Rotary Impact Tool Sensing for Anvil Rotation and Impact Frequency
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Solution Overview
Problem
Existing rotary impact tools lack effective sensors for accurately detecting the rotational position and impact frequency of the anvil and hammer components, leading to inefficiencies in controlling the tool's operation.
Innovation Solution
Incorporation of anvil and hammer sensors into a printed circuit board assembly within the rotary impact tool, spaced to avoid contact with the anvil lugs, allowing for precise detection of anvil and hammer rotations and impacts, with a controller to manage operation based on sensor feedback.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensors are placed close to the anvil and hammer components for detection, then measurement precision is improved, but the risk of contact and damage increases
Solution Approach 1:
The patent introduces non-contact sensors (such as Hall effect sensors or optical sensors) that detect the rotational position and impact frequency of the anvil and hammer components through magnetic fields or light fields without physical contact. This intermediary field-based detection method allows precise measurement while eliminating the risk of sensor contact and damage from the high-impact environment.
2Reliability
If sensors are positioned to avoid contact with moving parts, then reliability is improved, but measurement precision may deteriorate
Solution Approach 1:
The patent replaces mechanical contact-based sensing with non-contact sensing technologies such as Hall effect sensors that detect magnetic field changes or optical sensors that detect light reflections. This substitution eliminates the need for physical contact between sensors and moving parts while maintaining high measurement precision through field-based detection methods.
3Measurement precision
If multiple sensors are added to detect both anvil and hammer parameters, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent designs multi-functional sensors that can detect multiple parameters (rotational position, impact frequency, rotational speed) using a single sensing mechanism. For example, a Hall effect sensor can simultaneously measure magnetic field changes caused by rotational position and impact events, reducing the total number of sensors needed while maintaining comprehensive measurement capabilities.
Data Source
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AI summary
A rotary impact tool includes a motor housing, an electric motor supported in the motor housing, and a drive assembly for converting a continuous torque input from the motor to consecutive rotational impacts upon a workpiece. The drive assembly includes an anvil including an anvil lug and a hammer that is both rotationally and axially movable relative to the anvil. The hammer includes a hammer lug for imparting the consecutive rotational impacts upon the anvil lug. The rotary impact tool further comprises a printed circuit board assembly including a sensor that is configured to detect rotation of the anvil. The printed circuit board assembly is spaced from the anvil to define an axial gap therebetween.