Patent Publication Number: US-2021187697-A1

Title: Systems and methods for an automatic safety protocol in electrical tools

Description:
The present disclosure relates generally to the field of electrical tools, and more particularly to a system comprising a power tool and an automatic safety system communicatively coupled to the power tool. 
     Besides that, the present disclosure also relates to a method for controlling a power tool. 
     Power tools, such as angle grinders (e.g., side grinder or disc grinder), may be utilized on construction sites. 
     BACKGROUND 
     In certain situations, power tools may need additional features to help improve operator safety and efficiency. Indeed, it may be beneficial to have safety features built into the operating function of a power tool, in order to help an operator maintain control over the device even in critical or possible health threatening situations. For example, it may be beneficial to include safety protocols into an angle grinder, that are executed automatically before the angle grinder is engaged for its intended purpose. In particular, such automatic safety features may help an operator of the angle grinder maintain control of the device, thereby improving safety and efficiency during operation. 
     SUMMARY OF THE INVENTION 
     Additional or safety features on power tools which are to help improving the operator safety and efficiency are widely known by the prior art. Unfortunately, these prior art safety features on power tools are usually complicated to use or insufficient to guarantee a safe usage of the power tool. Most often it is somehow even possible to bypass or avoid these prior art safety features to operate the power tool. Without the proper employment of all the necessary safety features the usage power tool can be potentially dangerous for the user. 
     It is an object of the present invention to solve the above described problem and to provide a system comprising a power tool and an automatic safety system communicatively coupled to the power tool with which a safe and uncomplicated usage of a power tool is possible. 
     In particular, the present invention provides a system comprising a power tool; and an automatic safety system communicatively coupled to the power tool. 
     According to the invention one or more sensors are disposed about the power tool, wherein the one or more sensors are configured to gather data about a safety parameter related to an operation of the power tool; and a main detector is configured to receive the data gathered by the one or more sensors, wherein the main detector is configured to analyze the received data to determine whether to unlock the power tool for operation. By doing so, the power toll can only be unlocked and ready to be operated if all the safety parameters related to an operation of the power tool indicate a safe usage. 
     According to an advantageous embodiment of the present invention it is possible that the main detector comprises a wireless module configured to transmit information to a master control unit of the power tool. Thereby, wiring within the power tool can be reduced, in order to make the power tool less complicated and less expensive to manufacture. 
     According to another advantageous embodiment of the present invention it is possible that the main detector is configured to transmit an activation signal to the master control unit of the power tool to unlock the power tool for operation. This serves as a safety feature that the power tool will only be functional after master control receives an activation signal send by the main detector. 
     According to another advantageous embodiment of the present invention it is possible that the automatic safety system comprises interface circuitry configured to transmit information from the one or more sensors to the main detector. This ensures that the power tool can only be activated after at least one sensor has sent a signal. 
     According to another advantageous embodiment of the present invention it is possible that the one or more sensors comprises a safety handle sensor, and wherein the main detector is configured to receive data from the safety handle sensor to determine if a side handle of the power tool is properly installed. Hereby, the power tool can only activated in a safe way if a side handle has be installed properly. It is possible that the power tool is embodied as an angle grinder. 
     According to another advantageous embodiment of the present invention it is possible that the one or more sensors comprises a guard detection sensor, and wherein the main detector is configured to receive data from the guard detection sensor to determine if a protection guard of the power tool is properly installed. Hereby, the power tool can only activated in a safe way if a guard has be installed properly. It is possible that the power tool is embodied as an angle grinder. 
     According to another advantageous embodiment of the present invention it is possible that the one or more sensors comprises a tool detection sensor, and wherein the main detector is configured to receive data from the tool detection sensor to determine if a tool of the power tool is properly installed. Hereby, the power tool can only activated in a safe way if a tool has be installed properly. It is possible that the power tool is embodied as an angle grinder. 
     According to another advantageous embodiment of the present invention it is possible that the one or more sensors comprises a dust hood detection sensor, and wherein the main detector is configured to receive data from the dust hoot detection sensor to determine if a dust hood of the power tool is properly installed. Hereby, the power tool can only activated in a safe way if a dust hood has be installed properly. It is possible that the power tool is embodied as an angle grinder. 
     According to another advantageous embodiment of the present invention it is possible that the one or more sensors comprises a touch sensor, a position/orientation sensor, a force sensor, or a combination thereof. Hereby, the power tool can only activated in a safe way if the power tool is held in a correct manner, i.e. the operator of the power tool is applying a firm hand grip to the designated sections (e.g. handle) of the power tool. 
