Discontinuous drive tool assembly and method for detecting the rotational angle thereof

• US 7,958,944 B2
• Filed: 03/17/2009
• Issued: 06/14/2011
• Est. Priority Date: 03/17/2008
• Status: Active Grant

• Current Assignee: Stanley Black & Decker, Inc.
• Original Assignee: Stanley Black & Decker, Inc.
• Inventors: Schiappacasse, John M., Lehnert, Mark W.
• Primary Examiner(s): Smith; Scott A.
• Application Number:
  US12/405,969
• Publication Number:
  US 20090255700A1
• Time in Patent Office: 819 Days
• Field of Search: 173/1, 173/176, 173/183, 173/935, 173/93.6, 173/181, 173/182, 173/2, 173/93.5, 738/622.3
• US Class Current: 173/1
• CPC Class Codes: B25B 21/026 Impact clutches
• CPC Class Codes: B25B 23/1405 for impact wrenches or screwdrivers

Abstract

A discontinuous drive power tool assembly for generating rotational torque includes a spindle having a first end portion and a second end portion. The first end portion of the spindle is configured to engage and rotate an object. The tool assembly also includes a pulse hammer selectively engagable with the second end portion of the spindle, and a motor that includes a motor shaft engagable with the pulse hammer. The motor is configured to rotate the pulse hammer. The tool assembly also includes a rotational position sensor disposed adjacent the motor. The rotational position sensor is configured to measure the rotational position of a second portion of the motor shaft which is opposite the first end portion of the motor shaft during operation of the tool assembly.

Claims

1. A discontinuous drive power tool assembly for generating rotational torque, the tool assembly comprising:

a spindle having a first end portion and a second end portion, the first end portion being configured to engage and rotate an object;

a pulse hammer selectively engagable with the second end portion of the spindle;

a motor including a motor shaft having a first end portion engagable with the pulse hammer, the motor being configured to rotate the pulse hammer; and

a rotational position sensor disposed adjacent the motor, the rotational position sensor being configured to measure the rotational position of a second end portion of the motor shaft which is opposite the first end portion of the motor shaft during operation of the tool assembly, wherein the rotational position sensor comprises a magnet mounted to the second end portion of the motor shaft and an integrated circuit constructed and arranged to detect a rotational position of the magnet relative to a longitudinal axis of the motor shaft.

2. A discontinuous drive power tool assembly according to claim 1, further comprising a torque sensor configured to identify a moment in time when the tool is delivering a peak torque pulse to the object, the torque sensor being operatively connected to the integrated circuit so that the integrated circuit records the rotational position of the magnet at the time of the peak torque pulse.

3. A discontinuous drive power tool assembly according to claim 2, wherein the integrated circuit is programmed to record a plurality of rotational positions of the magnet with each position corresponding to different moment in time, and to add the plurality of rotational positions of the magnet for an absolute rotational position of the magnet, the motor shaft, the spindle, and the object.

4. A discontinuous drive power tool assembly according to claim 1, further comprising a coupler configured to selectively couple the pulse hammer and the motor shaft to the spindle to deliver a torque pulse to the spindle.

5. A discontinuous drive power tool assembly according to claim 1, wherein the motor is configured to rotate the spindle via the pulse hammer.

6. A discontinuous drive power tool assembly according to claim 1, wherein the tool assembly is configured to be powered by at least a compressed gas.

7. A sensing system for sensing a rotational position of a motor shaft of a discontinuous drive power tool assembly during operation of the tool assembly, the sensing system comprising:

a rotational position sensor disposed adjacent a rear end portion of the motor shaft, the rotational position sensor being configured to measure the rotational position of rear end portion of the motor shaft during operation of the tool assembly, the rotational position sensor comprising a magnet configured to be mounted to the rear end portion of the motor shaft and an integrated circuit constructed and arranged to detect a rotational position of the magnet relative to a longitudinal axis of the motor shaft during operation of the tool assembly; and

a torque sensor configured to identify a moment in time when the tool assembly is delivering a peak torque pulse to an object worked on by the tool assembly, the torque sensor being operatively connected to the integrated circuit so that the integrated circuit records the rotational position of the magnet at the time of the peak torque pulse.

8. A sensing system according to claim 7, wherein the integrated circuit is programmed to record a plurality of rotational positions of the magnet with each position corresponding to different moment in time, and to add the plurality of rotational positions of the magnet for an absolute rotational position of the magnet, the motor shaft, and the object.

9. A method for measuring angular displacement of an object rotated by a discontinuous drive power tool assembly, the method comprising:

sensing rotation of a shaft of a motor;

identifying a moment event when the shaft of the motor ceases or slows rotation concurrently with delivery of a peak torque pulse by the discontinuous drive power tool assembly;

measuring a first rotational reference angle position related to the angular displacement of the shaft of the motor when the moment event occurs;

rotating the motor shaft a predetermined amount;

identifying a subsequent moment event when an output shaft of the discontinuous drive power tool assembly delivers a torque pulse; and

measuring a subsequent rotational angle position related to the angular displacement of the shaft of the motor when the subsequent moment event occurs.

10. A method according to claim 9, further comprising storing the first rotational reference angle position and storing the second rotational angle position.

11. A method according to claim 10, further comprising determining the rotational angular displacement between the first rotational angle position and the subsequent rotational angle position.

12. A method according to claim 9, wherein the moment event and the subsequent moment event are identified by a torque sensor.

13. A method according to claim 9, wherein the first rotational reference angle position and the subsequent rotational angle position are measured with a rotational position sensor.