U.S. patent application number 12/000640 was filed with the patent office on 2008-04-24 for controller with information conveying backlight module and cable for connecting the controller to an automated tool.
This patent application is currently assigned to THE STANLEY WORKS. Invention is credited to Jeffrey S. Aranowski, Zuher N. Khalaf, Craig A. Montross, William L. Naumann, Doug Versele.
Application Number | 20080097635 12/000640 |
Document ID | / |
Family ID | 38461220 |
Filed Date | 2008-04-24 |
United States Patent
Application |
20080097635 |
Kind Code |
A1 |
Naumann; William L. ; et
al. |
April 24, 2008 |
Controller with information conveying backlight module and cable
for connecting the controller to an automated tool
Abstract
A controller that controls an automated tool that comprises a
monochromatic display, a backlighting module, and a processor. The
monochromatic display comprises a plurality of pixels that are
selectively activated and deactivated to convey information to a
user. The backlighting module provides a backlight for the display,
wherein the backlighting module is capable of controllably changing
the color of the backlight. The processor that controls the display
to selectively activate and deactivate the plurality of pixels to
convey information about the automated tool, and wherein the
processor controls the backlighting module such that the backlight
provided by the backlighting module conveys information about the
automated tool.
Inventors: |
Naumann; William L.;
(Chardon, OH) ; Montross; Craig A.; (Hartville,
OH) ; Khalaf; Zuher N.; (Troy, MI) ;
Aranowski; Jeffrey S.; (Macomb, MI) ; Versele;
Doug; (Westland, MI) |
Correspondence
Address: |
PILLSBURY WINTHROP SHAW PITTMAN, LLP
P.O. BOX 10500
MCLEAN
VA
22102
US
|
Assignee: |
THE STANLEY WORKS
New Britain
CT
|
Family ID: |
38461220 |
Appl. No.: |
12/000640 |
Filed: |
December 14, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
11388209 |
Mar 24, 2006 |
|
|
|
12000640 |
Dec 14, 2007 |
|
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Current U.S.
Class: |
700/95 |
Current CPC
Class: |
H01R 9/03 20130101; B25B
23/14 20130101; G05B 19/409 20130101 |
Class at
Publication: |
700/095 |
International
Class: |
G06F 19/00 20060101
G06F019/00 |
Claims
1. A controller that controls an automated tool, the controller
comprising: a monochromatic display that comprises a plurality of
pixels that are selectively activated and deactivated to convey
information to a user; a backlighting module that provides a
backlight for the display, wherein the backlighting module is
capable of controllably changing the color of the backlight; and a
processor that controls the display to selectively activate and
deactivate the plurality of pixels to convey information about the
automated tool, and wherein the processor controls the backlighting
module such that the backlight provided by the backlighting module
conveys information about the automated tool.
2. The controller of claim 1, wherein the information conveyed by
the plurality of pixels of the display is different from the
information conveyed by the color of the backlight provided by the
backlighting module.
3. The controller of claim 2, wherein information conveyed by the
plurality of pixels of the display comprises primary tool
information and the information conveyed by the color of the
backlight provided by the backlighting module comprises secondary
tool information.
4. The controller of claim 3, wherein primary tool information
comprises one or more of a current tool speed, a current applied
torque, a peak torque value, an angle of rotation, a snug torque
value, or a number of completed fastening operations.
5. The controller of claim 3, wherein the secondary tool
information comprises one or more of an operational condition, a
statistical control warning, a diagnostic warning, or a current
operating status.
6. The controller of claim 5, wherein an operation error comprises
a high torque condition, a low torque condition, a good torque
condition, a high angle of rotation condition, or a low angle of
rotation condition.
7. The controller of claim 5, wherein a diagnostic warning
comprises a current condition of the automated tool or a suggested
preventive maintenance.
8. The controller of claim 5, wherein a current operating status
comprises a standby condition, a currently operating condition, or
a non-standby condition.
9. The controller of claim 1, wherein the backlighting module
alternately changes the color of the backlight provided to the
display from one color to another in a blinking fashion to convey
information about the automated tool.