     Beyond that, the above described problem is also solved by a method for controlling a power tool. 
     According to the invention, the method comprises the steps
         receiving, via a main detector, one or more signals from one or more sensors disposed about the power tool, wherein the one or more sensors are configured to gather data about a safety parameter related to an operation of a power tool;   determining, via the main detector, whether to unlock the power tool for operation based on the data received from the one or more sensors; and   sending an activation signal to a control unit of the power tool, via the main detector, to unlock the power tool for operation.       

     By doing so, the power toll can only be unlocked and ready to be operated if all the safety parameters related to an operation of the power tool indicate a safe usage. 
     According to an advantageous embodiment of the present invention it is possible that the power tool is an angle grinder utilized on a construction site. 
     According to another advantageous embodiment of the present invention it is possible that determining whether to unlock the power tool comprises determining if a safety handle of the power tool is properly installed. Hereby, the power tool can only activated in a safe way if a safety handle has be installed properly. It is possible that the power tool is embodied as an angle grinder. 
     According to another advantageous embodiment of the present invention it is possible that determining whether to unlock the power tool comprises determining if a protection guard of the power tool is properly installed. Hereby, the power tool can only activated in a safe way if a protection guard has be installed properly. It is possible that the power tool is embodied as an angle grinder. 
     According to another advantageous embodiment of the present invention it is possible that determining whether to unlock the power tool comprises determining if the power tool is properly held and oriented by an operator. 
     According to another advantageous embodiment of the present invention it is possible that determining whether to unlock the power tool comprises determining if a tool of the power tool is properly installed or if a dust hood of the power tool is properly installed. Hereby, the power tool can only activated in a safe way if a tool or dust hood has be installed properly. It is possible that the power tool is embodied as an angle grinder. 
     Certain embodiments commensurate in scope with the originally claimed subject matter are summarized below. These embodiments are not intended to limit the scope of the claimed subject matter, but rather these embodiments are intended only to provide a brief summary of possible forms of the subject matter. Indeed, the subject matter may encompass a variety of forms that may be similar to or different from the embodiments set forth below. 
     In a first embodiment of the present invention, a system includes an angle grinder and an automatic safety system communicatively coupled to the angle grinder. The automatic safety system includes one or more sensors disposed about the angle grinder, where the one or more sensors are configured to gather data about a safety parameter related to an operation of the angle grinder. The automatic safety system also includes a main detector configured to receive the data gathered by the one or more sensors. The main detector is configured to analyze the received data to determine whether to unlock the angle grinder for operation. 
     In another embodiment of the present invention, a method is provided. The method includes receiving, via a main detector, one or more signals from one or more sensors disposed about the angle grinder, where the one or more sensors are configured to gather data about a safety parameter related to an operation of a power tool. The method also includes determining, via the main detector, whether to unlock the power tool for operation based on the data received from the one or more sensors. The method also includes sending an activation signal to a control unit of the power tool, via the main detector, to unlock the power tool for operation. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       These and other features, aspects, and advantages of the present disclosure will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein: 
         FIG. 1  is a perspective view of an embodiment of an angle grinder, having an automatic safety system communicatively coupled to the angle grinder, in accordance with aspects of the present embodiments; 
         FIG. 2  is a perspective view of the embodiment of the angle grinder of  FIG. 1 , in accordance with aspects of the present embodiments; 
         FIG. 3  is a perspective view of an embodiment of the automatic safety system of  FIG. 1 , having a main detector, a safety handle, and a body sleeve, in accordance with aspects of the present embodiments; 
         FIG. 4  is a schematic view of an embodiment of the automatic safety system of  FIG. 1 , illustrating a controller configured to interface with one or more sensing devices of the angle grinder, in accordance with aspects of the present embodiments; and 
         FIG. 5  is an embodiment of a process for executing a safety protocol for the angle grinder of  FIG. 1 , where the safety protocol is executed prior to activating the angle grinder for operation, in accordance with aspects of the present embodiments. 
     
    
    
     DETAILED DESCRIPTION 
     One or more specific embodiments of the present disclosure will be described below. In an effort to provide a concise description of these embodiments, all features of an actual implementation may not be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers&#39; specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure. 
     When introducing elements of various embodiments of the present disclosure, the articles “a,” “an,” “the,” and “said” are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. 
