Power Tool Gyro Sensing for Tilt and Kickback Detection
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Solution Overview
Problem
Existing power tools, such as routers, face challenges with kickback events and improper handling, which can lead to user injury and workpiece damage. Current safety features may not adequately detect and respond to these issues, especially in complex movements involving multiple axes.
Innovation Solution
The power tool incorporates a gyro sensor module with multiple gyro sensors to detect angular rotation and inclination about multiple axes, along with an accelerometer sensor module to detect linear acceleration. A controller processes these sensor signals to determine error conditions such as kickback, tilting, and excessive acceleration, and triggers notifications and automatic shut-off as needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If control systems monitor only rotational motion and current to detect kickback, then the system complexity is reduced, but the detection accuracy and reliability are insufficient for multi-axis kickback events
Solution Approach 1:
The patent transitions from monitoring only rotational motion (single dimension) to incorporating angular velocity and angular inclination measurements across multiple axes (multi-dimensional). The gyro sensor module measures angular velocity about a first axis and angular inclination of the first axis, adding dimensional depth to kickback detection and enabling comprehensive multi-axis event detection.
Solution Approach 2:
The gyro sensor module serves multiple functions: detecting angular velocity, measuring angular inclination, identifying kickback events, and monitoring tool orientation. This multi-functional sensor replaces the need for separate sensors for each measurement type, achieving high detection accuracy while managing system complexity through functional integration.
2Ease of operation
If actuators and sensors are used to automatically correct tool tilt, then tool control precision is improved, but the device complexity and cost increase significantly
Solution Approach 1:
The system continuously monitors tool orientation using the gyro sensor module and provides real-time feedback to the user through visual or haptic notifications when improper tilting is detected. This feedback mechanism guides users to maintain proper tool orientation without requiring complex automatic correction actuators, achieving ease of operation through user education rather than mechanical intervention.
Solution Approach 2:
Instead of the system automatically correcting user errors through complex actuators, the gyro sensor module enables the system to monitor and notify users of improper handling, allowing users to self-correct their technique. This approach improves ease of operation by empowering users to learn proper tool handling while avoiding the complexity of automatic correction mechanisms.
3Reliability
If gyro sensors monitor angular velocity and inclination about multiple axes, then error condition detection reliability is improved, but the device complexity increases
Solution Approach 1:
The gyro sensor module is designed as a multi-functional unit that simultaneously measures angular velocity about a first axis and angular inclination of the first axis from a reference axis. This single module performs multiple detection functions, improving error condition detection reliability across multiple axes while managing device complexity through integrated design.
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
This solution enhances safety and control during power tool operation by accurately detecting error conditions and preventing potential hazards through timely notifications and automatic shut-off, thereby reducing the risk of injury and damage.
Implementation Method 1
The gyro sensor module includes at least one gyro sensor configured to detect angular rotation of the housing about a first axis and angular inclination of the first axis from a reference first axis
Implementation Method 2
The accelerometer sensor module is configured to detect linear acceleration of the housing with respect to a workpiece in a direction parallel to the first axis, the second axis, and/or the third axis
Data Source
AI summary
A power tool including a housing, a motor mounted in the housing, and a tool holder operatively coupled to the motor. The power tool also includes a gyro sensor module mounted on the housing, which has at least one gyro sensor configured to detect angular rotation of the housing about a first axis and angular inclination of the first axis from a reference first axis. A controller is configured to receive sensor signals from the gyro sensor module, determine a first error condition of the power tool based on a threshold angular velocity being exceeded, and determine a second error condition of the power tool based on a threshold angular inclination being exceeded.