Power Tool Torque Dial with Magnetic Sensor
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing power tools, such as driver-drills and hammer driver-drills, have a limited torque setting range and require manual adjustment of a change ring, which is cumbersome and often requires grasping a hot part of the tool, making it difficult to set the desired torque accurately.
Innovation Solution
A power tool design featuring a rotatable dial with permanent magnets and a magnetic field sensor that allows for easy adjustment of the torque threshold by rotating the dial, enabling precise control of the motor's output torque without the need for manual manipulation of a change ring, thereby simplifying the torque setting process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a change ring is used for torque adjustment, then torque setting is possible, but the torque setting range is narrow and the operation is cumbersome
Solution Approach 1:
The patent replaces the mechanical change ring adjustment system with an electronic dial system. The dial includes a rotation operation unit with a rotary member that rotates about an axis, coupled to a rotation detection unit that detects the rotation amount and direction. This electronic detection system substitutes the mechanical spring-length adjustment, providing a wider torque setting range and easier one-handed operation without requiring manual manipulation of hot components.
Solution Approach 2:
The patent changes the parameter control method from mechanical (physical spring length) to electronic (rotation detection and control signal generation). The rotation detection unit converts the rotary member's mechanical rotation into electrical signals that control the motor's output torque threshold, allowing for broader and more precise torque settings while improving ease of operation.
2Ease of operation
If manual adjustment of change ring is required, then torque can be set, but user safety is compromised due to hot components
Solution Approach 1:
The patent replaces the manual mechanical adjustment of the change ring with an electronic dial system located on the enlarged-part housing. The rotation operation unit and rotation detection unit provide a contactless or minimal-contact interface that does not require grasping hot components, thereby eliminating thermal injury risk while maintaining torque adjustment functionality.
3Productivity
If one hand is occupied with tool operation, then drilling/screwing can be performed, but torque adjustment becomes difficult
Solution Approach 1:
The patent replaces the manual change ring adjustment with an electronic dial system that can be operated with minimal hand movement. The rotation operation unit allows torque setting through small rotational movements that can be made with the thumb or fingers while maintaining grip on the tool, enabling one-handed operation for both tool control and torque adjustment.
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
The solution provides a wider torque setting range with improved ergonomics, allowing for precise control of the motor's torque with one hand, reducing the risk of burns and enhancing user convenience by eliminating the need for manual adjustment of a hot component.
Implementation Method 1
the dial comprises a magnet or magnets. In this case, a magnetic field sensor that detects the magnetic field(s) generated by the magnet(s) is provided.
Data Source
AI summary
A driver drill includes a motor housing that holds an electric motor, an axis of rotation of a rotor of the electric motor extending in a front-rear direction of the driver drill, a grip housing having an upper end connected to a lower part of the motor housing and an enlarged-part housing connected to a lower end of the grip housing and spaced from the motor housing in an up-down direction of the driver drill that is perpendicular to the front-rear direction. A torque setting of the driver drill is changeable, and the driver drill is changeable between a setting unlocked state in which the torque setting is changeable and a setting locked state in which the torque setting is not changeable.