Power Tool Microcontroller Board for Low-Energy Usage Mode Detection

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Solution Overview

Problem

The challenge of integrating miniaturized, battery-powered sensor nodes for monitoring power tools is hindered by the limitations of battery lifetime, necessitating a solution that balances data collection and resource consumption while ensuring position-agnostic attachment and minimal maintenance.

Innovation Solution

A microcontroller board with a sensor, microprocessor, and output device that adjusts energy consumption based on detected usage modes, using low-energy detection for easier modes and higher-energy detection for more complex modes, featuring a dual-classifier system and energy-efficient design.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of information

If continuous monitoring of power tool usage is implemented, then data collection completeness is improved, but energy consumption increases

Engineering Contradiction:
Improveusage data completenessVSAvoidmicrocontroller energy consumption
Core Design Contradiction:
Loss of informationVSUse of energy by moving object

Solution Approach 1:

The microcontroller dynamically adjusts its monitoring and data transmission behavior based on detected usage modes. During idle periods or simple operations, monitoring intensity is reduced. During complex operations requiring detailed analysis, monitoring intensity increases. This dynamic adaptation allows comprehensive data collection when necessary while conserving energy during routine operations.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The system changes operational parameters such as sampling frequency, data transmission intervals, and processing depth based on the detected usage mode. For example, during idle modes, sampling frequency is reduced and transmission intervals are extended. During active complex operations, parameters are adjusted to capture more detailed usage data, optimizing the balance between data completeness and energy consumption.

Inventive Principle:
Principle #35Parameter changes

2Volume of moving object

If miniaturized battery-powered sensor nodes are used, then device size is reduced, but battery lifetime is limited

Engineering Contradiction:
Improvemicrocontroller board sizeVSAvoidbattery lifetime
Core Design Contradiction:
Volume of moving objectVSDuration of action of moving object

Solution Approach 1:

The microcontroller employs periodic operation with alternating active and sleep phases. During sleep phases, power consumption is minimized to extend battery life. During active phases, the microcontroller performs measurements, processes data, and communicates results. This periodic operation pattern allows the miniaturized device to function continuously while managing limited battery capacity effectively.

Inventive Principle:
Principle #19Periodic action

Solution Approach 2:

The system performs partial monitoring during low-activity periods, focusing only on essential parameters. Full monitoring and data processing are activated only when complex usage modes are detected. This selective approach ensures that the miniaturized sensor node can operate for extended periods on limited battery power while still capturing critical usage information.

Inventive Principle:
Principle #16Partial or excessive action

3Measurement precision

If multiple usage modes are detected with high precision, then measurement accuracy is improved, but device complexity increases

Engineering Contradiction:
Improveusage mode detection accuracyVSAvoidmicrocontroller board complexity
Core Design Contradiction:
Measurement precisionVSDevice complexity

Solution Approach 1:

The usage mode detection is segmented into multiple classification stages. A first classifier performs initial assessment using simple criteria to identify obvious usage modes. A second classifier performs more complex analysis only when needed to distinguish between similar or ambiguous modes. This segmented approach achieves high measurement precision for multiple usage modes while avoiding the complexity of implementing full complex analysis continuously.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The dual-classifier system acts as an intermediary between simple detection and complex analysis. The first classifier serves as a gateway that filters obvious cases, allowing the second classifier to focus only on ambiguous or complex scenarios. This intermediary structure enables accurate differentiation of multiple usage modes without requiring the entire system to operate at maximum complexity at all times.

Inventive Principle:
Principle #24Intermediary (Mediator)

4Ease of operation

If position-agnostic attachment is enabled, then ease of installation is improved, but sensor detection reliability may be reduced

Engineering Contradiction:
Improveattachment convenienceVSAvoidsensor detection reliability
Core Design Contradiction:
Ease of operationVSReliability

Solution Approach 1:

The microcontroller board is designed with universal attachment capabilities that allow installation in multiple positions on the power tool. Multiple sensors are strategically positioned and configured to detect usage parameters regardless of attachment location. The system includes compensation algorithms that adjust sensor readings based on detected orientation and position, ensuring reliable measurement accuracy while maintaining ease of installation in various locations.

Inventive Principle:
Principle #6Universality (Multi-functionality)

Data Source

PatentUS20250219509A1Microcontroller Board for a Power Tool, Monitoring System and Method
Publication Date: 2025.07.03 HILTI AG
  • US20250219509A1 patent drawing
  • US20250219509A1 patent drawing
  • US20250219509A1 patent drawing

AI summary

A microcontroller board attachable to a power tool. The microcontroller board is configured to detect a usage parameter of an attached power tool. The usage parameter represents at least one of a first, second, and third usage mode of the power tool. The microcontroller board has a sensor, a microprocessor, and an output device. The microcontroller board is configured to consume not more than a first energy for detecting the first usage mode while the power tool is in use according to the first usage mode and is configured to consume at least a second energy for detecting at least one of the usage modes other than the first usage mode when the power tool is being used according to the at least one of the usage modes other than the first usage mode. The second energy is at least a factor of 2 higher than the first energy.