CN222755371U - Powered Fastener Drivers - Google Patents

Abstract

A powered fastener driver includes a housing, a nosepiece extending from the housing, a driver blade movable within the nosepiece between a ready position and a driven position, a piston coupled to the driver blade for movement therewith, a driver cylinder within which the piston is movable, a magazine coupled to the nosepiece in which aligned fasteners can be received, a fastener delivery mechanism coupled to the nosepiece for individually delivering aligned fasteners in the magazine to a fastener driving channel in the nosepiece, the fastener delivery mechanism movable between a fastener acquisition position and a fastener delivery position, and a sensor for determining the position of the fastener delivery mechanism.

Description

Power fastener driver

Cross Reference to Related Applications

The present application claims priority to U.S. provisional patent application No. 63/593,695 filed on day 10, 2023 and U.S. provisional patent application No. 63/505,584 filed on day 6, 2023, and 27, the entire contents of both provisional patent applications are incorporated herein by reference.

Technical Field

The utility model relates to a powered fastener driver.

Background

Powered fastener drivers are used to drive fasteners (e.g., nails, tacks, staples, etc.) into workpieces. Such fastener drivers typically include a magazine in which fasteners are stored and a pusher mechanism for individually delivering fasteners from the magazine to a fastener driving channel, wherein the fasteners are impacted by a driver blade during a fastener driving operation.

Disclosure of utility model

In one aspect, the present utility model provides a powered fastener driver having a housing, a nosepiece extending from the housing, a driver blade movable within the nosepiece between a ready position and a driven position, a piston coupled to the driver blade for movement therewith, a driver cylinder within which the piston is movable, a magazine coupled to the nosepiece in which aligned fasteners can be received, a fastener delivery mechanism coupled to the nosepiece for individually delivering aligned fasteners in the magazine to a fastener driving channel in the nosepiece, the fastener delivery mechanism movable between a fastener acquisition position and a fastener delivery position, and a sensor for determining the position of the fastener delivery mechanism.

In another aspect, the present utility model provides a method of operating a powered fastener driver and includes monitoring a position of a fastener delivery mechanism, determining whether the fastener delivery mechanism has moved from a fastener acquisition position to a fastener delivery position, and allowing the fastener driver to fire when a trigger is actuated and when the fastener delivery position is detected.

In yet another aspect, the present utility model provides a powered fastener driver having a housing, a nosepiece extending from the housing, a workpiece contact mount slidably disposed on the nosepiece, the workpiece contact mount including at least one workpiece contact mount target, a driver blade movable within the nosepiece between a ready position and a driven position, a piston coupled to the driver blade for movement therewith, a driver cylinder within which the piston is movable, a magazine coupled to the nosepiece in which aligned fasteners can be received, a fastener delivery mechanism coupled to the nosepiece for individually delivering aligned fasteners in the magazine to fastener driving channels in the nosepiece, the fastener delivery mechanism including at least one actuator target, a first sensor for detecting movement of the at least one workpiece contact mount target and the workpiece contact mount, and a second sensor for detecting movement of the at least one actuator target and movement of the fastener delivery mechanism.

In yet another aspect, the present utility model provides a powered fastener driver comprising a housing, a nosepiece extending from the housing, a driver blade movable within the nosepiece between a ready position and a driven position, a piston coupled to the driver blade for movement therewith, a driver cylinder within which the piston is movable, a magazine coupled to the nosepiece in which aligned fasteners can be received, a fastener delivery mechanism coupled to the nosepiece for individually delivering aligned fasteners in the magazine to a fastener driving channel in the nosepiece, a fastener delivery mechanism movable between a fastener acquisition position and a fastener delivery position, and a sensor for detecting whether a fastener is in the fastener driving channel.

Other features and aspects of the utility model will become apparent by consideration of the following detailed description and accompanying drawings.

Drawings

FIG. 1 is a perspective view of a gas spring powered fastener driver.

FIG. 2 is a left side view of the gas spring powered fastener driver of FIG. 1.

Fig. 3 is a right side view of the fastener driver of fig. 1.

Fig. 4 is a front view of the fastener driver of fig. 1.

Fig. 5 is a rear view of the fastener driver of fig. 1.

FIG. 6 is a right side view of the fastener driver of FIG. 1 with a portion of the housing removed and having a partial cross-section through the reservoir cylinder.

FIG. 7 is a top view of the fastener driver of FIG. 1 with the housing and other portions removed.

FIG. 8 is a left side view of the fastener driver of FIG. 1 with the housing and other portions removed.

FIG. 9 is a right side view of the fastener driver of FIG. 1 with the housing and other portions removed.

FIG. 10 is a top view of a sensor mount for the fastener driver of FIG. 1.

Fig. 11 is a right side view of the sensor holder of fig. 10.

