Patent ID: 12202097

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' 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.1and2are perspective views of an embodiment a system100comprising a power tool101and an automatic safety system102communicatively coupled to the power tool. The power tool101is embodied as an angle grinder. In the illustrated embodiment, the angle grinder101includes an automatic safety system102communicatively coupled to the angle grinder101. In certain embodiments, the automatic safety system102includes a main detector104, a side handle106, and a body sleeve108. As further described with respect toFIGS.3-5, the automatic safety system102is 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 system102may be configured to send an activation signal to the control unit of the angle grinder101. The activation signal provided to the control unit of the angle grinder101allows the angle grinder101to be engaged for operation.

In certain embodiments, the angle grinder101includes 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 system102, as further explained with respect toFIG.5. The control unit is not shown in the figures. The control unit may be configured to unlock the angle grinder101, so that the operator is allowed to engage the angle grinder101by pushing the “START” or “ON” button. In certain embodiments, such as when the angle grinder101fails to successfully pass each safety check of the automatic safety protocol, the control unit may not receive any activation signals from the automatic safety system102, and the angle grinder101will remain in a safety lock position. In the safety lock position, the angle grinder101may be inoperable when the operator pushes the “START” or “ON” button. Accordingly, in this manner, the angle grinder101may be configured to reduce the likelihood of an accidental start and/or operation of the angle grinder101prior to a safety check of one or more components.

In certain embodiments, the automatic safety system102may be coupled to the body110of the angle grinder101. In particular, the automatic safety system102includes a body sleeve108that is configured to conform to the external shape of the body110. For example, the body sleeve108may be configured to wrap around a portion of the body110, thereby securing the automatic safety system102to the angle grinder101. In certain embodiments, the side handle106may be coupled to the main detector102of the automatic safety system102, as further described with respect toFIG.3. In certain embodiments, the main detector102may include an extension112that is configured to couple two sides of the main detector102. Further, each side of the main detector102may include an attachment114(shown inFIG.3) that secure the main detector102around the body110of the angle grinder101. In certain embodiments, the extension112may be conformed to fit the external surfaces of the body110and/or may be configured to fit into a groove of the external surface of the body100. In certain embodiments, the attachment114may additionally couple the side handle106to the main detector102.

In certain embodiments, a user interface115may be disposed on the main detector104, 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 interface115may 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 handle106is 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 system100. In certain embodiments, additional information, such as status of wireless communication, may be displayed and/or communicated to an operator via the user interface115.

FIG.3is a perspective view of an embodiment of the automatic safety system100ofFIG.1, having the main detector104, the safety handle106, and the body sleeve108, in accordance with aspects of the present embodiments. Further, the illustrated embodiment depicts one or more sensors116(or sensing devices116) disposed on the automatic safety system100and configured to gather safety and operating information related to the angle grinder101.

In certain embodiments, the one or more sensing devices116or sensors116may be configured throughout the angle grinder101. In certain embodiments, the sensors116may 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 handle106and the main detector104, and may be configured to provide a status signal regarding the position and depth of the side handle106. Specifically, the sensor116may be positioned proximate to the attachments114, and the sensor116may be configured to determine the depth or position to which the side handle106is installed with respect to the attachment114. The signal information related to the position and depth of the side handle106may be utilized to determine whether the side handle106is 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 sensors116may be configured to gather other types of information, such as information related to the dust hood and/or the disc selection. For example, the sensor116may 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 sensor116may 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 sensor116may 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 sensor116may be turned on by physical contact, and a signal may be sent to the controller122of the main detector104indicating 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 grinder101is needed. For example, in certain embodiments, one or more sensors may be disposed on the side handle106, and may be configured to determine whether the side handle106is properly held or positioned by an operator. Similarly, position/orientation sensors may be disposed on the body110or the body sleeve108to determine the same. In certain embodiments, the sensors116may be pressure sensors that detect whether an operator is in physical contact with the angle grinder101in 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 grinder101. Specifically, as further discussed with respect toFIGS.4and5, the sensors may be triggered based on an automatic safety protocol executed by the main detector104of the automatic safety system100. Further, as described with respect toFIGS.4and5, based on the information received, the automatic safety system100may be configured to send an activation signal to the control unit of the angle grinder101.

