POWER DRIVING TOOL WITH LATCH POSITION SENSOR

Abstract

A powered fastener driving tool including a latch with a position sensor, to detect the position of the driver during tool operation. The sensor communicates to the system controller, which determines, based on the position of the latch, if the motor should be energized or the motor braking energized. This latch sensor detection provides an accurate location of the driver to the system controller, helping prevent wear and tear on the lifter and driver, and increasing the life of the tool. The driver includes a plurality of through holes, in which the latch can engage when properly aligned. When the latch is engaged with a through hole, the sensor communicates to the controller than the motor may be energized. However, when the latch is not engaged with a through hole, the sensor communicates to the controller that the motor brake should be energized.

Claims

1. A driver machine configured for use in a fastener driving tool, said driver machine comprising: (a) a hollow cylinder having a movable piston therewithin; (b) a guide body that is sized and shaped to receive a fastener that is to be driven; (c) an elongated driver that is in mechanical communication with said piston, said driver being sized and shaped to push said fastener from an exit portion of said guide body, said driver extending from a first end to a second end and having an elongated face therebetween, said first end being proximal to said piston, said second end being distal from said piston and making contact with said fastener during a driving stroke, said driver exhibiting a plurality of protrusions at first predetermined locations in a surface of the driver; said driver having a plurality of openings at second predetermined locations in said surface of the driver; (d) a movable lifter that moves said driver toward a ready position during a return stroke; (e) a movable latch that is in mechanical communication with said driver during said return stroke, said latch being biased to engage said plurality of openings under predetermined conditions; (f) a magnet mounted to said latch; (g) a magnetic sensor mounted proximal to said latch; and (h) a system controller comprising: (i) a processing circuit, (ii) a memory circuit including instructions executable by said processing circuit, (iii) an input/output interface (I/O) circuit, said I/O circuit being in communication with said magnetic sensor so that an output signal produced by said magnetic sensor is signal-conditioned as a latch position signal when received at said processing circuit; (i) wherein: said system controller is configured to detect a position of said latch after said driving stroke and: (i) if the latch has moved to a first predetermined position, then said magnetic sensor will detect said magnet, and said return stroke will be permitted to occur; and (ii) if the latch has not moved to said first predetermined position, then said magnetic sensor will fail to detect said magnet, and said return stroke will be prevented from occurring.

2. The driver machine of claim 1, wherein: if said latch moved to a first predetermined position after said driving stroke, then said latch has moved into one of said plurality of openings in said driver.

3. The driver machine of claim 1, wherein: (a) if the latch has attempted to move into said plurality of openings in said driver at the end of said driving stroke, but, if the driver finished its driving stroke at a position that is out of specification along a driver track of said guide body, then (b) said latch is unable to actually move into one of said plurality of openings in said driver, and therefore, the magnet will be out of position and said magnetic sensor will fail to detect said magnet.

4. The driver machine of claim 1, wherein: (a) said lifter includes a plurality of extensions that are sized and shaped to engage with said plurality of protrusions of the driver; and (b) if said latch moved to a first predetermined position after said driving stroke, then said lifter will rotate such that at least one of said plurality of extensions forces said driver to undergo said return stroke by mechanically engaging with at least one of said plurality of protrusions.

5. The driver machine of claim 4, wherein: (a) said lifter is propelled by a motor which, when energized, rotates in a rotational direction; (b) to begin said driving stroke, said lifter is caused to rotate a small distance, which releases said driver from contact with the lifter and allows the driver to quickly move through said driving stroke; (c) during said driving stroke, said lifter will continue to coast in its rotational direction, even if the motor is turned off at that time; (d) after a predetermined time interval TA, said system controller determines whether the magnetic sensor is detecting said magnet, thereby determining whether or not the latch has moved to said first predetermined position at the end of said driving stroke; (e) under normal conditions, said magnet is detected and said motor will be re-energized to allow said lifter to continue rotating so that the lifter will engage with the plurality of protrusions of the driver to force said driver to undergo said return stroke; and (f) under abnormal conditions, said magnet is not detected and said motor will be quickly stopped from further rotating the lifter, so as to prevent the lifter from physically contacting the plurality of protrusions of the driver, and thus prevent damage to said driver machine.

6. The driver machine of claim 1, wherein: (a) said latch is pivotable, such that a first portion of the latch is mounted at a pivot axis that is fixed in place with respect to said guide body, and a second portion of the latch is free to move with respect to said pivot axis; (b) during said return stroke of the driver, said second portion of the latch slides along a surface of the driver and engages into said plurality of openings as the openings move by the position of the latch second portion; and (c) during said driving stroke of the driver, said second portion of the latch is initially held in a non-engagement orientation by a solenoid for a predetermined time interval TB, then after said predetermined time interval TB has expired, said latch is released from said non-engagement orientation, so that said second portion of the latch able to engage with one of said plurality of openings of the driver to prevent said driver from moving farther along a driver track in said guide body, in case said driver did not successfully complete a normal driving stroke.

7. The driver machine of claim 1, wherein: (a) said latch comprises a spring-loaded plunger that is mounted at about a right angle with respect to a movement of said driver; (b) during said return stroke of the driver, said latch is initially held in a non-engagement orientation by a solenoid for a first predetermined time interval TB, then after said first predetermined time interval TB has expired, said latch is released from said non-engagement orientation, so that said latch may engage into one of said plurality of openings in the driver to assist in holding said driver at a ready position, before said driving stroke; and (c) during said driving stroke of the driver, said latch is initially held in a non-engagement orientation by said solenoid for a predetermined time interval TC, then after said predetermined time interval TC has expired, said latch is released from said non-engagement orientation, so that the latch able to engage with one of said plurality of openings of the driver to prevent said driver from moving farther along a driver track in said guide body, in case said driver did not successfully complete a normal driving stroke.

