Power Tool Sensor Tag for Usage Tracking and Low-Power Transmission
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Solution Overview
Problem
Construction tools often lack the capability to measure, record, and transmit historical, current, or future usage information, and communication features to external devices, making it difficult to monitor and analyze their movement and usage effectively.
Innovation Solution
A sensor tag is coupled to the construction tool to measure raw sensor information, determine events, calculate aggregate times for each type of event, and wirelessly transmit this information to a remote computing device, while also conserving battery power by entering a confirmed sleep mode after successful data transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a sensor tag is added to measure and transmit usage data, then measurement capability and data tracking are improved, but device complexity increases
Solution Approach 1:
The system divides the measurement and communication functions into a separate sensor tag module that can be independently attached to the power tool. This segmentation allows the tool itself to remain simple while the sensor tag handles all measurement, processing, and wireless transmission functions, resolving the contradiction between adding measurement capability and increasing device complexity.
2Loss of information
If wireless transmission is enabled to send data to remote devices, then communication capability is improved, but energy consumption increases
Solution Approach 1:
The sensor tag transmits data periodically or event-triggered rather than continuously, and enters sleep mode between transmissions. This periodic action allows usage information to be transmitted effectively while significantly reducing battery consumption compared to continuous transmission.
Solution Approach 2:
The system uses feedback mechanisms where the sensor tag only transmits data when specific conditions are met (such as when the tool is placed in a docking station or when certain usage thresholds are reached). This feedback-driven transmission optimizes energy usage by avoiding unnecessary continuous communication.
3Productivity
If continuous monitoring is implemented to track tool usage, then productivity information is improved, but energy consumption increases
Solution Approach 1:
The sensor tag implements periodic sampling of usage data rather than continuous monitoring, and aggregates multiple measurements before transmission. This approach maintains accurate productivity tracking while reducing the frequency of high-energy operations such as wireless transmission and data processing.
Solution Approach 2:
The sensor tag performs preliminary data aggregation and processing during low-power periods, preparing data for transmission in advance. This preliminary action allows continuous monitoring functionality while deferring energy-intensive transmission operations to appropriate moments when the tool is docked or being used.
Data Source
AI summary
A method includes measuring raw sensor information of a tool over a period of time with a sensor tag coupled to an external surface of the tool. The method also includes determining one or more events of the tool based on the raw sensor information and calculating an aggregate time for each type of event from the one or more events determined over the period of time. The method also includes wirelessly transmitting a history of the one or more events from the sensor tag to a remote computing device. The history comprises the aggregate time for each type of event from the one or more types of events over the period of time.