Control module for flywheel operated hand tool

Abstract

A control module advantageously reduces cost and enhances reliability, design flexibility, ease of assembly, and performance of a flywheel operated hand tool. The control module includes a thin film printed circuit with non-contact speed sensing of a flywheel to more accurately set the target speed and control transfer kinetic energy thereof to a fastener, achieving a desired depth regardless of variations in component performance and battery voltage. The printed circuit also includes long service life thin film switches for responding to trigger and safety inputs. Furthermore, the control module responds to a user speed selection and to preset speed selection ranges to reconfigure the controls as appropriate to constraints of a fastener drive assembly and to user preferences.

1. A control module for a hand tool powered by DC power having a rotary member;
 comprising:
 a target speed adjustment circuit operable to electronically communicate a target speed signal, wherein said target speed signal represents a target speed for the rotary member; 
 a speed sensor circuit operable to electronically communicate a rotary speed signal, wherein said rotary speed signal represents a rotary speed of the rotary member, wherein said rotary speed is determined by a sensor; 
 a trigger circuit electronically operable to communicate a trigger signal, wherein said trigger signal represents engagement of a trigger by a user; and 
 a controller having a plurality of inputs and outputs; wherein the inputs of the controller comprise input signals comprising the target speed signal, the rotary speed signal, and the trigger signal; wherein the controller is operably configured to command the rotary member with electronic communication of a first command signal in response to a function comprising a first function of the input signals. 
   
     
     
       2. The control module of  claim 1 , wherein the controller is a microprocessor. 
     
     
       3. A control module for a hand tool powered by DC power having a rotary member;, comprising:
 a target speed adjustment circuit operable to electronically communicate an adjustable target speed signal, wherein said adjustable target speed signal represents a target speed for the rotary member and that is representative of user target speed input; 
 a speed sensor circuit operable to electronically communicate a rotary speed signal, wherein said rotary speed signal represents a rotary speed of the rotary member, wherein said rotary speed is determined by a sensor; 
 a trigger circuit electronically operable to communicate a trigger signal, wherein said trigger signal represents engagement of a trigger by a user; and 
 a controller having a plurality of inputs and outputs; , wherein the inputs of the controller comprise input signals comprising the adjustable target speed signal, the rotary speed signal, and the trigger signal;, wherein the controller is operably configured to command the rotary member with electronic communication of a first command signal in response to a function comprising a first function of the input signals;, wherein the controller is operably configured to command a clutch mechanism with electronic communciation communication of a second command signal in response to a function comprising a second function of the input signals;, wherein the clutch mechanism is operable to mechanically impart kinetic energy of the rotary member to a driving mechanism. 
 
     
     
       4. The control module of  claim 3 , said clutch mechanism comprising a solenoid. 
     
     
       5. A control module for a hand tool powered by DC power having a rotary member; , comprising:
 a target speed adjustment circuit operable to electronically communicate an adjustable target speed signal, wherein said adjustable target speed signal represents a target speed for the rotary member and that is representative of user target speed input; 
 a speed sensor circuit operable to electronically communicate a rotary speed signal, wherein said rotary speed signal represents a rotary speed of the rotary member, wherein said rotary speed is determined by a sensor; 
 a trigger circuit electronically operable to communicate a trigger signal, wherein said trigger signal represents engagement of a trigger by a user; and 
 a controller having a plurality of inputs and outputs; , wherein the inputs of the controller comprise input signals comprising the adjustable target speed signal, the rotary speed signal, and the trigger signal; , wherein the controller is operably configured to command the rotary member with electronic communication of a first command signal in response to a function comprising a first function of the input signals; 
 wherein the trigger circuit further comprises: a mechanical control for receiving a user input for operation of the hand tool;, and a thin film switch in physical communication with the mechanical control and in electrical communication with the controller. 
 