8. The driver machine of claim 1, wherein: said magnetic sensor comprises a Hall Effect Sensor.

9. The driver machine of claim 1, further comprising: a solenoid that controls a position of said latch, and a spring that biases said latch toward said driver; wherein said solenoid is operable in two predetermined conditions: (i) under a first predetermined condition, the solenoid is energized and causes said latch to move out of the way of said driver, so that the driver is unimpeded and is allowed to move from said ready position to a driven position; (ii) under a second predetermined condition, the solenoid is de-energized and allows said latch to be moved by the spring toward a position that may impede said driver, so that the latch will engage one of said plurality of openings and hold said driver from moving toward said driven position.

10. The driver machine of claim 9, wherein: said solenoid is operable in a third predetermined condition, in which the solenoid is de-energized and allows said latch to impede said driver, but, since the driver stopped movement at an out-of-specification position, the latch has not engaged one of said plurality of openings.

11. A latch system for a driving machine configured for use in a fastener driving tool, said system comprising: (a) an elongated driver, said driver extending from a first end to a second end and having an elongated face therebetween, said driver exhibiting a plurality of protrusions at first predetermined locations in a surface of the driver; said driver having a plurality of openings at second predetermined locations in said surface of the driver; (b) a movable lifter that moves said driver toward a ready position during a return stroke; (c) a movable latch that is in mechanical communication with said driver during said return stroke, said latch being biased to engage said plurality of openings under predetermined conditions, said latch including a detection zone at a predetermined location on at least a portion of the latch; (d) a latch position sensor capable of sensing the detection zone of the latch; and (e) a system controller comprising: (i) a processing circuit, (ii) a memory circuit including instructions executable by said processing circuit, (iii) an input/output interface (I/O) circuit, said I/O circuit being in communication with said latch position sensor so that an output signal produced by said latch position sensor is signal-conditioned as a latch position signal when received at said processing circuit; (f) wherein: said system controller is configured to determine a position of said latch after a driving stroke and: (i) if the latch has moved to a first predetermined position, then said latch position sensor will detect said detection zone, and said return stroke will be permitted to occur; and (ii) if the latch has not moved to said first predetermined position, then said latch position sensor will fail to detect said detection zone, and said return stroke will be prevented from occurring.

12. The latch system of claim 11, wherein: (a) if the latch has moved to said first predetermined position, then at least a portion of the latch has moved into one of said plurality of openings of the driver; and therefore (b) the driver, after said driving stroke, has moved to a location that is acceptable for allowing said return stroke to occur.

13. The latch system of claim 11, wherein said latch position sensor comprises one of: (a) a magnetic sensor; (b) an optical sensor; (c) a metal-detecting proximity sensor; and (d) a limit switch.

14. The latch system of claim 13, wherein: said magnetic sensor is a Hall Effect Sensor and a magnet is mounted to said latch at said detection zone.

15. The latch system of claim 11, wherein: said latch is pivotable.

16. The latch system of claim 15, wherein: said latch is biased towards said plurality of openings by a spring.

17. The latch system of claim 11, further comprising: a solenoid, said solenoid being in mechanical communication with said latch, and said solenoid being operable in three predetermined conditions: (i) under a first predetermined condition, the solenoid is energized and moves said latch away from said driver, so that the driver is unimpeded and allowed to move from said ready position to a driven position; (ii) under a second predetermined condition, the solenoid is de-energized and allows said latch to impede said driver, so that the latch will engage one of said plurality of openings and hold said driver during said return stroke. (iii) under a third predetermined condition, in which the solenoid is de-energized and allows said latch to impede said driver, but the latch has not engaged one of said plurality of openings.

18. The latch system of claim 17, wherein: if the third predetermined condition occurs after said driving stroke, then an error state is in effect, and the system controller will prevent actuation of said return stroke.

19. A method for operating a driving machine configured for use in a fastener driving tool, said method comprising: (a) providing an elongated driver, said driver extending from a first end to a second end and having an elongated face therebetween, said driver exhibiting a plurality of protrusions at first predetermined locations in a surface of the driver; said driver having a plurality of openings at second predetermined locations in said surface of the driver; (b) providing a movable lifter that moves said driver toward a ready position during a return stroke; (c) providing a movable latch that is in mechanical communication with said driver during said return stroke, said latch being biased to engage said plurality of openings under first predetermined conditions, said latch including a detection zone at a predetermined location on at least a portion of the latch; (d) providing a latch position sensor capable of sensing the detection zone of the latch; (e) providing a system controller that includes: (i) a processing circuit, (ii) a memory circuit including instructions executable by said processing circuit, (iii) an input/output interface (I/O) circuit, said I/O circuit being in communication with said latch position sensor so that an output signal produced by said latch position sensor is signal-conditioned as a latch position signal when received at said processing circuit; (f) inspecting a position of said latch after a driving stroke; and (g) determining if the latch has moved to a first predetermined position, using said latch position sensor to detect said detection zone, and (i) if so, then permitting said return stroke to occur; (ii) if not, then preventing said return stroke from occurring.

