Controlling method of electric tool and electric tool carrying out the controlling method

This application claims priority to and all the advantages of International Application No. PCT/CN2008/000345, filed on Feb. 13, 2008, which claims priority to Chinese Patent Application No. 200710020155.1, filed on Feb. 16, 2007.

The invention relates to a method for controlling an electric tool, preferably an electronic screw driver, which tool is supplied by an electric current for generating a rotational speed. It also relates to an electric tool, preferably an electric screw driver, for carrying out the method.

In the present power tools, such as electric screw drivers, which is driven by a rotary motor and screw into a board of wood via supplying current from a loaded power. The screws may have different diameters. And the shapes of the heads of different screws are different from each other. Thus different circumstance will occur when different screws are driven into the same board of wood. Additionally, if the same screw is driven into different material, the hardness of different pieces of wood may be different, current of the electric screw drivers will be different. Normally, during using of the screw drivers, the user should drill the screw head up to a surface close to the workpiece, thereby, the user needs to watch the drilling process very carefully in order to stop the motor when the screw head reaches the end. Thus, the screw may not go too deeply into the piece of wood what it undesirable. Otherwise, it can prevent the motor from overloading when the screw head is incautiously screwed into the wood board.

It is prior art to use some overload protection device. This may be a mechanical clutch, which disengage the tool bit from the driving motor when the motor current exceeds a predetermined limit value. A torque collar, which is rotatable and marked with plurality of scales, is provided in the front of the housing of which power tool has such overload protection device. These scales indicate the torque limiter. The user should preset the limited torque value by the rotatable torque collar, that is, when the output torque reaches or exceeds the predetermined value, the clutch will automatically start to disengage the tool bit of the power tool and the motor. Additionally, electric screwdrivers with such overload protection device has a sleeve extending from the front end of the housing, the front end of the sleeve is align with that of the tool bit of the electric screwdriver. When the screw head reaches the wood board surface, the front end of the sleeve also reaches it, if the screw is pressed further, the sleeve will be biased to actuate the clutch in the housing, thereby disengage the tool bit and the motor. However, the above mechanical clutch is complex in structure and it is complicated and costly to be made.

It is an object of the invention to provide a method for an electric tool which method makes sure in a tool that the work piece operated by the tool bit reaches a predetermined position, and that the work piece does not go beyond this position.

And it is also an object of the invention to provide a tool of the afore-mentioned type in which such method can be carried out.

According to one aspect of the invention, there is provided a method for controlling an electric tool, which is supplied by an electric current for generating a rotational speed, comprising the steps of

measuring the current supplied to said electric tool in dependence on time; forming the second or nth derivative of said current in dependence on time, said n≧3; generating a control signal according to said second or nth derivative; and changing the rotational speed of said electric tool in response to said control signal.

According to another aspect of the invention, there is provided an electric tool, having

a motor for driving a tool bit, such that the tool bit attains a rotational speed, a source for supplying an electric current to said motor, a sensor for measuring said current, and control means for detection of a pulse in the second or nth derivative of the variation of the slope of said current in the course of time, thereby generating a control signal, and for changing the rotational speed of said tool in response to said control signal.

According to one aspect of the invention, there is provided a method for controlling an electric tool, which is supplied by an electric current for generating a rotational speed, comprising the steps of

a. measuring the current supplied to said electric tool at a predetermined point of time, b. selecting at said predetermined point of time

b1) a first predetermined derivative value if the measured current is below a predetermined first threshold value or b2) a second predetermined derivative value if the measured current is above the predetermined first threshold value, wherein said second predetermined derivative value is higher than said first predetermined derivative value,

c. forming the first derivative of said current in dependence of time, d. generating a control signal from said first derivative when said first derivative has reached said first or second predetermined derivative value, and e. changing the rotational speed of said electric tool in response to said control signal.