10. The controller of claim 9, wherein the frequency of the
alternation between the colors of the backlight convey information
about the automated tool.
11. The controller of claim 1, wherein the information conveyed by
the color of the backlight is determined based on a user selectable
setting.
12. The controller of claim 1, wherein the backlighting module
comprises a plurality of groups of light emitting sources that
provide the backlight for the display, wherein each of the groups
of light emitting sources comprises one or more light emitting
sources that emit light of substantially the same color, and
wherein each of the groups of light emitting sources emit a color
of light that is unique to that group of light emitting
sources.
13. The controller of claim 1, wherein the processor receives one
or more signals associated with aspects of the automated tool from
one or more sensors that monitor the aspects of the automated tool,
the signals being generated by one or more sensors that monitor the
aspects of the automated tool, and wherein the processor determines
the information conveyed by one or both of the backlight color and
the plurality of pixels based on the received signals.
14. A system comprising: a connector that comprises a connection
interface on a first side, wherein the connection interface
comprises a first primary mating element, a second primary mating
element, a third primary mating element, a first secondary mating
element, a second secondary mating element, a third secondary
mating element, a fourth secondary mating element, a fifth
secondary mating element, a sixth secondary mating element, and a
seventh secondary mating element; and an automated tool the
comprises a tool interface adapted to interface with the connection
interface to removably connect the automated tool with the
connector such that: the automated tool receives three-phase AC
power over the first primary mating element, the second primary
mating element, and the third primary mating element, the automated
tool transmits a signal related to a rotary position of a motor
rotor associated with the automated tool over the first secondary
mating element and the third secondary mating element, the
automated tool receives a common return for the signals transmitted
on the first secondary mating element and the third secondary
mating element, the common return being received via the second
secondary mating element, the automated tool receives DC power over
the fourth secondary mating element, and DC power over the fifth
secondary mating element, and the automated tool transmits and
receives communications in the form of a CANbus signal carried by
the sixth secondary mating element and the seventh secondary mating
element.
15. The system of claim 14, wherein the automated tool receives a
phase T component of the three-phase AC power from the first
primary mating element, a phase R component of the three-phase AC
power from the second primary mating element, and a phase S
component of the three-phase AC power from the third primary mating
element.
16. The system of claim 14, wherein the automated tool transmits a
component of the signal related to the rotary position of the motor
rotor associated with the automated tool that indicates the cosine
of the rotary position of the motor rotor over the first secondary
mating element, and transmits a component of the signal related to
the rotary position of the motor rotor associated with the
automated tool that indicates the sine of the rotary position of
the motor rotor over the third secondary mating element.
17. The system of claim 14, wherein the automated tool receives a
+12V DC power over the fourth secondary mating element, and
receives a 12V DC return over the fifth secondary mating
element.
18. The system of claim 14, wherein the sixth secondary mating
element carries a +CANbus component of the CANbus signal, and the
seventh secondary mating element carries a -CANbus component of the
CANbus signal.
19. The system of claim 14, wherein coordinates of the positions of
the first primary mating element, the second primary mating
element, and the third primary mating element on the connection
interface with respect to a Cartesian coordinate system originating
substantially at the center of the connection interface and having
units of inches are approximately (0.000'', 0.010''), (-0.092'',
0.170''), and (0.092'', 0.170''), respectively.
20. The system of claim 14, wherein coordinates of the positions of
the first secondary mating element, the second secondary mating
element, the third secondary mating element, the fourth secondary
mating element, the fifth secondary mating element, the sixth
secondary mating element, and the seventh secondary mating element
on the connection interface with respect to a Cartesian coordinate
system originating substantially at the center of the connection
interface and having units of inches are approximately (-0.227'',
-0.112''), (-0.253'', -0.013''), (-0.238'', 0.095''), (0.238'',
0.095''), (0.164'', -0.013''), (0.129'', -0.092''), and (0.164'',
-0.196''), respectively.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional application of U.S. patent
application Ser. No. 11/388,209, filed Mar. 24, 2006, the content
of which is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates generally to the use of a backlight on
a monochromatic, pixilated display associated with a controller to
convey information about an automated control being controlled with
the controller.
