# Patent

## Title
Power tool

## Abstract

A power tool includes a driving unit for performing screw tightening operations; a motor for rotatably driving the driving unit; a trigger switch for turning on and off the motor; and a control circuit, accommodated in a main body of the power tool, for monitoring the screw tightening operations. The control circuit having a screw tightening completion detection unit for detecting completion of a screw tightening operation, a screw tightening count unit for counting the number of detected tightening operations, a screw tightening number setting unit for presetting the number of screws to be tightened, a screw tightening completion notifying unit for notifying completion of the screw tightening operations when the number of detected tightening operations reaches the preset number of screws.

## Background
FIELD OF THE INVENTION
The present invention relates to a power tool having a function of monitoring a screw tightening operation.
BACKGROUND OF THE INVENTION
When a product is assembled by a power tool or the like by repeatedly performing a screw tightening operation, and if checking the completion of a series of screw tightening operations solely relies on an operator, some of the screws may sometimes remain unfastened. Since occurrence of such case would lead to deterioration in quality and reliability of the product, the number of tightening operations needs to be checked in every operation process. Accordingly, excessive burdens are imposed on the operator though mistakes cannot be completely prevented.
To that end, there have been a number of proposals for inventions that are geared towards preventing forgetfulness of a screw tightening operation by using a controller that is connected to a power tool which counts the number of tightening operations (see, e.g., Japanese Patent Laid-open Applications Nos. H9−150338, 2003−123050 and 2005−125464).
Although the above prior art references can improve the drawbacks of forgetting the screw tightening operation, its applications are limited due to the fact that the power tool and the controller are connected with each other by a power cord. This problem may not be that serious when an operator is working in a restricted working area using a corded power tool or a pneumatic power tool connected to an air hose. However, when an operator is working in an unrestricted area, handling of tool and the controller would become troublesome, or restriction on the area where an operator can work may arise. Especially, in case of a cordless rechargeable power tool, the inherent advantages of the cordlessness diminish.
SUMMARY OF THE INVENTION
In view of the drawbacks of the prior art, the present invention provides a power tool capable of improving accuracy and efficiency of screw tightening operations by providing a function of monitoring the screw tightening operations in a main body of the power tool. Further, since a controller and the power tool need not be connected by a power cord, a working area restriction problem of the prior art can be avoided by the present invention.
In accordance with the present invention, there is provided a power tool including a driving unit for performing screw tightening operations; a motor for rotatably driving the driving unit; a trigger switch for turning on and off the motor; and, a control circuit, accommodated in a main body of the power tool, for monitoring the screw tightening operations. The control circuit has a screw tightening completion detection unit for detecting completion of a screw tightening operation; a screw tightening count unit for counting the number of detected tightening operations; a screw tightening number setting unit for presetting the number of screws to be tightened; and a screw tightening completion notifying unit for notifying completion of the screw tightening operations when the number of detected tightening operations reaches the preset number of screws.
With this configuration, the power tool main body can have the function of monitoring the screw tightening operations, thereby allowing the operator to complete the screw tightening operations without leaving any untightened screw. Accordingly, it is now possible to avoid a defective assembly of a product and reduce the operator's stress brought on by the fear of forgetting to tighten the screws. These effects will further improve the accuracy and the efficiency of the screw tightening operations. Moreover, unlike in the prior art, there is now no need to connect the power tool and the controller via a power cord.
It is preferable that a rechargeable battery pack is detachably attached to the main body of the power tool and supplying of electric power from the battery pack to the setting/display unit is cut off when a specific period of time elapses after completing the screw tightening operations. In such a case, waste of battery power can be prevented. Further, since the function of monitoring the screw tightening operations is implemented in the main body of the cordless-type power tool, the working area is not restricted, and the advantages of the cordless type can be fully utilized.
It is also preferable that the screw tightening number setting unit is provided with a hold function to prevent the preset number of screws to be fastened from being changed. Then, when the hold function is activated, the preset number of screws may not be changed accidentally. For instance, even if the screw tightening number setting unit is manipulated unintentionally during the operation, the preset number of screws is unchanged. Consequently, the preset number of screws can be precisely managed while maintaining the setting state during the operation.
The power tool may further include a storage unit for storing the present number of the screw tightening number setting unit and the counted number of the screw tightening count unit. In such a case, the preset number and the last counted number are stored in the storage unit, even when the battery is exchanged during the screw tightening operations, thereby allowing for a continuous screw tightening operations even after changing the battery.
Further, it is preferable that an input of setting data into the screw tightening number setting unit is disallowed during an operation of the motor. In such a case, even when a button of the screw tightening number setting unit is pressed accidentally during the screw tightening operation for example, preset data is not changed; and, hence, the preset number of screws can be precisely managed while maintaining the setting state during the operation.
It is preferable that in order to save the power of the battery pack, the power tool further includes a battery voltage measuring unit that can measure an output voltage of the battery pack, and supply of electric power to the screw tightening number setting unit from the battery pack is cut off when the measured voltage is less than or equal to a threshold value.
It is also preferable that a large and a small threshold values are provided; and supply if electric power to the screw tightening number setting unit is cut off if a battery pack voltage is less than or equal to the small threshold value and, supply of electric power to the motor is cut off if the battery pack voltage is less than or equal to the large threshold value.
In the present invention, the control circuit for monitoring the screw tightening operations is installed inside the main body of the power tool. This arrangement allows the screw tightening operations to be monitored from main body. Therefore, unlike in the prior art, the power tool and the controller need not be connected via the power cord. Thus, the working area is not restricted, and the efficiency of screw tightening operations is enhanced.
Since the control circuit for monitoring the screw tightening operations is embedded in the main body of the cordless type power tool having the attachable/detachable battery pack, the screw tightening operations can be completed without leaving any screws unfastened; and, further, the working area is not restricted, and the advantages of the cordless type can be fully enjoyed.



BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects and features of the present invention will become apparent from the following description of embodiments, given in conjunction with the accompanying drawings, in which:
FIG. 1 is a perspective view of a power tool in accordance with an embodiment of the present invention, the power tool being used in an L shape position;
FIG. 2 shows a side view of the power tool in FIG. 1;
FIG. 3 depicts a side cross sectional view of the power tool in FIG. 1;
FIG. 4 provides a side view of the power tool being used in a straight shape;
FIG. 5 presents a side cross sectional view of the power tool in FIG. 4;
FIG. 6 represents a perspective view of a power tool in accordance with another embodiment of the present invention, wherein a protruded elastomer is installed around an outer periphery of a lower front portion of a grip portion of the power tool;
FIG. 7 is a front view of a setting/display unit;
FIG. 8 offers diagrams explaining a count mode and a count setting in the setting/display unit;
FIG. 9 sets forth a diagram for explaining a function setting mode of the setting/display unit;
FIG. 10 sets forth a circuit diagram of a control circuit for monitoring screw tightening operations;
FIG. 11 shows a flow chart for explaining an exemplary operation of the control circuit; and
FIG. 12 illustrates a flow chart for explaining another exemplary operation of the control circuit.



DETAILED DESCRIPTION OF THE EMBODIMENTS
Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings that form a part hereof.
In this embodiment, an electric screwdriver will be described as an example of a power tool 1. However, the power tool 1 can be a cordless hammer drill, a cordless drill/driver, or any other device obvious to one skilled in the art, without departing from the scope of the present invention.
The power tool 1 includes a driving unit 24 for performing screw tightening operations; a motor 11 for rotatably driving the driving unit 24; a trigger switch SW for turning on and off the motor 11; an attachable/detachable rechargeable battery pack 9; and a housing 3 for accommodating therein the above components.
The driving unit 24 is provided with a clutch mechanism. As the screw tightening operation proceeds, a torque applied to a driver bit pressed against a screw to be tightened increases and reaches a specific level. At that moment, the clutch is driven to disengage a mechanical connection between the motor 11 and the corresponding driver bit. When a clutch is driven, a screw tightening completion detection unit 4 detects that and transmits a shut-off signal (pulse signal) to a screw tightening count unit 5.
The housing 3 of a power tool main body 2 can have a straight shape (T-shape) or an L-shape configuration for the balance of the main body 2. Here, as shown in FIGS. 1 to 5, a grip portion 12 and a body portion 13 are connected rotatably about a rotational shaft portion 14 such that an angle therebetween can be changed freely. The rotational shaft 14 allows the housing 3 of the main body 2 to be varied between the straight shape and the L-shape. Further, a structure for changing the angle about the rotational shaft portion 14 and maintaining changed angle can be configured properly without being limited to a specific one. By changing the angle of the grip portion 12 as set forth above, the shape of the housing 3 can be varied to provide an easy grip for an operator. In general, the L-shaped housing 3 is suitable for a horizontal or an upward screw tightening operation, whereas the straight-shaped housing 3 is suitable for a downward screw tightening operation.
The body portion 13 of the housing 3 has the driving unit 24, the motor 11, the trigger switch SW, a lock switch 15 for maintaining the off state of the trigger switch SW, and a control switch 16 for adjusting an output torque and a rotation speed of the motor 11. Installed at the clutch side of the motor 11 is a photo-interrupter 4a constituting the screw tightening completion detection unit 4. Upon the completion of a single screw tightening operation, the movement of the clutch is detected, and the detection signal is transmitted to the screw tightening count unit 5. The screw tightening completion detection unit 4 is not limited to employing the photo-interrupter 4a for detecting the completion of the screw tightening but may also employ a distance sensor or use a motor off signal.
The grip portion 12 of the housing 3 is provided with a battery pack mounting portion 17 for detachably mounting the battery pack 9. Further, a control circuit board 8a for monitoring the screw tightening operations is installed in the grip portion 12. Moreover, as illustrated in FIG. 5, a microcomputer 5a constituting the screw tightening count unit 5 is installed inside the grip portion 12 near the rotational shaft portion 14. The microcomputer 5a may also be installed inside a lower front portion 12a of the grip portion 12.
