TECHNICAL FIELD

Example embodiments generally relate to power tools, and, in particular, relate to improvements for a handheld fastening tool.

BACKGROUND

Fastening tools are commonly used in both commercial and private settings to tighten fasteners of various types for various purposes. Often referred to as nutrunners and screwdrivers, fastening tools may often be employed in an assembly or disassembly setting. In an assembly setting, a plurality of different operators may simultaneously be operating individual fastening tools to tighten fasteners on the object being assembled. In some cases, the plurality of different operators may be working on the same step in the assembly of the object, but in some other cases, the plurality of different operators may be working on different steps in the assembly of the object. In this regard, the steps of an assembly line may require the fasteners to be tightened to different torque ratings depending on the object being assembled and the particular step of the assembly. As such, the fastening tool may be operated differently depending on the desired use case.

The nature of tightening a fastener with a fastening tool requires the fastening tool to apply torque to the fastener to induce rotational motion of the fastener. As a result of the fastening tool applying high levels of torque, and depending on the use case, over-tightening or under-tightening fasteners is not only possible, but common. Over-tightened fasteners may be subjected to high torsional loads and high shear stresses, and may therefore be at risk of breaking the fastener, or damaging the object being assembled. Under-tightened fasteners may improperly fasten the object being assembled and may vibrate loose and fall out. Thus, creating a fastening tool that can limit the amount of torque applied to a fastener and communicate to the operator when this limit has been reached may reduce the likelihood of breaking a fastener or damaging the object and allow for a more favorable overall experience than other fastening tools could produce. Likewise creating a fastening tool that can alert the operator that a fastener is under-tightened may reduce the likelihood of improperly assembling an object and may thus make the object being assembled safer. BRIEF SUMMARY OF SOME EXAMPLES

Some example embodiments may provide for an output unit for transmitting torque from a fastening tool. The output unit may include an output spindle which may be configured to operably couple with a fastener at a first end of the output spindle, an input interface which may operably couple the output unit to the fastening tool, a drive assembly which may be operably coupled to a second end of the output spindle, a clutch which may be operably coupled to the drive assembly and to the input interface, a clutch sensor which may be configured to detect disengagement of the clutch and may generate a disengagement signal responsive to detecting the disengagement of the clutch, a control circuit which may be configured to receive the disengagement signal from the clutch sensor and may generate a completion signal responsive thereto, and a communications module which may be configured to transmit the completion signal to a wireless control box. The clutch may disengage responsive to reaching a predetermined torque value. The wireless control box may notify an operator of receipt of the completion signal.

Some example embodiments may provide for a fastening tool for applying torque to fasteners. The fastening tool may include a motor which may be configured to generate torque, a power source which may supply power to the motor, a trigger which may control the speed of the motor, and an output unit which may transmit the torque from the fastening tool to a fastener. The output unit may include an output spindle which may be configured to operably couple with a fastener at a first end of the output spindle, an input interface which may operably couple the output unit to the fastening tool, a drive assembly which may be operably coupled to a second end of the output spindle, a clutch which may be operably coupled to the drive assembly and to the input interface, a clutch sensor which may be configured to detect disengagement of the clutch and may generate a disengagement signal responsive to detecting the disengagement of the clutch, a control circuit which may be configured to receive the disengagement signal from the clutch sensor and may generate a completion signal responsive thereto, and a communications module which may be configured to transmit the completion signal to a wireless control box. The clutch may disengage responsive to reaching a predetermined torque value. The wireless control box may notify an operator of receipt of the completion signal. BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

Having thus described some example embodiments in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:

FIG. 1 illustrates a schematic overview showing a fastening tool for driving a fastener according to an example embodiment;

FIG. 2 depicts a schematic overview of the output unit according to an example embodiment; and

FIG. 3 depicts a schematic overview of the output unit according to an example embodiment.