[0004] 2. Description of Related Art
[0005] Some conventional automated tools are controlled via
controller devices that are operatively coupled thereto. Typical
controller devices include indicator lights that may be actuated to
indicate various information regarding the operation and/or
condition of a tool. These indicator lights may be of specific
colors to indicate certain completed assembly conditions, such as a
green indicator light to indicate a good or OK condition, and a red
indicator light to indicate a bad or Not OK condition. Very often,
these indicator lights are situated on the controller having a
label or pictogram to aid the user in identifying the meaning of
the indicator light.
[0006] The indicator lights, and the interpretation of their
meaning, can be a source of confusion to the user, especially when
a particular controller device has multiple indicator lights
simultaneously indicating the conditions of numerous control
variables. The use of multiple indicator lights also adds to the
cost of building such electronic controllers for power tools.
[0007] Additionally, controller devices typically indicate the
information on a graphic display (e.g., a pixilated display
separate from the indicator lights) to be readily visible to the
assembly tool operator during the course of a production assembly
process, but due to constraints in the size of the display, some
system information can only be displayed when requested by means of
a command manually inputted by a user via a user interface device.
In such cases, information indicating a need for immediate
attention may not be readily noticed by the user.
BRIEF SUMMARY OF THE INVENTION
[0008] One aspect of the invention relates to a controller that
controls an automated tool. In one embodiment, the controller
comprises a monochromatic display, a backlighting module, and a
processor. The monochromatic display comprises a plurality of
pixels that are selectively activated and deactivated to convey
information to a user. The backlighting module provides a backlight
for the display, wherein the backlighting module is capable of
controllably changing the color of the backlight. The processor
that controls the display to selectively activate and deactivate
the plurality of pixels to convey information about the automated
tool, and wherein the processor controls the backlighting module
such that the backlight provided by the backlighting module conveys
information about the automated tool.
[0009] Another aspect of the invention relates to a connector that
forms a portion of an operative link between an automated tool and
a controller that controls the automated tool, wherein information
and/or power are carried between the automated tool and the
controller via the operative link. In one embodiment the connector
comprises housing that carries a connection interface on a first
side. The connection interface comprises at least three primary
mating elements and at least seven secondary mating elements, the
primary mating elements having diameters between about 0.0616
inches and about 0.0635 inches and the secondary mating elements
having diameters between about 0.0295 inches and about 0.0305
inches.
[0010] Another aspect of the invention relates to a system that
comprises a connector and an automated tool. The connector
comprises a connection interface on a first side, wherein the
connection interface comprises a first primary mating element, a
second primary mating element, a third primary mating element, a
first secondary mating element, a second secondary mating element,
a third secondary mating element, a fourth secondary mating
element, a fifth secondary mating element, a sixth secondary mating
element, and a seventh secondary mating element. The automated tool
the comprises a tool interface adapted to interface with the
connection interface to removably connect the automated tool with
the connector such that (i) the automated tool receives three-phase
AC power over the first primary mating element, the second primary
mating element, and the third primary mating element, (ii) the
automated tool transmits a signal related to a rotary position of a
motor rotor associated with the automated tool over the first
secondary mating element and the third secondary mating element,
(iii) the automated tool receives a common return for the signals
transmitted on the first secondary mating element and the third
secondary mating element, the common return being received via the
second secondary mating element, (iv) the automated tool receives
DC power over the fourth secondary mating element, and DC power
over the fifth secondary mating element, and (v) the automated tool
transmits and receives communications in the form of a CANbus
signal carried by the sixth secondary mating element and the
seventh secondary mating element.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 illustrates a system, in accordance with one
embodiment of the invention.
[0012] FIG. 2 illustrates a cable that couples a tool and a
controller, in accordance with one embodiment of the invention.
[0013] FIG. 3 illustrates a housing included in a connector,
according to one embodiment of the invention.
[0014] FIG. 4 illustrates a housing included in a connector,
according to one embodiment of the invention.
[0015] FIG. 5 illustrates a housing included in a connector,
according to one embodiment of the invention.
[0016] FIG. 6 illustrates a housing included in a connector,
according to one embodiment of the invention.
