The present invention relates generally to fastener-driving tools used to drive fasteners into workpieces, and specifically to combustion-powered fastener-driving tools, also referred to as combustion tools or combustion nailers.
Combustion-powered tools are known in the art, and exemplary tools produced by Illinois Tool Works of Glenview, Ill., also known as IMPULSE® brand tools for use in driving fasteners into workpieces, are described in commonly assigned patents to Nikolich U.S. Pat. Re. No. 32,452, and U.S. Pat. Nos. 4,522,162; 4,483,473; 4,483,474; 4,403,722; 5,197,646; 5,263,439; 5,897,043 and 6,145,724 all of which are incorporated by reference herein.
Such tools incorporate a tool housing enclosing a small internal combustion engine. The engine is powered by a canister of pressurized fuel gas, also called a fuel cell. A battery-powered electronic power distribution unit produces a spark for ignition, and a fan located in a combustion chamber provides for both an efficient combustion within the chamber, while facilitating processes ancillary to the combustion operation of the device. Such ancillary processes include: mixing the fuel and air within the chamber, turbulence to increase the combustion process, scavenging combustion by-products with fresh air, and cooling the engine. The engine includes a reciprocating piston with an elongated, rigid driver blade disposed within a single cylinder body.
A valve sleeve is axially reciprocable about the cylinder and, through a linkage, moves to close the combustion chamber when a work contact element at the end of the linkage is pressed against a workpiece. This pressing action also triggers a fuel-metering valve to introduce a specified volume of fuel into the closed combustion chamber. Thus, the valve sleeve opens the combustion chamber for venting gases, and closes the combustion chamber for sealing prior to ignition.
In such tools, once fuel is injected into the combustion chamber, the fuel and air are mixed using turbulence created by a rotating fan blade. If the fuel and air are not mixed properly prior to ignition, either a weak combustion cycle or no combustion will occur. Therefore, it is important that sufficient time is provided for mixing to assure repeatable nailer operation and desired performance. Mixing time is defined as the interval from which fuel is injected into the combustion chamber and the fuel and air is uniformly mixed.
The time duration for achieving complete mixture depends on many parameters, including fuel metering time, fuel spray pattern, fuel spray velocity, fan configuration and rotational velocity (RPM), and engine and fuel temperatures. Of these, the most significant are fan RPM, engine temperature and fuel temperature. The faster the fan RPM, the less time is required for mixing due to increased turbulence within the chamber. Considering higher tool and fuel operating temperatures, the gas molecules are more energetic, which in turn reduces available mixing time. In addition, higher fuel cell temperatures increase the pressure of the fuel, which gives the fuel spray/jet greater velocity as it is injected into the combustion chamber, which promotes mixing. The opposite trends of the previous conditions will cause increased required mixing times.
In view of the above conditions, there is a need for an improved combustion nailer configured for monitoring and controlling such parameters, and providing improved tool performance.
The above-listed needs are met or exceeded by the present combustion nailer featuring a control system for monitoring and adjusting tool operating parameters such as fuel and air mixing times, ignition timing, battery voltage, fuel cell temperatures and/or pressures, and tool and ambient temperatures. Receiving inputs from tool systems, the control system adjusts controllable tool parameters such as fuel/air mix times, and promotes homogeneous fuel/air mixing prior to ignition. As a result of the present system, tool operation is more stable, with nail drive consistency improved. Also, the control system prevents nailer operation if the tool is out of position at any time during the drive cycle.
More specifically, a combustion-powered fastener-driving tool includes a tool housing, a power source associated with the housing and including a cylinder head, a cylinder and a piston reciprocating in the cylinder, a valve sleeve reciprocating relative to the cylinder, a chamber switch and a trigger switch. The cylinder head, the cylinder, the valve sleeve and the piston combine to define a combustion chamber. The closing of both switches is required for initiating an ignition of the power source for driving the piston down the cylinder. A fan is disposed in the combustion chamber, and a control system includes a control program associated with the housing, connected to the power source, the chamber switch and the trigger switch, and configured for providing a designated ignition delay period after fuel is injected into the combustion chamber and when the chamber switch is closed, the delay period being variable as a function of monitored tool parameters. In the present application, the terms mixing delay and ignition delay are used interchangeably.
