization
3Measurement precision
If multiple sensible features are used on the hammer, then position and speed determination precision increases, but manufacturing complexity increases
Solution Approach 1:
The patent combines multiple magnetic features into a single integrated magnetic assembly or uses a single magnetic feature with multiple detectable characteristics (such as a magnet with specific geometric features or multiple magnets arranged in a pattern). This consolidation maintains the ability to determine both position and speed with high precision while significantly simplifying the manufacturing process compared to attaching multiple separate magnetic components
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
Improved durability of hammer and anvil components, reduced vibrations, increased efficiency, and precise control of torque output by optimizing impact timing and energy transfer.
Implementation Method 1
The sensor is configured to generate an output signal indicative of a rotational characteristic of the hammer by sensing the first sensible feature of the hammer and the second sensible feature of the hammer
Data Source
AI summary
Position sensing related to a component within a power tool. The component within the power tool is, for example, a hammer of an impact mechanism and can include one or more sensible features that allow a controller of the power tool to precisely determine the position, speed, and acceleration of the component. One or more sensors can be used to determine the rotational position of the hammer and the axial position of the hammer. The rotational position of the hammer can then be used to calculate, for example, rotational speed and acceleration of the hammer. With precise determinations of the rotational and axial position of the hammer, the controller of the power tool is able to precisely time the impact between the hammer and the anvil to optimize the impact between the hammer and the anvil (e.g., to maximize energy transfer between the hammer and the anvil).