[0017] FIG. 7 illustrates a housing included in a connector,
according to one embodiment of the invention.
[0018] FIG. 8 illustrates an elevation view of a configuration of
mating elements arranged on a connection interface of a connector,
according to one embodiment of the invention.
[0019] FIG. 9 includes a table that includes the coordinates of
specific locations of mating elements on a connection interface
where the coordinates are based on a Cartesian coordinate system
originating substantially at the center of the connection
interface, according to one embodiment of the invention.
[0020] FIG. 10 is a diagram illustrating connections between mating
elements of a connector and the conductor lines disposed within a
cable, in accordance with one or more embodiments of the
invention.
[0021] FIG. 11 illustrates a cross-sectional view of a cable that
shows a layout of conductor lines within a cable jacket, according
to one embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0022] FIG. 1 illustrates a system 10, in accordance with one
embodiment of the invention. System 10 includes a tool 12 and a
controller 14 that is operatively coupled to tool 12 for the
purpose of controlling one or more aspects of the operation of tool
12. In order to control tool 12, information is transmitted from
controller 14 to tool 12. Additionally, feedback information
generated by one or more sensors associated with tool 12 is
transmitted from tool 12 to controller 14. The sensors associated
with tool 12 may comprise one or more of a torque sensor, a motor
temperature sensor, a motor rotor position sensor (e.g., an angle
of rotation sensor), and/or other sensors. In one embodiment, tool
12 and controller 14 are coupled via a cable (e.g., the cabling
discussed further below). However, this is not limiting, and in
other embodiments, tool 12 may be operatively coupled to controller
14 via a wireless link, a network connection, and/or other
operative communication links.
[0023] As shown in FIG. 1, controller 14 comprises a processor 16,
a pixilated display 18, and a backlighting module 20. In one
embodiment, pixilated display 18 is a monochromatic display that
comprises a plurality of pixels that are selectively activated and
deactivated to convey information to a user. For example, pixilated
display 18 may comprise an LCD, an OLED array, a micro-mirror
device, or another display. Backlighting module 20 provides a
backlight for display 18. Backlighting module 20 is capable of
controllably changing the color of the backlight provided to
display 18. Processor 16 controls display 18 to selectively
activate and deactivate the plurality of pixels included therein to
convey information about tool 12, a task, job, or operation
associated with tool 12 (e.g., a future operation, a completed
operation, a current operation, etc.), and/or other information.
Further, processor 16 controls backlighting module 20 such that the
backlight provided by backlighting module 20 conveys information
about automated tool 12. For instance, the color of the backlight
may convey information, the alternation (or blinking) of colors of
the backlight may convey information, or the backlight may
otherwise convey information. As will be described further below,
in some instances, the information conveyed by the pixels of
display 18 is different from the information conveyed by the
backlight provided backlighting module 20.
[0024] In one embodiment, tool 12 includes a fluid- or
electric-powered tool that may be used in production environments
to secure threaded fasteners (e.g., nuts and bolts) into joints.
Tool 12 includes a handheld unit coupled to controller 14. In
another embodiment, tool 12 may include a tool that is carried on
an automated machine capable of positioning tool 12 (e.g., a CNC
controlled machine, etc.). One handheld embodiment of tool 12
includes a high-speed, low-torque motor coupled to a planetary gear
transmission to reduce the speed and increase the torque. The
output of the gear transmission is in turn coupled to an output
head. For example, an output head having a square or hexagonal
drive spindle as the output shaft. Various interchangeable bits or
sockets are connected to the output head in order to drive threaded
fasteners, e.g., bits or sockets appropriate for driving various
bolts, nuts and screws. As was mentioned above, tool 12 is equipped
with torque and angle sensing transducers to enable closed-loop
control by controller 14.
