The present disclosure relates to handheld power tools and, particularly, to handheld power tools having a double trigger pull to actuate various operating functions of the handheld power tool.
Handheld power tools commonly include a trigger that an operator may selectively depress to actuate the power tool. Advanced handheld power tools may also include predetermined operating configurations to assist an operator with various fastening and other like needs. The configurations are groupings of torque and speed settings. Target torque, shift down torque, free speed and shift down speed are examples of common settings. For clarity, shift down point is the torque at which speed changes from free speed to shift down speed. The tool may also control off of a target angle, rather than torque. The settings are grouped and stored in a configuration so that the configuration routine may be performed over and over again.
Such advanced power tools may also include an electronic display screen (e.g., liquid crystal display (LCD), an organic light emitting diode (OLED) display), and/or one or more separate indicator lights (e.g., LEDs) to serve as a human-machine interface. Typically, buttons associated with the electronic display screen change the operating configuration of the power tool as needed.
In certain circumstances, such as on an assembly line, there may be a need to install four or five different types of screws onto a product at a single station on that line. Each screw may have its own fastening speed and/or torque requirements. Traditionally, to perform these operations, four or five different power tools, each set to a particular configuration corresponding to each of the four or five screws, may be employed. The operator at the station may use a different power tool for each fastening operation.
Employing the more advanced power tools, the on-board buttons and LED screens allows the operator to set a single power tool to the individual four or five operating configurations needed. Under these circumstances, however, the operator may still use two hands—one to hold the tool and the other to press the button(s) to change the operating configuration. Obviously this takes time and might distract from the task at hand.
Accordingly, an illustrative embodiment of the present disclosure provides for a power tool that multi-purposes the single trigger that operates the rotating (i.e., fastening) function to also select the particular operating configuration of the power tool. In a further embodiment of the present disclosure, the trigger member of the power tool will be able to detect a multiple quick pull and release operation of the trigger to indicate the configuration of the power tool is to be changed rather than run the power tool. In a still further embodiment, a controller on the power tool may poll the trigger to detect multiple quick pull and release operations of the trigger member to signal advancement of the operating configuration to a new operating configuration. It is appreciated that in illustrative embodiments, successive quick double pull and release operations on the trigger may toggle the operating configuration of the power tool through multiple operating configurations until the desired operating configuration is reached.
An illustrative embodiment of the present disclosure provides a handheld power tool. This handheld power tool comprises hand grip and output portions, and a control system. The hand grip portion includes a handlegrip and a trigger movable with respect to the handlegrip. The output portion includes a rotating output shaft rotated by a motor when initiated by the trigger. The trigger includes multi-purpose functionality that initiates both rotation of the output shaft by the motor and change from one of a plurality of operating configurations of the output shaft to a new one of the plurality of operating configurations. The control system polls the trigger to detect multiple pull-and-release operations on the trigger to signal advancement of the plurality of operating configurations to the new one of the plurality of operating configurations. Multiple pull-and-release operations of the trigger changes to the new one of the plurality of operating configurations of the output shaft. The plurality of operating configurations is related to at least one of torque and speed of the output shaft. When the trigger is pulled and held the motor rotates the output shaft.
In the above and other embodiments, the handheld power tool may further comprise: an indicator visible on the exterior of the power tool that indicates each one of the plurality of operating configurations, wherein the indicator is selected from the group consisting of a plurality of lights and a display screen; the trigger being released during the pull-and-release operation polled by the control system occurs within about 0.5 seconds of the trigger being pulled; the trigger being pulled a second time within about 0.5 seconds after released during a second of the pull-and-release operation and released again within about 0.5 seconds of the trigger being pulled the second time, at which point the control system will change to the new one of the plurality of operating configurations of the output shaft; the plurality of operating configurations of the output shaft are selected from the group consisting of change in rotational speed of the output shaft and change in torque of the output shaft; successive multiple pull-and-release operations on the trigger toggles through successive operating configurations of the plurality of operating configurations of the power tool; a switch system operably engaged with the trigger and includes a linear Hall Effect sensor and an elongate trigger magnet having a first pole and a second pole, wherein the trigger magnet is mounted on the trigger such that the first pole is located proximate a rear end of the trigger and the second pole illustratively located proximate a front end of the trigger; wherein the linear Hall Effect sensor is electrically connected to the control system to detect the pull-and-release operation; the linear Hall Effect sensor being configured to provide a signal to the control system based on the pull-and-release operation; wherein the control system is configured to control a voltage applied to the motor; a switch system operably engaged with the trigger and includes a slide-by sensing configuration; wherein the slide-by configuration includes magnet that slides past a sensor in a direction from a first pole to a second pole during trigger depression, and in a direction from the second pole to the first pole during trigger release; wherein the sensor is electrically connected to the control system to detect the pull-and-release operation; the handgrip portion being located in-line with the output portion; and the handgrip portion being located about transverse to the output portion.
