Universal Controller for Cordless Power Tools with Electronic Identification

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Solution Overview

Problem

Existing cordless power tools require dedicated controllers for each type, leading to increased inventory costs and complexity, as well as potential mismatches between tool and battery types, which can result in improper operation or safety issues.

Innovation Solution

A universal controller for cordless power tools that uses tool-specific and battery-specific identifiers, such as resistors, to select appropriate operational modes and prevent mismatches, allowing a single controller to operate multiple tool types and battery packs by defining performance limits through an electronic menu or library.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If dedicated controllers are used for different power tools, then each tool type can be optimized for its specific operation, but inventory complexity and costs increase

Engineering Contradiction:

Improvetool operation optimizationVSAvoidinventory complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent implements a universal controller that can operate multiple different power tool types (drill, impact driver, ratchet, screwdriver) by detecting tool type through electronic identifiers and automatically configuring appropriate operational parameters. This eliminates the need for separate dedicated controllers for each tool type, reducing inventory complexity while maintaining tool-specific optimization through software-based configuration rather than hardware specialization.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The controller changes its operational parameters dynamically based on the detected tool type. By modifying control parameters such as current limits, duty cycles, and power delivery characteristics according to the specific tool requirements, the single universal controller adapts to different tool types without requiring dedicated hardware for each, thus resolving the contradiction between optimization and inventory complexity.

Inventive Principle:

Principle #35Parameter changes

2Device complexity

If a universal controller is used for multiple tool types, then inventory is reduced, but tool-battery mismatch errors may occur

Engineering Contradiction:

Improveinventory complexityVSAvoidtool-battery compatibility

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The system incorporates feedback mechanisms where the controller reads electronic identifiers from both the tool and battery, compares their compatibility, and provides feedback control. If a mismatch is detected (e.g., incompatible voltage, amperage, or tool-battery pairing), the controller prevents operation or alerts the user, ensuring reliable matching while maintaining the benefits of a universal controller design.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

Before allowing operation, the controller performs preliminary identification and validation of tool and battery compatibility through electronic identifiers. This preliminary checking action prevents mismatched combinations from operating, ensuring reliability is established before use while maintaining inventory simplicity.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If tool-specific identifiers are implemented, then proper operation can be ensured, but manufacturing complexity increases

Engineering Contradiction:

Improveproper operation assuranceVSAvoidassembly complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent uses simple, inexpensive electronic identifiers (such as resistors or integrated circuit chips) that can be easily manufactured and installed. These low-cost components provide reliable tool and battery identification without adding significant manufacturing complexity, as they are standard electronic parts that can be incorporated during conventional assembly processes.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The system replaces complex mechanical or physical identification methods with electronic identifiers and digital communication protocols. This substitution simplifies manufacturing by using standard electronic components rather than mechanical coding systems, reducing assembly complexity while ensuring reliable operation through precise electronic recognition and validation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS9878432B2Cordless power tools with a universal controller and tool and battery identification

Publication Date: 2018.01.30 INGERSOLL RAND IND US INC

AI summary

A handheld power tool having an electric motor held in a power tool body and a universal controller in the power tool body in communication with the electric motor. The universal controller is in communication with an electronic component that defines a tool type identifier in the power tool body. The handheld power tool also has a battery pack releasably attachable to the power tool body, the battery pack having an on-board electronic identifier. The universal controller has a plurality of different operational control modes for a plurality of different tool types and a plurality of different battery packs with different battery characteristics. The controller can automatically select an appropriate control mode based on the tool type identifier and the battery pack identifier.