Method for Detecting a First Operating State of a Handheld Power Tool
20220176527 · 2022-06-09
Inventors
- Juergen Winterhalter (Stuttgart, DE)
- Simon Erbele (Nufringen, DE)
- Tobias Zibold (Stuttgart, DE)
- Stefan Mock (Remshalden, DE)
- Wolfgang Herberger (Stuttgart, DE)
- Dietmar Saur (Moessingen, DE)
Cpc classification
B25F5/00
PERFORMING OPERATIONS; TRANSPORTING
B25B23/1475
PERFORMING OPERATIONS; TRANSPORTING
International classification
Abstract
Method for detecting a first operating state of a handheld power tool, wherein the handheld power tool has an electric motor. In this case, the method comprises the steps of: (S1) determining a signal of an operating variable of the electric motor; (S2) comparing the signal of the operating variable with at least one model signal waveform typical of the state, wherein the model signal waveform typical of the state is assigned to the first operating state; (S3) deciding whether the first operating state is present, wherein the decision at least partially depends on whether the model signal waveform typical of the state is identified in the signal of the operating variable in step S2. Additionally disclosed is a handheld power tool, particularly an impact driver, with an electric motor and a control unit, wherein the control unit is designed to execute a method according to the disclosure.
Claims
1. A method for detecting a first operating state of a handheld power tool having an electric motor, the method comprising: ascertaining a signal of an operating quantity of the electric motor; comparing the signal of the operating quantity with at least one state-typical model signal form to identify whether the state-typical model signal form is in the signal of the operating quantity, the state-typical model signal form having been assigned to the first operating state; and detecting the first operating state depending at least partially on whether the state-typical model signal form is identified in the signal of the operating quantity in step.
2. The method as claimed in claim 1, wherein the state-typical model signal form is an oscillation curve.
3. The method as claimed in claim 1, wherein one of (i) the operating quantity is a speed of the electric motor and (ii) the operating quantity correlates the speed of the electric motor.
4. The method as claimed in claim 1, the ascertaining further comprising: recording the signal of the operating quantity as one of (i) a temporal progression of measured values of the operating quantity and (ii) a temporal progression of measured values of a quantity of the electric motor that correlates with the temporal progression.
5. The method as claimed in claim 1, the ascertaining further comprising: recording the signal of the operating quantity as a temporal progression of measured values of the operating quantity; and transforming the temporal progression of the measured values of the operating quantity into a temporal progression of the measured values of a quantity of the electric motor that correlates with the temporal progression of the measured values of the operating quantity.
6. The method as claimed in claim 1, the ascertaining further comprising: storing the signal of the operating quantity as a sequence of measured values in a memory of the handheld power tool.
7. The method as claimed in claim 6, the ascertaining further comprising: segmenting the sequence of measured values such that the signal of the operating quantity always comprises a predetermined number of measured values.
8. The method as claimed in claim 1, the comparing further comprising: comparing the signal of the operating quantity with the state-typical model signal form using at least one of (i) a frequency-based comparison process and (ii) a comparative comparison process to determine whether at least one predetermined threshold value is satisfied.
9. The method as claimed in claim 8, wherein the frequency-based comparison process includes at least one of (i) bandpass filtering and (ii) frequency analysis, the predetermined threshold value being at least 85% of a predetermined limiting value.
10. The method as claimed in claim 8, wherein the comparative comparison process includes at least one of (i) parameter estimation and (ii) cross-correlation, the predetermined threshold value being to at least 50% of a concordance of the signal of the operating quantity with the state-typical model signal form.
11. The method as claimed in claim 1, wherein: the comparing further comprises determining a quality of the identification of the state-typical model signal form in the signal of the operating quantity; and the detecting further comprises detecting the first operating state at least partially based on the determined quality.
12. The method as claimed in claim 1, wherein: the comparing further comprises determining a deviation of the identification of the state-typical model signal form in the signal of the operating quantity; and the detecting further comprises detecting the first operating state at least partially based on the determined deviation.