20. The method of claim 19, wherein: (a) if the latch has moved to said first predetermined position, then at least a portion of the latch has moved into one of said plurality of openings of the driver; and therefore (b) the driver, after said driving stroke, has moved to a location that is acceptable for allowing said return stroke to occur.

21. The latch system of claim 19, further comprising the step of: biasing said latch toward said plurality of openings using a spring.

22. The latch system of claim 19, further comprising the step of: providing a solenoid to move said latch away from said plurality of openings, under second predetermined conditions, to allow a driving stroke to occur.

23. The latch system of claim 19, wherein: said latch position sensor comprises a magnetic sensor, and a magnet is mounted to said latch at said detection zone.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0026] The accompanying drawings incorporated in and forming a part of the specification illustrate several aspects of the technology disclosed herein, and together with the description and claims serve to explain the principles of the technology. In the drawings:

[0027] FIG. 1 is a front perspective view of a fastener driving tool, constructed according to the principles of the technology disclosed herein.

[0028] FIG. 2 is a front perspective view, in partial cut-away, showing the driver and latch of the fastener driving tool of FIG. 1.

[0029] FIG. 3 is a front perspective view, in partial cut-away, showing a properly-aligned latch that is engaged in a through-hole in the driver of the fastener driving tool of FIG. 1.

[0030] FIG. 4 is a front perspective view, in partial cut-away, showing the latch misaligned with a driver through-hole of the fastener driving tool of FIG. 1.

[0031] FIG. 5 is a side perspective view, in partial cut-away, showing the latch position sensor and a properly-aligned latch engaged with a driver through-hole of the fastener driving tool of FIG. 1.

[0032] FIG. 6 is a side perspective view, in partial cut-away, showing the latch position sensor and the latch misaligned with a driver through-hole of the fastener driving tool of FIG. 1.

[0033] FIG. 7 is a block diagram showing some of the major electronic and electrical components for the fastener driving tool of FIG. 1.

[0034] FIG. 8 is a perspective view of the piston, driver, lifter, and latch, depicting an energized solenoid position of the fastener driving tool of FIG. 1.

[0035] FIG. 9 is a front elevational view of the piston, driver, lifter, and latch, depicting an energized solenoid position of the fastener driving tool of FIG. 1.

[0036] FIG. 10 is a rear elevational view of the piston, driver, lifter, and latch, depicting an energized solenoid position of the fastener driving tool of FIG. 1.

[0037] FIG. 11 is a perspective view of the piston, driver, lifter, and latch, depicting a latch engaged position of the fastener driving tool of FIG. 1.

[0038] FIG. 12 is a front elevational view of the piston, driver, lifter, and latch, depicting a latch engaged position of the fastener driving tool of FIG. 1.

[0039] FIG. 13 is a rear elevational view of the piston, driver, lifter, and latch, depicting a latch engaged position of the fastener driving tool of FIG. 1.

[0040] FIG. 14 is a perspective view of the piston, driver, lifter, and latch, depicting a latch misaligned position of the fastener driving tool of FIG. 1.

[0041] FIG. 15 is a front elevational view of the piston, driver, lifter, and latch, depicting a latch misaligned position of the fastener driving tool of FIG. 1.

[0042] FIG. 16 is a rear elevational view of the piston, driver, lifter, and latch, depicting a latch misaligned position of the fastener driving tool of FIG. 1.

[0043] FIG. 17 is a flow chart showing some of the important logical steps performed by the controller of the fastener driving tool of FIG. 1, in which the driver is ready to drive a fastener.

[0044] FIG. 18 is a flow chart showing some of the important logical steps performed by the controller of the fastener driving tool of FIG. 1, in which the lifter is ready to return the driver to a ready position.

DETAILED DESCRIPTION

[0045] Reference will now be made in detail to the present preferred embodiment, an example of which is illustrated in the accompanying drawings, wherein like numerals indicate the same elements throughout the views.

[0046] It is to be understood that the technology disclosed herein is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings. The technology disclosed herein is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless limited otherwise, the terms “connected,” “coupled,” or “mounted,” and variations thereof herein are used broadly and encompass direct and indirect connections, couplings, or mountings. In addition, the terms “connected” or “coupled” and variations thereof are not restricted to physical or mechanical connections or couplings. Furthermore, the terms “communicating with” or “in communications with” refer to two different physical or virtual elements that somehow pass signals or information between each other, whether that transfer of signals or information is direct or whether there are additional physical or virtual elements therebetween that are also involved in that passing of signals or information. Moreover, the term “in communication with” can also refer to a mechanical, hydraulic, or pneumatic system in which one end (a “first end”) of the “communication” may be the “cause” of a certain impetus to occur (such as a mechanical movement, or a hydraulic or pneumatic change of state) and the other end (a “second end”) of the “communication” may receive the “effect” of that movement/change of state, whether there are intermediate components between the “first end” and the “second end,” or not. If a product has moving parts that rely on magnetic fields, or somehow detects a change in a magnetic field, or if data is passed from one electronic device to another by use of a magnetic field, then one could refer to those situations as items that are “in magnetic communication with” each other, in which one end of the “communication” may induce a magnetic field, and the other end may receive that magnetic field, and be acted on (or otherwise affected) by that magnetic field.

[0047] The terms “first” or “second” preceding an element name, e.g., first inlet, second inlet, etc., are used for identification purposes to distinguish between similar or related elements, results or concepts, and are not intended to necessarily imply order, nor are the terms “first” or “second” intended to preclude the inclusion of additional similar or related elements, results or concepts, unless otherwise indicated.

