This invention relates to fastener driving devices and more particularly to a control circuit for cordless fastener driving tools of the type including clinching mechanisms for securing cartons in a closed manner.
Power operated fastener driving tools are traditionally used in industrial applications where compressed air provides a convenient power source. Because of the nature of the compressed air power source and the expense involved in heavy duty industrial fastener driving tools, such tools are generally not suitable for use in fastening jobs where maneuvering is required, space is limited, or compressed air is not available. Manually operated fastener driving tools are also used in industrial applications. However, in many of the jobs where manually operated fastener driving tools are used, considerable operator fatigue may be involved because a manual fastener driving tool requires a large user actuation force.
One solution is to use electric motors to drive the fastening device. What is needed is effective and suitable control mechanism to utilize for a fastener driving tool.
According to an embodiment of the invention, a power tool is provided including a housing; a driver configured to move downward during a drive stroke and upward during a return stroke; an electric motor configured to drive the driver; and a control unit. The control unit is configured to control a supply of power form a power source to the motor and brake the motor upon or within a predetermined time after the driver reaches approximately its uppermost upward position to stop the motor prior to the completion of the return stroke. According to an embodiment, the driver is configured to drive a fastener into a workpiece during the drive stroke.
According to an embodiment of the invention, a sensor is arranged to detect a position of a moving component associated with the driver. In an embodiment, the sensor is a Hall Effect sensor, and a sense magnet is provided inside or in association with the moving component. The sense magnet is sensable by the Hall Effect sensor when the moving component reaches a predetermined position. In another embodiment, the sensor is a switch that is mechanically actuated when the moving component reaches a predetermined position.
In an embodiment, the sensor is configured to provide a position signal to the control unit when the moving component reaches a predetermined position, and the control unit is configured to brake the motor upon receiving the position signal from the sensor. In another embodiment, the sensor provides a variable voltage to the control unit indicative of the position the moving component and the control unit is configured to brake the motor when the variable voltage exceeds a predetermined threshold.
According to an embodiment, the power tool further includes: a crank arm connected to the motor; and a connecting rod pivotably coupled to the driver at one end portion thereof and pivotably connected to the crank arm at an opposite end portion thereof, the connecting rod being configured to pull the driver downward through the drive stroke when the crank arm rotates with the motor. The moving component may be one of the connecting rod or the driver, in which case the sensor is arranged to detect a predetermined axial position of the moving component. Alternatively, the moving component may be the crank arm, in which case the sensor is arranged to detect a predetermined angular position of the moving component. In a yet further embodiment, the moving component is a mount connecting the driver to the connecting rod, and the sensor is arranged to detect a predetermined axial position of the moving component.
In an embodiment, the motor comprises a positive terminal and a negative terminal, and the control unit is configured to brake the motor by activating a switch to short the positive and negative terminals of the motor. In an embodiment, the control unit is configured to stop supply power to the motor at a predetermined time before it brakes the motor. In an embodiment, the tool includes an input switch actuated by a user, and the control unit is configured to supply power to drive the motor when the input switch is actuated by the user.
The numerous advantages of the present invention may be better understood by those skilled in the art by reference to the accompanying figures. In the drawings, like reference numerals designate corresponding parts throughout the several views.
The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure. Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.
Reference will now be made in detail to the present embodiments of the invention, examples of which are illustrated in the accompanying drawings.
Referring now more particularly to the drawings, there is shown in
As shown in
In an embodiment, the handle 6 extends from the housing section 4 to a handle end portion 16 having a battery pack 18. The battery pack 18 is configured to engage the handle end portion 16 and provide power to a motor 26 in the motor transmission unit 12 such that the tool 2 can drive one or more nails which are fed from the magazine 10. Although the battery pack 18 is illustrated as being connected to the handle end portion 16, the battery pack 18 can be located anywhere on the tool 2.
Provided in the vertical section 8 of the housing section 4 is the driver 23 of the fastener driving assembly. A driver mounting block, i.e. mount 22 is located in a drive channel and moves through successive operating cycles, each of which includes a downward drive stroke and an upward return stroke. The mount 22 has connected thereto, the driver 23. Actuation of the driver 23 drives staples, which are sequentially fed from the magazine 10 to a drive track 20 within the housing 4, into a clincher assembly 40, which may also be referred to herein as a clincher, then into the workpiece W. As shown, the driver 23 is connected to the upper end of the mount 22 and is forced to follow the linear motion of the mount. In an embodiment, the mount is integral with the driver.