According to another aspect of the invention, the electric tool, may comprise

a) a motor for driving a tool bit, such that the tool bit attains a rotational speed, b) a source for supplying an electric current to said motor, c) a sensor for measuring said current, and d) control means

d1) for detection of a variation of the slope of said current in the course of time, d2) for selecting a first or second predetermined derivative value in dependence of the value of said current at a predetermined point of time, d3) for generating a control signal from said first or second predetermined value, and d4) for changing the rotational speed of said electric tool in response to said control signal.

Compared with the prior art, the present invention automatically detects whether the work piece operated by the tool bit reaches a predetermined position by providing electronic control means. It may make sure that the screw is driven into a piece of wood and does not go beyond the predetermined position once detect that the work piece reaches the position and carries out the changing action. There is no complicated mechanical clutch so that it is simple to be made and the cost is decreased.

Other embodiments and advantages will be obvious from the following description of the drawings, depicting specific embodiments of the invention.

FIG. 1 is a typical diagram of an electronic screw driver in the prior art, wherein the current is illustrated versus time.

FIG. 2 is a diagram, wherein the first derivative of the current of FIG. 1 is depicted versus time.

FIG. 3 is a diagram, wherein the second derivative of the current of FIG. 1 is depicted versus time.

FIG. 4 is a work principle chart, which a power tool of the present invention in accordance with the first version of the invention is illustrated.

FIG. 5 is a diagram of an electronic screw driver, wherein two currents i 1 , i 2 of different conditions are illustrated versus time.

FIG. 6 is a diagram, wherein the first derivatives di/dt of the currents i 1 and i 2 are depicted versus time.

FIG. 7 is a diagram, wherein control signals s 1 , s 2 obtained from processing of the derivatives of FIG. 6 are illustrated versus time.

FIG. 8 is a work principle chart, which a power tool of the present invention in accordance with the second basis version of the invention is illustrated.

FIG. 9 illustrates the second derivation of the current versus time of an electronic screw driver, as FIG. 3 .

FIG. 10 shows the third derivation of the current versus time, as obtained from FIG. 9 .

FIG. 11 is a work principle chart, which a power tool of the present invention in accordance with the third version of the invention is illustrated.

The control method of the present invention adapted to be used on many kinds of power tools. Electric screwdriver is described below as a preferred embodiment.

According to FIG. 1 , an i(t) diagram of an electronic screw driver is illustrated. With regard to FIG. 4 , the user presses the screw driver 2 against a working head 14 which shall be driven into a board of wood 16 , the working head in this embodiment is a screw. Pressing is performed with approximately constant pressure. The letter t represents the time that the screw drilling into the board and consequently the position of screw in the board. And the letter i represents the current supplied to the electric motor of the screw driver and thereby the load or force that is provided by the motor.

Curve in FIG. 1 contains a first portion A, a second portion K and a third portion B. Wherein, the first portion A is an increasing slope and which represents the screwing process of the screw main body drilling into the board of wood. This rise may be linear or slightly bended or curved. The second portion is followed with the first portion A. It may be called as knee portion K. This knee portion K is a positive variation of the slope. In other words: It is a sudden variation having on upward inclination with respect to the first portion A. This represents the start of touching on the surface of the wood board by the screw head. And the third portion B is followed with the knee portion K. This rise may again be linear or slightly bonded or curved. Yet, the curve B is much steeper than the curve A.

In fact, curve shown in FIG. 1 represents the working condition of a power tool which does not carry out the control method of the present invention, the third portion B of the curve represents that high current will be generated in the power tool and may lead to insert even the head into the piece of wood. Therefore, it is essential to take some action to avoid such an excessive current following the knee portion K.

When the screw is drill to a position responding to the knee portion K, further drilling will insert the screw head into the wooden board and maybe damage the motor. Therefore, the invention is based on the automatically detection of the knee portion K and then start precaution measures automatically.

The detection of the knee portion K in this embodiment will be explained with regard to FIGS. 2 and 3 .

In FIG. 2 the first derivative di/dt of the current i versus time t of the diagram of FIG. 1 is shown. The first and third portion A and B in FIG. 1 respectively are corresponding lines parallel to the base line of t in this figure, while the second portion K is a sharp positive increase or rise curve in this diagram.

