Patent Publication Number: US-2023151630-A1

Title: Levelling System

Description:
BACKGROUND AND SUMMARY OF THE INVENTION 
     The invention relates to a levelling system. 
     Structural attachments, for example columns or posts, can be orientated with respect to a base, for example a concrete foundation, by means of threaded adjustment fasteners, such as screw bolts or nuts. Positioning of the adjustment fasteners can be effected using a bubble level, which can be tedious, in particular if a plurality of structural attachments needs to be orientated. 
     It can be considered an object of the invention to facilitate positioning of a structural attachment in a particularly easy, efficient, reliable and cost-effective manner. 
     The invention provides a system comprising a power tool comprising a rotation output shaft for rotationally driving a levelling mechanism for a structural attachment, and a rotation drive mechanically connected to the rotation output shaft to rotationally drive the rotation output shaft, a remote unit comprising a first structural attachment contact structure for being placed into contact with the structural attachment, wherein the remote unit is detached from the power tool so that it can be moved independently of the power tool at least by a certain distance, and a control arrangement comprising an orientation device configured to provide orientation data relating to the orientation of the first structural attachment contact structure, and a drive controller, which is connected to both the rotation drive and to the orientation device, wherein the drive controller is configured to influence action of the rotation drive in response to orientation data provided by the orientation device. 
     A fundamental idea of the invention can be seen in providing a system comprising a power tool for rotationally operating a levelling mechanism for the structural attachment, and a remote unit, which is intended to be placed on the structural attachment while the levelling mechanism for the structural attachment is operated. This remote unit acquires orientation data relating to the orientation of the structural attachment, and a drive controller controls rotation of the power tool dependent on the orientation data, whereby an automated levelling system can be provided. 
     The structural attachment that is to be orientated can preferably be a steel column, which is intended to be orientated vertically. But generally, all types of structural attachments could be used, and the target orientation does not necessarily have to be vertical. 
     The levelling mechanism that is intended to be rotationally operated by the power tool can be any mechanism that is suitable to translate rotational motion, in particular rotational motion imparted by the power tool, into linear motion, in particular into linear motion of a stop for the structural attachment. The levelling mechanism could for example include a screw drive, i.e., a mechanism that converts rotational motion into linear motion by means of meshing screw thread. The screw drive could for example include a screw with a shoulder for the structural attachment, wherein rotation of the screw within the base causes the screw, including the shoulder, to axially move relatively to the base. The screw drive could also include a nut arranged on a correspondingly threaded rod, wherein rotation of the nut with respect to the threaded rod causes the nut to axially move relatively to the threaded rod. The levelling mechanism could also be more complex and include, for example, a rack and pinion mechanism. 
     The power tool is preferably a handheld power tool. The rotation output shaft can be coupled to the external levelling mechanism so as to rotationally drive the levelling mechanism, i.e., so that rotation of the rotation output shaft causes a corresponding part of the levelling mechanism to co-rotate. For being rotationally coupled to the levelling mechanism, the rotation output shaft can, for example, have a chuck, in which a bit that corresponds to the corresponding part of the levelling mechanism can be arranged. In another embodiment, the bit that corresponds to the corresponding part of the levelling mechanism can be integrally formed on the rotation output shaft. The rotation drive is configured for setting the rotation output shaft into rotation. 
     The remote unit and the power tool might be mechanically connected, for example by a transmission cable that might be provided to transfer data between the remote unit and the power tool, or by a captive filament intended to prevent loss of the remote unit. In this case, the remote unit can be moved independently of the power tool by a certain distance only. It is, however, particularly preferred that the remote unit and the power tool are mechanically separate elements. In this case, the remote unit can be moved fully independently of the power tool. A wireless transmission path can be provided to transfer data between the remote unit and the power tool. 
     The first structural attachment contact structure is intended to be placed into mechanical contact with the structural attachment, so that the first structural attachment contact structure touches the surface of the structural attachment. In this touching position, the orientation of the remote unit corelates to the alignment of the structural attachment. 