[0048] In addition, it should be understood that embodiments disclosed herein include both hardware and electronic components or modules that, for purposes of discussion, may be illustrated and described as if the majority of the components were implemented solely in hardware.

[0049] However, one of ordinary skill in the art, and based on a reading of this detailed description, would recognize that, in at least one embodiment, the electronic based aspects of the technology disclosed herein may be implemented in software. As such, it should be noted that a plurality of hardware and software-based devices, as well as a plurality of different structural components may be utilized to implement the technology disclosed herein. Furthermore, if software is utilized, then the processing circuit that executes such software can be of a general purpose computer, while fulfilling all the functions that otherwise might be executed by a special purpose computer that could be designed for specifically implementing this technology.

[0050] It will be understood that the term “circuit” as used herein can represent an actual electronic circuit, such as an integrated circuit chip (or a portion thereof), or it can represent a function that is performed by a processing circuit, such as a microprocessor or an ASIC that includes a logic state machine or another form of processing element (including a sequential processing circuit). A specific type of circuit could be an analog circuit or a digital circuit of some type, although such a circuit possibly could be implemented in software by a logic state machine or a sequential processor. In other words, if a processing circuit is used to perform a desired function used in the technology disclosed herein (such as a demodulation function), then there might not be a specific “circuit” that could be called a “demodulation circuit;” however, there would be a demodulation “function” that is performed by the software. All of these possibilities are contemplated by the inventors, and are within the principles of the technology when discussing a “circuit.”

[0051] Referring now to FIG. 1, a first embodiment of a fastener driving tool is generally designated by the reference numeral 10. This tool 10 is mainly designed to linearly drive fasteners such as nails and staples. The tool 10 includes an outer housing 20, a handle portion 22, a magazine portion 24 for holding fasteners, an exit portion 28, and a trigger 26. The tool 10 also includes a motor 40 (see FIG. 2), which acts as a prime mover for the tool. A battery pack may be attached near the rear of the handle portion 22, and this battery provides electrical power for the motor 40 as well as for the control system.

[0052] Referring now to FIG. 2, a driver machine subassembly (“S/A”) is generally designated by the reference numeral 70. (See FIG. 8 for the best view of this driver machine S/A 70.) The driver machine S/A 70 includes a piston 32, an elongated driver 36, and a latch subassembly (“S/A”) 68. Note that the piston 32 is contained within a hollow cylinder 30, and this cylinder 30 also contains pressurized gas above the piston. When a user pulls the trigger 26, this pressurized gas forces the piston 32 to drive a fastener into a substrate. The tool 10 also includes a printed circuit board that contains a controller 50 (see FIG. 7).

[0053] One potential problem with this type of mechanism is the possibility of the driver stopping at a position that is out of specification, and, if that occurs, the lifter may have trouble engaging the driver teeth, such that the driver cannot be properly lifted back to its ready position. In some situations, the driver ends up in a position in which the mechanical “pins” of the lifter end up impacting directly against the “driver teeth” and, in that situation, these mechanical components can jam together; and under more severe conditions, the rotary motion of the lifter pins impacting the driver teeth at an inappropriate place may actually break the driver at the point of contact.

[0054] In view of these potential operating conditions that can be out of specification, a latch position sensor 170 has been designed to detect if the latch has properly engaged with the driver. Note that the latch is designed to “catch” the driver at times when the driver should not be allowed to move through an entire driving stroke, as discussed below.

[0055] A guide body 34 constrains the driver 36 during a “driving stroke.” The guide body 34 helps line up the driver 36 with a fastener from the magazine 24 that is to be driven into a substrate. The driver 36 has a plurality of openings 38 (or “through holes”) on one of its faces into which a movable latch 60 (also referred to as “pivotable latch”) may engage. The opening 38 is illustrated as an oval (see FIG. 8 for the best view), which is a preferred shape for this opening, rather than a circle. Of course, other shapes could be used, such as a rectangle, although that may be more difficult to machine than the oval that is illustrated in FIG. 2.

[0056] The movable latch 60 is part of the latch S/A 68 (see FIG. 8), which also includes a latch magnet 62, a latch position sensor 170, a spring-loaded plunger 66 (which biases the latch 60 towards the driver 36), and a solenoid 164. Note that the latch magnet 62 is embedded inside a small cylindrical portion of the latch 60. When the solenoid 164 is activated, the plunger 66 is retracted, thereby pulling the latch 60 away from the driver 36. The solenoid 164 is only activated when the user is pulling the trigger 26 and the tool 10 is about to drive a fastener.

[0057] Referring now to FIG. 3, the latch 60 is in an “engaged position.” In other words, the latch 60 has successfully engaged one of the plurality of openings 38. Note that one of a plurality of lifter pins 42 is shown, including (optionally) a roller 44 (see FIG. 10). In this “engaged” mode of operation, the driver can be lifted, due to the electronic control system, as described below.

[0058] Referring now to FIG. 4, in this view the latch 60 has not successfully engaged one of the plurality of openings 38. This unsuccessful engagement is referred to herein as the “misaligned position.” Note that the latch has not failed; quite the opposite—the misaligned latch cannot perform its typical function because the driver stopped at an improper position, also referred to as an “out of specification” position, as described below in greater detail. If this occurs after the driver has undergone a driving stroke, then the lifter will not be able to successfully engage the driver to force the driver to undergo a return stroke. Indeed, such a misaligned position could cause the lifter to literally break the driver, if that lifting function is not prevented from occurring. And note that it is the driver being out of position that causes this situation, not the latch.

