Electric Tool Overload Warning via Separate Lighting Control
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Solution Overview
Problem
Existing electric tools face issues with overload, leading to potential damage to the tool or its components, particularly in battery-operated tools, due to high resistance from workpieces or excessive current output from battery packs.
Innovation Solution
A control system that couples an electric tool with a separate lighting device, using sensors to monitor operating parameters and transmit information wirelessly to control the lighting device, which outputs light pulses or varying intensity to warn the user of potential overload conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the electric tool is switched off when current consumption or temperature exceeds admissible limit values, then the electrical load is protected from damage, but the user is interrupted in work and quality losses occur in processing the workpiece
Solution Approach 1:
The lighting device provides preliminary warning to the user before the electrical load reaches critical temperature or current limits. By using optical output to alert the user in advance, the system allows the user to adjust operation manually, preventing forced switch-off while still protecting the electrical load from damage.
2Reliability
If a conservative admissible limit value for current is used, then the electrical load is protected from damage, but the electric tool operates with reduced capacity
Solution Approach 1:
The system continuously monitors current consumption and temperature with sensors, and provides real-time feedback to the user through the lighting device. This feedback mechanism allows the electrical load to operate at higher current levels closer to its true limits, as the user is actively informed and can respond to warnings, thereby increasing power capacity while maintaining protection.
3Reliability
If the electric tool is switched off depending on temperature, then the electrical load is protected from overheating, but it takes relatively long until the electrical load is sufficiently cooled down
Solution Approach 1:
The lighting device provides preliminary warning before the electrical load reaches critical temperature. This allows the user to take preventive action by reducing load or adjusting operation, avoiding the need for complete switch-off and lengthy cooling periods. The preliminary optical warning enables proactive management of thermal conditions.
4Power
If the maximum current output of the battery pack is high, then the battery pack provides sufficient power, but the electrical load could be damaged in case of doubt
Solution Approach 1:
The control system continuously monitors current consumption and provides real-time feedback through the lighting device. This allows the battery pack to safely operate at high current output levels, as the user is immediately informed when approaching safe limits and can adjust operation accordingly, preventing damage while maximizing power delivery.
Data Source
AI summary
A control system is disclosed for an electric tool and a lighting device. The control system includes a first control circuit and a sensor for the electric tool and a second control circuit for the lighting device. The sensor is configured to generate a sensor signal depending on a value of an operating parameter of the electric tool. The first control circuit is configured to transmit information relating the operating parameter value to the second control circuit depending on the sensor signal. The second control circuit is configured to control a light source of the lighting device depending on the transmitted information to emit one or more light pulses, wherein a pulse parameter relating to a pulse duration, a pulse amplitude, a frequency, and/or a duty cycle of the light pulses, and/or emitted light intensity, depends on the operating parameter value.