Multi-Speed Power Tool Electronic Clutch With Wireless Torque Mapping
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Solution Overview
Problem
Existing power tools lack sophisticated torque control mechanisms, leading to inefficiencies and user experience issues, particularly in applications requiring precise torque settings and adaptive modes.
Innovation Solution
A brushless DC motor power tool with an electronic clutch system that includes a continuously rotating clutch collar and a remote device for customizable torque settings, allowing for more precise torque control and adaptive modes through wireless communication, simulating the feel of a mechanical clutch without additional hardware.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a mechanical clutch system is used to provide torque control settings, then the tool provides tactile feedback and discrete torque levels, but the device complexity increases and the number of settings is limited
Solution Approach 1:
The patent replaces the mechanical clutch system with an electronic clutch mechanism. The electronic clutch uses a motor to rotate the output member and an electronic control system to regulate torque, eliminating the need for complex mechanical clutch hardware while maintaining tactile feedback through haptic engagement of the electronic clutch mechanism.
Solution Approach 2:
The patent creates a virtual representation of the mechanical clutch settings through an electronic interface. The electronic display shows torque level indicators that correspond to the clutch settings, allowing users to select and monitor torque levels electronically while the electronic clutch mechanism physically engages to provide tactile feedback similar to traditional mechanical clutches.
2Adaptability or versatility
If multiple discrete clutch settings are provided, then the tool offers specific torque levels, but the adaptability to different applications is limited
Solution Approach 1:
The patent implements a dynamic clutch collar that can be continuously rotated rather than limited to discrete positions. The electronic control system continuously adjusts the torque level based on the rotational position of the clutch collar, allowing for infinite torque settings within the operational range. This dynamic adjustment capability provides adaptability to different applications without requiring multiple discrete clutch positions.
Solution Approach 2:
The patent changes the torque control parameter from discrete stepped values to continuous adjustable values. The electronic clutch mechanism allows the torque level to be varied continuously by rotating the clutch collar to different angular positions, with the electronic control system translating the rotational position into corresponding torque levels. This parameter change enables infinite torque settings within the operational range.
3Adaptability or versatility
If an electronic clutch system with continuous rotation is implemented, then infinite torque settings are achieved, but the ease of understanding the torque level decreases
Solution Approach 1:
The patent implements feedback mechanisms including visual indicators on an electronic display that show the current torque level corresponding to the clutch collar position. The system provides real-time feedback to the user about the selected torque level, making it easier to understand and select appropriate settings. The feedback loop allows users to see the relationship between clutch collar position and torque output, improving ease of operation despite the continuous adjustment capability.
4Reliability
If traditional mechanical clutch hardware is used, then the tool provides reliable torque control, but additional hardware increases device complexity
Solution Approach 1:
The patent replaces traditional mechanical clutch hardware with an electronic clutch mechanism driven by a motor. The electronic control system uses sensors and control algorithms to regulate torque delivery, providing reliable torque control without the complexity of traditional mechanical clutch components. The electronic system maintains reliability through precise electronic control while reducing mechanical complexity.
Data Source
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AI summary
A power tool and a method of operating a power tool including a motor, a clutch collar including a plurality of settings, a wireless transceiver operable to form a wireless connection with a remote device, and a processor coupled to the clutch collar and the wireless transceiver. The processor receives, via the wireless transceiver, a mapping including a plurality of torque levels corresponding to the plurality of settings. The processor detects that the clutch collar is set to a setting of the plurality of settings. The processor is further determines the torque level for the setting from the mapping and detects, during the operation of the power tool, that a torque of the power tool exceeds the torque level. The processor is also configured to generate an indication that the torque exceeds the torque level. The indication may include flashing a light, ratcheting the motor, and stopping the motor.