As can be seen from FIG. 5, the lower front portion 12a of the grip portion 12 is provided with a setting/display unit 6a constituting a screw tightening number setting unit 6; and a piezoelectric buzzer 7a constituting a screw tightening completion notifying unit 7. In this embodiment, the lower front portion 12a of the grip portion 12 is protruded more forward in a front direction F compared to a hand-grip portion of the grip portion 12, so that the lower front portion 12a is not touched by a hand when the grip portion 12 is held by the hand. Accordingly, an operator can easily hold the grip portion 12 without touching the setting/display unit 6a that is exposed at the lower front portion 12a. 
Here, the lower front portion 12a of the grip portion 12 indicates a portion positioned below the hand-grip portion of the grip portion 12, while facing forward along the front direction F when the grip portion 12 is held by a hand. Further, the front direction F is the same as that along which an output (driven bit) side of the body portion 13 directs when the body portion 13 and the grip portion 12 form the L-shape by bending.
As depicted in FIG. 7, the setting/display unit 6a, exposed at the lower front portion 12a of the grip portion 12, includes a display part 18 and setting buttons 19. The display portion 18 has an LED part 18a for displaying numerical values and an upper and a lower lamp 18b and 18c for indicating selected count-up and count-down mode, respectively. The setting buttons 19 have a “mode” button 19a, a “reset” button 19d, a “+” button 19b and a “−” button 19c. In addition, a reference numeral 20 in FIG. 7 represents an LED light for supporting an operation in the dark environment.
Hereinafter, an exemplary method of using the setting/display unit 6a will be described with reference to FIGS. 8 and 9. When the trigger switch SW of the power tool main body 2 is turned on, the LED part 18a of the display portion 18 is turned on as shown in FIG. 8, so that it is possible to set or change a required number of tightening operations. To begin with, if the “mode” button 19a is briefly pressed, a count-up/down selection mode is executed in which one of the upper lamp 18b and the lower lamp 18c blinks. If the upper lamp 18b blinks by pressing the “+” button 19b, the count-up mode is selected. On the other hand, if the lower lamp 18c blinks by pressing the “−” button 19c, the count-down mode is selected. Next, if the “mode” button 19a is briefly pressed again, the selected mode is stored, and a setting value change mode is executed in which the LED part 18a blinks. In that state, the number of tightening operations can be set by pressing the “+” button 19b or the “−” button 19c. In this example, the number of tightening operations can be set up to 99. Thereafter, when the “mode” button 19a is briefly pressed again, the setting value is stored. An order of executing the count up/down selection mode and the setting value change mode can be changed.
Meanwhile, if the “mode” button 19a is pressed longer (e.g., more than 2 seconds), a sound setting mode illustrated in FIG. 9 is initiated and in this example, “F1” is displayed on the LED part 18a. In this state, moreover, whenever the “+” button 19b or the “−” button 19c is pressed once, one of alarm sounds having different pitches (in this example, alarm sounds having three different frequencies) is produced one after another. If the “mode” button 19a is pressed while one of the alarm sounds having a specific pitch is produced, the alarm sound having that pitch is selected and stored. As a result, it is possible to prevent multiple operators working in a same area from being confused by the alarm sounds of adjacent operators. Next, if the “mode” button 19a is briefly pressed, the character displayed on the LED part 18a is switched from “F1” to “F2”, and an erroneous count correcting mode is executed. If an erroneous count occurs due to stoppage of the motor 11 during the operation for example, the erroneous count can be corrected by pressing the “+” button 19b, the “−” button 19c and the “reset” button 19d during the state where the LED 18A displays “F2”.
Moreover, in this embodiment, a double tightening count prevention function is provided. The double tightening count prevention function is executed when a double tightening operation (tightening check-out operation) that tightens a same screw twice is carried out within a predetermined time period. For example, if the count time is set to one second, only a tightening operation performed not within one second after the completion of the previous one is counted, whereas a second tightening operation performed within one second is not counted.