DETAILED DESCRIPTION

Some example embodiments now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all example embodiments are shown. Indeed, the examples described and pictured herein should not be construed as being limiting as to the scope, applicability or configuration of the present disclosure. Rather, these example embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like reference numerals refer to like elements throughout. Furthermore, as used herein, the term “or” is to be interpreted as a logical operator that results in true whenever one or more of its operands are true. As used herein, operable coupling should be understood to relate to direct or indirect connection that, in either case, enables functional interconnection of components that are operably coupled to each other.

FIG. 1 illustrates a schematic overview showing a fastening tool 100 for driving a fastener 110 according to an example embodiment. The fastening tool 100 may include a power source 120, an output unit 130 and a wireless control box 140. In some example embodiments, the fastening tool 100 may be operable without the inclusion of the output unit 130 and the wireless control box 140. In this regard, the fastening tool 100 may be embodied as a nutrunner, cordless screwdriver, drill or the like, to which the output unit 130 may be operably coupled without limiting the functionality of the fastening tool 100. The fastening tool 100 may further include a motor 102, a shaft 104 and a drive interface 106. The motor 102 may be operably coupled to the shaft 104 at a first end of the shaft 104 via a set of planetary reduction gears, and the drive interface 106 may be operably coupled to the shaft 104 at a second end of the shaft 104. The fastening tool 100 may thus be configured to direct power from the power source 120 to the motor 102 responsive to the actuation of a trigger 108 by an operator. In this regard, the trigger 108 may control the operation of the fastening tool 100. Responsive to the actuation of the trigger 108, the motor 102 may generate torque. The torque may be translated to the shaft 104 via operable coupling with the motor 102 and thus to the drive interface 106 of the fastening tool 100 via operable coupling with the shaft 104. Accordingly, the fastening tool 100 may be used to tighten a fastener 110 responsive to operably coupling the drive interface 106 to the fastener 110 and actuating the trigger 108 to generate torque via the motor 102. In an example embodiment, the power source 120 may be a source of electricity such as an AC to DC converter connected to mains power or a battery supplying the motor 102 with a DC electric current. In some other cases, the power source 120 may be a source of compressed air, and the motor 102 and thus the fastening tool 100 may be pneumatically powered. The inclusion of the output unit 130 with the fastening tool 100 may not change the internal operations of the fastening tool 100. In this regard, the output unit 130 may operably couple to the shaft 104 and to the fastener 110, and may transfer torque from the fastening tool 100 to the fastener 110 accordingly. In some cases, the output unit 130 may define a predetermined torque rating to which the fastening tool 100 must tighten the fastener 110 in order for the fastener 110 to be considered properly tightened.

The wireless control box 140 may be disposed separate from the fastening tool 100 and from the output unit 130. The wireless control box 140 may include processing circuitry 142, a radio module 144, an output switch 146 and a power source 148. The processing circuitry 142 of the wireless control box 140 may be configured to generate an indication of completion or non-completion of a task of tightening the fastener 110 to a predetermined torque rating in response to the radio module 144 receiving a signal from the output unit 130. In this regard, the radio module 144 may be configured to communicate with the output unit 130 to determine if the fastener 110 has been successfully tightened to the predetermined torque rating or if the fastener 110 failed to be successfully tightened to the predetermined torque rating. Accordingly, the output unit 130 may communicate a plurality of signals to the radio module 144. As will be described below, among the plurality of signals may be a signal of successful completion of tightening the fastener 110 to the predetermined torque rating, otherwise known as a completion signal, a signal of incompletion of tightening the fastener 110 to the predetermined torque rating, and a section completion signal. The processing circuitry 142 may be configured to generate a visual indication via an output switch 146 in the form of illuminating a first light or LED, an audible beep noise having a first tone, a haptic alert, or any combination thereof, in order to provide the necessary feedback to the operator in response to receiving a signal of successful completion of tightening the fastener 110 to the predetermined torque rating. In some other cases, the processing circuitry 142 may be configured to generate a visual indication via an output switch 146 in the form of illuminating a second light or LED, an audible beep noise having a second tone, a haptic alert, or any combination thereof, in order to provide feedback to the operator in response to receiving a signal of an unsuccessful and incomplete attempt at tightening the fastener 110 to the predetermined torque rating. For example, if the fastener 110 is broken or damaged and fails to tighten on the object being assembled, the output unit 130 may be able to determine that the predetermined torque rating was not reached, and thus determine that the task of tightening the fastener 110 is incomplete. In some embodiments, the wireless control box 140 may be disposed within visible or audible range so the operator may be able to see and/or hear the indications that the wireless control box 140 generates. In some embodiments, the power source 148 may be a standard DC source of electricity such as a battery or mains power via an AC -DC converter. In some embodiments, the output switch 146 may be a physical relay. In some cases, the output switch 146 may be a solid state relay.