[0025] In the embodiment of FIG. 1, controller 14 controls the
power supply for tool 12, and also monitors such variables as the
current tool speed and current applied torque. In a typical
fastening application, fasteners are tightened to a predetermined,
specified torque. As tool 12 tightens fasteners at specified speeds
and to specified torque levels, controller 14 controls the motor of
tool 12 automatically so that the tightening speed and torque
applied to the fastener and joint meets the specified limits. In
one embodiment, controller 14 also serves the purpose of measuring
the final or peak torque applied to each fastener. The value of
this peak torque is then displayed on controller 14 at the
completion of each tightening operation by the pixels of display
18. Other data, such as the angle of rotation of the fastener from
a specified low, or snug torque value to the final or peak torque
value may also be displayed. Occasionally, the number of completed
fastening operations for a particular assembly may also be
displayed.
[0026] The values of these measured variables may also be compared
to production control limits for each variable, and backlighting
module 20 may be controlled to provide a backlight that indicates
when the values are in or out of these control limits. The
backlight may be controlled according to a backlighting scheme in
which one or more aspects of the backlight are assigned to one or
more system and/or operation conditions according to predetermined
criteria. For example, the backlight may include specific colors to
indicate certain completed assembly conditions, such as a green
color to indicate a good or OK condition, and a red color to
indicate a bad or Not OK condition.
[0027] In one embodiment, control of backlighting module 20 by
processor 16 includes adjusting the backlight to convey other
assembly system information such as statistical control warnings,
system error codes, or diagnostic warnings indicating the condition
of system 10 or the need for preventative maintenance. For
instance, the use of the backlight to convey this critical system
information may alert the user when an operation or process of tool
12 is out of control, or for differentiating when system 10 is in
need of maintenance and when system 10 is in good working order.
These and other types of information may be considered secondary
system information, as compared to the primary system information
conveyed by the pixels of display 18, and may be of interest to
those users with supervisory or maintenance responsibilities.
[0028] In one backlighting scheme, in accordance with one
embodiment of the invention, when system 10 is in a standby
condition with tool idle 12 and controller 14 turned on, the
backlight color is white to indicate a standby condition while the
pixels of display 18 indicate the torque value for which system 10
is adjusted. To initiate a normal operation cycle, the operator of
tool 12 (in a handheld implementation of tool 12) guides tool 12 to
the fastener and actuates the start switch located on tool 12. This
action places controller 14 into the run mode and the backlight
color is changed to a blue color indicating an in-cycle condition
of operation. As the fastener is tightened, the torque will
increase until either the operator aborts the cycle by releasing
the start switch, or until the selected target torque is reached
and controller 14 turns off tool 12. If the operator aborts the
fastening cycle, and the peak torque applied to the fastener is
less than the minimum specified torque, then the backlight color
will change to a yellow color indicating a low torque condition. If
the selected target torque is reached and the torque is within a
specified limit corresponding to the target torque, then the
backlight will change to a green color indicating a good torque
condition. Under certain conditions, the peak torque applied to the
fastener during a fastening cycle may exceed the maximum specified
limit torque. In this case the backlight will change to a red color
indicating a high torque condition. In any of these cases, the
pixels of display 16 can be controlled independently of the
backlight color by processor 16 to display, for example, the peak
value of the torque for that tightening cycle, the angle of
rotation of the fastener beyond a defined snug torque, or any other
assembly data or a combination thereof. Alternately, the words OK
or Not OK, or the words Low, OK, or High may be displayed using the
pixels of display 18, independently of the backlight color.
[0029] As another example of a possible implementation of a
backlighting scheme, the backlight color of the backlight provided
by backlighting module 18 may be used to display statistical
process control conditions. In such applications, controller 14 has
the ability to continuously record the peak torque values in its
memory and perform various statistical process control calculations
on this information. If the calculations indicate that the process
is statistically under control, the backlight color may be green,
indicating a normal process. But if the calculations indicated that
the process has exceeded statistical limits, the backlight color
may be changed to red, indicating an assembly operation is trending
toward an out of control condition.
[0030] In yet another example of a possible backlighting scheme,
the backlight color may be used to display diagnostic conditions of
system 10. In this backlighting scheme, controller 14 has the
ability to continuously monitor various system health conditions,
such as for example, the condition of a torque sensing transducer
associated with tool 12, the efficiency of the motor drive system
associated with tool 12, the number of completed cycles by tool 12,
and/or other system health conditions. If all monitored conditions
are normal, the display backlighting is displayed as green,
indicating system 10 is in normal health. But if any condition
indicates that system 10 is in need of service, the backlight color
would be changed to red, indicating a need for service. In other
related implementations, the colors of the backlight may indicate a
specific area or component of system 10 that need servicing and/or
or a type of service that system 10 is in need of.
