Universal Control Module for Power Tools
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Solution Overview
Problem
Existing motor control systems require dedicated analog or digital circuitry for specific motor applications, leading to inefficiencies and increased complexity due to differing components, tolerances, and control software for each motor type.
Innovation Solution
A universal control module is designed to control multiple motors and applications, featuring a configurable printed circuit board with a spacer for tolerance adjustment, an auxiliary board for speed sensing, and a variable speed dial wheel, allowing for adaptable motor control within a power tool housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If dedicated control circuitry is used for each motor application, then operational reliability is improved, but device complexity increases
Solution Approach 1:
The control module is designed with a universal printed circuit board that can control multiple different motor types and power tool applications through a single standardized platform, eliminating the need for separate dedicated control circuits for each application while maintaining operational reliability through consistent control architecture
2Manufacturing precision
If different components with differing values and tolerances are used for each motor application, then manufacturing precision is improved, but ease of manufacture deteriorates
Solution Approach 1:
The system maintains manufacturing precision by allowing parameter adjustments through software configuration and component selection on a standardized hardware platform, enabling different control characteristics for various motor types without requiring completely different hardware designs, thus improving ease of manufacture while preserving precision
3Adaptability or versatility
If a universal control module is used for multiple motor applications, then adaptability is improved, but manufacturing precision may deteriorate
Solution Approach 1:
The control module employs dynamic configuration capabilities through programmable microcontrollers and adjustable parameters that allow the system to adapt to different motor applications while maintaining precise control through software-based parameter optimization for each specific application
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The universal control module simplifies motor control by enabling a single module to manage various motor applications, reducing complexity and increasing versatility while maintaining precise speed control and operational reliability.
Implementation Method 1
a pick-up coil assembly for sensing speed of a motor of the power tool
Implementation Method 2
potting material within the shroud that encloses the pick-up coil
Data Source
AI summary
The universal control module is designed for controlling the operation of a plurality of motors and/or configured for a plurality of different motor applications. In an example, the control module is configurable within a housing of a power tool. The control module includes a top cover, a bottom cover and a printed circuit board (PCB) with control components thereon. The control module includes a spacer configured between the top and bottom covers and attached to the PCB for providing tolerances for the control components during a soldering process to fixedly attach the control components to the PCB.