13. The method as claimed in claim 1, the detecting further comprising: detecting the first operating state based on less than ten impacts of an impact mechanism of the handheld power tool.
14. The method as claimed in claim 1, wherein the handheld power tool is an impact wrench and the first operating state is an impact mode.
15. A handheld power tool comprising: an electric motor; a pick-up configured to measure values of an operating quantity of the electric motor and a control unit configured to: ascertain a signal of an operating quantity of the electric motor; compare the signal of the operating quantity with at least one state-typical model signal form to identify whether the state-typical model signal form is in the signal of the operating quantity, the state-typical model signal form having been assigned to a first operating state; detect the first operating state depending at least partially on whether the state-typical model signal form is identified in the signal of the operating quantity.
16. The method as claimed in claim 2, wherein the state-typical model signal form is a trigonometric oscillation curve.
17. The method as claimed in claim 6, wherein the memory of the handheld power tool is a ring memory.
18. The method as claimed in claim 9, wherein the predetermined threshold value is at least one of (i) at least 90% of the predetermined limiting value and (ii) at least 95% of the predetermined limiting value.
19. The method as claimed in claim 13, wherein the first operating state is identified based on at least one of (i) less than ten impact-oscillation periods of the electric motor, (ii) less than six impacts of the impact mechanism of the handheld power tool, in particular less than six impact-oscillation periods of the electric motor, (iii) less than four impacts of the impact mechanism of the handheld power tool, and (iv) less than four impact-oscillation periods of the electric motor.
20. The method as claimed in claim 14, wherein the handheld power tool is a rotary impact wrench, and the first operating state is a rotary impact mode.
Description
[0059] The invention will be elucidated in more detail in the following with reference to the figures. Shown are:
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[0070] According to the embodiment represented, the handheld power tool 100 is capable of being connected mechanically and electrically to a battery pack 190 for its mains-independent power supply. In
[0071] An electric motor 180, supplied with power by the battery pack 190, and a transmission 170 are arranged in the housing 105. The electric motor 180 is connected to an input spindle via the transmission 170. Furthermore, within the housing 105 in the region of the battery pack 190 a control unit 370 is arranged which for the purpose of controlling and/or regulating the electric motor 180 and the transmission 170 acts on these, for instance by means of a set motor speed n, a selected angular momentum, a desired transmission gear x or such like.
[0072] The electric motor 180 is capable of being actuated—that is to say, capable of being switched on and off—via a manual switch 195, for instance, and may be any type of motor, for instance an electronically commutated motor or a DC motor. In principle, the electric motor 180 is capable of being controlled or regulated electronically in such a manner that both a reversing mode and specifications with regard to the desired motor speed n and the desired angular momentum are capable of being realized. The mode of operation and the structure of a suitable electric motor are sufficiently well-known from the prior art, so a detailed description will be dispensed with here for the sake of conciseness of the description.
[0073] A tool receptacle 140 is rotatably mounted in the housing 105 via an input spindle and an output spindle. The tool receptacle 140 serves for receiving a tool and may have been directly molded onto the output spindle or connected thereto in the form of an attachment.
[0074] The control unit 370 is connected to a power-source and is designed in such a manner that it is able to drive the electric motor 180 in electronically controllable manner by means of various current signals. The various current signals provide for differing angular momenta of the electric motor 180, the current signals being passed to the electric motor 180 via a control line. The power-source may take the form, for instance, of a battery or—as in the exemplary embodiment represented—a battery pack 190 or a mains connection.
[0075] Furthermore, operating elements not represented in detail may have been provided, in order to set various operating modes and/or the direction of rotation of the electric motor 180.
[0076] In
[0077] In the present example shown in
[0078] The motor speed and motor current are operating quantities which, in the case of handheld power tools 100, are ordinarily captured by a control unit 370 without additional effort. The ascertaining of the signal of an operating quantity 200 of the electric motor 180 has been labeled as method step S1 in
[0079] In
[0080] In the first region 310, the rotary impact wrench is operating in the operating state of screwing without impact.