In another embodiment, a combustion-powered fastener-driving tool is provided and includes a tool housing, a power source associated with the housing including a cylinder head, a cylinder and a piston reciprocating in the cylinder, a valve sleeve reciprocating relative to the cylinder, the cylinder head, the cylinder, the valve sleeve and the piston combining to define a combustion chamber. A chamber switch is closed upon the valve sleeve closing the combustion chamber. The closing of the chamber and a trigger switch is required for initiating an ignition of the power source for driving the piston down the cylinder. A fan is disposed in the combustion chamber and is powered by a fan motor. A control system includes a control program associated with the housing, connected to power source, the fan motor, the chamber switch and the trigger switch, and is configured for providing a designated ignition delay period after fuel metering and the closing of the chamber switch, the delay period being extendable with decreases in at least one of engine temperature, battery voltage, fan motor speed, fuel system pressure, fuel cell temperature and ambient temperature.
In still another embodiment, a combustion-powered fastener-driving tool includes a tool housing, a power source associated with the housing including a cylinder head, a cylinder and a piston reciprocating in the cylinder, a valve sleeve reciprocating relative to the cylinder, a chamber switch and a trigger switch. The cylinder head, the cylinder, the valve sleeve and the piston combine to define a combustion chamber. The closing of both switches is required for initiating an ignition of the power source for powering the piston down the cylinder. A fan is disposed in the combustion chamber. A control system includes a control program associated with the housing, connected to the power source, the act of fuel metering (mechanical or electromechanical), and the chamber switch is configured for providing a designated ignition delay period. The program is configured for aborting the ignition, thereby aborting the power source cycle, if the chamber switch is opened during the ignition delay. For further tool operations, the operator repeats the normal operating sequences of tool operation.
Referring now to
When the tool is in a sequential operating mode, through depression of a trigger 26, which inherently closes a trigger switch (not shown, the terms trigger and trigger switch are used interchangeably) an operator induces combustion within the combustion chamber 18, causing the driver blade 24 to be forcefully driven downward into a nosepiece 28. The nosepiece 28 guides the driver blade 24 to strike a fastener that had been delivered into the nosepiece via a fastener magazine 30.
Included in the nosepiece 28 is a workpiece contact element 32, which is connected, through a linkage or upper probe 34 to a reciprocating valve sleeve 36, which partially defines the combustion chamber 18. Depression of the tool housing 12 against a workpiece causes the workpiece contact element 32 to move relative to the tool housing 12, from a rest position (
In the rest position, the combustion chamber 18 is not sealed, since there is an annular gap 40 separating the valve sleeve 36 and a cylinder head 42, which accommodates a chamber switch or head switch 44 and a spark plug or other spark generator 46. Specifically, there is an upper gap 40U near the cylinder head 42, and a lower gap 40L near the upper end of the cylinder 20. In the preferred embodiment of the present tool 10, the cylinder head 42 also is the mounting point for a cooling fan 48 and a fan motor 49 powering the cooling fan. The fan 48 and at least a portion of the motor 49 extend into the combustion chamber 18 as is known in the art and described in the patents which have been incorporated by reference above. In the pre-firing position the combustion chamber 18 is sealed by virtue of contact between the valve sleeve 36 and combustion chamber seals 36a and 36b, and is defined by the piston 22, the valve sleeve 36, the cylinder head 42, and a top 20a of the cylinder 20.
In the sequential operating mode, firing is enabled when an operator presses the workpiece contact element 32 against a workpiece. This action overcomes the biasing force of the spring 38, causes the valve sleeve 36 to move upward relative to the housing 12, and sealing the combustion chamber 18 until the chamber switch 44 is activated. This operation also induces a measured amount of fuel to be released into the combustion chamber 18 from a fuel canister 50 (shown in fragment).