FIG. 10 shows a circuit diagram of a control circuit 8, formed on the control circuit board 8a, for monitoring screw tightening operations. When the trigger switch SW is turned on, a CPU 21 is supplied with a power supply voltage. The CPU 21 has a power self-maintenance unit 22 for self-holding the power supplied thereto and a battery voltage measuring unit 25 for detecting the voltage of the supplied power. The CPU 21 receives a shut-off signal from the photo-interrupter 4a serving as the screw tightening completion detection unit 4 and a input setting signal from the setting/display unit 6a. Reference numerals 50, 51 and 52 in FIG. 10 indicate a circuit voltage driving device, a motor driving FET and a break FET, respectively.
Hereinafter, an exemplary operation of the control circuit 8 will be described with reference to the flow charts of FIGS. 11 and 12. As shown in FIG. 11, when the trigger switch SW is turned on (Step 1), an initial process (circuit conduction and storage retrieval) is performed (Step 2). Next, the display portion 18 is turned on (Step 3) only when a battery pack output voltage (referred to as “battery voltage” hereinafter) is determined to be higher than a first threshold. At this time, the display portion 18 displays thereon preset data (e.g., a preset number (initial value of count value) “10” in case of the count-down mode is selected). When the battery voltage is determined to be higher than a second threshold which is greater than the first threshold), the motor 11 is driven to perform the screw tightening operation (Step 4).
Thereafter, when a tightening torque becomes a specific value (i.e., when the clutch is driven), the shut-off signal (pulse signal) is transmitted from the photo-interrupter 4a to the CPU 21, and the CPU 21 automatically stops the motor 11. At this time, the number of tightening operations, i.e., “1” is counted by the screw tightening count unit 5, so that the number displayed on the display portion 18 is switched from “10” to “9” (if the count-up mode was selected, the number displayed on the display portion 18 is switched from “0” to “1”). When the number of tightening operations reaches the preset number eventually, the alarm sound is produced from the piezoelectric buzzer 7a, thereby notifying the operator of the completion of the tightening operations and preventing the operator from forgetting to tighten all the screws. When the number of tightening operations reaches the preset number, and the number displayed on the setting/display unit 6a automatically returns to the original number (e.g., “10”) (Step 5), thereby completing the corresponding screw tightening operations.
In case where the setting data are renewed after the motor 11 is stopped, it is first determined whether or not the battery voltage is higher than the first threshold, as shown in FIG. 12. Only when the battery voltage is determined to be higher than the first threshold, the display portion 18 is turned on (Step 6). Next, when a new setting number is inputted, the newly inputted number is stored as a renewed number of tightening operations (Step 7). Meanwhile, if a specific period of time elapses without receiving a setting number, the power to the setting/display unit 6a is disconnected to turn off the display portion 18 (Step 8).
According to the above configuration, the power tool main body 2 is equipped with the function of monitoring the screw tightening operations, thereby preventing an operator from forgetting to tighten all the screws. Accordingly, it is possible to avoid a defective assembly of a product and reduce an operator's burden accompanied by the potential forgetfulness of the screw tightening operation, thereby improving the accuracy and the efficiency of the screw tightening operations. Moreover, unlike in the prior art, there is no need to connect the power tool and the controller via the power cord. Especially, by providing the function of monitoring a screw tightening operation to the cordless rechargeable power tool having the attachable/detachable battery pack 9 of this example, the working area is no longer restricted. Consequently, the advantages of the cordless type can be fully utilized.
Further, by disposing the screw tightening number setting unit 6 and the screw tightening completion notifying unit 7 at the lower front portion 12a of the grip portion 12, the body portion 13 or the grip portion 12 of the housing 3 need not to be enlarged and, also, gripping of the grip portion 12 is not hindered. Further, the grip portion 12 is not subject to great impacts or vibrations, compared to the heavy body portion 13 having therein the motor 11, when the power tool 1 is dropped during its use. Therefore, it is possible to effectively prevent damages from being inflicted on the components of the screw tightening number setting unit 6 and the screw tightening completion notifying unit 7.
Moreover, the power from the battery pack 9 to the setting/display unit 6a is disconnected after a specific period of time elapses after the completion of the screw tightening operations. Therefore, the waste of the battery in the battery pack 9 can be avoided. Also, when a measured battery voltage is lower than or equal to a specific value (first threshold), the power to the setting/display unit 6a is disconnected. Further, when a measured battery voltage is lower than or equal to the second threshold greater than the first threshold, the power to the motor 11 is stopped. Accordingly, power can be saved and, further, the burden on the battery pack 9 can be reduced.