     
     
       6. A control module for a hand tool powered by DC power having a rotary member; , comprising:
 a target speed adjustment circuit operable to electronically communicate an adjustable target speed signal, wherein said adjustable target speed signal represents a target speed for the rotary member and that is representative of user target speed input; 
 a speed sensor circuit operable to electronically communicate a rotary speed signal, wherein said rotary speed signal represents a rotary speed of the rotary member, wherein said rotary speed is determined by a sensor; 
 a trigger circuit electronically operable to communicate a trigger signal, wherein said trigger signal represents engagement of a trigger by a user; and 
 a controller having a plurality of inputs and outputs, wherein the inputs of the controller comprise input signals comprising the adjustable target speed signal, the rotary speed signal, and the trigger signal; , wherein the controller is operably configured to command the rotary member with electronic communication of a first command signal in response to a function comprising a first function of the input signals;, wherein the first command signal is received by a direct current electric motor, wherein the direct current electric motor is in mechanical communication with the rotary member. 
 
     
     
       7. The control module of  claim 1 , further comprising a battery. 
     
     
       8. A control module for a hand tool powered by DC power having a rotary member; , comprising:
 a target speed adjustment circuit operable to electronically communicate an adjustable target speed signal, wherein said adjustable target speed signal represents a target speed for the rotary member and that is representative of user target speed input; 
 a speed sensor circuit operable to electronically communicate a rotary speed signal, wherein said rotary speed signal represents a rotary speed of the rotary member, wherein said rotary speed is determined by a sensor; 
 a trigger circuit electronically operable to communicate a trigger signal, wherein said trigger signal represents engagement of a trigger by a user; and 
 a controller having a plurality of inputs and outputs; , wherein the inputs of the controller comprise input signals comprising the adjustable target speed signal, the rotary speed signal, and the trigger signal; , wherein the controller is operably configured to command the rotary member with electronic communication of a first command signal in response to a function comprising a first function of the input signals; 
 wherein the target speed adjustment circuit further comprises a variable potentiometer, wherein the variable potentiometer is operable to vary the target speed signal and where said adjustable target speed signal comprises a preset target speed range within which a user may adjust said target speed of said rotary member. 
 
     
     
       9. The control module of  claim 8 , wherein the variable potentiometer is operable to be varied by a speed adjustment knob. 
     
     
       10. A control module for a hand tool powered by DC power having a rotary member; , comprising:
 a target speed adjustment circuit operable to electronically communicate an adjustable target speed signal, wherein said adjustable target speed signal represents a target speed for the rotary member and that is representative of user target speed input; 
 a speed sensor circuit operable to electronically communicate a rotary speed signal, wherein said rotary speed signal represents a rotary speed of the rotary member, wherein said rotary speed is determined by a sensor; 
 a trigger circuit electronically operable to communicate a trigger signal, wherein said trigger signal represents engagement of a trigger by a user; and 
 a controller having a plurality of inputs and outputs; , wherein the inputs of the controller comprise input signals comprising the adjustable target speed signal, the rotary speed signal, and the trigger signal; , wherein the controller is operably configured to command the rotary member with electronic communication of a first command signal in response to a function comprising a first function of the input signals; further comprising and  
 a mode circuit electronically operable to communicate a mode signal, wherein the mode signal represents a desired mode of constancy of rotation of the rotary member;, wherein the mode circuit comprises a mode selection switch, wherein said mode selection switch is responsive to a user's mode selection between continuous and non-continuous mode, wherein the mode signal further represents a user's mode selection of desired mode of constancy of rotation of the rotary member,;  
 wherein the inputs of the controller further comprise an input signal comprising a mode signal, wherein the controller is responsive to the mode signal by commanding the rotation of the rotary member in accordance with the user's mode selection. 
 
     
     
       11. A control module for a hand tool powered by DC power having a rotary member;, comprising:
 a target speed adjustment circuit operable to electronically communicate an adjustable target speed signal, wherein said adjustable target speed signal represents a target speed for the rotary member and that is representative of user target speed input; 
 a speed sensor circuit operable to electronically communicate a rotary speed signal, wherein said rotary speed signal represents a rotary speed of the rotary member, wherein said rotary speed is determined by a sensor; 
 a trigger circuit electronically operable to communicate a trigger signal, wherein said trigger signal represents engagement of a trigger by a user; and 
 a controller having a plurality of inputs and outputs;, wherein the inputs of the controller comprise input signals comprising the adjustable target speed signal, the rotary speed signal, and the trigger signal;, wherein the controller is operably configured to command the rotary member with electronic communication of a first command signal in response to a function comprising a first function of the input signals; further comprising a mode circuit electronically operable to communicate a mode signal, and 
 a safety circuit electronically operable to communicate a safety signal, wherein the safety signal is operable to prevent kinetic energy from being imparted from the rotary member; 
 wherein the inputs of the controller further comprise an input signal comprising the safety signal, wherein the controller is configured to respond to a safety signal by commanding the prevention of the impartation of kinetic energy from the rotary member. 
 