As shown in
The clincher assembly 40, which is shown in more detail in
As shown in
The clincher assembly 40, crank arm 34 and crankshaft 32 are actuated by a manual actuating mechanism or trigger assembly, generally indicated at 50, shown in
The motor 26 is actuated by the trigger assembly 50. The trigger assembly 50 is mechanically coupled to handle 6 and electrically coupled to motor 26 such that the trigger assembly selectively provides electric power to motor assembly. The motor 26 includes a rotatable output shaft 30 that extends into the gear reduction mechanism 28, which reduces the rotational speed of the output shaft 30 and causes rotation of the crankshaft 32 at the reduced rotational speed.
The electric motor 26 provides a power source to the tool 2 to operate the clincher assembly 40 as shown in
With the tool 2 provided with a staple supply in the manner indicated above, the staples being formed in a U-shaped or flat configuration; and with the leading staple S disposed within the drive track 20, it will be understood that when the user actuates the trigger member 52, the connecting rod 36 will be moved through a drive stroke carrying with it the mount 22, and the clincher assembly 40.
Referring now more particularly to
The body of the clincher arms 44 can be metallic and formed from steel, for example. Alternatively, the body of the clincher arms can be titanium or other rigid metal. Other materials that can be used to form the clincher arms include a rigid resin material, plastic or a composite material. Further, a combination of materials or material properties can be used for the clincher arms.
The motor 26 drives the transmission or gear reduction mechanism 28, which in turn can actuate and advance the mount 22 to cause the driver 23 to strike the crown C of the leading staple S shown in
For the purpose of effecting the movement of the mount 22 through successive operative cycles of movement, the battery pack 18 supplies energy to an electric motor. The motor 26, can be carried by the housing 4 or the motor-transmission unit 12 in a position parallel to the handle 6 and rearwardly of the housing section 4. The gear reduction mechanism 28, which may be a planetary gear reduction mechanism, is also carried by the housing 4 or motor-transmission unit 12. The gear reduction mechanism 28 is rotatably connected to the motor 26 through the motor output shaft 30 so that the rotation of the motor output shaft 30 rotates the gear reduction mechanism 28. The gear reduction mechanism 28 transmits a rotational force to the crankshaft 32. The crankshaft 32 is rotatably connected to the crank arm 34. The rotational energy of the motor 26 is transmitted through the gear reduction mechanism 28 to the crankshaft 32 to reduce the speed of rotation and increase the torque applied to the crank arm 34. The crank arm 34 rotates along a circular path about the crankshaft 32. When the trigger member 52 is actuated and the safety is engaged, a connection is made between the battery 18 and a microprocessor unit. If the voltage of the battery 18 is within predetermined operating limits (in terms of voltage, current and temperature) the microprocessor applies a voltage to the motor 26, which begins the actuation sequence. The motor 26 will rotate the crankshaft 32, which in turn simultaneously advances the mount 22 and extends the clincher arms 44 driving the staple into the carton or workpiece W. The motor 26 will then continue to turn, returning both the driver 23 and clincher arms 44 until the mount 22 is sensed by a proximity sensor signaling to the microprocessor that the cycle has concluded. At this point, the microprocessor sends a braking signal to the motor 26 and waits for the user to release and re-engage the trigger 52 prior to another cycle commencing. As a result, the torque is applied to the crank arm 34.
An aspect of the invention is discussed herein with reference to
In an aspect of the invention, in order to prevent the driver mounting block 22 and other components from moving between the operating cycles, an automatic motor braking mechanism is provided. Conventional braking mechanisms in power tools typically involve braking the motor by shorting the motor field windings when a user turns off the tool or releases the trigger switch. According to an embodiment of the invention, the braking mechanism in the fastener driving tool 2 is executed automatically via controller 66 coupled to a sensor 62 arranged to detect an almost uppermost position of the mechanical components of the fastener driving tool 2. According to embodiment, the sensor 62 is provided to monitor the position of the connecting rod 36 and/or the driver mounting block 22. The sensor 62 may be a Hall Effect sensor arranged to sense a sense magnet (not shown) positioned within the connecting rod 36 or the driver mounting block 22. The sensor 62 in this case senses the magnetic flux above a certain threshold generated by the sense magnet. Accordingly, once the sense magnet reaches a predetermined position, which may be indicative of the uppermost position of the connecting rod 36 and the driver mounting block 22, the Hall Effect sensor 62 issues a position signal to controller 66 located on a circuit board 64, as will be described below in detail.
It is noted that the Hall Effect sensor 62 is one example of a contactless sensor, although other types of contact or contactless position and/or proximity sensors may also be utilized. For example, sensor 62 may be a proximity sensor arranged to sense when the connecting rod 36 or the driver mounting block 22 reaches a predetermined position. Alternatively, sensor 62 may be a single-pole-single-throw switch that is mechanically actuated by the top of the rod 36 or the driver mounting block 22 when they reach their uppermost position. In yet another embodiment, sensor 62 may be an inductor that yields a variable voltage based on the position of the sense magnet.