[0031] It should be appreciated that the specific example of colors
provided above are exemplary in nature, and that any color or
combination of colors may be implemented in the described
backlighting schemes. Further, in some backlighting schemes, the
color of backlight may be alternately changed from one color to
another in a blinking fashion to indicate certain conditions and/or
an urgency of the indicated condition(s). For instance, the on and
off cycle rate can be altered such that a more rapid rate indicates
a more urgent need for attention. Additionally, the backlighting
schemes described above are not intended to be limiting, as other
backlighting schemes for conveying primary system information,
secondary system information, or a combination of primary and
secondary system information via the backlight provided by
backlighting module 20 are contemplated within the scope of the
invention.
[0032] In one embodiment, a plurality of backlighting schemes are
stored at controller 14 (e.g., by processor 16), and the user is
enabled to select a backlighting scheme for implementation using an
input interface 22 associated with controller 14. Input interface
22 may include any device or devices that would enable the user to
input information to controller 14. For instance, input interface
22 may comprise a keyboard, a keypad, a knob, a switch, a button, a
touchpad, a touch screen, a dial, a mouse, a trackball, a graphical
user interface, a joystick, or other devices that enable the input
of information to an electronic device. In some instances, input
interface 22 enables the user to adjust an existing backlighting
scheme. For example, the user may adjust one or more of the
backlighting colors, one or more of the types of secondary system
information, and/or other aspects of the backlighting scheme.
[0033] In one embodiment of the invention, display 18 and
backlighting module 20 may include a unit that is currently
commercially available and uses one or more multi-colored light
emitting diodes as a light source for the graphic display
backlight. The multi-colored light emitting diodes used in such
displays make use of a separate group of one or more diode elements
for two or more three primary colors and provide the ability to
selectively switch on selected ones of the primary colors with
different degrees of intensity, thereby providing the possibility
of selecting a large spectrum of background colors for the graphic
display screen. In another embodiment, backlighting module 20
includes one or more light sources that emit white light, and
includes a plurality of filters that correspond to a plurality of
colors. In this embodiment, the color of the backlight is changed
by positioning the filters to filter the light emitted by the light
sources so that only light of a selected color is provided as the
backlight. It should be appreciated that other embodiments of
backlight module 20 may be implemented.
[0034] As was discussed briefly above, tool 12 and controller 14
are operatively coupled with each other. In one embodiment, tool 12
and controller 14 are coupled by a cable that enables the
transmission of information and/or power therebetween. FIG. 2
illustrates a cable 24 that couples tool 12 and controller 14, in
accordance with one embodiment of the invention. As can be seen in
FIG. 2, cable 24 includes a first connector 26 and a second
connector 28. Cable body 30 runs between connectors 26 and 28 and
houses a plurality of conductor lines that carry signals between
connectors 26 and 28. Cable 24 includes a cable jacket 32 that
substantially covers cable 24 to protect the components contained
therein. In one embodiment, cable jacket 32 is formed from
polyurethane.
[0035] In one embodiment, connector 26 is configured to enable a
releasable connection between cable 24 and a tool (e.g., tool 10 of
FIG. 1), and connector 28 is configured to enable a releasable
connection between cable 24 and a tool controller (e.g., controller
12 of FIG. 1). In another embodiment, connector 26 is configured to
enable a releasable connection between cable 24 and a tool, and
connector 28 is configured to enable a releasable connection
between cable 24 and another cable (e.g. a cable in connection with
a tool controller). In one embodiment, connector 26 is configured
to enable a releasable connection between a tool, and connector 28
is configured to enable a releasable connection between cable 24
and either of a tool controller or another cable.
[0036] FIGS. 3-7 illustrate a housing 34 included in connector 26,
according to one embodiment of the invention. The specific
dimensions of housing 34 shown in FIGS. 3-7 are provided for
illustration of one embodiment of the invention, and are given in
inches. These dimensions are not intended to be limiting. Referring
to FIG. 3, housing 34 is shown in perspective. As is shown in FIG.