     The control arrangement comprises the orientation device and the drive controller. The orientation device provides orientation data relating to the orientation of the first structural attachment contact structure, such as roll and pitch of the first structural attachment contact structure with respect to the field of gravity. The orientation device preferably comprises at least one sensor, such as an accelerometer, a gyroscope, or a combination of these sensors and other sensors, all preferably located at, in particular in, the remote unit. Preferably, the orientation device includes a three-axis accelerometer to detect orientation relative to the field of gravity and a plurality of gyroscopes to detect rotation. Other sensors, such as magnetometers, could be used in various modifications. An example of a specific sensor is the Invensense MPU-6050 among others. In addition to the at least one sensor, the orientation device might include at least one processor to compute the orientation based on input from the at least one sensor. 
     The drive controller is connected to both the rotation drive and to the orientation device, in particular for signal transfer. In particular, the drive controller can be electronically connected to the rotation drive and/or connected to communicate with the orientation device, unidirectionally or bidirectionally, and possibly also including a wireless transmission path. The drive controller is configured to influence action of the rotation drive in response to orientation data provided by the orientation device. It might for example accelerate, decelerate or reverse rotation of the rotation drive in response to orientation data provided by the orientation device. 
     The orientation data is preferably angular orientation data relating to the angular orientation of the first structural attachment contact structure, in particular with respect to the field of gravity. This angular orientation data could for example be pitch or roll of the first structural attachment contact structure. Relying on angular orientation data can provide a particular reliable and easy-to-use system at low effort. 
     According to another preferred embodiment of the invention, the drive controller can be configured to stop the rotation drive when the first structural attachment contact structure reaches a threshold inclination. Thus, the rotation output shaft will stop rotating and the levelling mechanism will no longer be actuated when the predetermined threshold inclination is reached. This can provide a particular easy and reliable operation mode. 
     Preferably, the drive controller is configured to decelerate the rotation drive when the first structural attachment contact structure approaches a threshold inclination. 
     Accordingly, the drive controller causes the rotation of the rotation output shaft to become slower as the difference between the actual inclination of the first structural attachment contact structure and the threshold inclination decreases. This can counteract unwanted overshooting, potentially further improving reliability and/or speed of operation. 
     Preferentially, the threshold inclinations mentioned above can be one and the same. 
     It is particularly preferred that the threshold inclination is vertical alignment of the first structural attachment contact structure, i.e., alignment parallel to the field of gravity. Accordingly, the drive controller can be configured to stop the rotation drive when the first structural attachment contact structure reaches vertical alignment, and/or the drive controller can be configured to decelerate the rotation drive when the first structural attachment contact structure approaches vertical alignment. This can further improve handling and reliability. 
     The drive controller can, advantageously, be configured to reverse the rotation drive in response to orientation data provided by the orientation device. This can allow automatic correction in case of overshooting scenarios, which in term can further improve reliability and ease of use. 
     The rotation drive preferably includes an electric motor, in particular for actuating the rotation output shaft. In this case, the power tool is an electric power tool. 
     The drive controller could include an auxiliary braking mechanism for braking the electric motor in response to orientation data provided by the orientation device. However, it is particularly preferred that the drive controller is configured to modify the characteristics of electric power supplied to the electric motor, for example from a battery, in response to orientation data provided by the orientation device. In this case, control takes place via electronics, which can further increase reliability and/or reduce costs. For example, the drive controller could include a H-bridge, electrically connected to both the electric motor and to a power source such as a battery, and the H-bridge can be set in response to orientation data provided by the orientation device. 
     As already mentioned above, the orientation device can, advantageously, include at least one accelerometer that is provided at the remote unit, more preferably in the remote unit. This can permit determining inclination in a particularly easy and effective manner. The accelerometer can be, preferably, a MEMS accelerometer 
     The first structural attachment contact structure could include a plurality of distinct contact points, which can be preferably arranged so as to lie within a virtual plane. Preferably, however, the first structural attachment contact structure includes a plane, i.e., flat surface, which can provide for a particularly reliable mechanical contact with the structural attachment at low effort. 
     In other preferred embodiment of the invention, the remote unit comprises a second structural attachment contact structure for being placed into contact with the structural attachment, and the orientation device is configured to provide orientation data relating to the orientation of the first structural attachment contact structure and of the second structural attachment contact structure. The first structural attachment contact structure and the second structural attachment contact structure are preferably arranged in a perpendicular relationship. Accordingly, two-dimensional orientation data is acquired and processed, which can improve functionality and speed up installation of more complex configurations. In particular, the orientation device can, advantageously, include at least two accelerometers that are provided at the remote unit, preferably a three-axis-accelerometer. 
