Power tools

• US 20040144552A1
• Filed: 04/17/2003
• Published: 07/29/2004
• Est. Priority Date: 03/16/2000
• Status: Active Grant

• Current Assignee: Makita Corporation
• Original Assignee: Makita Corporation
• Inventors: Watanabe, Masahiro, Suzuki, Hitoshi
• Granted Patent: US 7,036,605 B2
• Time in Patent Office: Days
• US Class Current: 173/2
• CPC Class Codes: B25B 21/02 with means for imparting impact to screwdriver blade or nut socket
• CPC Class Codes: B25B 23/1405 for impact wrenches or screwdrivers
• CPC Class Codes: B25B 23/1475 for impact wrenches or screwdrivers
• CPC Class Codes: B25F 5/00 Details or components of portable power-driven tools not particularly related to the operations performed and not otherwise provided for

Abstract

Power tools are taught that may include, for example, means for detecting impact sounds generated, e.g. by a hammer strikes an anvil or by oil pulse from an oil unit. The detecting means may include a receiver (30) adapted to selectively convert sound within a narrow frequency range into electric signals. Preferably, the impact sounds fall within the narrow frequency range of the receiver (30). A processor 38 may be utilized to control the motor (22) in order to stop the rotation of the hammer when a predetermined number of impact sounds has been detected by the detecting means. In addition or in the alternative, various means for setting various operating conditions are taught, including dials 34, sound sensors 30, keypads and remote control devices 250. Further, means for performing maintenance condition status checks are taught.

Claims

1. A tightening tool comprising:

a drive source,

an anvil,

a hammer coupled to the drive source and adapted to strike the anvil and thereby rotate the anvil,

a sound sensor adapted to detect impact sounds generated when the hammer strikes the anvil, the sound sensor comprising a receiver adapted to selectively convert sounds within a narrow frequency range into electric signals, wherein the impact sounds fall within the narrow frequency range and

a processor coupled to the sound sensor and the drive source, wherein the processor controls the operation of the drive source based upon on a number of impact sounds detected by the detecting means.

2. A tightening tool as defined in claim 1, wherein the receiver comprises a piezoelectric buzzer.

3. A tightening tool as defined in claim 1, wherein the receiver comprises a piezoelectric ceramic material.

4. A tightening tool as defined in claim 3, wherein the piezoelectric ceramic material is adhered to a metal plate to thereby form a diaphragm.

5. A tightening tool as defined in claim 4, wherein the diaphragm is node mounted within a resonant cavity.

6. A tightening tool comprising:

an anvil,

a hammer for impacting the anvil so that the anvil rotates,

a sound sensor adapted to selectively convert impact sounds within a narrow frequency range into electric signals and to attenuate sounds outside the narrow frequency range,

a comparator adapted to compare the level of the electric signals generated by the sound sensor with a reference level and

a processor programmed to count a number of impacts based upon the number of times that the electrical signal exceeds the reference level and to control a drive source to rotate the hammer based upon the detected number of impacts.

7. A tightening tool as defined in claim 6, wherein the sound sensor comprises a piezoelectric buzzer.

8. A tightening tool as defined in claim 7, wherein the sound sensor comprises a piezoelectric ceramic material.

9. A tightening tool as defined in claim 8, wherein the piezoelectric ceramic material is adhered to a metal plate to thereby form a diaphragm.

10. A tightening tool as defined in claim 9, wherein the diaphragm is node mounted within a resonant cavity.

11. An apparatus comprising:

an anvil,

a hammer adapted to strike the anvil in order to generate a relatively large torque and

a piezoelectric material proximally disposed to the hammer and anvil, wherein the piezoelectric material selectively detects impact sounds generated by the hammer striking the anvil.

12. An apparatus as in claim 11, wherein the piezoelectric material is a piezoelectric ceramic material.

13. An apparatus as in claim 12, wherein the piezoelectric ceramic material is adhered to a metal plate to thereby form a diaphragm.

14. An apparatus as in claim 13, wherein the diaphragm is node mounted within a resonant cavity.

15. An apparatus as in claim 13, further comprising a microprocessor, wherein the microprocessor is programmed to count a number of impact sounds based upon signals generated by the piezoelectric material.

16. An apparatus as in claim 15, wherein the microprocessor is further programmed to stop the hammer from impacting the anvil when a pre-selected number of impact sounds have been detected.

17. An apparatus as in claim 16, further comprising a comparator, wherein the comparator receives electric signals generated by the piezoelectric material and generates output signals representative of hammer impacts, wherein the output signals from the comparator are supplied to the microprocessor.

18. An apparatus as in claim 11, further comprising a microprocessor adapted to count the hammer impacts and stop the hammer from striking the anvil when the pre-selected number of impact sounds have been counted.