3, housing 34 comprises a first portion 36 and a second portion 38
that are generally cylindrical in shape and are coaxial. First and
second portions 36 and 38 are separated by an annular protrusion
40. Second portion 38 has a smaller diameter than first portion 36.
First portion 36 includes a slot 42 formed axially therein, and a
protruding ridge 44 that runs axially along the cylindrical outer
wall of first portion 36. In one embodiment, housing 34 is molded
from plastic, and is adapted to interface with a size 15, Amphenol
MIL SPEC Series III plug.
[0037] Housing 34 carries a connection interface 46. Connection
interface 46 is formed with a substantially circular cross-section
and is seated within the cylinder formed by first portion 36.
Connection interface 46 comprises a plurality of mating elements
48. Mating elements 48 enable connector 26 to mate with a
compatible connector (e.g., a connector associated with a tool, a
connector associated with another cable, etc.) so as to enable the
conductor lines carried within cable 24 to be operatively coupled
with corresponding conductor lines in the compatible connector. In
one embodiment, one or more of mating elements 48 comprise sockets.
In another embodiment, one or more of mating elements 48 comprise
pins. More particular descriptions one or more embodiments of
connection interface 46, including the aspects and arrangement of
mating elements 48, are provided below.
[0038] FIG. 4 illustrates a dimensioned side elevation view of
housing 34, according to one or more embodiments of the invention.
More specifically, in the elevation view of FIG. 4, housing 34 is
rotated so that slot 42 is aligned horizontally with the axis of
portions 36 and 38.
[0039] FIG. 5 shows a dimensioned side elevation view of housing
34, in accordance with one embodiment of the invention. In the view
shown in FIG. 5, housing 34 is rotated about axis of portions 36
and 38 by approximately 90 degrees to show protruding ridge 44. In
addition, the view shows one of relief surfaces 50 straight on.
[0040] FIG. 6 illustrates a dimensioned elevation view of housing
34, according to one embodiment of the invention. In FIG. 6, a
straight ahead elevation of connection interface 46 is
provided.
[0041] FIG. 7 shows a dimensioned elevation view of housing 34, in
accordance with one embodiment of the invention. In FIG. 7, housing
34 is depicted to illustrate a straight on view of second portion
38.
[0042] FIG. 8 illustrates an elevation view of one configuration of
mating elements 48 (illustrated in FIG. 8 as connection elements
48a-48p) on connection interface 46, according to one embodiment of
the invention. In the embodiment shown, mating elements 48a-48p
comprise primary mating elements 48a-48d and secondary mating
elements 48e-48p. In some instances, primary mating elements
48a-48d have diameters between about 0.0616 inches and about 0.0635
inches, and secondary mating elements 48e-48p have diameters
between about 0.0295 inches and about 0.0305 inches. In one
embodiment, the specific locations of mating elements 48a-48p are
located substantially at the coordinates shown in the table in FIG.
9, with respect to a Cartesian coordinate system originating
substantially at the center of connection interface 46. The units
of the coordinate system are inches. The layout of mating elements
48 on connection interface 46 depicted in FIG. 8 and described by
the table of FIG. 9 represents an embodiment of connection
interface 46 that provides for enhancements in conductor spacing
(e.g., for insulation purposes), common mode rejection (e.g. for
electrical noise suppression), and providing mating elements 48 in
a configuration that fits within a size 15 connector shell.
[0043] Primary mating elements 48a-48c are configured to carry AC
power. In one embodiment, primary mating elements 48a-48c carry
three phase AC power with primary mating element 48b carrying a
first phase (e.g., phase R), primary mating element 48c carrying a
second phase (e.g., phase S), and primary mating element 48a
carrying a third phase (e.g., phase T). In one embodiment, primary
mating element 48d is kept at a ground potential (e.g., zero
potential, etc.). The AC power carried by primary mating elements
48a-48d may be implemented by a connected tool to power a rotary
motor (or another motor) in the tool.
