Power Tool PCB Interface for Multi-Input Motor Control
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Solution Overview
Problem
Existing power tools lack efficient and precise control over motor operational characteristics such as torque, direction, and speed, due to limited sensor capabilities and integration with user input devices.
Innovation Solution
A power tool design incorporating a centrally-located circuit board with multiple sensors to simultaneously sense the positions of various user input devices, such as triggers, dials, and switches, allowing the controller to accurately set and adjust motor operational characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple sensors are integrated on a single circuit board to sense positions of multiple user input devices, then measurement precision and control accuracy are improved, but device complexity increases
Solution Approach 1:
The patent combines multiple sensors (first sensor, second sensor, third sensor) onto a single circuit board to sense positions of multiple user input devices simultaneously. This merging approach improves measurement precision by providing accurate position data from multiple devices while consolidating the sensing infrastructure into one integrated board, thereby managing complexity through unified design rather than multiple separate sensing systems.
Solution Approach 2:
The circuit board is designed with multi-functionality to serve as a central hub for sensing multiple different user input devices (triggers, dials, sliders, switches, knobs) through its multiple sensors. This universal sensing platform allows the same circuit board to handle various input types, improving measurement accuracy across all devices while avoiding the complexity of separate dedicated sensing boards for each input type.
2Reliability
If non-contact sensors are used to detect trigger position, then reliability and response speed are improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent replaces mechanical contact-based trigger detection with non-contact sensors that detect the position of a target portion on the trigger. This substitution improves reliability by eliminating wear and contact issues while enabling faster response times. The non-contact nature of the sensing allows the trigger mechanism to move freely without mechanical interference, enhancing both reliability and speed despite the need for precise sensor-to-target alignment.
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
Enables precise and efficient control of motor operations, improving user experience and tool performance by accurately responding to user inputs and maintaining optimal motor settings.
Implementation Method 1
The first non-contact sensor is configured to detect a position of the target portion as the target portion moves between the first position and the second position
Implementation Method 2
The second non-contact sensor is configured to provide a wake signal to a controller in response to the target portion being moved from the first position
Data Source
AI summary
A power tool includes a housing, a motor at least partially disposed in the housing, a controller configured to control an operational characteristic of the motor, and a circuit board. The circuit board is connected to the controller. The circuit board includes a first sensor portion configured to sense a first position of a first user input device, a second sensor configured to sense a second position of a second user input device, and a third sensor configured to sense a third position of a third user input device.