According to FIG. 2 , the second derivative d 2 i/dt 2 of the current I shown in FIG. 1 is formed in dependence on time t. The values in the first and third portion are zero after being derivated twice, whereas the second portion K is shown as a parabola with downward opening. A kind of peak signal p is formed in the top region of the parabola, which is a particular region including the vertex. With regard to FIG. 4 , a control signal s is generated when the peak signal p is formed. Of course, in the preferred embodiment, a predetermined threshold value v is set. The control signal s is only generated if the peak signal p is positive and exceeds the predetermined threshold value v. It is easy for a skilled person in this art, the control signal s may be generated after the first derivative of current i in dependence on time t is formed. For example, via a capacitor, the control signal s is generated after detection of the first derivative exceeding a predetermined threshold value.

FIG. 4 illustrates an electric tool which carries out the control method of the above mentioned. Here below electric screw driver is also illustrated as the preferred embodiment. The electric screw driver 2 includes a working assembly 4 , a power source 18 and a switch 20 . The working assembly 4 includes an electric motor 6 for driving a tool bit 8 to rotate, and driving a screw 14 into a wooden board 16 . The working head 14 is connected to the electric motor 6 via a mechanical spring, a clutch system 12 and a chuck 10 in serial. Of course, in the present embodiment, the clutch system 12 may be omitted. A power source 18 , in this example is a DC source or a rechargeable battery, supplies an electric DC current i to the motor 6 , provided a hand trigger switch 20 is closed. Of course, it is easy for a skilled person in this art, AC power source may be used to substitute the DC source of this embodiment.

An electronic control device 22 and a current sensor 24 are connected between the power supply 18 and the electric motor 6 . The electric screw driver 2 also includes a first differentiating member 26 and a second differentiating member 28 . In the present embodiment, the current sensor 24 detects the current i supplied to the motor and delivers a signal proportional to the current i measured by the sensor 24 , to the first differentiating member 26 . This first differentiating member 26 gets a first derivative di/dt in dependence on time t shown as FIG. 2 , and generates a signal proportional to the first derivative, and then delivers it to the second differentiating member 28 . The second differentiating member 28 gets again a second derivative shown as FIG. 3 . Thus, the second differentiating member 28 generates a control signal s when a preset condition, which the peak signal p as mentioned above is positive and its value exceeds the predetermined threshold value v is occurred. In this embodiment, the control signal is used for reducing or interrupting the energy supply to the motor 6 . In other words, the control signal s is used to bring the motor current i to a lower value or to zero for decreasing the rotational speed of the motor or stopping the motor. Of course, the control signal s may also be used to reverse the current i to obtain a quick stop of the motor 6 . In this embodiment, the control signal s will be transmitted to a electronic control device 22 , and corresponding actions will be carried out by the electronic control device 22 . These actions may happen immediately or after a predetermined delay time after the occurrence of the peak signal p. The delay may be happened in the electronic control device 22 or be provided by a separate delay unit.

In FIG. 4 , the electronic control device may includes a switch in the form of a transistor for turning off the current i supplying to the motor.

In the preferred embodiment, the electronic control device 22 may contain a microprocessor. And that the functions of the first differentiating members 26 and the second differentiating member 28 and possibly a delay member may be fulfilled by the software present in this microprocessor. In other words, the whole electronic control device 22 is a microprocessor.

In other alternative embodiments, the current i supplied to the motor 6 is measured in consecutive time intervals Δt, which may be equal to each other. The measured current i is digitally processed. In doing so, the first time derivatives di/dt measured in two consecutive time intervals Δt are compared with each other. If this comparing shows that the first time derivative in two consecutive time intervals Δt are substantially different from each other (this corresponds to the second derivative mentioned above), that means the screw head has reached the wood board 16 , and the afore-mentioned control signal s is generated.

The afore-mentioned embodiment automatically detects whether the work piece operated by the tool bit reaches a predetermined position by providing electronic control means. It makes sure that the working head does not go beyond the predetermined position once detection of the working head reaches the position and carries out corresponding actions.