     
     
       12. A control module for a hand tool powered by DC power having a rotary member;, comprising:
 a target speed adjustment circuit operable to electronically communicate an adjustable target speed signal, wherein said adjustable target speed signal represents a target speed for the rotary member and that is representative of user target speed input; 
 a speed sensor circuit operable to electronically communicate a rotary speed signal, wherein said rotary speed signal represents a rotary speed of the rotary member, wherein said rotary speed is determined by a sensor; 
 a trigger circuit electronically operable to communicate a trigger signal, wherein said trigger signal represents engagement of a trigger by a user; and 
 controller having a plurality of inputs and outputs;, wherein the inputs of the controller comprise input signals comprising the adjustable target speed signal, the rotary speed signal, and the trigger signal;, wherein the controller is operably configured to command the rotary member with electronic communication of a first command signal in response to a function comprising a first function of the input signals; further comprising and  
 a safety circuit electronically operable to communicate a safety signal, wherein said safety signal is operable to allow kinetic energy to be imparted from the rotary member; 
 wherein the inputs of the controller further comprise an input signal comprising the safety signal, wherein the controller is configured to respond to a safety signal by allowing the impartation of kinetic energy from the rotary member. 
 
     
     
       13. The control module of  claim 12 , further comprising:
 a mechanical safety control for receiving a safety input for detecting one or more safety conditions; and 
 a safety thin film switch in physical communication with the mechanical safety control and in electrical communication with the controller. 
 
     
     
       14. The control module of  claim 13 , wherein the mechanical safety control is responsive to pressure on a safety sensor. 
     
     
       15. The control module of  claim 12 , wherein the safety signal has a limited temporal duration, wherein said temporal duration is preset at a safety time-out value, wherein the safety signal ceases at the expiration of the temporal duration at the safety time-out value. 
     
     
       16. A control module for a hand tool powered by DC power having a rotary member;, comprising:
 a target speed adjustment circuit operable to electronically communicate an adjustable target speed signal, wherein said adjustable target speed signal represents a target speed for the rotary member and that is representative of user target speed input; 
 a speed sensor circuit operable to electronically communicate a rotary speed signal, wherein said rotary speed signal represents a rotary speed of the rotary member, wherein said rotary speed is determined by a sensor; 
 a trigger circuit electronically operable to communicate a trigger signal, wherein said trigger signal represents engagement of a trigger by a user; and 
 a controller having a plurality of inputs and outputs;, wherein the inputs of the controller comprise input signals comprising the adjustable target speed signal, the rotary speed signal, and the trigger signal;, wherein the controller is operably configured to command the rotary member with electronic communication of a first command signal in response to a function comprising a first function of the input signals;, wherein the controller is responsive to one or more enabling conditions, wherein the controller is operable to command the impartation of kinetic energy from the rotary member in the presence of said one or more enabling conditions. 
 
     
     
       17. The control module of  claim 16 , wherein said one or more enabling conditions comprise:
 a trigger signal; 
 a safety signal; and 
 a rotary speed signal, wherein said rotary speed signal is approximately equal to a target speed signal. 
 
     
     
       18. The control module of  claim 16 , wherein the controller is operable to prevent the impartation of kinetic energy from the rotary member in the absence of one or more enabling conditions. 
     
     
       19. A control module for a hand tool powered by DC power having a rotary member;, comprising:
 a target speed adjustment circuit operable to electronically communicate an adjustable target speed signal, wherein said adjustable target speed signal represents a target speed for the rotary member and that is representative of user target speed input; 
 a speed sensor circuit operable to electronically communicate a rotary speed signal, wherein said rotary speed signal represents a rotary speed of the rotary member, wherein said rotary speed is determined by a sensor; 
 a trigger circuit electronically operable to communicate a trigger signal, wherein said trigger signal represents engagement of a trigger by a user; and 
 a controller having a plurality of inputs and outputs;, wherein the inputs of the controller comprise input signals comprising the adjustable target speed signal, the rotary speed signal, and the trigger signal;, wherein the controller is operably configured to command the rotary member with electronic communication of a first command signal in response to a function comprising a first function of the input signals; 
 wherein said rotary member further comprises a ring magnet comprising a plurality of radially arrayed pairs of magnetic poles and wherein the rotational speed of said rotary member is directly sensed by a transducer sensing alternating north and south magnetic fields during rotation of said rotary member. 
 