     Present embodiments are directed to safety features that are built into the operating features of a power tool, such as an angle grinder. Specifically, the present embodiments generally relate to a safety protocol that is automatically executed by the angle grinder prior to use. In particular, as noted above, the safety protocol may be beneficial in improving operator safety and in helping an operator maintain control over the angle grinder. For example, in certain situations, if a side handle of the angle grinder is improperly installed, an operator may lose control of the angle grinder during a kickback situation. As a further example, if a protection guard is improperly installed, the operator may be injured by hot sparks during operation of the angle grinder. In certain situations, an operator may unintentionally forget to manually perform safety checks prior to operating the angle grinder. In other situations, it may be inefficient and cumbersome for an operator to perform safety checks prior to each use of the angle grinder. Accordingly, there is a need for an automatic safety protocol that will determine whether certain accessories of the angle grinder are properly installed and/or whether the angle grinder is generally safe to operate. 
     In certain embodiments, the safety protocol may be a series of safety checks that detect the status of one or more operating or safety parameters of the angle grinder. Once the angle grinder executes and passes each safety check of the protocol, the angle grinder may be configured for operation. In certain embodiments, the safety checks include determining whether the safety side handle is properly installed and held, whether the protection guard is properly installed, and whether the angle grinder is properly positioned and oriented (e.g., held properly by the operator). In certain embodiments, the safety checks include determining whether a proper disc accessory is selected and installed and/or whether a dust hood is properly installed. It should be noted that while one or more safety features are described with respect to the safety protocol of the present embodiments, the listed safety features are not limiting or cumulative. Indeed, in other embodiments of the safety protocol, other safety features that are of interest to operation of an angle grinder may be incorporated into the safety protocol. In this manner, the safety protocol may be automatically executed to perform one or more series of desired safety checks for a power tool, such as an angle grinder. 
     With the foregoing in mind,  FIGS. 1 and 2  are perspective views of an embodiment a system  100  comprising a power tool  101  and an automatic safety system  102  communicatively coupled to the power tool. The power tool  101  is embodied as an angle grinder. In the illustrated embodiment, the angle grinder  101  includes an automatic safety system  102  communicatively coupled to the angle grinder  101 . In certain embodiments, the automatic safety system  102  includes a main detector  104 , a side handle  106 , and a body sleeve  108 . As further described with respect to  FIGS. 3-5 , the automatic safety system  102  is configured to execute an automated safety protocol with one or more safety checks. In particular, after successful completion of the automated safety protocol, the automatic safety system  102  may be configured to send an activation signal to the control unit of the angle grinder  101 . The activation signal provided to the control unit of the angle grinder  101  allows the angle grinder  101  to be engaged for operation. 
     In certain embodiments, the angle grinder  101  includes a gear housing, a disc holder, a disc accessory configured to couple to the disc holder. The gear housing and the disc accessory are not shown in the figures. 
     In particular, the gear housing includes a control unit configured to receive one or more activation signals from the automatic safety system  102 , as further explained with respect to  FIG. 5 . The control unit is not shown in the figures. The control unit may be configured to unlock the angle grinder  101 , so that the operator is allowed to engage the angle grinder  101  by pushing the “START” or “ON” button. In certain embodiments, such as when the angle grinder  101  fails to successfully pass each safety check of the automatic safety protocol, the control unit may not receive any activation signals from the automatic safety system  102 , and the angle grinder  101  will remain in a safety lock position. In the safety lock position, the angle grinder  101  may be inoperable when the operator pushes the “START” or “ON” button. Accordingly, in this manner, the angle grinder  101  may be configured to reduce the likelihood of an accidental start and/or operation of the angle grinder  101  prior to a safety check of one or more components. 
     In certain embodiments, the automatic safety system  102  may be coupled to the body  110  of the angle grinder  101 . In particular, the automatic safety system  102  includes a body sleeve  108  that is configured to conform to the external shape of the body  110 . For example, the body sleeve  108  may be configured to wrap around a portion of the body  110 , thereby securing the automatic safety system  102  to the angle grinder  101 . In certain embodiments, the side handle  106  may be coupled to the main detector  102  of the automatic safety system  102 , as further described with respect to  FIG. 3 . In certain embodiments, the main detector  102  may include an extension  112  that is configured to couple two sides of the main detector  102 . Further, each side of the main detector  102  may include an attachment  114  (shown in  FIG. 3 ) that secure the main detector  102  around the body  110  of the angle grinder  101 . In certain embodiments, the extension  112  may be conformed to fit the external surfaces of the body  110  and/or may be configured to fit into a groove of the external surface of the body  100 . In certain embodiments, the attachment  114  may additionally couple the side handle  106  to the main detector  102 . 