[0059] In “normal” operating conditions, a rotatable lifter 48 is used to engage a plurality of driver protrusions 46 (also referred to as “driver teeth”) (see FIG. 8), which returns (or “lifts”) the driver 36 to a “ready position.” The lifter 48 includes the plurality of lifter pins 42, which engage the driver teeth 46 during a lift stroke. Optionally, rollers 44 (see FIG. 10) may be mounted on the lifter pins 42 to help the lifter 48 more smoothly rotate and engage with the driver teeth 46.

[0060] Driver 36 is rather elongated, and as an individual element can best be seen in FIG. 8. The main body of its elongated face is substantially rectangular. There are multiple protrusions or teeth 46 that are positioned along one of the longitudinal edges of the driver. In the illustrated embodiment, these teeth 46 protrude in a transverse direction from the longitudinal centerline of driver 36, and they are spaced-apart from one another along the outer longitudinal left edge of the driver 36. The positions of teeth 46 are clearly illustrated in FIG. 8. It will be understood that the precise positions for the teeth 46 could be at different locations from those illustrated for the driver 36, without departing from the principles of the technology disclosed herein.

[0061] Referring now to FIG. 5, the latch 60 is depicted in the engaged position. Note that a latch position sensor 170 is illustrated above the latch 60 (in this view). The latch position sensor 170 detects the latch 60 based on the location of the latch magnet 62. The latch position sensor may be a Hall-effect sensor, for example, or it may be another type of magnetic sensor. If the latch position sensor 170 detects the latch magnet 62, then the sensor 170 communicates a signal to the system controller 50, which then infers that the driver 36 is in the proper position.

[0062] It will be understood that the latch position sensor may be any variety of sensor type as long as it can reliably detect the position of the latch, and preferably is of a non-contact type sensor. Certainly, an optical sensor could be used to detect the movements of a specific portion of the latch, such as a protruding tab, for example. The sensor would typically be “looking for” some type of “detection zone” on the movable latch, and that detection zone may well be at a different location on the latch itself, depending on the type of sensor that is being used as the “latch position sensor” to perform these functions. The main basic types of sensors that are recommended include a magnetic sensor, an optical sensor, a metal-detecting proximity sensor; and a limit switch. Most of these types of sensors typically are non-contact sensors.

[0063] Referring now to FIG. 6, the latch 60 is depicted in the misaligned position. Note that, in this orientation, the latch magnet 62 is not beneath the latch position sensor 170. In this situation, since the sensor 170 cannot detect the latch magnet 62, the sensor 170 communicates a signal to the system controller 50 that the driver 36 is not in the proper position. These sensor (or latch) “states,” and how the system deals with them, will be discussed in greater detail below (see FIGS. 17-18).

[0064] Latch Positions

[0065] In order to better understand the latch sensor concept, a brief discussion describing the various latch states is warranted. The concept of the latch is first and foremost a safety concept. The latch engages the driver so that the tool cannot drive a fastener unless it is safe for a human user. The latch also holds the driver in the ready position, or any other position in which the latch has engaged an opening, in other words, the latch is in mechanical communication with the driver. This mechanical communication allows the latch to be used as a driver position indicator. Three basic positions of the latch are described below, illustrating this driver position indicator/latch sensor concept.

[0066] The first latch position occurs when the solenoid is energized, and the latch is moved out of the way of the driver. The solenoid retracts the spring-loaded plunger, which pulls the latch away from the driver, thereby leaving the driver unimpeded by the latch. Note that the spring is mounted in a way to bias the latch towards the driver when the solenoid is not energized. This “energized position” is used only when driving a fastener. Note that this first position is not detected by the controller, in the illustrated embodiment.

[0067] The second latch position occurs when the latch successfully engages with one of the driver openings. This is the “engaged position.” In this second position, the latch sensor will communicate to the controller that it is safe to lift the driver. Therefore, the controller will engage the motor and lift the driver back to the ready position. (See the flow chart logic of FIGS. 17 and 18.)

[0068] However, the third latch position can be the most important, which occurs when the latch has not successfully engaged one of the driver openings (the “misaligned position”). This third latch position may occur after a user has pulled the trigger. The system controller energizes the lifter motor which causes the lifter to slightly rotate. Then the system controller waits to detect the latch, and if it does not the lifter motor is de-energized. At this point, the LEDs blink indicating a jam. (Again, see the flow chart logic.) Alternatively, as noted above, if the latch ends up in a misaligned position after the driver has undergone a driving stroke, that means that the latch is attempting to do its job, but that it cannot—because the driver is mispositioned. The latch position sensor will detect this situation, and its job is then to prevent the lifter from engaging the driver. In such a circumstance, the misaligned latch and its associated latch position sensor will indeed be performing a primary function, which is to keep the tool from potentially being damaged.

[0069] Referring now to FIG. 7, a printed circuit board that contains the controller is generally designated by the reference numeral 50. A trigger switch 166 (which sense the position of the trigger) provides an input to the control system 50. There are also other input devices used with the system controller, including a safety element position sensor 168, and the latch position sensor 170.

[0070] The tool's system controller will typically include a microprocessor or a microcomputer integrated circuit 150 that acts as a processing circuit. At least one memory circuit 152 will also typically be part of the controller, including Random Access Memory (RAM) and Read Only Memory (ROM) devices. To store user-inputted information (if applicable for a particular tool model), a non-volatile memory device would typically be included, such as EEPROM, NVRAM, or a Flash memory device.