19. An apparatus as in claim 18, wherein the piezoelectric material is a piezoelectric ceramic material.

20. An apparatus as in claim 19, wherein the piezoelectric ceramic material is adhered to a metal plate to thereby form a diaphragm.

21. An apparatus as in claim 20, wherein the diaphragm is node mounted within a resonant cavity.

22. A power tool comprising:

an anvil,

a hammer adapted to intermittently strike the anvil in order to generate increased torque,

a drive source adapted to rotate the hammer,

a switch coupled to the drive source in order and adapted to couple the drive source to a power supply,

means for setting an operating condition for the power tool and

a processor coupled to the setting means, the processor receiving information concerning a set operating condition and controlling the drive source according to the set operating condition after the switch has been actuated.

23. A power tool as in claim 22, wherein the operating condition set by the setting means is predetermined according to a plurality of operation modes.

24. A power tool as defined in claim 22, further comprising an impact sound sensor adapted to detect sounds generated when the hammer strikes the anvil, wherein the processor receives impact sound information from the impact sound sensor and controls the drive source based upon the operating condition set by the setting means and the impact sound information received from the impact sound sensor.

25. A power tool adapted to be controlled according to a set operating condition, comprising

means for detecting physical information and for outputting an electric signal based upon detected physical information,

means for distinguishing the electric signal received from the detecting means from an electric signal that corresponds to the set operating condition and

means for setting the operating condition based upon the electric signal when the electric signal is identified as the electric signal for setting the operating condition,

26. A power tool as in claim 25, further comprising means for controlling the driving force of the tool according to the operating condition set by the setting means and the detecting means also serves to detect physical information that is used when a control means controls the driving force.

27. A power tool as defined in claim 25, further comprising a switch coupled to a drive source in order to actuate the drive source, wherein the distinguishing means identifies the signal outputted from the detecting means to set the operating condition when the switch is operated under a particular condition.

28. A power tool that is controlled based on a set operating condition comprising:

means for detecting physical information and generating an electric signal in response to the detected physical information,

a memory storing a operating condition setting program,

a switch adapted to start the operating condition setting program and

means for setting the operating condition in response to the electric signal outputted by the detecting means and in accordance with the operating condition setting program.

29. A power tool as in claim 28, further comprising means for warning the operator if a pre-set maintenance condition level has been exceeded.

30. A power tool comprising:

means for detecting physical information and generating an electric signal in response to detected physical information,

a memory storing an operating condition setting program,

means for inputting operating condition parameters,

a processor adapted to execute the operating condition setting program in order to input operating condition parameters,

a switch coupled to the drive source in order and adapted to couple the drive source to a power supply,

means for setting an operating condition for the power tool;

a processor coupled to the setting means, the processor receiving information concerning a set operating condition and controlling the drive source according to the set operating condition after the switch has been actuated.

31. A power tool comprising:

means for generating an elevated torque, wherein the generating means emits impact sounds when the elevated torque is generated, wherein the impact sounds fall within a narrow frequency range and

means for detecting impact sounds within the narrow frequency range and for attenuating frequencies outside the narrow range.

32. A power tool as defined in claim 31, wherein the detecting means comprises a piezoelectric material.

33. A power tool as defined in claim 31, wherein the detecting means comprises a piezoelectric ceramic material.

34. A power tool as defined in claims 32 or 33, wherein the piezoelectric material is adhered to a metal plate to thereby form a diaphragm.

35. A power tool as defined in claim 34, wherein the diaphragm is node mounted within a resonant cavity.

36. A power tool as defined in any of claims 31-35, wherein the detecting means attenuates by at least 50% frequencies more than 10% lower or 10% higher than a peak frequency representative of the impact sounds.

37. A power tool as defined any of claims 31-36, wherein the detecting means comprises a piezoelectric buzzer having a peak frequency of 4 kHz.

38. A power tool as defined in any of claims 31-37, wherein the means for generating an elevated torque comprises:

an anvil and

a hammer for impacting the anvil so that the anvil rotates.

39. A power tool as defined in any of claims 31-38, wherein the detecting means generates electric signals based upon the impact sounds and the power tool further comprises:

means for comparing the level of the electric signals with a reference level;

means for counting the number of impact sounds based upon the number of times that the electrical signals exceed the reference level; and

means for controlling a drive source coupled to the means for generating an elevated torque in accordance with the counted number of impacts.

40. A power tool as defined in any of claims 31-38, wherein the detecting means generates electric signals based upon the impact sounds and the power tool further comprise:

means for comparing the level of the electric signals with a reference level;

a processor programmed to count the number of impact sounds based upon the number of times that the electrical signals exceed the reference level and to control a drive source coupled to the means for generating an elevated torque in accordance with the counted number of impacts.

41. A power tool comprising means for driving a fastening object, characterized in further comprising:

means for setting an operating condition for the power tool;

a processor coupled to the setting means, the processor receiving information concerning a set operating condition and controlling the driving means according to the set operating condition.