     
     
       20. The control module of  claim 3 , wherein said clutch mechanism comprises a conical clutch plate having a conical friction surface and wherein said rotary member comprises a conical cavity for receiving said conical friction surface upon engagement of the clutch mechanism. 
     
     
       21. The control module of  claim 20 , wherein said control module for a hand tool comprises a control module for a hand held fastener driving tool. 
     
     
       22. The control module of  claim 21 , wherein said adjustable target speed signal comprises a preset target speed range within which a user may adjust said target speed of said rotary member to compensate for at least one of variations in a workpiece and u desired depth of fastener insertion. 
     
     
       23. A control module for a hand tool powered by DC power having a rotary member;, comprising:
 a target speed adjustment circuit operable to electronically communicate an adjustable target speed signal, wherein said adjustable target speed signal represents a target speed for the rotary member and that is representative of user target speed input; 
 a speed sensor circuit operable to electronically communicate a rotary speed signal, wherein said rotary speed signal represents a rotary speed of the rotary member, wherein said rotary speed is determined by a sensor; 
 a trigger circuit electronically operable to communicate a trigger signal, wherein said trigger signal represents engagement of a trigger by a user; and 
 a controller having a plurality of inputs and outputs, wherein the inputs of the controller comprise input signals comprising the adjustable target speed signal, the rotary speed signal, and the trigger signal;, wherein the controller is operably configured to command the rotary member with electronic communication of a first command signal in response to a function comprising a first function of the input signals; 
 wherein said target speed of said rotary member is independent of user displacement of said trigger. 
 
     
     
       24. The control module of  claim 20 , wherein said driving mechanism comprises a linearly moving fastener driver for driving a fastener into a workpiece. 
     
     
       25. A control module for a hand held fastener driving tool powered by DC power having a rotary member;, comprising:
 a target speed adjustment circuit operable to electronically communicate an adjustable target speed signal, wherein said adjustable target speed signal represents a target speed for the rotary member and that is representative of user target speed input; 
 a speed sensor circuit operable to electronically communicate a rotary speed signal, wherein said rotary speed signal represents a rotary speed of the rotary member, wherein said rotary speed is determined by a sensor; 
 a trigger circuit electronically operable to communicate a trigger signal, wherein said trigger signal represents engagement of a trigger by a user; and 
 a controller having a plurality of inputs and outputs;, wherein the inputs of the controller comprise input signals comprising the adjustable target speed signal, the rotary speed signal, and the trigger signal;, wherein the controller is operably configured to command the rotary member with electronic communication of a first command signal in response to a function comprising a first function of the input signals;, wherein said controller is operably configured to command a clutch mechanism with electronic communication of a second command signal in response to a function comprising a second function of the input signals, and wherein the clutch mechanism is operable to mechanically impart kinetic energy of the rotary member to a driving mechanism. 
 
     
     
       26. The control module of  claim 25 , wherein said clutch mechanism comprises a conical clutch plate having a conical friction surface and wherein said rotary member comprises a conical cavity for receiving said conical friction surface upon engagement of the clutch mechanism. 
     
     
       27. The control module of  claim 26 , wherein said rotary member further comprises a ring magnet comprising a plurality of radially arrayed pairs of magnetic poles and wherein the rotational speed of said rotary member is directly sensed by a transducer sensing alternating north and south magnetic fields during rotation of said rotary member. 
     
     
       28. A hand tool, comprising:
 a rotary inertial member;   an electric motor coupled to turn the rotary inertial member;   a magazine containing a plurality of fasteners;   a reciprocating driven mechanism positioned to sequentially drive one of the plurality of fasteners into a workpiece;   an energy transfer mechanism responsive to an engagement signal to couple the rotary inertial member to the reciprocating driven mechanism; and   a controller operatively configured to sense a parameter representative of rotational speed of the rotary inertial member, to command the electric motor to accelerate the rotary inertial member to a target speed in response to a user input, wherein the target speed is representative of an adjustable user-defined target speed input, and to generate an engagement signal in response to a determination of a firing condition.   
     