FIG. 2 depicts a schematic overview of the output unit 130 according to an example embodiment. The output unit 130 may operably couple to the fastening tool 100 at the second end of the shaft 104, and instead of the drive interface 106. In this regard, the output unit 130 may do the job of the drive interface 106 and transfer torque generated by the motor 102 to the fastener 110. In some embodiments, the output unit 130 may include an input interface 150, a clutch 160, a drive assembly 170, and an output spindle 180. Each of the input interface 150, the clutch 160, the drive assembly 170 and the output spindle 180 may be configured to assist in the transfer of torque from the motor 102 to the fastener 110. The input interface 150 may operably couple the output unit 130 to the shaft 104 of the fastening tool 100. In this regard, the input interface 150 may be configured to receive torque directly from the motor 102 via the shaft 104. The input interface 150 may be configured with a quick connect mechanism to enable the operator to easily and securely attach and detach the output unit 130 to/from the fastening tool 100 respectively. The input interface 150 may also operably couple to the clutch 160 of the output unit 130. As will be described below, the clutch 160 may be configured to disengage responsive to the predetermined torque rating being reached. Thus, the disengagement of the clutch 160 may indicate the complete and successful tightening of the fastener 110.

The clutch 160 may operably couple the input interface 150 to the drive assembly 170 and thus may ultimately transfer torque to the output spindle 180 and the fastener 110. In some embodiments, the clutch 160 may be a ball and detent type torque limiter. In this regard, the clutch 160 may rely on balls or rollers that may be disposed in detents formed between two clutch plates that may be biased together by a spring force. In order to transfer torque from the input interface 150 to the drive assembly 170, the balls or rollers may remain in their respective detents and roll in place in order to transfer torque from a first clutch plate that may be operably coupled to the input interface 150 to a second clutch plate that may be operably coupled to the drive assembly 170. As long as the second clutch plate can be rotated with the amount of torque transferred by the first clutch plate, the drive assembly 170 may keep rotating. However, in some embodiments, the clutch 160 may be configured such that the balls or rollers may roll out of their respective detents and the first and second clutch plates may disengage with each other at the predetermined torque rating. In other words, the clutch plates may rely on the spring force in order to retain the balls in their respective detents and continue to transfer torque to transfer the torque from the input interface 150 to the drive assembly 170. Once the clutch plates require the predetermined amount of torque from the input interface 150 to keep rotating the drive assembly 170, the spring force keeping the two clutch plates engaged via the balls may be overcome by the torque from the motor 102 and thus the balls may roll out of their detents and disengage. Once the clutch plates disengage, they may no longer transfer torque from the input interface 150 to the drive assembly 170, and instead may independently spin relative to each other. In this regard, the clutch 160 is configured to transfer all torque up to the predetermined torque rating from the input interface 150 to the drive assembly 170, but once the torque reaches the predetermined torque rating and the clutch 160 disengages, the clutch 160 may cease to transfer the torque from the input interface 150 to the drive assembly 170. Accordingly, the clutch 160, and its respective spring force between clutch plates, may define the predetermined torque rating for the output unit 130. In this regard, the predetermined torque rating for the fastening tool 100 may be changed by the operator by removing the output unit 130 from the fastening tool 100 and replacing it with another output unit 130 configured to disengage at a different predetermined torque rating. In some embodiments, the spring force may be adjustable and the operator may set their desired predetermined torque rating before operating the fastening tool 100. In some embodiments, the clutch 160 may be a slip type clutch or any other suitable type of clutch mechanism.