[0081] In a second region 320, the rotary impact wrench is operating in a rotary impact mode. The rotary impact mode is characterized by an oscillating progression of the signal of the operating quantity 200; the shape of the oscillation may be, for instance, trigonometric or oscillating in some other way. In the present case, the oscillation has a progression that may be designated as a modified trigonometric function, the upper half-wave of the oscillation having a pointy-hat or tooth-like shape. This characteristic shape of the signal of the operating quantity 200 in the impact-screwing mode arises by virtue of the raising and releasing of the impact-mechanism striker and of the system chain—amongst other things, of the transmission 170—located between the impact mechanism and the electric motor 180.
[0082] The qualitative signal form of the impact mode is accordingly known in principle by reason of the inherent properties of the rotary impact wrench. In the method according to the invention shown in
[0083] In other applications, the first operating state to be detected may be characterized by signal forms other than oscillations, for instance by discontinuities or rates of growth of the function f(x). In such cases, the state-typical model signal form is characterized by precisely these parameters instead of by oscillations.
[0084] In
[0085] In a preferred configuration of the inventive method, the state-typical model signal form 240 can be established in method step S0. The state-typical model signal form 240 may have been saved, calculated or stored within the device.
[0086] In an alternative embodiment, the state-typical model signal form can, alternatively and/or additionally, be made available to the handheld power tool 100, for instance from an external data device.
[0087] In a method step S2 of the method according to the invention, the signal of the operating quantity of the electric motor 180 is compared with the state-typical model signal form 240. In the context of the present invention, the “comparing” feature is to be interpreted broadly and in the sense of a signal analysis, so that a result of the comparison may be, in particular, also a partial or slight concordance of the signal of the operating quantity 200 of the electric motor 180 with the state-typical model signal form 240, in which connection the degree of concordance of the two signals can be ascertained by various methods which will be mentioned at a later point.
[0088] In a method step S3 of the method according to the invention, the decision as to whether the first operating state obtains is made, at least partially, on the basis of the result of the comparison. In this connection, the degree of concordance is a parameter that is capable of being set at the factory or by the user for the purpose of setting a sensitivity of the detection of the first operating state.
[0089] In practical applications there may be provision that method steps S1, S2 and S3 are carried out repetitively during the operation of a handheld power tool 100, in order to monitor the operation for the presence of the first operating state. For this purpose, a segmentation of the ascertained signal of the operating quantity 200 can take place in method step S1, so that method steps S2 and S3 are implemented in respect of signal segments, preferentially always of the same fixed length.
[0090] For this purpose, the signal of the operating quantity 200 can be stored as a sequence of measured values in a memory, preferentially a ring memory. In this embodiment, the handheld power tool 100 includes the memory, preferentially the ring memory.
[0091] As already mentioned in connection with
[0092] One embodiment provides that the signal of the operating quantity 200 is recorded in method step S1 as a temporal progression of measured values of the operating quantity and, in a method step S1a following method step S1, a transformation takes place of the temporal progression of the measured values of the operating quantity into a progression of the measured values of the operating quantity as a quantity of the electric motor 180 correlating with the temporal progression, such as, for instance, the angle of rotation of the tool receptacle 140 or the angle of rotation of the motor.
[0093] The advantages of this embodiment will be described in the following with reference to
[0094] The illustration includes two signal progressions of the operating quantity 200 in the first operating mode—that is to say, in the case of a rotary impact wrench, in the rotary impact-screwing mode. In both cases, the signal includes a wavelength of an oscillation curve assumed in idealized manner to be sinusoidal, the signal of shorter wavelength, T1, exhibiting progression with higher impact frequency, and the signal of longer wavelength, T2, exhibiting a progression with lower impact frequency.
[0095] Both signals can be generated with the same handheld power tool 100 at various motor speeds and are, amongst other things, dependent on the speed of rotation that the user requests from the handheld power tool 100 via the operating switch.