[0044] Secondary mating elements 48e-48p are configured to carry
various information, power, and shielding signals. In one
embodiment, secondary mating elements 48j and 48k carry one or more
digital information signals. In this embodiment, secondary mating
element 48l carries a shielding signal that shields the digital
information signals carried by secondary mating elements 48j and
48k from noise. In some instances, the digital information signals
carried by secondary mating elements 48j and 48k comprise a CANbus
signal (e.g., a - CANbus signal, a + CANbus signal, etc.). The
digital information signals carried by secondary mating elements
48j and 48k enable control information to be transmitted to the
tool and feedback information to be transmitted to the controller.
The feedback information may be generated by the sensor(s)
associated with the tool. Information may be transmitted by the
digital information signals at a rate of 500 kbps.
[0045] In one embodiment, secondary mating elements 48h and 48i
carry DC power. In this embodiment, secondary mating element 48o
carries a shielding signal that shields the DC power carried by
secondary mating elements 48h and 48i from noise. In some
instances, the DC power carried by secondary mating elements 48h
and 48i comprise a +12V DC power and a 12V DC return. The DC power
carried by secondary mating elements 48h and 48i may power some or
all of the sensors associated with the tool.
[0046] In one embodiment, secondary mating elements 48e and 48g
carry one or more motor position output signals that indicate a
rotary position of a motor rotor associated with the tool. In this
embodiment, secondary mating element 48f carries a common return
for the motor position output signals carried by secondary mating
elements 48e and 48g. In some instances, the motor position output
signals carried by secondary mating elements 48e and 48g comprise a
cosine output signal and a sine output signal, respectively.
Additionally, secondary mating element 48n may carry a shielding
signal that shields the motor position output signals carried by
secondary mating elements 48e-48g from noise.
[0047] FIG. 10 is a diagram illustrating connections between mating
elements 48a-48p and the conductor lines disposed within cable
jacket 34 (see FIG. 2). As can be seen from FIG. 10, the conductor
lines comprise a first twisted triad 52, a second twisted triad 54,
a third twisted triad 56, a twisted pair 58, a first unpaired
conductor 60, a second unpaired conductor 61, a first shield 62
(that shields first twisted triad 52), a second shield 64 (that
shields second twisted triad 54), a third shield 66 (that shields
twisted pair 58), and a fourth shield 68 (that acts as an overall
shield).
[0048] In one embodiment, the conductor lines in first twisted
triad 52 are coupled to secondary mating elements 48h, 48i, and
48p. The conductor lines in second twisted triad 54 are coupled to
secondary mating elements 48e-48g. The conductor lines in third
twisted triad 56 are coupled to primary mating elements 48a-48c.
The conductor lines in twisted pair 58 are coupled to secondary
mating elements 48j and 48k. First and second unpaired conductors
60 and 61 are both coupled to primary mating element 48d. In one
embodiment, primary mating elements 48a-48d comprise pins with
primary mating element 48d extending away from connection interface
46 farther than primary mating elements 48a-48c. First shield 62,
second shield 64, third shield 66, and fourth shield 68 are coupled
to secondary mating element 48o, secondary mating element 48n,
secondary mating element 48l, and secondary mating element 48m,
respectively.
[0049] FIG. 11 shows a cross-sectional view of cable 24 that shows
a layout of the conductor lines within cable jacket 36, according
to one embodiment of the invention. As is shown in FIG. 11 (and
represented in the diagram of FIG. 10), the conductor lines of
first and second twisted triads 52 and 54 are 26awg, the conductor
lines of twisted pair 58 are 28awg, the conductor lines of third
twisted triad 56 are 18awg, and first and second unpaired
conductors are both 20awg. Fillers 70 are disposed within cable 24
in order to maintain the positions of the conductor lines within
cable jacket 34 and shield 68.
[0050] The configurations of and connections between the conductor
lines within cable jacket 36 and mating elements 48 in connection
interface 46 disclosed above provide various enhancements. For
example, cable 24 is provided at a reduced cost (due to a reduction
of mating elements, cabling components, and assembly labor), a
lighter weight, a smaller cable diameter (resulting in an improved
flexibility of cable 24), and other enhancements.
* * * * *