It is further noted that while the sensor 62 is commonly positioned to monitor the position of the connecting rod 36 or the driver mounting block 22, sensor 62 may be alternatively positioned to sense longitudinal upward movement of other mechanical components such as upper pivot pin 37 or linkage 42. If sensor 62 is a Hall Effect sensor, the sense magnet may in that case be placed within or in contact with one of these components. Furthermore, sensor 62 may be positioned to sense radial position of the crank arm 34 or the pivot point 35 and issue the position signal when these components reach a predetermined rotationally position, e.g., after 355 degrees of a cycle.
Referring now to
In addition to switches S1 and S3, the circuit diagram includes a switch SW1, which is a safety switch coupled to the safety trigger switch 60 shown in
Control unit U2, which corresponds to controller 66 shown in
Control unit U2 uses the inputs from switches S1 and S3 and nodes SS and TH to determine whether to supply battery power to the motor 26. Specifically, control unit U2 controls a transistor switch Q1 arranged on the path of current from battery node B+ to supply battery power to the M+ motor terminal. Each time the trigger switch 52 is actuated by the user, control unit U2 provides battery power to run the motor 26.
According to an embodiment, in order to brake the motor after the completion of a cycle, sensor 62 issues a position signal when the connecting rod 36 and/or driver mounting block 22 reaches a predetermine (i.e., substantially uppermost) position. When sensor 62 issues the position signal via switch S3 to the control unit U2, control unit U2 interrupts battery power to the motor via transistor switch Q1 and brakes the motor 26 via a second transistor switch Q2 arranged between the two motor terminals M+ and M−. Control unit U2 may activate switch Q2 immediately or after a predetermined delay after transistor switch Q1 is closed. By shorting the motor terminals M+ and M−, the switch Q2 allows for the back EMF (Electro-Magnetic Field) of the motor 26 to flow in the opposite direction of the motor rotation, which stops motor 26 from freewheeling.
According to an embodiment, it takes approximately 15 milliseconds to brake the motor, which is sufficient time for the connecting rod 36 to stop before (or at initial stages of) its downward movement. Accordingly, after a staple has been embedded into the workpiece W, the motor continues to rotate until the connecting rod 36 and the associated mechanical components return to their uppermost position, thereby concluding the cycle. The control unit U2 waits until the user releases and re-engages the trigger switch 52 prior to commencing another cycle.
In the embodiment describe above a sensor 62 issues a logic position signal to the control unit U2 indicative of the uppermost position of one of the mechanical components such as the connecting rod 36 or the driver mounting block 22, and the control unit U2 brakes the motor in accordance with the logic position signal. It is envisioned, however, that some sensing mechanisms may be used to provide a variable analog signal to the control unit U2. For example, sensor 62 may be an inductor that yields a variable voltage based on the position of the sense magnet. In that case, the control unit U2 will be configured to monitor the variable voltage provided by the inductor and brake the motor when the variable voltage reaches a predetermined threshold.
It must be noted that while the above description is in reference to a fastener driving tool, the braking mechanism disclosed herein may be used with any other tool that involves axial movement of a mechanical components via a rotating motor. For example, the braking mechanism describes herein may be used with an electric nailer. Also, while the control unit in this embodiment is configured to brake the motor during every upward stroke after a staple has been fired into the workpiece W, the control unit may alternatively be configured to allow for
It will be appreciated that the above description is merely exemplary in nature and is not intended to limit the present disclosure, its application or uses. While specific examples have been described in the specification and illustrated in the drawings, it will be understood by those of ordinary skill in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the present disclosure as defined in the claims. Furthermore, the mixing and matching of features, elements and/or functions between various examples is expressly contemplated herein, even if not specifically shown or described, so that one of ordinary skill in the art would appreciate from this disclosure that features, elements and/or functions of one example may be incorporated into another example as appropriate, unless described otherwise, above. Moreover, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from the essential scope thereof. Therefore, it is intended that the present disclosure not be limited to the particular examples illustrated by the drawings and described in the specification as the best mode presently contemplated for carrying out the teachings of the present disclosure, but that the scope of the present disclosure will include any embodiments falling within the foregoing description and the appended claims.
This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/665,645 filed Jun. 28, 1012. This application also claims the benefit of priority from U.S. Provisional Patent Application Ser. No. 61/665,516, filed Jun. 28, 2012, and United States Provisional Patent Application Ser. No. 61/772,105, filed Mar. 4, 2013, the entire contents of both of which are incorporated herein by reference.
Number | Date | Country | |
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61665645 | Jun 2012 | US |