     
       29. The hand tool of claim 28, wherein the user input comprises a continuous mode selection. 
     
     
       30. The hand tool of claim 28, wherein the controller is further operatively configured to sense a time out condition and to cease commanding the electric motor to accelerate the rotary inertial member to the target speed. 
     
     
       31. The hand tool of claim 28, wherein the firing condition comprises satisfying a trigger fire mode. 
     
     
       32. The hand tool of claim 28, wherein the firing condition comprises satisfying a bottom fire mode. 
     
     
       33. The hand tool of claim 28, further comprising a portable electrical power source to power the controller and the electric motor. 
     
     
       34. The hand tool of claim 33, wherein the portable electrical power source comprises a battery. 
     
     
       35. The hand tool of claim 28, wherein the controller is further operatively configured to sense the parameter representative of the rotational speed decreasing to a second target speed lower and to then cease commanding the engagement signal to disengage the energy transfer mechanism. 
     
     
       36. The hand tool of claim 28, further comprising a feedback circuit responsive to rotation of the motor operable to provide the parameter representative of the rotational speed of the rotary inertial member. 
     
     
       37. The hand tool of claim 28, further comprising a sensor coupled to the rotary inertial member to produce the parameter representative of the rotational speed. 
     
     
       38. The hand tool of claim 28, wherein the controller is further operably configured to access a mode setting selected from a group consisting of a continuous mode and an intermittent mode, and, in response to the user input comprising a user dispense command, to initiate acceleration of the rotary inertial member toward and maintaining the target speed when the accessed mode setting is continuous mode, and to initiate acceleration of the rotary inertial member toward the target speed when the accessed mode setting is intermittent mode. 
     
     
       39. The hand tool of claim 28, wherein the energy transfer mechanism comprises a movable member positioned to selectively contact the rotary inertial member, the reciprocating driven mechanism tangentially coupled to an engaged combination of the rotary inertial member and the movable member. 
     
     
       40. The hand tool of claim 28, wherein the energy transfer mechanism is responsive to the engagement signal to couple an adjacent lateral face of the rotary inertial member to the reciprocating driven mechanism. 
     
     
       41. The hand tool of claim 28, wherein the energy transfer mechanism is responsive to the engagement signal to mechanically couple the rotary inertial member to the reciprocating driven mechanism, wherein the hand tool further comprises a battery providing electrical power to the electric motor and the controller. 
     
     
       42. A hand tool, comprising:
 a rotary inertial member;   an electric motor coupled to turn the rotary inertial member;   a magazine containing a plurality of fasteners;   a reciprocating driven mechanism positioned to sequentially drive one of the plurality of fasteners into a workpiece;   an energy transfer mechanism responsive to an engagement signal to couple the rotary inertial member to the reciprocating driven mechanism; and   a controller operatively configured to sense a parameter representative of rotational speed of the rotary inertial member, to command the electric motor to accelerate the rotary inertial member to a target speed in response to a user input, and to generate an engagement signal in response to a determination of a firing condition, wherein the controller is further operatively configured to respond to the firing condition which comprises a trigger signal, a safety signal, and the parameter representative of the rotational speed being approximately equal to the target speed.   
     
     
       43. A hand tool, comprising:
 a rotary inertial member;   an electric motor coupled to turn the rotary inertial member;   a magazine containing a plurality of fasteners;   a reciprocating driven mechanism positioned to sequentially drive one of the plurality of fasteners into a workpiece;   an energy transfer mechanism responsive to an engagement signal to couple the rotary inertial member to the reciprocating driven mechanism; and   a controller operatively configured to sense a parameter representative of rotational speed of the rotary inertial member, to command the electric motor to accelerate the rotary inertial member to a target speed in response to a user input, and to generate an engagement signal in response to a determination of a firing condition, wherein the user input comprises a user dispense command, wherein the controller is further operably configured to sense and time a held safety signal, to sense a trigger signal, and to determine the user dispense command when the held safety signal precedes and is simultaneous with the trigger signal so long as the held safety signal precedes the trigger signal by no more than a valid trigger time-out value.   
     
     
       44. The control module of claim 3, wherein the controller is a microprocessor. 
     
     
       45. The control module of claim 3, further comprising a battery.