42. A power tool as in claim 41, wherein the operating condition set by the setting means is predetermined according to a plurality of operation modes.

43. A power tool as defined in claims 41 or 42, wherein the setting means comprises:

means for detecting physical information and for outputting an electric signal based upon detected physical information,

means for distinguishing the electric signal received from the detecting means from an electric signal corresponding to the set operating condition and

means for setting the operating condition based on the electric signal when the electric signal is identified as the electric signal for setting the operation condition,

44. A power tool as defined in claims 41-43, further comprising a switch coupled to a drive means, wherein the switch actuates the drive means and the processor initiates a new operating condition that has been set by the setting means when the switch is actuated.

45. A power tool as defined in claims 41-44, further comprising a memory storing a driving condition setting program that communicates with the processor.

46. A power tool as defined in claims 41-45, wherein the setting means comprises a remote control device.

47. A power tool as defined in claims 41-45, wherein the setting means comprises a sound sensor adapted to detect impact sounds, wherein the processor receives impact sound information from the sound sensor and controls a drive means based upon the operating condition set by the setting means and the impact sound information received from the sound sensor.

48. A power tool as defined in claim 47, wherein the sound sensor comprises a piezoelectric material.

49. A power tool as defined in claims 41-45, wherein the setting means comprises a mechanical dial.

50. A power tool as defined in claim 41-49, further comprising means for warning the operator that maintenance is recommended or required.

51. A power tool comprising:

means for storing actual use information concerning one or more components of the power tool,

means for comparing the stored actual use information to a pre-set maintenance level and

means for determining whether the pre-set warning level has been exceeded.

52. A power tool as in claim 51, further comprising means for warning the operator when the pre-set warning level has been exceeded.

53. A power tool as in claim 51, further comprising means for disabling a motor when the pre-set warning level has been exceeded to prevent further operation of the power tool until maintenance is performed on the power tool.

54. A power tool as in claim 51, further comprising means for warning the operator when the pre-set warning level has been exceeded and means for disabling a motor when a second pre-set warning level has been exceeded to prevent further operation of the power tool until maintenance is performed on the power tool.

55. A power tool as in claims 51-54, further comprising means for transmitting the stored actual use information to an external device.

56. A power tool as in claims 51-55, further comprising means for changing the pre-set maintenance level.

57. A power tool as in claim 56, wherein the changing means comprises a remote control device.

58. A power tool as in claim 56, wherein the changing means comprises a sound sensor.

59. A power tool as in claim 56, wherein the changing means comprises a mechanical dial.

60. A method of operating a power tool comprising:

storing a maintenance condition level in a memory,

storing actual use information concerning the power tool in a memory,

using a processor to compare the actual use information to the maintenance condition level.

61. A method as in claim 60, further comprising warning the operator when the actual use information exceeds the maintenance condition level.

62. A method as in claim 60, further comprising disabling a motor when the actual use information exceeds the maintenance condition level.

63. A method as in claim 60, further comprising warning the operator when the actual use information exceeds the maintenance condition level and disabling a motor when the actual use information exceeds a second maintenance condition level.

64. A method as in any of claims 60-63, further comprising re-setting the maintenance condition level.

65. A method as in claim 64, wherein the maintenance condition level is re-set with a remote control device.

66. A method as in claim 64, wherein the maintenance condition level is re-set with a mechanical dial

67. A method as in claim 64, wherein the maintenance condition level is re-set with a sound sensor and an operator strikes the power tool in order to input new maintenance condition level information.

68. A power tool comprising:

a memory adapted to store actual use information concerning one or more components of the power tool and

a processor programmed to compare the stored actual use information to a pre-set maintenance level and determine whether the pre-set warning level has been exceeded.

69. A power tool as in claim 68, further comprising means for warning the operator when the pre-set warning level has been exceeded.

70. A power tool as in claim 69, wherein the warning means is an audible sound.

71. A power tool as in claim 69, wherein the warning means is a visible display.

72. A power tool as in claim 68, wherein the processor is further programmed to disable a motor when the pre-set warning level has been exceeded.

73. A power tool as in claim 68, further comprising means for warning the operator when the pre-set warning level has been exceeded and the processor is programmed to disable a motor when a second pre-set warning level has been exceeded.

74. A power tool as in claim 68, further comprising means for transmitting the stored actual use information to an external device.

75. A power tool as in claim 68, further comprising a remote control device adapted to re-set the maintenance condition level.

76. A power tool as in claim 68, further comprising a sound sensor coupled to the processor, wherein the sound sensor receives operator initiated impact sound and the processor is adapted to receive new maintenance condition level information via the sound sensor.

77. A power tool as in claim 68, further comprising a mechanical dial adapted to re-set the maintenance condition level.