FIG. 8 is a work principle chart, which a power tool of the present invention in accordance with the second basis version of the invention is illustrated.

In FIGS. 5-8 , a second basic version of the method and the power tool according to the invention is illustrated. Various embodiments will be described in dependence on the basic version of the invention.

The diagram of FIG. 5 shows the motor current i versus time t. In the present embodiment, the motor current i is a DC current of an electric screw driver which drives a tool bit. Two measured current curves A 1 and A 2 are illustrated. Again, the principle of clocking is used for measuring and processing the motor current i. It is a known technology for a person skilled in the art, the applicant will not describe it in detail. In the diagram of FIG. 6 , derivatives of the current curve A 1 and A 2 , respectively, are shown. The first curve A 1 relates to a relatively soft work-piece, such as wood, and/or a relatively small screw, while the second curve A 2 relates to a harder work-piece and/or a bigger screw. Whatever the condition is, measuring and processing for these curves A 1 , A 2 is done in the control device 22 (shown in FIG. 8 ). In the preferred embodiment, the control device comprises a microprocessor.

In a preferred first embodiment of the second basic version, at a predetermined point of time T 1 , the current i is specifically measured. In the microprocessor, there is stored a single threshold value, which will be termed first threshold value P 1 . This first threshold value P 1 may be, for instance, P 1 =5A at T 1 . If i 1 <5A at T 1 , it is determined that a soft board is worked on, and if i 1 >5A at T 1 , it is determined that a hard board is worked on. With regard to FIG. 6 , if i 1 <5A, the microprocessor will assign a first predetermined derivative value q 1 , and if i 1 >5A, the microprocessor will assign a second predetermined derivative value q 2 . Both predetermined derivative values q 1 , q 2 are stored in the microprocessor. The first predetermined derivative value q 1 may be, for instance, q 1 =0.4 A/s, and the larger second predetermined derivative value q 2 may be, for instance, q 2 =1 A/s. Thus, if the motor current i 1 is below P 1 at T 1 , the first predetermined derivative value q 1 is selected, and if the current i 1 is above P 1 at T 1 , the second predetermined derivative value q 2 is selected.

In FIG. 6 , the first derivative of the current according to curve A 1 and curve A 2 is depicted as curves a 1 and a 2 , respectively.

It will be realized from FIG. 6 that there is a steep increase portion of the curves a 1 and a 2 which is corresponding to the strongly bend portion of the curves A 1 and A 2 , i.e. where the curve A 1 and A 2 have a knee portion K 1 and K 2 , respectively. As afore-mentioned, the knees K 1 and K 2 represent that the screw heads touch the wooden work piece. These knees K 1 and K 2 are used in the microprocessor to form control signals s 1 and s 2 (as shown in FIG. 7 ), respectively. The predetermined first derivative values q 1 , q 2 are located at the steep increase of the curves a 1 , a 2 , respectively.

As shown in FIG. 7 , the first control signal s 1 is generated in the microprocessor at the point of time t 1 , when the first derivative di/dt has reached the first predetermined derivative value q 1 . When the second curve A 2 has to be considered according to the measurement at the point of time T 1 , the second control signal s 2 is generated at the point of time t 2 , when the first derivative di/dt has reached the second predetermined derivative value q 2 .

In response to the control signal s 1 or s 2 , the rotational speed of the DC motor attached to the power tool is reduced or the motor is even stopped.

In other words: At the predetermined point of time T 1 , for instance 1 or 2 seconds after starting the motor, the microprocessor reads the current i. If there is a small screw and/or a soft work-piece of wood, the current i is also relatively small, and the current will follow the first curve A 1 shown as FIG. 5 . The measured current at the first point of time T 1 is the first current i 1 , which may be e.g. 3A, the microprocessor selects the first predetermined derivative value q 1 (stored therein) to be compared with the first derivative di/dt. When di/dt reaches q 1 , the corresponding point of time is t 1 , the corresponding current is i 1 , the speed of the motor will be reduced by the first control signal s 1 generated from the first predetermined derivative value q 1 . If the working head is a bigger screw and/or the work piece is a piece of harder wood board, the current will follow the second curve A 2 shown as FIG. 5 . Thus, the measured current at the point of time T 1 is the second current i 2 which is higher than the first current i 1 , for instance, i 2 −7A. Therefore, at T 1 the microprocessor will select the predetermined derivative value q 2 (stored therein). As soon as the value of di/dit on the curve a 2 reaches q 2 , the corresponding point of time is t 2 , the corresponding current supplied to the motor is i 2 , the speed of the motor will be reduced by the generated second control signal s 2 .