[0096] If, for instance, the “wavelength” parameter is now to be drawn upon for the purpose of defining the state-typical model signal form 240, in the present case at least two different wavelengths T1 and T2 would accordingly have to have been saved as possible parts of the state-typical model signal form in order that the comparison of the signal of the operating quantity 200 with the state-typical model signal form 240 leads to the result “concordance” in both cases. Since the motor speed may change over time generally and to a great extent, this has the consequence that the wavelength being sought also varies, and as a result the methods for detecting this impact frequency would have to be adapted accordingly.
[0097] Given a large number of possible wavelengths, the cost of the process and of the programming would increase correspondingly quickly.
[0098] In the preferred embodiment, the time values on the abscissa are therefore transformed into values correlating with the time values, such as, for instance, acceleration values, higher-order jolt values, power values, energy values, frequency values, values of angle of rotation of the tool receptacle 140, or values of angle of rotation of the electric motor 180. This is possible, because by virtue of the fixed gear ratio of the electric motor 180 relative to the impact mechanism and to the tool receptacle 140 a direct, known dependence of the motor speed on the impact frequency arises. By virtue of this normalization, an oscillation signal of constant periodicity is obtained that is independent of the motor speed, this being represented in
[0099] Correspondingly, in this embodiment of the invention the state-specific model signal form 240 can be established to be valid for all speeds by a single parameter of the wavelength via the quantity correlating with time, such as, for instance, the angle of rotation of the tool receptacle 140 or the angle of rotation of the motor.
[0100] In a preferred embodiment, the comparison of the signal of the operating quantity 200 takes place in method step S2 with a comparison method, the comparison method encompassing at least one frequency-based comparison method and/or a comparative comparison method. The comparison method compares the signal of the operating quantity 200 with the state-typical model signal form 240 as to whether at least one predetermined threshold value is satisfied. The frequency-based comparison method encompasses at least bandpass filtering and/or frequency analysis. The comparative comparison method encompasses at least parameter estimation and/or cross-correlation. The frequency-based comparison method and the comparative comparison method will be described in more detail in the following.
[0101] In embodiments with bandpass filtering, the input signal, transformed to a quantity correlating with time, where appropriate as described, is filtered through a bandpass filter, the pass-range of which represents the predetermined threshold value. The pass-range arises out of the state-typical model signal form 240. It is also conceivable that the pass-range coincides with a frequency established in connection with the state-typical model signal form 240. In the case where amplitudes of this frequency exceed a previously established limiting value, as is the case in the first operating state, the comparison in method step S2 then leads to the result that the signal of the operating quantity 200 resembles the state-typical model signal form 240, and that the first operating state is consequently being carried out. The establishment of a limiting value of amplitude may in this embodiment be interpreted as a method step S2a, following method step S2, of a determination of the quality of the concordance of the state-typical model signal form 240 with the signal of the operating quantity 200, on the basis of which it is decided in method step S3 whether or not the first operating state obtains.
[0102] In embodiments that use frequency analysis as a frequency-based comparison method, the signal of the operating quantity 200 is transformed from a time-domain into the frequency-domain with appropriate weighting of the frequencies on the basis of the frequency analysis, for instance on the basis of fast Fourier transformation (FFT), in which connection the term “time-domain” according to the above statements is to be understood at this point both as “progression of the operating quantity over time” and as “progression of the operating quantity as a quantity correlating with time”.
[0103] Frequency analysis in this manifestation is sufficiently well-known as a mathematical tool of signal analysis from many fields of technology and is used, amongst other things, to approximate measured signals as series expansions of weighted periodic harmonic functions of varying wavelength.
[0104] In this case, the weighting factors indicate whether and to what extent the corresponding harmonic functions of a certain wavelength are present in the signal being examined.
[0105] In relation to the method according to the invention, it can accordingly be established with the aid of frequency analysis whether and with what amplitude the frequency assigned to the state-typical model signal form 240 is present in the signal of the operating quantity 200. As mentioned in connection with bandpass filtering, a limiting value of the amplitude can be established which is a measure of the degree of the concordance of the signal of the operating quantity 200 with the state-specific model signal form 240. If the amplitude of the frequency assigned to the state-specific model signal form 240 in the signal of the operating quantity 200 exceeds this limiting value, in method step S3 it is established that the first operating state obtains.