In this embodiment, the setting/display unit 6a of the control circuit 8 is provided with a hold switch 10 for preventing a data change on the display portion 18, as shown in FIG. 10. A manipulation portion of the hold switch 10 is provided on a side surface near the setting/display unit 6a disposed at the lower front portion 12a of the grip portion 12 (see FIG. 1). When the hold switch 10 is in a conducting state (ON), input to the setting/display unit 6a is allowed, whereas when the hold switch 10 is in a non-conducting state (OFF), input to the setting/display unit 6a is not allowed. By keeping the hold switch 10 to be ON, input to the setting/display unit 6a is possible. Further, by keeping the hold switch 10 to be OFF, the number of tightening operations will not change even if the setting/display unit 6a is touched accidentally during the operation. In other words, while the hold switch 10 is OFF, the change of numerals is disallowed even when the buttons of the display portion 18 are pressed. In the case where the setting/display unit 6a is disposed at the power tool main body 2, the number of tightening operations may be changed by accidentally touching the buttons of the setting/display unit 6a during the operation. However, the setting change during the operation can be prevented by activating the hold function of the embodiment of the present invention. As a result, the number of tightening operations can be precisely managed while maintaining the setting state.
There can be provided, instead of the hold switch 10, a configuration that disallows an input of setting data during an operation of the motor 11. For example, a circuit can be configured to cancel manipulation signals from the setting/display unit 6a when a signal for turning the motor 11 ON is inputted. Accordingly, even when the buttons of the setting/display unit 6a are accidentally pressed during the operation, the setting data or the count number will not change, as in the case of activating the hold switch 10.
The CPU 21 in the present embodiment has a storage (not shown) for storing therein the count number or the setting data of the setting/display unit 6a. As a result, it is possible to keep a preset number of tightening operations or a last count number in the storage unit when the battery is exchanged during the screw tightening operations. Therefore, the screw tightening operations can be continued after changing the battery.
In the present embodiment, the display of the number of tightening operations on the setting/display unit 6a provided at the lower front portion 12a of the grip portion 12 can be displayed upside down to accommodate the angle change between the straight shape and the “L” shape of the power tool 1. Accordingly, when an operator use the power tool 1 by holding the grip portion 12 heading either upward or downward, it is easy for the operator to read data on the setting/display unit 6a and perform a smooth screw tightening operations. Displaying characters or symbols upside down can be done by, e.g., pressing together the “+” button 19b and the “−” button 19c. By doing so, an embedded changeover switch is switched over, and a display control circuit allows the characters or the symbols to be displayed on the display portion upside down.
FIG. 6 shows another embodiment of the present invention which describes an example where a protruded elastomer 30 is installed around an outer periphery of the lower front portion 12a of the grip portion 12. Elastomer 30 is designed to absorb the impacts when the power tool main body 2 is dropped during its use. Accordingly, the grip portion 12 is protected from large impacts or vibrations and, it is also possible to prevent the breakage of the screw tightening number setting unit 6 and its components (the setting/display unit 6a, the piezoelectric buzzer 7a and the control circuit 8). As set forth above, the durability of the power tool 1 can be further enhanced with the addition of an elastomer 30 so that the power tool 1 can be used under severe conditions. As a result, the power tool of the present invention can be adaptively used in various product manufacturing processes or construction sites. Further, the elastomer 30 can be simply provided to the housing by 2-color injection molding of the elastomer resin and molding resin of the housing.
The power tool of the present invention can be applied both to a cord type power tool and a rechargeable type power tool.
While the invention has been shown and described with respect to the embodiments, it will be understood by those skilled in the art that various changes and modification may be made without departing from the scope of the invention as defined in the following claims.