In a preferred second embodiment of the second basic version, at a predetermined point of time T 1 , the current i is also specifically measured. Here it will be determined in the microprocessor whether the measured value of the motor current i at T 1 is below a predetermined first threshold value P 1 , such as the illustrated current value i 1 , or whether it is above the predetermined first threshold value P 1 , but below a larger second predetermined threshold value P 2 , such as the illustrated current value i 2 . If it corresponds to the first current value i 1 , the first curve A 1 is assigned a predetermined derivative value q 1 . And if it corresponds to the second current value i 2 , the second curve A 2 is assigned a larger predetermined derivative value q 2 . From now on, the method will follow the steps as explained in the first embodiment. The first derivative di/dt at the knees K 1 , K 2 is again used in the microprocessor to form a control signal s 1 or s 2 , respectively.

It will be noted that in the first embodiment just one predetermined threshold value P 1 is used, whereas in the second embodiment two predetermined threshold values P 1 and P 2 are used.

This may also apply to the second embodiment: If the working head is a very big screw and/or the work-piece is specifically hard, a third threshold value P 3 (shown in FIG. 5 ) and a third predetermined derivative value q 3 (shown in FIG. 6 ) which stored therein will be used in the microprocessor. It should be mentioned that then the set of predetermined threshold values P 1 , P 2 and P 3 as well as the predetermined derivative values q 1 , q 2 and q 3 is stored in the microprocessor for being individually called upon a request in accordance with the measured current i 1 , i 2 , and i 3 , respectively, at a predetermined point of time T 1 . Of course, even more sets of predetermined threshold values P and predetermined derivative values q may be used.

With a number of tests, (e.g. with different screws in specification and different kinds of wood in material and specification), the predetermined threshold values P and the predetermined derivative values q should be determined and stored in the microprocessor.

FIG. 8 illustrates an electric tool 2 , in particular a screw driver, incorporating an embodiment of the present invention in accordance with the second basic version. Most of the members of the illustrated embodiment are the same with or similar to the members of FIG. 4 . Therefore, the same reference numerals will be used.

The working assembly 4 of the electric screw driver shown on the right side of FIG. 8 includes an electric DC motor 6 for driving a tool bit 8 attached to a chuck 10 . The chuck 10 is connected to the electric motor 6 via a mechanical spring and a clutch system 12 . The tool bit 8 is provided for rotating and thereby driving a screw 14 into a wooden board 16 . A power source 18 is a DC source, or maybe a rechargeable battery, supplies an electric DC current i to the motor 6 , provided a hand trigger switch 20 is closed.

The power supply 18 is connected to the electric motor 6 via an electronic control device 22 and a current sensor 24 . The current sensor 24 measures the current supplied to the motor and generates a signal proportional to the measured current and delivers a signal to a differentiating member 26 . This differentiating member 26 generates a signal proportional to the first derivative di/dt in dependence on time t. The output of the differentiating member 26 is connected to the input of a storage and processing unit 32 .