     In certain embodiments, a user interface  115  may be disposed on the main detector  104 , and include one or more visual indicia configured to provide information to an operator regarding the status of one or more safety or operating parameters. In certain embodiments, the user interface  115  may include one or more LEDs indicators of one or more different colors, such that each color identifies a status of a different feature or component. For example, in certain embodiments, an LED light and color may be utilized to indicate whether a protection guard is installed properly. Likewise, in certain embodiments, an LED light may be utilized to indicate whether the side handle  106  is installed properly. Similarly, in other embodiments, other types of visual indicia, (e.g., text, pictures, patterns of light, alerts, etc.) may be utilized to indicate information to the operator. In certain embodiments, a graphics display may be utilized to display safety and/or operating features derived from the safety protocol executed by the automatic safety system  100 . In certain embodiments, additional information, such as status of wireless communication, may be displayed and/or communicated to an operator via the user interface  115 . 
       FIG. 3  is a perspective view of an embodiment of the automatic safety system  100  of  FIG. 1 , having the main detector  104 , the safety handle  106 , and the body sleeve  108 , in accordance with aspects of the present embodiments. Further, the illustrated embodiment depicts one or more sensors  116  (or sensing devices  116 ) disposed on the automatic safety system  100  and configured to gather safety and operating information related to the angle grinder  101 . 
     In certain embodiments, the one or more sensing devices  116  or sensors  116  may be configured throughout the angle grinder  101 . In certain embodiments, the sensors  116  may be configured for a specific function and may be located in a specific location. For example, a side handle detection sensor (or switch) may be located proximate to the connection between the side handle  106  and the main detector  104 , and may be configured to provide a status signal regarding the position and depth of the side handle  106 . Specifically, the sensor  116  may be positioned proximate to the attachments  114 , and the sensor  116  may be configured to determine the depth or position to which the side handle  106  is installed with respect to the attachment  114 . The signal information related to the position and depth of the side handle  106  may be utilized to determine whether the side handle  106  is properly installed. As a further example, a guard detection sensor (or switch) may be located proximate to the protection guard, and may be configured to provide a status signal regarding whether the protection guard was properly installed. 
     In certain embodiments, the sensors  116  may be configured to gather other types of information, such as information related to the dust hood and/or the disc selection. For example, the sensor  116  may be a touch sensor (e.g., membrane switch or other kind of thin layer sensor) that is attached near the installation interface to detect the dust hood. When the dust hood is installed, the sensor  116  may be turned on by physical contact, and a signal may be sent to the controller of the main detector to indicate that the dust hood is installed. Similarly, the sensor  116  may be a touch sensor (e.g., membrane switch or other kind of thin layer sensor) that is attached near the gear housing to detect the disc. When the protection guard is installed, the sensor  116  may be turned on by physical contact, and a signal may be sent to the controller  122  of the main detector  104  indicating the disc is installed. 
     In certain embodiments, the sensors may be position/orientation sensors, and may be disposed in locations where an orientation or position of the angle grinder  101  is needed. For example, in certain embodiments, one or more sensors may be disposed on the side handle  106 , and may be configured to determine whether the side handle  106  is properly held or positioned by an operator. Similarly, position/orientation sensors may be disposed on the body  110  or the body sleeve  108  to determine the same. In certain embodiments, the sensors  116  may be pressure sensors that detect whether an operator is in physical contact with the angle grinder  101  in appropriate locations. Indeed, any type of sensor (e.g., accelerometers, temperature sensors, proximity and displacement sensors, image sensors, touch sensors, level sensors, gyroscopes, force, or speed sensors, etc.) may be utilized to gather safety and/or operating parameter information related to the angle grinder  101 . Specifically, as further discussed with respect to  FIGS. 4 and 5 , the sensors may be triggered based on an automatic safety protocol executed by the main detector  104  of the automatic safety system  100 . Further, as described with respect to  FIGS. 4 and 5 , based on the information received, the automatic safety system  100  may be configured to send an activation signal to the control unit of the angle grinder  101 . 
     In certain embodiments, interface circuitry  120  (e.g., wires) may be provided through the automatic safety system  100  to communicatively couple the sensors  116  with the main detector  104 . For example, one or more wires may extend between the body sleeve  108  and the main detector  104 , between the side handle  106  and the main detector  104 , as well as through the extension  112  of the main detector  104 . 
