Wireless Electronic Clutch Control for Multi-Speed Power Tools
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Solution Overview
Problem
Conventional power tools lack advanced torque control mechanisms, leading to inefficiencies and user experience limitations, particularly in adapting to varying torque requirements during operations.
Innovation Solution
A power tool with an electronic clutch system that includes a wireless transceiver and processor, allowing for customizable torque settings via a clutch collar, which can rotate continuously and communicate with a remote device to adjust torque levels dynamically, providing precise control and feedback to the user.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional power tools are used without electronic clutch, then device complexity is reduced, but torque control precision deteriorates
Solution Approach 1:
The patent replaces traditional mechanical clutch mechanisms with an electronic clutch system that uses a motor, sensor, and controller to achieve precise torque control. The motor controls the clutch collar position electronically, eliminating the need for complex mechanical torque limiting mechanisms while providing superior torque precision through electronic feedback and control algorithms.
Solution Approach 2:
The patent implements a feedback mechanism where a sensor detects the position of the clutch collar and provides this information to a controller. The controller continuously monitors torque levels and adjusts motor operation to maintain the desired torque setting, creating a closed-loop control system that achieves precise torque control through continuous feedback and adjustment.
2Adaptability or versatility
If electronic clutch with wireless communication is added, then adaptability improves, but device complexity increases
Solution Approach 1:
The patent integrates multiple functions into a single electronic control system. The same motor and sensor assembly that provides torque control also enables wireless communication capabilities through the controller. The system can store multiple torque profiles, receive wireless commands, and adapt to different applications, providing universal adaptability without requiring separate dedicated mechanisms for each function.
Solution Approach 2:
The patent combines the clutch control mechanism with wireless communication functionality in an integrated electronic system. The controller manages both the motor-driven clutch collar positioning and wireless data transmission, merging what could be separate systems into a unified architecture that reduces overall complexity while maintaining adaptability.
3Ease of operation
If continuous torque adjustment is enabled, then ease of operation improves, but manufacturing complexity increases
Solution Approach 1:
The patent replaces fixed, discrete torque settings with a dynamic, continuously adjustable torque control system. The motor enables the clutch collar to be positioned at any point within its range, allowing torque to be adjusted continuously rather than in fixed increments. This dynamic system is controlled electronically, making it easier to operate while the modular electronic architecture facilitates manufacturing.
Data Source
AI summary
A power tool and a method of operating a power tool including a motor, a clutch collar including a plurality of settings, a wireless transceiver operable to form a wireless connection with a remote device, and a processor coupled to the clutch collar and the wireless transceiver. The processor receives, via the wireless transceiver, a mapping including a plurality of torque levels corresponding to the plurality of settings. The processor detects that the clutch collar is set to a setting of the plurality of settings. The processor is further determines the torque level for the setting from the mapping and detects, during the operation of the power tool, that a torque of the power tool exceeds the torque level. The processor is also configured to generate an indication that the torque exceeds the torque level. The indication may include flashing a light, ratcheting the motor, and stopping the motor.