A power tool and methods are provided for detecting objects (e.g., flesh or other materials) in the operating path of a power tool's output component (e.g., saw blade or drill bit). An object detection sensor in the power tool generates an output signal indicative of a type of material detected in the operating path of the power tool. A power tool controller receives the object detection sensor output and determines when a material in the operating path of the power tool changes. The controller changes operation of a motor of the power tool (e.g., increasing or decreasing speed or stopping the motor) in response to the detected material change. The object detection sensor may include, for example, an RF sensor, a capacitive sensor, a camera, a conductivity probe, or an ultrasound probe.

A power tool includes a control for the motor of the power tool that senses an operating characteristic of the motor and controls the operation of the power tool based on the sensed characteristic. The sensed characteristic includes variations in reluctance of the motor. A controller may sense changes on load on the motor as a result of interaction between a working element such as a saw blade or drill bit and the work piece. The controlled operation may include variation in speed or torque or both, or may include stopping the motor. Emergency conditions may be sensed by changes in reluctance.

A system includes a first brake actuator for controlling pressure applied to a first brake, a BCU configured to receive a first plurality of inputs and to output a first BCU control signal for controlling the first brake actuator based on the first plurality of inputs, and a first switch coupled between the first brake actuator and the BCU. The system also includes a backup controller designed to receive a second plurality of inputs, determine a first backup control signal for controlling the first brake actuator based on the second plurality of inputs, determine that the BCU is functioning improperly based on the second plurality of inputs, and control the first switch to prevent the first BCU control signal from controlling the first brake actuator and to output the first backup control signal to the first brake actuator in response to determining that the BCU is functioning improperly.

A system includes a first brake actuator for controlling pressure applied to a first brake, a BCU configured to receive a first plurality of inputs and to output a first BCU control signal for controlling the first brake actuator based on the first plurality of inputs, and a first switch coupled between the first brake actuator and the BCU. The system also includes a backup controller designed to receive a second plurality of inputs, determine a first backup control signal for controlling the first brake actuator based on the second plurality of inputs, determine that the BCU is functioning improperly based on the second plurality of inputs, and control the first switch to prevent the first BCU control signal from controlling the first brake actuator and to output the first backup control signal to the first brake actuator in response to determining that the BCU is functioning improperly.

A power tool and methods are provided for detecting objects (e.g., flesh or other materials) in the operating path of a power tool's output component (e.g., saw blade or drill bit). An object detection sensor in the power tool generates an output signal indicative of a type of material detected in the operating path of the power tool. A power tool controller receives the object detection sensor output and determines when a material in the operating path of the power tool changes. The controller changes operation of a motor of the power tool (e.g., increasing or decreasing speed or stopping the motor) in response to the detected material change. The object detection sensor may include, for example, an RF sensor, a capacitive sensor, a camera, a conductivity probe, or an ultrasound probe.

A control method for a power tool for rotary tools comprises rotating a tool holder continuously about a working axis by a rotary drive. A rotary movement of a handle about the working axis is sensed by a motion sensor. A first angle of rotation of the handle is estimated by a first motion estimator, wherein rotary movements beneath a limit value are discounted. A second angle of rotation of the handle is estimated by a second motion estimator, wherein rotary movements beneath the limit value are taken into account. A measure for reducing the torque output of the rotary drive is activated when the first angle of rotation exceeds a first triggering threshold (A1), and when the second angle of rotation exceeds a second triggering threshold (A2) and at the same time a power output of the rotary drive exceeds a power threshold (L).

A manufacturing process switch with a housing consisting of a first member and a second member. The first member is rotatable from a closed position to an open position. A proximity sensor is secured to the housing that detects the proximity of the first member to the second member and generates a signal when the first member is in the open position. An engagement device is secured to the housing for retaining the first member to the second member in the closed position. A cable attachment mechanism is attached to the first member of the housing and securable to a cable of a tool. The first member is rotatable from the closed position to the open position when a breakaway force is applied to the cable attachment mechanism. The manufacturing process is stopped when the first member is in the open position.

An electric power tool includes an output shaft, drivable by an associated drive motor, and a brake apparatus for braking the output shaft rotating in the unpowered state of the associated drive motor. The output shaft is mounted in a rotatable manner in an associated housing and the brake apparatus has a magnetic-field brake unit with at least one first and one second brake element. The first brake element is arranged radially with respect to the output shaft in a rotationally fixed manner in the associated housing and includes at least one first and one second magnetic pole configured to generate a magnetic field that alternates in the circumferential direction of the output shaft. The second brake element is magnetically conductive and rotationally connected to the output shaft via an activatable coupling device.

A power tool includes a control for the motor of the power tool that senses an operating characteristic of the motor and controls the operation of the power tool based on the sensed characteristic. The sensed characteristic includes variations in reluctance of the motor. A controller may sense changes on load on the motor as a result of interaction between a working element such as a saw blade or drill bit and the work piece. The controlled operation may include variation in speed or torque or both, or may include stopping the motor. Emergency conditions may be sensed by changes in reluctance.

One aspect is a hydraulic ironworker system having a hydraulic ironworker configured with hydraulic power to deliver controlled force to metal workpieces. An accessory tool is coupled to the hydraulic ironworker via a harness assembly and configured to receive the hydraulic power from the hydraulic ironworker. A remote pushbutton assembly is removably coupled to the harness assembly and configured to control hydraulic power from the hydraulic ironworker to the accessory tool and further configured with an emergency stop button that, when actuated, disables all power to the hydraulic ironworker system. A safety plug assembly is configured to alternately couple to the harness assembly in place of the remote pushbutton assembly. Power to the hydraulic ironworker system is disabled until one of the remote pushbutton and safety plug assemblies is attached on the harness assembly.