Ratchet Tool Dynamic Speed Control for Torque Management
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Solution Overview
Problem
Conventional electric ratchet tools are limited in their ability to dynamically adjust torque and rotational speed, often resulting in inefficient operation and potential damage to workpieces due to sudden speed increases, especially when trying to apply high torque.
Innovation Solution
The ratchet tool incorporates a controller and human-machine interaction assembly that allows for selectable modes and adjustable rotational speeds, including a detection mechanism to change the direction of rotation based on load parameters, and a speed adjustment assembly that adjusts the gear ratio or electronic parameters to maintain optimal torque and speed settings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the motor rotates at high speed to improve productivity, then the tightening efficiency increases, but the workpiece may be damaged due to sudden speed increases
Solution Approach 1:
The patent implements dynamic speed adjustment by allowing the motor rotational speed to be continuously modified during operation based on real-time detection of tightening force and rotational speed parameters. The controller dynamically adjusts the speed to prevent sudden increases that could damage the workpiece, while still achieving high productivity when conditions allow.
Solution Approach 2:
The patent employs a feedback mechanism where sensors continuously monitor the tightening force and rotational speed, and this information is fed back to the controller. The controller uses this feedback to automatically adjust the motor speed, preventing workpiece damage while maintaining optimal tightening efficiency. The feedback loop ensures the system responds to actual operating conditions rather than following a fixed speed profile.
2Force
If the motor applies high torque to tighten fasteners, then the tightening force increases, but the motor may enter locked-rotor state causing operation interruption
Solution Approach 1:
The patent implements periodic reciprocating motion of the drive shaft, alternating between forward and reverse rotation. This periodic action prevents the motor from entering locked-rotor state by continuously changing the direction of torque application, allowing the motor to maintain high tightening force while ensuring continuous operation. The reciprocating motion is particularly useful when encountering resistant fasteners.
Solution Approach 2:
The patent dynamically adjusts the torque and rotational speed based on real-time detection of motor load and operational parameters. When the motor approaches locked-rotor conditions, the controller dynamically modifies the torque profile and may initiate reciprocating motion, thereby maintaining reliable continuous operation while still achieving the required tightening force.
3Device complexity
If the ratchet tool uses a fixed gear ratio to simplify the structure, then the device complexity decreases, but the torque and speed cannot be optimized for different working conditions
Solution Approach 1:
The patent changes the operational parameters of the existing gear system by dynamically adjusting the motor rotational speed and torque through electronic control, rather than using multiple physical gear ratios. This allows the single gear structure to adapt to different working conditions by varying the input parameters to the motor, maintaining simplicity while achieving versatility.
Solution Approach 2:
The patent makes the single gear structure universal by combining it with a controllable motor system that can operate across a wide range of speeds and torques. The same gear mechanism serves multiple functions by processing different motor output parameters, eliminating the need for multiple specialized gear sets while maintaining adaptability to various tightening requirements.
4Device complexity
If the motor rotates in only one direction to simplify the ratcheting mechanism, then the device complexity decreases, but the tool cannot adjust rotational direction for different fastening needs
Solution Approach 1:
The patent implements dynamic directional control by allowing the motor to switch between clockwise and counter-clockwise rotation based on operational requirements. The pawl and ratchet gear remain relatively simple in structure, but the motor's rotational direction is dynamically controlled through electronic switching, providing versatility without significantly increasing mechanical complexity.
Solution Approach 2:
The patent replaces complex mechanical direction-reversal mechanisms with electronic control of the motor. Instead of using additional mechanical components to reverse the drive shaft direction, the system uses electronic commutation to control the motor's rotation direction, thereby maintaining simplicity in the ratcheting mechanism while achieving directional adaptability.
Data Source
AI summary
A ratchet tool includes a drive shaft rotating about a first axis; a ratcheting mechanism driven by the drive shaft; a trigger switch, where a motor corresponds to different output rotational speeds according to different trigger strokes of the trigger switch; a human-machine interaction assembly coupled to a controller; and a controller configured to adjust, according to a setting of the human-machine interaction assembly, an output rotational speed or a range of output rotational speeds of the motor when the trigger switch has a maximum trigger stroke.