     According to another preferred embodiment of the invention, the control arrangement includes a wireless data transmitter provided at the remote unit and a wireless data receiver provided at the power tool. Accordingly, a wireless transmission path is provided, in particular to transfer orientation data from the remote unit to the power tool, or for connecting subunits of the orientation device or of the drive controller. 
     It can be, preferably, provided that at least a subunit of the drive controller is removably attached to the power tool. This allows particular versatile use of the power tool, since the subunit of the drive controller can be mounted when the power tool is used for levelling purposes and can be subsequently removed when the power tool is used for other purposes. It is also possible that not only a subunit, but all of the drive controller is removably attached to the power tool. 
     The power tool can for example be a drill or an impact wrench. An impact wrench can for example be provided when the levelling mechanism comprises a concrete screw embedded in a concrete substrate, as the impact wrench can provide the torque required for this purpose in a particular effective manner. 
     In particular, the levelling mechanism is not a part of the described system. However, the invention also relates to a levelling arrangement, comprising a system as described, and a levelling mechanism for a structural attachment, wherein the levelling mechanism comprises a screw drive configured to be rotationally actuated by the power tool. The screw drive is able to convert rotation into linear motion for levelling the structural attachment. In particular, a screw drive can be configured as described above. 
     Features that are described here in connection with the levelling arrangement can also be used in connection with the system, and features that are described here in connection with the system can also be used in connection with the levelling arrangement. 
     The invention is explained in greater detail below with reference to preferred exemplary embodiments, which are depicted schematically in the accompanying drawings. 
     Individual features of the exemplary embodiments presented below can be implemented either individually or in any combination within the scope of the present invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG.  1    is a side view of a levelling arrangement, including a system according to the invention; 
         FIG.  2    is a perspective view of the structural attachment and of the remote unit shown in  FIG.  1   ; 
         FIG.  3    is another perspective view of the remote unit shown in  FIG.  1   ; and 
         FIG.  4    shows, in perspective view, another type of structural attachment that can be levelled by means of the system of  FIG.  1   . 
     
    
    
     DETAILED DESCRIPTION OF THE DRAWINGS 
       FIGS.  1  to  3    illustrate an embodiment of a levelling arrangement, including a system according to the invention. The system can be used for vertically levelling a structural attachment  1  (a column in the shown embodiment), with respect to a base  9  (a concrete foundation in the present embodiment). The structural attachment  1  comprises a baseplate  3  and a beam  4  attached thereto. In the present embodiment, the beam  4  is, by way of example, a hollow square beam. However, other beam shapes are also possible, e.g., an I-beam, as shown in  FIG.  4   , or a hollow circular beam. The structural attachment  1  is mounted on the foundation by means of screws  6 , which are anchored in the base  9 , which project through the baseplate  3 , and which are each provided with a shoulder  5 , wherein the shoulders  5  each form a stop for the baseplate  3 . Rotating a screw  6  with respect to the base  9  causes axial displacement of the shoulder  5  and therefore corresponding displacement of the structural attachment  1  resting on the respecting shoulder  5 . The screws  6  thus provide a screw drive type levelling mechanism for the structural attachment  1 , which levelling mechanism is operated by rotation. 
     The system comprises a power tool  50 , an electric power tool and more specifically an impact wrench in the present embodiment, for rotationally driving the screws  6 . The power tool  50  comprises a rotation output shaft  51  for rotationally entraining the screws  6  so as to rotate together with the rotation output shaft  51 . The power tool  50  furthermore comprises a rotation drive  59  for rotationally driving the rotation output shaft  51  (together with a screw  6  engaged by the rotation output shaft  51 ). In the present embodiment, the power tool  50  is an electrical power tool and the rotation drive  59  thus includes an electric motor  58  for agitating the rotation output shaft  51 . The power tool  50  is cordless, and as such, it includes a battery  55 , which is in particular rechargeable, and which powers the relevant components, in particular the electric motor  58 . 