[0106] In embodiments in which the comparative comparison method is used, the signal of the operating quantity 200 is compared with the state-typical model signal form 240, in order to find out whether the measured signal of the operating quantity 200 exhibits at least a concordance of 50% with the state-typical model signal form 240 and hence the predetermined threshold is reached. It is also conceivable that the signal of the operating quantity 200 is compared with the state-typical model signal form 240, in order to ascertain a deviation of the two signals from one another.
[0107] In embodiments of the method according to the invention in which parameter estimation is used as comparative comparison method, the measured signal of the operating quantities 200 is compared with the state-typical model signal form 240, in the course of which estimated parameters are identified for the state-typical model signal form 240. With the aid of the estimated parameters, a degree of the concordance of the measured signal of the operating quantities 200 with the state-typical model signal form 240 can be ascertained as to whether the first operating state obtains. The parameter estimation in this connection is based on the balancing calculation which is a mathematical optimization method known to a person skilled in the art. With the aid of the estimated parameters, the mathematical optimization method enables the state-typical model signal form 240 to be assimilated to a series of measured data of the signal of the operating quantity 200. Depending a degree of the concordance of the estimated parameters of the state-typical model signal form 240 with the measured signal of the operating quantity 200, the decision can be made as to whether the first operating state obtains.
[0108] With the aid of the balancing calculation of the comparative method of parameter estimation, a measure of a deviation of the estimated parameters of the state-typical model signal form 240 from the measured signal of the operating quantity 200 can also be ascertained.
[0109] In order to decide whether a sufficient concordance or a sufficiently small deviation of the state-typical model signal form 240 with the estimated parameters from the measured signal of the operating quantity 200 obtains, a determination of the deviation is implemented in method step S2a following method step S2. If the deviation of the state-typical model signal form 240 from the measured signal of the operating quantity of 70% is ascertained, the decision can be made as to whether the first operating state was identified in the signal of the operating quantity and whether the first operating state obtains.
[0110] In order to decide whether a sufficient concordance of the state-specific model signal form 240 with the signal of the operating quantity 200 obtains, in another embodiment, in a method step S2a following method step S2, a determination of quality for the estimated parameters is implemented. In the course of the quality determination, values for a quality between 0 and 1 are ascertained, in which connection it holds that a higher value represents a higher concordance between the state-typical model signal form 240 with the signal of the operating quantity 200. In the preferred embodiment, the decision as to whether the first operating state obtains is made in method step S3 at least partially on the basis of the condition that the value of the quality within a range of 50%.
[0111] In one embodiment of the inventive method, the method of cross-correlation is used as comparative comparison method in method step S2. Like the mathematical methods described in the foregoing, the method of cross-correlation is also known as such to a person skilled in the art. In the case of the method of cross-correlation, the state-typical model signal form 240 is correlated with the measured signal of the operating quantity 200.
[0112] In comparison with the method of parameter estimation presented above, the result of the cross-correlation is again a signal sequence with an added signal length consisting of a length of the signal of the operating quantity 200 and of the state-typical model signal form 240, which represents the similarity of the time-shifted input signals. The maximum of this output sequence represents the point in time of the highest concordance of the two signals—that is to say, of the signal of the operating quantity 200 and of the state-typical model signal form 240—and is therefore also a measure of the correlation itself, which in this embodiment is used in method step S3 as a decision criterion for the existence of the first operating state. In the implementation in the method according to the invention, a significant difference from the parameter estimation is that any state-typical model signal forms can be used for the cross-correlation, whereas in the case of parameter estimation the state-typical model signal form 240 must be able to be represented by parameterizable mathematical functions.
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[0116] In
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[0118] The invention is not restricted to the exemplary embodiment described and represented; rather, it also encompasses all expert further developments within the scope of the invention defined by the claims.
[0119] In addition to the embodiments described and illustrated, further embodiments are conceivable which may encompass further modifications and also combinations of features.