Tightening Tool Motor Speed Control for Heat and Battery Drain
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Solution Overview
Problem
Existing tightening tools often overheat and battery-powered tools quickly drain their batteries due to inefficient energy use, leading to reduced productivity and the need for frequent cooling or battery changes.
Innovation Solution
A method for controlling the electric motor of a tightening tool by adjusting the motor speed based on the tool's efficiency, reducing heat generation and power consumption, thereby extending battery life and improving productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the tightening tool operates at high power to maintain productivity, then the tightening speed and torque are sufficient, but the tool overheats and requires frequent cooling periods
Solution Approach 1:
The patent applies dynamic speed adjustment by continuously monitoring torque buildup and adapting motor speed in real-time. The control system reduces motor speed when torque approaches the target value, preventing excessive heat generation while maintaining high productivity during the majority of the tightening cycle where higher speeds are beneficial.
Solution Approach 2:
The patent changes the operating parameters of the motor by adjusting speed based on the tightening phase. During the acceleration and mid-tightening phases, high speed is maintained for productivity, while during the final torque buildup phase, speed is reduced to minimize heat generation, thus resolving the contradiction between productivity and temperature.
2Productivity
If the tightening tool operates at high power to maintain productivity, then the tightening performance is sufficient, but the battery drains quickly requiring frequent changes
Solution Approach 1:
The system dynamically adjusts motor speed based on the tightening phase and torque feedback. By reducing speed only when necessary during torque buildup rather than maintaining constant high speed, the battery consumption is significantly reduced while maintaining high productivity during the majority of the tightening cycle.
Solution Approach 2:
The operating parameters are changed by reducing motor speed during the final torque buildup phase. This parameter change reduces power consumption during the most energy-intensive portion of the tightening operation, extending battery life while maintaining overall productivity through high-speed operation during other phases.
3Power
If a higher rated motor is used to ensure sufficient power for all tightening operations, then the tool can handle all torque requirements, but the tool becomes heavier and more expensive
Solution Approach 1:
The patent changes the operating parameters by dynamically adjusting motor speed during operation. This allows a lower-rated motor to deliver equivalent performance to a higher-rated motor by optimizing speed throughout the tightening cycle, particularly by reducing speed during torque buildup to minimize power requirements.
Solution Approach 2:
The system uses torque feedback to adjust motor speed in real-time. By monitoring torque buildup and reducing speed when torque approaches the target value, the control system enables a smaller motor to achieve the same tightening performance as a larger motor would provide at constant high speed, reducing tool weight.
Data Source
AI summary
A method of controlling an electric motor of a tightening tool during a tightening operation, the method comprising: a) controlling the electric motor to run at a first motor speed using a first motor speed setpoint value, b) obtaining a torque or motor current value of the electric motor, c) determining a second motor speed setpoint value lower than or equal to the first motor speed setpoint value, based on an efficiency of the tightening tool at the torque or motor current value and the first motor speed setpoint value, d) setting the second motor speed setpoint value as the first motor speed setpoint value, e) controlling the electric motor to run at a second motor speed using the first motor speed setpoint value after step d), and repeating steps b)-e) until a predetermined motor speed or torque has been reached.