[0071] The processing circuit 150 communicates with external inputs and outputs, which it does by use of an input/output interface circuit 154. The processing circuit 150, memory circuit 152, and the interface (I/O) circuit 154 communicate with one another via a system bus 156, which carries address lines, data lines, and various other signal lines, including interrupts.

[0072] I/O circuit 154 has the appropriate electronics to communicate with various external devices, including input-type devices, such as sensors and user-controlled switches, as well as output-type devices, such as a motor and indicator lamps. The signals between the I/O interface circuit 154 and the actual input and output devices are carried by signal pathways, typically a number of electrical conductors, grouped under the general designation 158 on FIG. 7.

[0073] Some of the output devices include a lifter motor 40 (also referred to as “M”), a brake circuit 140 (also referred to as “B”), and one or more light emitting diodes 162 (also referred to as “LEDs”). Each of the output devices will typically have a driver circuit, such as a motor driver circuit 160 for the lifter motor 40. The position of the latch 60 is controlled by an electromechanical device, such as a solenoid or a motor, as desired by the system designer.

[0074] The input devices for the tool 10 can include various sensors, including the trigger switch 166, safety contact element switch 168, and the latch position sensor 170. If the switches 166 and 168 are standard electromechanical devices (such as limit switches), then typically no driver circuit is necessary. However, if the trigger switch and safety element switch comprise solid state sensing elements, then some type of interface circuit could be needed, and those circuits are included on FIG. 7 in the reference numerals 166 and 168, respectively.

[0075] The tool 10 also includes a position sensor that can detect (or infer) certain physical positions of the driver 36. As discussed above, this sensor is referred to as the latch position sensor 170. As noted above, it is desired that this sensor is a “non-contact” device, and in the illustrated embodiment, this sensor is a magnet sensor.

[0076] Additional input and output devices could be included with the fastener driving tool 10, if desired. For example, a small display could be added, to show certain information about usage or the condition of the tool. Other types of sensing devices or output devices could also be added, if desired by the system designer, without departing from the principles of the technology disclosed herein.

[0077] Referring now to FIGS. 8-10, the driver machine S/A 70 is in a “ready to fire” position (the “ready” position). The plurality of openings 38 and the driver protrusions 46 are clearly depicted. Note that the movable latch 60 has been moved away from the driver 36. In this view, the solenoid 164 is energized, which causes the solenoid plunger 66 to retract, thereby also retracting the latch 60 away from the driver 36. In this operating state, the latch magnet 62 is not in a detectable range of the latch sensor 170 (in this retracted position) and, as noted above, this would cause a misaligned position alert if the controller was not already programmed to ignore this solenoid energized state.

[0078] The retracted state of the latch 60 is also clearly visible in FIG. 9. Note that the latch sensor 170 is not directly over the latch magnet 62. FIG. 10 depicts a clear view of one of the lifter pins 42 holding a driver tooth 46. In the longer-term ready condition (or “state”), the latch 60 would also be engaged in one of the plurality of openings 38 to help secure the driver 36. However, in this “just about to drive” ready condition depicted in FIG. 10, since the latch 60 has disengaged from the driver, the lifter 48 merely needs to rotate a bit more to push the driver 36 up a very small amount until the driver tooth 46 clears that lifter pin 42, and then the tool performs a driving stroke and drives a fastener into a substrate.

[0079] Referring now to FIGS. 11-13, the driver machine S/A 70 is illustrated with the latch 60 in the engaged position. Here, the lifter pin 42 is safely positioned between two of the driver teeth 46 and is ready for a lift stroke. The latch magnet 62 is under the latch sensor 170, which means the sensor 170 communicates to the system controller 50 that the latch 60 is in the engaged position and the motor 40 should be energized to perform that lifting stroke.

[0080] FIG. 12 depicts how deep the latch 60 engages with the opening 38. The latch 60 provides a secure engagement in the event a lifter pin 42 does not properly engage one of the driver teeth 46. During a lift stroke, the lifter pins 42 routinely engage and slip off the driver teeth 46, as the lifter rotates in normal operation. The latch 60 ensures that the driver 36 doesn't slip during that lift cycle.

[0081] FIG. 13 illustrates again how securely the latch 60 engages into the opening 38 of the driver. Note also how secure the engagement is between the lifter pin 42 and the driver teeth 46. When the lifter rotates to begin a lifting stroke, the spring-loaded latch slips out of the driver opening 38, and then slides along the smooth side face of the driver until it encounters the next driver opening 38. But this “in and out” movement of the driver continues throughout the lifting stroke. However, if the driver should somehow be released by human error, the latch will catch the downward-moving driver at one of its openings 38, and hold it there.

[0082] Referring now to FIGS. 14-16, the driver machine S/A 70 is in a misaligned position. The tool has attempted to drive a fastener; however, something occurred in a way that the driver 36 did not properly align with the lifter pins 42 or the latch 60 (for example, the driver 36 could have jammed, because a fastener became misaligned). Note that the latch 60 is not engaged with the opening 38, thereby preventing the latch magnet 62 from pivoting to its correct position within the detection field of the latch sensor 170. Therefore, the latch sensor 170 communicates with the system controller 50 that the latch is in a disengaged position, and therefore, the controller should energize the brake motor to prevent a lifting stroke.