Upon a pulling of the trigger 26, the spark plug 46 is energized, igniting the fuel and air mixture in the combustion chamber 18 and sending the piston 22 and the driver blade 24 downward toward the waiting fastener. As the piston 22 travels down the cylinder 20, it pushes a rush of air which is exhausted through at least one petal or check valve 52 (
To ensure that the piston 22 returns to the prefiring position of
More specifically, and while other types of lockout devices are contemplated and are disclosed in the co-pending application Ser. No. 11/028,432 incorporated by reference, the exemplary lockout device 60 includes an electromagnet 62 configured for engaging a sliding cam or latch 64 which transversely reciprocates relative to valve sleeve 36 for preventing the movement of the valve sleeve 36 for a specified amount of time. This time period is controlled by a control system 66 (
Also included in the tool 10 is at least one temperature sensor, such as a thermistor or other device which measures temperature and is connectable to the control system 66 to provide inputs to the control program 66a. The present temperature sensors include a first sensor 70 mounted on or associated with the housing 12 as far as effectively possible from the power source 14 to sense ambient temperature or temperature independent of heat generated during combustion. A second sensor 72 is mounted in operational proximity to the fuel cell 50 for sensing the temperature of the fuel cell. As is the case with the sensor 70, it is preferred that the sensor 72 is located sufficiently close to the fuel cell 50 but also far enough from the power source 14 to sense fuel cell temperature independent of power source temperature. A third optional sensor is a power source sensor 74 located in operational proximity to the power source 14, such as on or near the cylinder 20. The tool 10 may be provided with one, two or all three of the above-identified sensors 70-74, all of which are connected to the program 66a in a known manner. The location and programming of temperature sensors is disclosed in greater detail in copending U.S. patent application Ser. No. 11/028,020 filed Jan. 3, 2005, which is incorporated by reference. It will be understood that the control system 66 includes the control program 66a, the control module 67 and the trigger switch 26, the chamber switch 44, sensors and related circuitry.
The tool 10 may also be optionally equipped with a fuel metering system, designated and shown schematically at 76 (
It will be appreciated that the fuel metering system 76 is powered by a battery 78 (shown hidden) and controlled by the control program 66a. The battery 78 is also used to power the control system 66 and all electronic operational functions of the tool 10. As is known in the art, the battery 78 may take the form of at least one rechargeable unit or at least one conventional disposable battery.
As is known, the control program 66a is operable in either a sequential or a repetitive cycle operating system, and the details of such a system are disclosed in commonly assigned U.S. patent application Ser. No. 11/028,450, published as US Patent Application No. 2005/0173487A1 which is incorporated by reference. In summary, in sequential operation, as described above, the chamber switch 44 must be closed by upward movement of the valve sleeve 38 to the valve sleeve prefiring position before the trigger 26 can be pulled to initiate combustion. In repetitive cycle operation, the user maintains the trigger 26 pulled during tool operation, and each subsequent ignition is initiated by the closing of the chamber switch 44, with every tool actuation against the workpiece.
Referring now to
At t4, the user closes the trigger switch 26, which begins an ignition cycle between t4 and t5. During this time, the control system 66 generates a sufficient electrical charge for activating the spark plug 46. Upon conclusion of the ignition cycle at t5, the engine cycle 82 begins, including ignition of the fuel/air mixture in the combustion chamber 18, movement of the piston 22 and the driver blade 24 down the cylinder 20 to drive a fastener, the exhaust of combustion by-product gases through the valve 52, and the return of the piston 22 to the pre-firing position shown in
Referring now to
Similar to the sequential operation depicted in
Referring to
As described above, the temperature sensors 70-74, the chamber switch 44, the trigger switch 26, the fuel metering system 76, the battery 78, the fan motor 49 and the spark plug 46 are all connected to the control program 66a. For example, if sensed temperature from any of the sensors 70-74 is less than for example 50° F., the tool 10 is operating under relatively cold conditions, and additional mixing time is desirable for more efficient combustion. Thus, the program 66a is configured so that the delay 80 is increased as the sensed temperature falls below 50° F. as seen in graphs A, E and F. The delay 80 may be increased with decreasing temperatures as the temperature falls progressively below 50° F. It will be understood in all of the graphs A-F that the duration of the delay 80 may vary to suit the situation.