     The system also includes a remote unit  20 . The remote unit  20  and the power tool  50  are separate, and therefore, the remote unit  20  can be positioned independently of the power tool  50 . The remote unit comprises a housing  27 . This housing  27  is generally L-shaped, comprising a first arm  41  and a second arm  42 , wherein the second arm  42  is are arranged in a generally perpendicular relationship with respect to the first arm  41 . The remote unit  20  comprises a first structural attachment contact structure  28 , which is provided on the first arm  41 , as well as a second structural attachment contact structure  29 , which is provided on the second arm  42 . The first structural attachment contact structure  28  is a plane provided on the housing  27  of the remote unit  20  and also the second structural attachment contact structure  29  is a plane provided on the housing  27  of the remote unit  20 , wherein the first structural attachment contact structure  28  extends perpendicular to the second structural attachment contact structure  29 . Together, the first structural attachment contact structure  28  and the second structural attachment contact structure  29  form a L-shaped receptacle for the structural attachment  1 , in particular for its beam  4 . The first structural attachment contact structure  28  and the second structural attachment contact structure  29  are intended to be brought into physical contact with the structural attachment  1 , in particular with the beam  4  thereof, when the system is used as intended. 
     The system further includes an orientation device  21  that is configured to provide orientation data, in particular tilt orientation data, of the remote unit  20 . In the present case, the orientation device  21  includes three accelerometer  25 ′,  25 ″,  25 ′″ that are located at the remote unit  20 , namely within the housing  27  thereof. These three accelerometers  25 ′,  25 ″,  25 ′″ form a three-axis accelerometer. In the present embodiment, the entirety of the orientation device  21 , including a processor for processing the signal of the accelerometers  25 ′,  25 ″,  25 ′″, is located at the remote unit  20 . The remote unit  20  further includes a wireless data transmitter  22  for transmitting the orientation data provided by the orientation device  21  to a wireless data receiver  52  provided on the power tool  50 . 
     The power tool  50  comprises a drive controller  53 ,  54 , which is connected to the rotation drive  59  so as to communicate with the rotation drive  59 , and which is configured for controlling the rotation drive  59 , in particular the electric motor  58  thereof. In particular, the drive controller  53 ,  54  can be configured to modify the characteristic of electric power supplied to the electric motor  58 , which can for example be achieved by means of a H-bridge included in the drive controller  53 ,  54 . The drive controller  53 ,  54  is also connected to the wireless data receiver  52  so as to communicate with the wireless data receiver  52 , in particular for transferring orientation data from the wireless data receiver  52  to the drive controller  53 ,  54 . 
     In the present embodiment, the power tool  50  comprises a removable unit  60 , which can be removed from the remainder of the power tool  50  when no automatic levelling function is required. In the present embodiment, this removable unit includes the wireless data receiver  52  and a subunit, denoted with reference numeral  53 , of the drive controller  53 ,  54 . 
     The drive controller  53 ,  54  is configured to influence action, in particular rotation, of the rotation drive  59  in response to orientation data relating to the orientation of the first structural attachment contact structure  28 , and preferably also to the orientation of the second structural attachment contact structure  29 , as provided by the orientation device  21 . In use, the remote unit  20  is placed at the structural attachment  1  so that the first structural attachment contact structure  28  and the second structural attachment contact structure  29  both touch the structural attachment  1 , so that the orientation of the remote unit  20  corresponds to the orientation of the structural attachment  1 . The rotation output shaft  51  is then brought into rotational engagement with the levelling mechanism, in particular with one of the screws  6  thereof, and the rotation drive  59  is then actuated to actuate the levelling mechanism. The drive controller  53 ,  54  can then automatically slow down rotation of the rotation drive  59  and therefore of the rotation output shaft  51  when a predefined threshold inclination of the remote unit  20  (and thus of the structural attachment  1 ) is approached, and fully stop rotation of the rotation drive  59  when the predefined threshold inclination is reached, wherein the predefined threshold inclination could be for example vertical alignment of the first structural attachment contact structure  28 . The drive controller  53 ,  54  could also automatically reverse rotation of the rotation drive  59  and therefore of the rotation output shaft  51  in case of an overshoot of the threshold inclination.