Method for detecting a bit jam condition using a freely rotatable inertial mass

1. A method for detecting a bit jam condition in a power tool having a tool drivably connected to a motor to impart rotary motion about a rotational axis to the tool, comprising:

disposing an inertial mass comprised of a solid cylindrical body in a housing of the power tool, the inertial mass being freely rotatable about its longitudinal axis and axially aligned with the rotational axis of the tool;

monitoring rotational motion of the housing of the power tool in relation to the inertial mass; and

determining when angular velocity of the rotational motion exceeds a predefined velocity threshold indicative of a bit jam condition.

2. The method of claim 1 wherein the power tool further includes a motor drivably coupled to the rotary shaft to impart rotary motion thereto, such that the predefined velocity threshold is based on speed of the motor.

3. The method of claim 1 further comprises activating a protective operation when the angular velocity of the rotational motion exceeds the predefined velocity threshold.

4. The method of claim 1 further comprises monitoring direction of the rotational motion and activating a protective operation when the angular velocity of the rotational motion exceeds the predefined velocity threshold and the direction of the rotational motion does not change within a predefined time period.

5. The method of claim 1 further comprises monitoring rotational displacement of the housing in relation to the inertial mass and activating a protective operation when the angular velocity of the rotational motion exceeds the predefined velocity threshold and when the rotational displacement exceeds a predefined displacement threshold.

6. The method of claim 5 wherein the predefined displacement threshold is on the order of 45 degrees.

7. The method of claim 1 further comprises determining when rotational displacement of the rotational motion exceeds a predefined displacement threshold indicative of a bit jam condition.

8. The method of claim 7 wherein the power tool further includes a motor drivably coupled to the rotary shaft to impart rotary motion thereto, such that the predefined displacement threshold is based on speed of the motor.

9. The method of claim 8 further comprises setting the predefined displacement threshold at a first value for low motor speeds and at a second value for high motor speeds, where the first value is higher than the second value.

10. The method of claim 7 further comprises activating a protective operation when the rotational displacement exceeds the predefined displacement threshold.

11. The method of claim 7 further comprises activating a protective operation when the rotational displacement exceeds the predefined displacement threshold within a predefined time period.

12. The method of claim 7 wherein the step of monitoring rotational displacement further comprises maintaining a measure of rotational displacement over time.

13. A method for detecting a bit jam condition in a power tool having rotary shaft configured to hold a tool bit, comprising:

disposing an inertial mass comprised of a solid cylindrical body in a housing of the power tool, the inertial mass being freely rotatable about an axis of rotation during operation of the tool and the axis of rotation being axially aligned with a rotational axis of the tool bit;

monitoring rotational motion of the housing of the power tool in relation to the inertial mass;

computing angular velocity of the housing in relation to the inertial mass;

determining a direction of the angular velocity of the housing in relation to the inertial mass; and

activating a protective operation when the angular velocity exceeds a predefined velocity threshold and the direction of the angular velocity does not change within a predefined period of time.

14. The method of claim 13 further comprises continuing operation of the power tool when the angular velocity exceeds the predefined velocity threshold but the direction of the angular velocity changes within the predefined period of time.

15. The method of claim 13 further comprises monitoring rotational displacement of the housing in relation to the inertial mass and activating a protective operation when the angular velocity of the rotational motion exceeds the predefined velocity threshold and when the rotational displacement exceeds a predefined displacement threshold.

16. The method of claim 13 wherein the power tool further includes a motor drivably coupled to the rotary shaft to impart rotary motion thereto, such that the predefined velocity threshold is based on speed of the motor.

17. The method of claim 16 further comprises setting the predefined displacement threshold at a first value for low motor speeds and at a second value for high motor speeds, where the first value is higher than the second value.

18. The method of claim 13 wherein the inertial mass is further defined as a wheel coupled via a bearing to an axle.

19. The method of claim 18 further comprises an optical sensor operable to detect demarcations on the wheel, where the spacing between demarcations correlate to a known displacement.

20. A method for detecting a bit jam condition in a power tool having a rotary shaft configured to hold a tool bit, comprising:

disposing an inertial mass in a housing of the power tool, the inertial mass being freely rotatable about an axis of rotation and the axis of rotation being axially aligned with the rotary shaft;

setting the predefined displacement threshold at a first value for low motor speeds and at a second value for high motor speeds, where the first value is higher than the second value;

arranging a sensing element in fixed relation to the housing to detect rotational motion of the housing in relation to the inertial mass;

determining rotational displacement of the housing in relation to the inertial mass based on input from the sensing element; and

activating a protective operation when the rotational displacement of the housing exceeds a predefined displacement threshold.