Power Tool Current Monitoring for Fastener Swaging Verification
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Solution Overview
Problem
Existing power tools lack effective clutch control systems that can accurately verify the proper installation of fasteners and provide feedback on installation quality, especially when dealing with various fastener materials and modes of connection, and often suffer from mechanical wear and complexity in clutch mechanisms.
Innovation Solution
A method for operating power tools that involves monitoring current supplied to the motor, determining the rate of change of current, and using thresholds to verify the engagement and completion of fastener swaging, with feedback mechanisms to indicate installation quality, including visual, audible, or wireless communication of results.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a mechanical clutch is used to interrupt power transmission when torque exceeds a threshold, then the tool can prevent torque transmission to protect the fastening mechanism, but the mechanical clutch components wear over time and add excessive bulk and weight to the tool
Solution Approach 1:
The patent replaces the mechanical clutch system with an electronic control system that uses a sensor to detect torque or force and a controller to interrupt or reduce power transmission electronically. This eliminates the need for mechanical clutch components, thereby reducing bulk and weight while maintaining the protection function.
2Device complexity
If an electronic clutch is used to sense output torque and interrupt power transmission, then the tool can reduce mechanical wear and bulk, but existing electronic clutches are overly complex and fail to include verification of proper fastener installation
Solution Approach 1:
The patent incorporates a feedback mechanism where the sensor continuously monitors torque or force during fastener installation, and the controller processes this information to determine when installation is complete and whether it was successful. This provides verification of proper fastener installation while maintaining the benefits of the electronic clutch system.
3Measurement precision
If the power tool monitors current supplied to the motor and determines rate of change of current, then the tool can accurately verify engagement and completion of fastener swaging, but the control system becomes more complex
Solution Approach 1:
The patent uses the motor's own current characteristics as the sensing mechanism. The sensor detects current supplied to the motor, and the controller analyzes the rate of change of current to determine engagement and completion of fastener swaging. This approach uses existing motor parameters for verification without requiring additional sensing components, thereby maintaining simplicity while achieving accurate measurement.
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 accurate verification of fastener installation quality and provides feedback on potential faults, supporting a wide range of fastener materials and types, while reducing mechanical wear and complexity in clutch systems.
Implementation Method 1
receiving measures of current supplied to a motor of the power tool during operation of the power tool
Data Source
Figure 1
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Figure 3A~3C
AI summary
A method is presented for operating a power tool during installation of a deformable fastener. The method includes: receiving measures of current supplied to a motor of the power tool during operation of the power tool; determining rate of change of the current during operation of the power tool; determining occurrence of the power tool engaging the fastener based on the magnitude of the current supplied to the motor; determining occurrence of the power tool swaging the fastener based on the rate of change of the current; determining completion of the power tool swaging the fastener based on the magnitude of the current and the rate of change of the current; and verifying quality of the installation of the fastener using the determination of the occurrence of the power tool engaging the fastener and the determination of the completion of the power tool swaging the fastener.