       FIG. 4  is a schematic view of an embodiment of the automatic safety system  100  of  FIG. 1 , illustrating the main detector  104  having a controller  122  configured to interface (via the interface circuitry  120 ) with one or more sensing devices  116  of the angle grinder  101 . In certain embodiments, the main detector  104  may include communications circuitry  124  having a wireless module  126  and a transceiver  128 . As noted above, the user interface  115  may include (optionally) a display  130  and one or more LEDS  132 . 
     In certain embodiments, the controller  122  may be communicatively coupled to a processor  134  and a memory  136 . The processor  134  may be configured to execute instructions stored on the memory  136  to carry out the automatic safety protocol operations of the automatic safety system  100 . The memory  136  may be configured to store instructions that are loadable and executable on the processor  134 . In certain embodiments, the memory  136  may be volatile (such as random access memory (RAM)) and/or non-volatile (such as read-only memory (ROM), flash memory, etc.). The controller  122  may also include additional removable storage and/or non-removable storage including, but not limited to, magnetic storage, optical disks, and/or tape storage. In some implementations, the memory  136  may include multiple different types of memory, such as static random access memory (SRAM), dynamic random access memory (DRAM), or ROM. 
     In particular, the controller  122  may be configured to execute instructions that carry out the automatic safety protocol operations, and may be configured to receive data/information from the one or more sensors  116 . For example, when triggered, the automatic safety protocol may conduct a series of safety checks throughout the angle grinder  101 , as further described with respect to  FIG. 5 . Each safety check may be an executable instruction that is configured to check the safety or operability status of a component or a feature of the angle grinder  101 . In certain embodiments, the sensors  116  may be configured to automatically provide data or information to the controller  122 . In certain embodiments, an operator can initiate the safety protocol by pressing a button or indicating a command through the user interface  115  of the angle grinder  101 . In response to each safety check, a sensor  116  may be configured to provide a detection signal regarding a status (information/data) of the component or feature to the controller  122 . Based on the received information, the controller  122  may be configured to determine whether the angle grinder  101  passed the safety check or failed the safety check. Once all of the safety checks (or a desired number or a desired type of safety checks) are positively passed, the controller  122  may be configured to send an activation signal to the control unit of the angle grinder  101 . 
     In certain embodiments, the main detector  104  may include a power source  138 . The power source  138  may be a replaceable and/or rechargeable power source (e.g., battery powered) disposed within the main detector  104 . In certain embodiments, the main detector  104  may be powered by a power source disposed within the side handle  106 , or may be powered via an external power source. 
     In certain embodiments, the main detector  104  may include communications circuitry  124  having a wireless module  126  and/or a transceiver  128 . In certain embodiments, the main detector  104  may be configured to transmit the information gathered by the sensors  116  to the control unit of the angle grinder  101 . In such embodiments, the main detector  104  may or may not include a controller  122 , processor  134 , and/or a memory  136  to execute and/or process information. In other embodiments, the main detector  104  may be configured to receive and analyze the information received from the sensors  116  to determine whether the angle grinder  101  is ready to be operated. In either embodiment, the wireless module may be utilized to transmit data and/or the activation signal to the main control of the angle grinder  101 . In certain embodiments, the wireless module  126  and/or the transceiver  128  may be incorporated in the control unit of the angle grinder  101 . 
       FIG. 5  is an embodiment of a process  140  for executing an automatic safety protocol for the angle grinder  101  of  FIG. 1 , where the automatic safety protocol is executed prior to activating the angle grinder  101  for operation. In the illustrated embodiment, one or more steps of the process  140  may be executable by the controller  122  of the main detector  104  and/or by a master control unit of the angle grinder  101 . Master control unit is not shown in the figures. In certain embodiments, the process  140  includes receiving one or more signals from the sensor  116  (block  142 ) and performing a series of safety checks on the angle grinder  101  (block  144 ). Specifically, in certain embodiments, the process  140  includes determining if the safety handle is properly installed (block  146 ), determining if the guard is properly installed (block  148 ), and/or determining if the device is properly oriented (block  150 ) (e.g., determining if the side handle  106  and/or the body sleeve  108  and/or the body  110  is properly held and/or positioned). In certain embodiments, the process  140  includes determining if the proper disc is selected and/or installed (block  152 ), and/or determining if dust hood is properly installed (block  154 ). If the signals received from the sensors  116  indicate that the safety features are in alignment with the desired status, the process  140  is configured to send an activation signal to the master control unit of the angle grinder  101 . In certain embodiments, the activation signal is configured to unlock the angle grinder  101 , so that the operator may engage the angle grinder  101  for use. 
     This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.