## Claims

1. A power tool comprising:
a driving unit for performing screw tightening operations;
a motor for rotatably driving the driving unit;
a trigger switch for turning on and off the motor; and
a control circuit, accommodated in a main body of the power tool, for monitoring the screw tightening operations,
wherein the control circuit has a screw tightening completion detection unit for detecting completion of a screw tightening operation; a screw tightening count unit for counting the number of detected tightening operations; a screw tightening number setting unit for presetting the number of screws to be tightened; and a screw tightening completion notifying unit for notifying completion of the screw tightening operations when the number of detected tightening operations reaches the preset number of screws,
wherein a rechargeable battery pack is detachably attached to the main body of the power tool; and supplying of electric power from the battery pack to the setting/display unit is cut off when a specific period of time elapses after completing the screw tightening operations, and
wherein the power tool further comprises a storage unit for storing the preset number of the screw tightening number setting unit and the counted number of the screw tightening count unit.

2. The power tool of claim 1, wherein the screw tightening number setting unit is provided with a hold function to prevent the preset number of screws to be fastened from being changed.

3. The power tool of claim 1, wherein an input of setting data into the screw tightening number setting unit is disallowed during an operation of the motor.

4. The power tool of claim 1, further comprising a battery voltage measuring unit that can measure an output voltage of the battery pack; and supply of electric power to the screw tightening number setting unit from the battery pack is cut off when the measured voltage is less than or equal to a threshold value.

5. The power tool of claim 4, wherein a large and a small threshold values are provided; and supply of electric power to the screw tightening number setting unit is cut off if a battery pack voltage is less than or equal to the small threshold value and, supply of electric power to the motor is cut off if the battery pack voltage is less than or equal to the large threshold value.

6. The power tool of claim 1, wherein a large and a small threshold values are provided; and supply of electric power to the screw tightening number setting unit is cut off if a battery pack voltage is less than or equal to the small threshold value and, supply of electric power to the motor is cut off if the battery pack voltage is less than or equal to the large threshold value.

7. The power tool of claim 1, wherein the screw tightening number setting unit includes buttons for presetting the number of screws to be tightened and setting a pitch of an alarm sound which is produced when the number of detected tightening operations reaches the preset number of screws.

8. The power tool of claim 7, wherein the photo-interrupter is installed at a clutch side of the motor and detects movement of the clutch to transmit a detection signal to the screw tightening count unit upon the completion of the screw tightening operation.

9. The power tool of claim 8, wherein the rotational shaft allows the housing of the main body to be varied between a straight shape and an L-shape.

10. The power tool of claim 1, wherein the screw tightening completion detection unit is a photo-interrupter.

11. The power tool of claim 1, further comprising a housing including a grip portion a body portion connected rotatably about a rotational shaft portion.