The storage and processing unit 32 has stored therein, according to the afore-mentioned first embodiment, a single threshold value P 1 and a first and second predetermined derivative value q 1 and q 2 , respectively. At a predetermined point of time T 1 , the storage and processing unit 32 selects the first predetermined derivative value q 1 , if the measured current i 1 is below the threshold value P 1 , or it selects the second predetermined derivative value q 2 , if the measured current i 2 is above the threshold value P 1 . The second predetermined derivative value q 2 is larger than the first predetermined derivative value q 1 . The storage and processing unit 32 also generates a corresponding control signal s 1 or s 2 , when the first derivative di/dt has reached the first or second predetermined derivative value q 1 , q 2 . Here the screw head has reached the piece of wood. And the storage and processing unit 32 supplies the control signal s 1 or s 2 to the electronic control device 22 . This control device 22 provides for reducing or interrupting the energy supply to the motor 6 . In other words, the control signal s 1 , s 2 is used to bring the motor current i to zero or to another lower value for stopping the motor or decreasing the rotational speed of the motor to substantially zero. In the present embodiment the control signal s acts on an electronic control circuit 30 for this purpose. This control may happen immediately or after a predetermined delay time after the occurrence of the signal p. This signal s 1 or s 2 may also be used for reversing the current I to obtain a quick stop of the motor 6 .

In the preferred embodiment, the electronic control device 22 may contain a microprocessor, and the functions of the differentiating member 26 , the storage and processing unit 32 and also of the electronic control circuit 30 and possibly of a delay member (not shown) for delaying signal s may be fulfilled by the software of this microprocessor. In other words: the whole electronic control device 22 may be represented by a microprocessor.

In FIGS. 9-11 a third basic version of the method and the power tool according to the invention is illustrated. It is an extent based on the first version as explained with reference to FIGS. 1-4 . Therefore, only the differences will now be described. This third basic version uses the third derivative of the current i in dependence on time for reducing the speed of a tool 2 .

In this embodiment, the method follows the various steps shown in and described with reference to FIGS. 1 to 3 . In FIG. 9 the second derivative d 2 i/dt 2 in dependence on time t is shown as a repetition, which has already been shown in FIG. 3 . Shown as FIG. 10 , the third derivative d 3 i/dt 3 is generated from the second derivative d 2 i/dt 2 . And when the peak of the third derivative d 3 i/dt 3 appears and when its value is positive and it exceeds a given threshold value v 1 , the control signal s is generated. The signal s is correspondingly used for reducing the speed of the electric tool 2 .

A skilled person in the art knows accordingly to generate a control signal s through measuring the 4 th , 5 th or higher nth derivative. It is easy to conclude, so the applicant will not describe in details here.

Shown as the circuit illustrated in FIG. 11 , it will be noted that the output signal of the second differentiating member 28 is supplied to a third differentiating member 34 , in which the third derivative d 3 i/dt 3 is formed. Of the output signal of the third differentiating member 34 , the positive pulse p 1 is fed into the electronic control circuit 30 . It is considered to be the control signal s. By means of the electronic control circuit 30 , it causes a reduction or even complete elimination of the DC current i in the motor 6 .

Again it must be noted that all elements composed of the control device 22 can be replaced by a microprocessor.

In accordance with the afore-mentioned second embodiment, the storage and processing unit 32 may have stored therein a predetermined derivative value q 2 . Or it may contain plurality sets of predetermined derivative values q 1 , q 2 , q 3 . . . and threshold value P 1 , P 2 , P 3 for processing.

The procedure and protection apparatus described above in FIGS. 5-8 again have the advantage that a fast and reliable response is obtained when the head of the screw 14 reaches the board 16 . The protection apparatus is all-electronic.

It should be noted that the first derivative, the second derivative or the higher derivative is not only a derivative defined in mathematics, but also simple equivalents based on the differentiating principle of engineering practice. For example, the first derivative may also be represented as a current change Δi between consecutive time intervals Δt, that is Δi/Δt. In order to be easily used in engineering, Δt should be a extremely small constant value, such as Δt=10 ms. Thus, if the differences of the current is checked continuously, a counting for a first derivative should be realized equivalently. Accordingly, similar equivalents for the second derivative and the nth derivative, n≧3, should be contained in the meaning of derivative in the present invention.

Electric screw driver is illustrated above as a preferred embodiment, of course, the control method of the present invention may also be used on other power tools, such as electric drill, electric wrench and so on. It is easy to be realized according to the above mentioned embodiments for a person skilled in the art, so the applicant will not describe in details.