Another illustrative embodiment of the present disclosure provides a method of switching through a plurality of operational conditions of a handheld power tool. The method comprising the steps of: providing the handheld power tool that has a handlegrip and a trigger movable with respect to the handlegrip, and an output portion that includes a rotating output shaft rotated by a motor when initiated by the trigger; polling a sensor related to the trigger to determine if the trigger has been pulled; polling the sensor related to the trigger to determine if the trigger has been released after being pulled within a predefined period of time; operating the motor if the trigger was not released within the predetermined period of time; polling the sensor related to the trigger to determine if the trigger has been pulled a second time within a second predetermined period of time; polling the sensor related to the trigger to determine if the trigger has been released after being pulled the second time within a third predefined period of time; and switching to a new operating condition of the plurality of operational conditions if the trigger was released within the third predetermined period of time.
In the above and other embodiments, the method of switching through a plurality of operational conditions of the handheld power tool may further comprise: polling multiple, successive, trigger pulls-and-releases to advance to successive new operational configurations of the plurality of operational configurations without operating the motor; wherein the predetermined period of time is about 0.5 seconds; and wherein the second and third predetermined periods of time is each about 0.5 seconds.
Additional features of the present disclosure will become apparent to those skilled in the art upon considering the following description exemplifying the disclosure as presently perceived.
The present disclosure will be described hereafter with reference to the attached drawings which are given as non-limiting examples.
Corresponding reference characters indicate corresponding parts throughout the several views. The exemplification set out herein illustrates various embodiments of the disclosure, and such exemplification is not to be construed as limiting the scope of the disclosure in any manner.
The figures and descriptions provided herein may have been simplified to illustrate aspects that are relevant for a clear understanding of the herein described structures, while eliminating, for the purpose of clarity, other aspects that may be found in typical structures. Those of ordinary skill may recognize that other elements and/or operations may be desirable and/or necessary to implement the structures described herein. Because such elements and operations would be known in the art, and because they do not facilitate a better understanding of the present disclosure, a discussion of such elements and operations may not be provided herein. The present disclosure, however, is deemed to inherently include all such elements, variations, and modifications to the described aspects that would be known to those of ordinary skill in the art.
Unless otherwise defined, the term “cordless” power tool refers to power tools that do not require plug-in, hard wired electrical connections to an external power source to operate. Rather, the cordless power tools have electric motors that are powered by on-board batteries, such as rechargeable batteries. A range of batteries may fit a range of cordless tools. Different cordless power tools may have a variety of electrical current demand profiles that operate more efficiently with batteries providing a suitable range of voltages and current capacities. The different cordless (e.g., battery powered) power tools may include, for example, screwdrivers, ratchets, nutrunners, impact tools and the like, including the tools of the present disclosure.
A front perspective view of an illustrative embodiment of power tool 10 is shown in
A trigger member 150 forming a part of trigger system 100 is located on a front side of the handle 32 such that the operator's finger (e.g., index finger) may be positioned proximate trigger member 150 when the operator is holding handle 32. Handle 32 defines a heightwise axis H-H. In the case of pistol grip handle 32, an operator will ordinarily wrap his or her fingers around the heightwise axis H-H.
Rotary drive head 60 may define a tool drive axis D-D (e.g., the axis of rotation of rotary drive head 60) that is transverse to (and intersects) heightwise axis H-H. According to some embodiments, axes D-D and H-H form an angle in the range of from about 70 degrees to about 90 degrees. Right housing member 22 and left housing member 24 may be formed of any suitable material(s) or compositions(s). According to some embodiments, the entirety of each housing member 22, 24 are formed of the same material or composition. According to some embodiments, housing members 22, 24 are formed of a polymeric material. According to some embodiments, the housing members 22, 24 are formed of glass-filled nylon.
Drive motor assembly 50 and battery pack 70 are contained in or attached to housing 30. In an illustrative embodiment, motor assembly 50 is contained in the upper chamber or main body 34, and battery pack 70 is releasably mounted on the lower end of handle 32. Construction and operation of drive motor assemblies and battery packs in handheld power tools are well known to those of skill in the art and will not be discussed in detail herein. Drive motor assembly 50 may include an electric motor 52 arranged and configured (directly or via a gear case, linkage or gear system) to selectively drive (e.g., rotate) drive head 60 using power supplied from battery pack 70. Illustratively, motor 52 is a DC electric motor.
An illustrative embodiment of the present disclosure provides for different torque and speed operating configurations to be selected by depressing trigger member 150 in a particular manner. Illustratively, trigger system 100 is configured so that if trigger member 150 is depressed and held, drive motor 50 in power tool 10 rotates. But trigger system 100 may be further configured to poll for a trigger pull that is then released quickly, illustratively within about 0.5 seconds from pulling it. Trigger member 150 may then be polled a second time to determine if it was pulled and released within about 0.5 seconds. If trigger member 150 has been quickly pulled and released twice in a row then trigger system 100 is configured to send a signal to control system 80 located in power tool 10 to cause drive motor assembly 50 to change rotational speed and/or torque to a new predefined configuration such as faster, slower and/or greater or lower torque to match the necessary operational parameters of the fastener or other object being rotated. This allows the operational configuration of power tool 10 to be changed by simply double pull and releasing the trigger member at a common location the operator will already have his or her finger. This is contrast to depressing other buttons or other activation means on the tool that may be cumbersome or relatively time consuming to operate in order to change the operational configuration of the tool.