[0083] FIG. 15 depicts the latch 60 touching the side face of the driver 36, instead of engaging in one of the openings 38. The misalignment between the latch sensor 170 and the latch magnet 62 is also depicted. FIG. 16 illustrates one of the lifter pins 42 touching a driver tooth 46. When the system controller detects this disengaged latch position, the lifter motor is de-energized, and the LEDs blink to indicate a jam. First, nothing is holding the driver 36 in place, since neither the latch 60 or a lifter pin 42 is engaged with an opening 38 or a driver tooth 46, respectively. Second, if the lifter 48 further rotated when in this state, it could cause damage to both the lifter pins 42 and the driver teeth 46, which could permanently damage the tool 10. This condition is the reason why the system controller's 50 knowledge of where the latch 60 is positioned (either engaged or misaligned) is important: to protect the user, and to prolong the life of the tool.

[0084] Referring now to FIG. 17, a flowchart shows several steps in the operation of the tool relating to the drive sequence and the latch function. First, at a step 200 that begins a “Release Driver Routine,” the user pulls the trigger 26 and presses the tool 10 against a substrate, which communicates to the system controller 50 that it should release the driver. Then, at a decision step 210, the controller 50 determines if the lifter is in the ready position. If it is, then the solenoid 164 is energized at a step 220. If the lifter is not in the ready position, then at a decision step 212 the controller 50 determines if this is the first drive after power up. If not, then the solenoid 164 is energized at step 220. However, if it is the first drive after power up, then at a decision step 214 the controller 50 determines if the latch is fully engaged. If yes, then the controller 50 energizes the motor to lift the driver to the ready position at a step 216. After lifting the driver to the ready position, at a step 218, the routine ends, and the logic returns to other tasks.

[0085] On the other hand, if the logic flow is now in the other branch at step 220, in which the solenoid was energized to disengage the latch, the controller 50 then starts the motor at a step 222 (at a “max on” 100% duty cycle). This action moves the lifter a small amount, which releases the driver at a step 224, and the driver drives the fastener. Next, at a step 226, the controller 50 de-energizes the motor to start slowing the lifter. At a step 228, the controller 50 communicates to the latch solenoid and allows it to return to the biased “locked” position—i.e., the solenoid is de-energized, which releases the latch so that its spring-loading will pivot the latch toward the driver. Then, at a decision step 230, the controller 50 determines if the latch is in the fully engaged position. If yes, then the controller 50 goes to step “A” to continue that branch of the logic flow (see FIG. 18). If no, then at a step 240 the system enters a “LOCK OUT” mode.

[0086] Note that at step 214, if the latch is not in the fully engaged position, the system also enters the LOCK OUT mode at this same step 240. The LOCK OUT mode forces the tool to return all functions to a normal non-actuated state. The system controller 50 instructs a red LED to pulse that is visible to a user, at a step 242. Additionally, at a step 244, the system controller 50 instructs a different LED to also pulse. These pulsing LEDs continue until the tool is powered off or goes into sleep mode. As a practical note, the user may simply pull the battery out, for example. However, until the system is powered off the tool cannot be used.

[0087] Referring now to FIG. 18, the logic flow at step A (from FIG. 17) is directed to a step 250, where the system controller 50 begins the Driver Return Routine. (This could also be referred to as the “Driver Lift Routine.”) First, at a step 252, the controller 50 energizes the motor (again, at a “max on” 100% duty cycle). Then, at a decision step 254, the controller 50 determines if the lifter has rotated once “in time.” This “time” variable is set in the code programmed into the system controller memory (as determined by the tool's system designer). If it did not, then the controller logic moves to step “B” (see FIG. 17), which in turn returns to the LOCK OUT mode at step 240.

[0088] However, if one rotation “in time” properly occurred, then at a decision step 258, the controller 50 determines if the lifter rotated a second time in the proper time frame. Again, this “time” variable is set in the code programmed into the system controller memory. If the result is yes, then at a step 260 the controller 50 stops the motor, and captures shot data. (The lifting stroke has successfully completed.) If not, then the controller logic moves to step B, again (see FIG. 17). After stopping the motor in step 260, the controller moves to a step 270, and the lifter and driver have reached the “Ready” position.

[0089] At step 270, the latch 60 should now be inserted into one of the driver openings 38, to act as a safety device that will prevent the driver from “shooting” at an inappropriate time. As discussed above, the latch will have to be withdrawn from the opening 38 (by action of the solenoid) before the next driving stroke may occur. The logic flow is now directed to a step 272, which is the end of this routine (EOR), and the logic returns to other tasks.

[0090] Alternatively, at step 270, the latch 60 may instead rest on the driver 36 edge. In this configuration, the driver 36 is being held in the ready position solely by one of the lifter pins 42. However, if the driver 36 does slip off the lifter pin 42, the driver 36 will not move far until the latch 60 does move into engagement with one of the openings 38.

[0091] Note that some of the embodiments illustrated herein do not have all of their components included on some of the figures herein, for purposes of clarity. To see examples of such outer housings and other components, especially for earlier designs, the reader is directed to other U.S. patents and applications owned by Senco. Similarly, information about “how” the electronic controller operates to control the functions of the tool is found in other U.S. patents and applications owned by Senco. Moreover, other aspects of the present tool technology may have been present in earlier fastener driving tools sold by the Assignee, Kyocera Senco Industrial Tools, Inc., including information disclosed in previous U.S. patents and published applications. Examples of such publications are patent numbers U.S. Pat. Nos. 6,431,425; 5,927,585; 5,918,788; 5,732,870; 4,986,164; 4,679,719; 8,011,547, 8,267,296, 8,267,297, 8,011,441, 8,387,718, 8,286,722, 8,230,941, 8,602,282, 9,676,088, 10,478,954, 9,993,913, 10,549,412, 10,898,994, 10,821,585 and 8,763,874; also published U.S. patent application No. 2020/0156228, published U.S. patent application No. 2021/0016424, published U.S. patent application No. 2020/0070330, and published U.S. patent application No. 2020/0122308. These documents are incorporated by reference herein, in their entirety.