In certain embodiments, interface circuitry120(e.g., wires) may be provided through the automatic safety system100to communicatively couple the sensors116with the main detector104. For example, one or more wires may extend between the body sleeve108and the main detector104, between the side handle106and the main detector104, as well as through the extension112of the main detector104.

FIG.4is a schematic view of an embodiment of the automatic safety system100ofFIG.1, illustrating the main detector104having a controller122configured to interface (via the interface circuitry120) with one or more sensing devices116of the angle grinder101. In certain embodiments, the main detector104may include communications circuitry124having a wireless module126and a transceiver128. As noted above, the user interface115may include (optionally) a display130and one or more LEDS132.

In certain embodiments, the controller122may be communicatively coupled to a processor134and a memory136. The processor134may be configured to execute instructions stored on the memory136to carry out the automatic safety protocol operations of the automatic safety system100. The memory136may be configured to store instructions that are loadable and executable on the processor134. In certain embodiments, the memory136may be volatile (such as random access memory (RAM)) and/or non-volatile (such as read-only memory (ROM), flash memory, etc.). The controller122may 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 memory136may include multiple different types of memory, such as static random access memory (SRAM), dynamic random access memory (DRAM), or ROM.

In particular, the controller122may 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 sensors116. For example, when triggered, the automatic safety protocol may conduct a series of safety checks throughout the angle grinder101, as further described with respect toFIG.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 grinder101. In certain embodiments, the sensors116may be configured to automatically provide data or information to the controller122. In certain embodiments, an operator can initiate the safety protocol by pressing a button or indicating a command through the user interface115of the angle grinder101. In response to each safety check, a sensor116may be configured to provide a detection signal regarding a status (information/data) of the component or feature to the controller122. Based on the received information, the controller122may be configured to determine whether the angle grinder101passed 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 controller122may be configured to send an activation signal to the control unit of the angle grinder101.

In certain embodiments, the main detector104may include a power source138. The power source138may be a replaceable and/or rechargeable power source (e.g., battery powered) disposed within the main detector104. In certain embodiments, the main detector104may be powered by a power source disposed within the side handle106, or may be powered via an external power source.

In certain embodiments, the main detector104may include communications circuitry124having a wireless module126and/or a transceiver128. In certain embodiments, the main detector104may be configured to transmit the information gathered by the sensors116to the control unit of the angle grinder101. In such embodiments, the main detector104may or may not include a controller122, processor134, and/or a memory136to execute and/or process information. In other embodiments, the main detector104may be configured to receive and analyze the information received from the sensors116to determine whether the angle grinder101is 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 grinder101. In certain embodiments, the wireless module126and/or the transceiver128may be incorporated in the control unit of the angle grinder101.

FIG.5is an embodiment of a process140for executing an automatic safety protocol for the angle grinder101ofFIG.1, where the automatic safety protocol is executed prior to activating the angle grinder101for operation. In the illustrated embodiment, one or more steps of the process140may be executable by the controller122of the main detector104and/or by a master control unit of the angle grinder101. Master control unit is not shown in the figures. In certain embodiments, the process140includes receiving one or more signals from the sensor116(block142) and performing a series of safety checks on the angle grinder101(block144). Specifically, in certain embodiments, the process140includes determining if the safety handle is properly installed (block146), determining if the guard is properly installed (block148), and/or determining if the device is properly oriented (block150) (e.g., determining if the side handle106and/or the body sleeve108and/or the body110is properly held and/or positioned). In certain embodiments, the process140includes determining if the proper disc is selected and/or installed (block152), and/or determining if dust hood is properly installed (block154). If the signals received from the sensors116indicate that the safety features are in alignment with the desired status, the process140is configured to send an activation signal to the master control unit of the angle grinder101. In certain embodiments, the activation signal is configured to unlock the angle grinder101, so that the operator may engage the angle grinder101for 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.