Power Tool Safety Interlock Using Sensor-Based Pre-Operation Checks

Solution Overview

Problem

Existing power tools, such as angle grinders, often lack effective and uncomplicated safety features, making them potentially dangerous for operators, as these features can be complicated to use or easily bypassed.

Innovation Solution

A system comprising a power tool and an automatic safety system communicatively coupled to the power tool, which includes sensors to gather data on safety parameters and a main detector to analyze this data, ensuring the power tool can only be operated if all safety parameters indicate a safe usage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If prior art safety features are added to power tools, then operator safety is improved, but device complexity increases and ease of operation deteriorates

Engineering Contradiction:

Improveoperator safetyVSAvoidsafety feature complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The system performs safety checks before allowing the power tool to operate. Sensors detect safety conditions (guard position, handle installation, disc installation) and the control unit prevents operation until all conditions are met, ensuring safety is established in advance rather than during operation

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The power tool automatically monitors its own safety conditions through integrated sensors and control circuitry. The system self-checks for proper assembly and operation conditions without requiring external monitoring equipment or complex manual safety procedures

Inventive Principle:

Principle #25Self-service

2Reliability

If prior art safety features are added to power tools, then operator safety is improved, but ease of operation deteriorates

Engineering Contradiction:

Improveoperator safetyVSAvoidoperation simplicity

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The power tool automatically monitors its own safety conditions through integrated sensors and control circuitry. The system self-checks for proper assembly and operation conditions without requiring external monitoring equipment or complex manual safety procedures

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The control unit receives signals from sensors monitoring safety conditions and provides feedback by either enabling or disabling operation. The system continuously monitors and adjusts its operational state based on real-time safety condition feedback, ensuring only safe operations are permitted

Inventive Principle:

Principle #23Feedback

3Reliability

If manual safety checks are required before operation, then operator safety is improved, but productivity deteriorates due to time loss

Engineering Contradiction:

Improveoperator safetyVSAvoidoperation time

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The system performs safety checks before allowing the power tool to operate. Sensors detect safety conditions (guard position, handle installation, disc installation) and the control unit prevents operation until all conditions are met, ensuring safety is established in advance rather than during operation

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The power tool automatically monitors its own safety conditions through integrated sensors and control circuitry. The system self-checks for proper assembly and operation conditions without requiring external monitoring equipment or complex manual safety procedures

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS12202097B2Systems and methods for an automatic safety protocol in electrical tools

Publication Date: 2025.01.21 HILTI AG

AI summary

A system includes a power tool and an automatic safety system communicatively coupled to the power tool. The automatic safety system includes one or more sensors disposed about the power tool, where the one or more sensors are configured to gather data about a safety parameter related to an operation of the power tool. The automatic safety system also includes a main detector configured to receive the data gathered by the one or more sensors. The main detector is configured to analyze the received data to determine whether to unlock the power tool for operation.