The clutch 160 may be configured to transfer the torque from the motor 102 of the fastening tool 100 to the drive assembly 170 via the input interface 150. In some embodiments, the drive assembly 170 may include planetary gears. In this regard the drive assembly 170 may be configured to convert the relatively high rotational velocity of the shaft 104 and the motor 102 into higher torque outputs for the output spindle 180. Additionally, planetary gears may remain coaxial with the clutch 160 and the output spindle 180 and as such, the drive assembly 170 may minimize the amount of physical space it occupies in the output unit 130. Accordingly, the output unit 130 may be better suited for tightening the fastener 110 in a variety of use cases due to the more efficient use of space and the efficient conversion of rotational velocity into torque through the ratio of the planetary gears in the drive assembly 170. In some embodiments, the output spindle 180 may be operably coupled to the planetary gears to accordingly transfer torque from the planetary gears to the fastener 110. In this regard, the output spindle 180 may include an orifice configured to operably couple to the fastener 110 in order to effectively transfer torque thereto.

The output unit 130 shown schematically in FIG. 2 may also include a clutch sensor 190, a control circuit 200, an energy storage unit 210, and a communications module 220. In this regard, the clutch sensor 190 may be configured to monitor the clutch 160 and may detect the clutch 160 disengaging responsive to the torque applied to the fastener 110 reaching the predetermined torque rating of the output unit 130. In some cases, the clutch sensor 190 may transmit a disengagement signal to the control circuit 200, and the control circuit 200, powered by the energy storage unit 210, may then determine that the fastener 110 has been properly tightened due to the fact that the clutch 160 has disengaged . Responsive to determining that the clutch 160 has disengaged, the control circuit 200 may generate a completion signal and transmit the completion signal to the wireless control box 140 via the communications module 220. The communications module 220 may be a one way or a two- way radio operating in a predetermined frequency band. In some cases, the communications module 220 may operate in the ISM (industrial, scientific, and medical) band of 2.4 GHz to communicate with the radio module 144 of the wireless control box 140. In some other cases, the communications module 220 may operate in any of the ultra-high frequency bands of 315 MHz, 434 MHz, 868 MHz, or 915 MHz to communicate with the radio module 144 of the wireless control box 140.

In some cases, the energy storage unit 210 may be a conventional battery, which may be rechargeable or non-rechargeable. In some other cases, the energy storage unit 210 may be a capacitor or a supercapacitor which may be rechargeable. In an example embodiment, the clutch sensor 190 may be a mechanical switch that trips responsive to detecting the action of the clutch 160 disengaging. In some cases, the clutch sensor 190 may be a magnetic sensor such as a Hall effect sensor in tandem with a permanent magnet in order to detect the clutch 160 disengaging. In some other embodiments, the clutch sensor 190 may be an optical sensor. In some other cases, the clutch sensor 190 may be a piezo-electric vibration sensor that may be configured to detect the vibration created by the clutch 160 disengaging. In an example embodiment, the clutch sensor 190 may be a microphone configured to hear the sound created by the clutch 160 disengaging. In some cases, the clutch sensor 190 may be an accelerometer configured to detect a shift of the clutch 160 responsive to the clutch 160 disengaging. In an example embodiment, the clutch sensor 190 may be a capacitive sensor to detect the clutch 160 disengaging.