In another illustrative embodiment, not only can trigger member 150 be polled for trigger pull to determine if it was twice pulled and released to change to the next operational configuration but also be polled again to switch power tool 10 to still another operational configuration. Further illustratively, trigger system 100 may be configured to allow the operator to cycle through several different preset operating configurations for power tool 10 simply by twice pull and release trigger member 150 multiple times until the desired operating configuration is reached. The different operating conditions may include pre-set values, such as torque, speed, shift down speed, shift down point, angle, etc. This allows the operator to keep his or her hand on pistol grip 32 and finger on trigger member 150 while being able to both run power tool 10 and change its operating configuration mode. The display screen may display the configuration number which it has moved to, either briefly or permanently. In an illustrative embodiment, there may be available LEDs outside of the screen—read, yellow, green, blue, for example. These may be configured to flash a certain number of times to tell the user which configuration number the tool was set to, or cycle through a pattern to indicate that the new configuration input was received.
A rear perspective view of power tool 10 is shown in
In use, HMI 92 may be used in known or any suitable manner by the operator to input commands to control system 80 and/or to display data from the control system 80 to the operator. These structures help indicate to the operator the current operating condition of power tool 10 as well as changing its operating condition. Illustratively, buttons 132 may be manipulated to input commands. Data may be displayed as indicia on the display screen 104 viewable by the operator. Fastener 5B illustratively attaches display module 102 to housing 30.
Although effective, under certain operating environments power tool 10 may experience, the operator may be wearing gloves or may otherwise be in a position where actuating buttons 132 is inconvenient. Accordingly, the quick double pull/release of trigger member 150 may be a more convenient way to change operating configurations of power tool 10 as an alternative to operating buttons 132. It is further appreciated that display screen 104 or even light pipe portions 170A, 170B, 170C, may be set to display current configuration modes set by double pulling trigger member 150. It will become clear to the skilled artisan upon reading this disclosure that by providing configuration mode selection through successive double pull/releases of trigger member 150, either alone or in combination with configuration indicators via display screen 104 and/or light pipe portions 170A, 170B, 170C, for example, the operator may now switch through one or more operating configuration modes using just one hand, and confirming changes to said configuration mode through visual inspection of the rear (or other portions) of power tool 10. (See, also,
An enlarged, fragmentary, left side view of trigger member 150 and associated components of power tool 10 are shown in
Power tool 10 includes illustrative control system 80 with switch system 210 shown diagrammatically in
According to illustrative embodiments, control system 80 as shown in
Incorporating the operation of trigger member 150 with control system 80, an illustrative double pull/release operation to switch operating configurations may be implemented. Such a system 300 is shown in the flow chart depicted in
When switching configurations such as those configurations recited above and as indicated at 318 in
In an illustrative embodiment, it is appreciated that the number of potential configuration options may vary. For example, depending on the needs for power tool 10, this double trigger pull can toggle between just first and second configurations or toggle through more than three distinct operating configurations. In a further illustrative embodiment, power tool 10 may have eight pre-programmed operating configurations that can be cycled through and used before repeating configuration 1 again. Additionally, it may not be required that power tool 10 has operated in the current configuration before advancing to the next configuration. For example, a double trigger pull and release (such as 304 and 312) may illustratively advance power tool 10 from configuration 1 to configuration 2. But controller 80 can poll an immediate subsequent pull and release operation (304 and 312) to advance to the next configuration rather than run at the current configuration. For example, power tool 10 may be currently set at configuration 2 at 324 and detect two successive sets of double pull and release functions 304 and 312 to advance the operating configuration of power tool 10 past configuration 3 and to configuration 1 without any intermediary operation of power tool 10.
Another illustrative embodiment of a power tool 410 having a primary switch 412 and a reconfigurable secondary switch 422 is shown in
When the operator activates primary switch 412 (e.g., depresses the trigger 412), primary switch 412 connects motor 416 to the energy source such as battery 418 coupled to power tool 410 to supply energy to motor 416. The supply of energy to motor 416 will cause rotation of a rotor of motor 416, thereby driving an output 430 of (for instance, via a drive train included in the power tool 10).
It is appreciated that in certain embodiments, the quick pull and release operation may be employed in power tools that include a secondary switch in order to operate. In the illustrative embodiment, secondary switch 422 may slide from side-to-side such that portions of the secondary switch 422 pass through apertures formed in the side walls of the housing 414. Secondary switch 422 or other like structure may be required to be depressed before primary switch 412 will activate to run motor 416. It is appreciated that the quick pull and release operation may be configured to switch between configurations (as previously discussed) without the need to depress secondary switch 422, or only upon depression of secondary switch 422 depending on how power tool 410 is needed to operate.
Although certain embodiments have been described and illustrated in exemplary forms with a certain degree of particularity, it is noted that the description and illustrations have been made by way of example only. Numerous changes in the details of construction, combination, and arrangement of parts and operations may be made. Accordingly, such changes are intended to be included within the scope of the disclosure.