[0092] It will be understood that the logical operations described in relation to the flow charts of FIGS. 17-18 can be implemented using sequential logic (such as by using microprocessor technology), or using a logic state machine, or perhaps by discrete logic; it even could be implemented using parallel processors. One preferred embodiment may use a microprocessor or microcontroller (e.g., microprocessor 150) to execute software instructions that are stored in memory cells. In fact, the entire microprocessor 150, along with RAM and executable ROM, may be contained within a single ASIC, in one mode of the technology disclosed herein. Of course, other types of circuitry could be used to implement these logical operations depicted in the drawings without departing from the principles of the technology disclosed herein. In any event, some type of processing circuit will be provided, whether it is based on a microprocessor, a microcomputer, a microcontroller, a logic state machine, by using discrete logic elements to accomplish these tasks, or perhaps by a type of computation device not yet invented; moreover, some type of memory circuit will be provided, whether it is based on typical RAM chips, EEROM chips (including Flash memory), by using discrete logic elements to store data and other operating information, or perhaps by a type of memory device not yet invented. In general, the memory circuit of a particular electronic product will contain instructions that are executable by the processing circuit of that same particular electronic product.

[0093] It will also be understood that the precise logical operations depicted in the flow charts of FIGS. 17-18, and discussed above, could be somewhat modified to perform similar, although perhaps not exact, functions without departing from the principles of the technology disclosed herein. The exact nature of some of the decision steps and other commands in these flow charts are directed toward specific future models of automatic fastener driving tools (those involving FUSION Senco nailers or screwdriving tools, for example) and certainly similar, but somewhat different, steps would be taken for use with other models or brands of fastener driving tools in many instances, with the overall inventive results being the same.

[0094] It will be further understood that any type of product described herein that has moving parts, or that performs functions (such as computers with processing circuits and memory circuits), should be considered a “machine,” and not merely as some inanimate apparatus. Such “machine” devices should automatically include power tools, printers, electronic locks, and the like, as those example devices each have certain moving parts. Moreover, a computerized device that performs useful functions should also be considered a machine, and such terminology is often used to describe many such devices; for example, a solid-state telephone answering machine may have no moving parts, yet it is commonly called a “machine” because it performs well-known useful functions.

[0095] As used herein, the term “proximal” can have a meaning of closely positioning one physical object with a second physical object, such that the two objects are perhaps adjacent to one another, although it is not necessarily required that there be no third object positioned therebetween. In the technology disclosed herein, there may be instances in which a “male locating structure” is to be positioned “proximal” to a “female locating structure.” In general, this could mean that the two male and female structures are to be physically abutting one another, or this could mean that they are “mated” to one another by way of a particular size and shape that essentially keeps one structure oriented in a predetermined direction and at an X-Y (e.g., horizontal and vertical) position with respect to one another, regardless as to whether the two male and female structures actually touch one another along a continuous surface. Or, two structures of any size and shape (whether male, female, or otherwise in shape) may be located somewhat near one another, regardless if they physically abut one another or not; such a relationship could still be termed “proximal.” Or, two or more possible locations for a particular point can be specified in relation to a precise attribute of a physical object, such as being “near” or “at” the end of a stick; all of those possible near/at locations could be deemed “proximal” to the end of that stick. Moreover, the term “proximal” can also have a meaning that relates strictly to a single object, in which the single object may have two ends, and the “distal end” is the end that is positioned somewhat farther away from a subject point (or area) of reference, and the “proximal end” is the other end, which would be positioned somewhat closer to that same subject point (or area) of reference.

[0096] It will be understood that the various components that are described and/or illustrated herein can be fabricated in various ways, including in multiple parts or as a unitary part for each of these components, without departing from the principles of the technology disclosed herein. For example, a component that is included as a recited element of a claim hereinbelow may be fabricated as a unitary part; or that component may be fabricated as a combined structure of several individual parts that are assembled together. But that “multi-part component” will still fall within the scope of the claimed, recited element for infringement purposes of claim interpretation, even if it appears that the claimed, recited element is described and illustrated herein only as a unitary structure.

[0097] All documents cited in the Background and in the Detailed Description are, in relevant part, incorporated herein by reference; the citation of any document is not to be construed as an admission that it is prior art with respect to the technology disclosed herein.

[0098] The foregoing description of a preferred embodiment has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the technology disclosed herein to the precise form disclosed, and the technology disclosed herein may be further modified within the spirit and scope of this disclosure. Any examples described or illustrated herein are intended as non-limiting examples, and many modifications or variations of the examples, or of the preferred embodiment(s), are possible in light of the above teachings, without departing from the spirit and scope of the technology disclosed herein. The embodiment(s) was chosen and described in order to illustrate the principles of the technology disclosed herein and its practical application to thereby enable one of ordinary skill in the art to utilize the technology disclosed herein in various embodiments and with various modifications as are suited to particular uses contemplated. This application is therefore intended to cover any variations, uses, or adaptations of the technology disclosed herein using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this technology disclosed herein pertains and which fall within the limits of the appended claims.