In an example embodiment, the control circuit 200 may monitor the operation of the drive assembly 170. In this regard, the control circuit 200 may detect that the drive assembly 170 was in operation, but if the control circuit 200 does not receive the disengagement signal from the clutch sensor 190, then the control circuit 200 may generate and transmit an incompletion signal to the wireless control box 140 via the communications module 220 to indicate that the fastener 110 has not been properly tightened to the predetermined torque rating of the output unit 130. In some cases, the control circuit 200 may also be configured to track the number of successful disengagement signals that may be received from the clutch sensor 190. In this regard, the control circuit 200 may generate a section completion signal and transmit it to the wireless control box 140 via the communications module 220 responsive to a predetermined number of successful disengagement signals being received. As such, the processing circuitry 142 of the wireless control box 140 may be configured to generate a visual indication via an output switch 146 in the form of illuminating a third LED, an audible beep noise having a third tone, a haptic alert, or any combination thereof, in order to provide feedback to the operator in response to receiving a predetermined number of disengagement signals of successful and complete attempts at tightening the fastener 110 to the predetermined torque rating. Accordingly, the output unit 130 may be configured to track the progress of assembling object and convey the completion of a predetermined number of fasteners 110 to the operator to indicate the completion of assembling a section of the object. In other words, the output unit 130 may be configured to track patterns, and after every “X” number of disengagement signals representing “X” number of completely tightened fasteners 110, the wireless control box 140 may indicate that feedback to the operator.

FIG. 3 depicts a schematic overview of the output unit 130 according to an example embodiment. In the example depicted in FIG. 3, the output unit 130 may be substantially similar to the output unit 130 embodied in FIG. 2, but may further comprise an energy harvester 230. In an example embodiment, the energy harvester 230 may be operably coupled to the input interface 150 and the clutch 160. As such, the energy harvester 230 may be a generator, resolver or a magneto configured to charge the energy storage unit 210 by converting the rotational kinetic energy of the input interface 150 into electrical potential energy to store in the energy storage unit 210. In this regard, the energy storage unit 210 may be electrically operably coupled to the energy harvester 230 in order to be recharged while the fastening tool 100 and the output unit 130 are in use. In an example embodiment, the energy storage unit 210 may power the communications module 220 and the clutch sensor 190 via the control circuit 200. In some embodiments, the clutch sensor 190 may utilize the energy harvester 230. In this regard, the energy harvester 230 may be operably coupled to the input interface 150 and an angle sensor, such as an encoder, may be operably coupled to the output spindle 180. The clutch sensor 190 may indicate that the tool is in operation when the energy harvester 230 starts to generate a voltage, and the clutch sensor 190 may indicate that the tightening is successful if the energy harvester 230 still generates voltage while the encoder signals that the output spindle 180 is no longer rotating. This scenario may indicate that the output spindle 180 may have stopped turning, but also that the clutch 160 may be disengaged, which may be a sign that the fastener has been tightened to the predetermined torque rating. In some cases, the implementation of the energy harvester 230 may not have any impacts to the transfer of torque from the input interface 150 to the clutch 160, and may not affect the overall ability of the output unit 130 and fastening tool 100 to tighten the fastener 110. In some cases, the energy harvester 230 may be a vibration driven piezo electric device. In an example embodiment, the energy harvester 230 may harvest energy from light in the form of a solar panel. In some cases, the energy harvester 230 may further include a charge controller that is electrically operably coupled to the energy storage unit 210 to protect the energy storage unit 210 from undervoltage and from being overcharged.

Some example embodiments may provide for an output unit for transmitting torque from a fastening tool. The output unit may include an output spindle which may be configured to operably couple with a fastener at a first end of the output spindle, an input interface which may operably couple the output unit to the fastening tool, a drive assembly which may be operably coupled to a second end of the output spindle, a clutch which may be operably coupled to the drive assembly and to the input interface, a clutch sensor which may be configured to detect disengagement of the clutch and may generate a disengagement signal responsive to detecting the disengagement of the clutch, a control circuit which may be configured to receive the disengagement signal from the clutch sensor and may generate a completion signal responsive thereto, and a communications module which may be configured to transmit the completion signal to a wireless control box. The clutch may disengage responsive to reaching a predetermined torque value. The wireless control box may notify an operator of receipt of the completion signal.