Also, referring now to graph B, as the battery 78 loses its charge, the fan motor 49 and other tool components may operate more slowly, also requiring a relatively longer mixing delay 80 for effective combustion. More specifically, as battery voltage drops below 5.5 volts DC in a 6 volt system, the delay 80 will be progressively longer. It is contemplated that the voltage threshold may vary with the application. Similarly, as seen in graph C, as fan motor speed measured in revolutions per minute (RPM) drops below a designated amount, preferably 10,000 RPM, the mixing delay 80 will progressively increase. The RPM threshold for extension of the delay 80 may also vary with the application.
Further, referring to graph D, as fuel pressure decreases as measured by the program 66a through a pressure transducer 84 connected to the fuel metering system 76 (
Another feature of the control program 66a is depicted at box 86, in which, during monitoring of the chamber switch 44, the control program determines that the chamber switch opens, thus opening the combustion chamber 18 during the mixing delay 80, the ignition will be aborted. As known, the chamber switch 44 is typically positioned to close when the combustion chamber 18 is approximately sealed and when the workpiece contact element 32 is close to full actuation. In tool use applications such as sheathing, where the user is driving fasteners at a rapid pace, the user can potentially withdraw the tool 10 from the work surface during the mixing cycle or prior to ignition. This can potentially lead to variable height nails in the workpiece, and is unacceptable to the user. Also, this condition can be aggravated when long mix times are required, such as on the order of 50 msec or longer. The abort feature 86 provides more consistent tool results for the user and will alert the user to adjust his operating speed.
Thus, it will be seen that the present combustion nailer control system monitors and adjusts mixing delay periods depending on monitored tool functions, and aborts tool operation when out of sequence conditions occur. The present tool control system extends mixing delay as a function of sensed temperatures, fuel pressures, fan RPM and/or battery voltage. As a result, tool misfires are prevented and tool operation is more reliable. Furthermore, tool performance is more consistent.
While a particular embodiment of the present variable ignition delay for a combustion nailer has been described herein, it will be appreciated by those skilled in the art that changes and modifications may be made thereto without departing from the invention in its broader aspects and as set forth in the following claims.
This application claims priority pursuant to 35 USC §120 based on U.S. Ser. No. 60/737,680 filed Nov. 17, 2005.
Filing Document | Filing Date | Country | Kind | 371c Date |
---|---|---|---|---|
PCT/US2006/044598 | 11/17/2006 | WO | 00 | 6/19/2009 |
Publishing Document | Publishing Date | Country | Kind |
---|---|---|---|
WO2007/061808 | 5/31/2007 | WO | A |
Number | Name | Date | Kind |
---|---|---|---|
4132210 | Long | Jan 1979 | A |
4403722 | Nikolich | Sep 1983 | A |
4483473 | Wagdy | Nov 1984 | A |
4483474 | Nikolich | Nov 1984 | A |
4522162 | Nikolich | Jun 1985 | A |
RE32452 | Nikolich | Jul 1987 | E |
5197646 | Nikolich | Mar 1993 | A |
5263439 | Doherty et al. | Nov 1993 | A |
5415136 | Doherty et al. | May 1995 | A |
5897043 | Veoukas et al. | Apr 1999 | A |
6102270 | Robinson | Aug 2000 | A |
6145724 | Shkolnikov et al. | Nov 2000 | A |
6223963 | Aparacio, Jr. | May 2001 | B1 |
6318615 | Walter | Nov 2001 | B1 |
6722550 | Ricordi et al. | Apr 2004 | B1 |
6783045 | Shima et al. | Aug 2004 | B2 |
6983871 | Shima et al. | Jan 2006 | B2 |
7021251 | Ohmori et al. | Apr 2006 | B2 |
7341171 | Moeller et al. | Mar 2008 | B2 |
7487898 | Moeller et al. | Feb 2009 | B2 |
20040182336 | Ohmori et al. | Sep 2004 | A1 |
20050173487 | Moeller et al. | Aug 2005 | A1 |
Number | Date | Country | |
---|---|---|---|
20090314817 A1 | Dec 2009 | US |
Number | Date | Country | |
---|---|---|---|
60737680 | Nov 2005 | US |