The output unit of some embodiments may include additional features, modifications, augmentations and/or the like to achieve further objectives or enhance performance of the output unit. The additional features, modifications, augmentations and/or the like may be added in any combination with each other. Below is a list of various additional features, modifications, and augmentations that can each be added individually or in any combination with each other. For example, the control circuit may be powered by an energy storage unit. In an example embodiment, the energy storage unit may be disposed in the output unit and may not power the fastening tool. In some cases, the energy storage unit may be rechargeable. In an example embodiment, the output unit may further include an energy harvester which may be configured to generate energy to charge the energy storage unit. In some cases, the drive assembly may include planetary gears. In an example embodiment, the clutch sensor may be a mechanical switch, a piezo-electric vibration sensor, an optical sensor a magnetic sensor, a capacitive sensor, a microphone or an accelerometer. In some cases, the energy harvester may be a generator that may generate a voltage responsive to being turned by the motor. In an example embodiment an encoder may be operably coupled to the output spindle. In some cases, the clutch sensor may detect the voltage generated by the energy harvester and a signal generated by the encoder. In an example embodiment, the clutch sensor may determine that the clutch may be disengaged responsive to the energy harvester generating the voltage and the encoder signal indicating the output spindle may be stationary. In some cases, the communications module may be a radio module operating in the 315 MHz, 434 MHz, 868 MHz, 915 MHz, 2.4 GHz Bluetooth Low Energy, or 2.4 GHz bands. In an example embodiment, the clutch sensor may be configured to detect a fault in the operation of the fastening tool. In some cases, the fault may include the fastening tool being operated but the clutch not slipping. In an example embodiment, the wireless control box may notify the operator of the fault by displaying a non-completion indication responsive to receiving a non-completion signal from the communications module. In some cases, the control circuit may be configured to track the total count of completion signals and may generate a section completion signal responsive to a predetermined number of completion signals being transmitted to the wireless control box via the communications module.

Some example embodiments may provide for a fastening tool for applying torque to fasteners. The fastening tool may include a motor which may be configured to generate torque, a power source which may supply power to the motor, a trigger which may control the speed of the motor, and an output unit which may transmit the torque from the fastening tool to a fastener. The output unit may include an output spindle which may be configured to operably couple with a fastener at a first end of the output spindle, an input interface which may operably couple the output unit to the fastening tool, a drive assembly which may be operably coupled to a second end of the output spindle, a clutch which may be operably coupled to the drive assembly and to the input interface, a clutch sensor which may be configured to detect disengagement of the clutch and may generate a disengagement signal responsive to detecting the disengagement of the clutch, a control circuit which may be configured to receive the disengagement signal from the clutch sensor and may generate a completion signal responsive thereto, and a communications module which may be configured to transmit the completion signal to a wireless control box. The clutch may disengage responsive to reaching a predetermined torque value. The wireless control box may notify an operator of receipt of the completion signal.

Many modifications and other embodiments of the inventions set forth herein will come to mind to one skilled in the art to which these inventions pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the inventions are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Moreover, although the foregoing descriptions and the associated drawings describe exemplary embodiments in the context of certain exemplary combinations of elements and/or functions, it should be appreciated that different combinations of elements and/or functions may be provided by alternative embodiments without departing from the scope of the appended claims. In this regard, for example, different combinations of elements and/or functions than those explicitly described above are also contemplated as may be set forth in some of the appended claims. In cases where advantages, benefits or solutions to problems are described herein, it should be appreciated that such advantages, benefits and/or solutions may be applicable to some example embodiments, but not necessarily all example embodiments. Thus, any advantages, benefits or solutions described herein should not be thought of as being critical, required or essential to all embodiments or to that which is claimed herein. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.