Fig. 12 is a left side view of the sensor holder of fig. 10.

FIG. 13 is a flowchart showing a method of operating a gas spring powered fastener driver.

FIG. 14 is a right side view of another fastener driver with a portion of the housing removed and having a partial cross-section through the reservoir cylinder.

FIG. 15 is a top view of the fastener driver of FIG. 14 with the housing and other portions removed.

FIG. 16 is a left side view of the fastener driver of FIG. 14 with the housing and other portions removed.

FIG. 17 is a right side view of the fastener driver of FIG. 14 with the housing and other portions removed.

FIG. 18 is a top view of a sensor mount for the fastener driver of FIG. 14.

Fig. 19 is a right side view of the sensor holder of fig. 18.

FIG. 20 is a left side view of the sensor mount of FIG. 18;

FIG. 21 is a block diagram of a gas spring powered fastener driver.

FIG. 22 is a flow chart showing another method of operating a gas spring powered fastener driver.

FIG. 23 is a flow chart showing yet another method of operating a gas spring powered fastener driver.

FIG. 24 is a flow chart showing yet another method of operating a gas spring powered fastener driver.

Before any embodiments of the disclosure are explained in detail, it is to be understood that the disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The disclosure is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.

Detailed Description

Referring to fig. 1-6, an embodiment of a gas spring powered fastener driver 100 is illustrated. The fastener driver 100 is operable to drive fasteners, such as nails from a collated roll or coil, into a workpiece. The fastener driver 100 includes a housing 102 having a first housing shell 104 joined to a second housing shell 106. The housing 102 includes a head portion 108 having a handle portion 110 and a drive unit housing portion 112 extending therefrom. The housing 102 also includes a battery receptacle portion 114 extending from the handle portion 110 and sized and shaped to receive a removable battery pack 116 therein. Further, the housing 102 includes a fastener delivery portion 120 that extends along the drive unit housing portion 112 from a front end piece 121 to a cartridge receptacle portion 124 adjacent the battery receptacle portion 114. A workpiece contact mount 122 is slidably disposed on nose piece 121.

As shown, the cassette receptacle portion 124 is generally cylindrical and is sized and shaped to receive a coiled arrangement of fasteners therein. A cassette cover 126 is rotatably disposed on the housing 102 and provides access to a cassette 128 that is removably disposed within the cassette receptacle portion 124. The cassette 128 is a can-type cassette containing a coiled arrangement of rows of staple strips. During operation of the fastener driver 100, individual fasteners are sequentially loaded from the magazine 128 to the nosepiece 121 via the fastener delivery portion 120.

As shown in fig. 2, the fastener driver 100 defines a drive axis 130 along which fasteners are driven from the fastener driver 100 into a workpiece. Further, as depicted, the fastener driver 100 includes a first left wear pad 132 disposed on the head portion 108 of the first housing shell 104 proximate the nose piece 121. The first left wear pad 132 extends in a direction parallel to the drive axis 130. The fastener driver 100 further includes a second left wear pad 134 disposed on the head portion 108 of the first housing shell 104 proximate an end of the head portion 108 opposite the nose piece 121. The second left wear pad 134 extends in a direction perpendicular to the drive axis 130. As further shown in fig. 2, the fastener driver 100 includes a third left wear pad 136 disposed on the cartridge receptacle portion 124 at an angle relative to the drive axis 130.

Fig. 3 indicates that fastener driver 100 includes a first right wear pad 142 disposed on head portion 108 of second housing shell 106 proximate nose piece 121. The first right wear pad 142 extends in a direction parallel to the drive axis 130. Fastener driver 100 further includes a second right wear pad 144 disposed on head portion 108 of second housing shell 106 proximate an end of head portion 108 opposite nose piece 121. The second right wear pad 144 extends in a direction perpendicular to the drive axis 130. As further shown in fig. 3, the fastener driver 100 includes a third right wear pad 146 disposed on the cartridge receptacle portion 124 at an angle relative to the drive axis.

As shown in fig. 4, the fastener driver 100 further includes a first wear plate 148 adjacent the third left wear pad 136 and a second wear plate 149 adjacent the third right wear pad 146. Wear plates 148, 149 are molded into the cartridge receptacle portion 124 such that they face in a forward direction, i.e., the same direction as the nose piece 121 and the same direction as the fasteners are driven from the fastener driver 100. The wear plates 148, 149 are constructed of a material having a relatively high hardness and thus a relatively high wear resistance. For example, the wear plates 148, 149 are made of metal (e.g., high carbon alloy steel).

Fig. 6-9 illustrate the internal components of the fastener driver 100. As shown, the fastener driver 100 includes a reservoir cylinder 150 disposed within the head portion 108 of the housing 102. The reservoir cylinder 150 includes a valve port 152 in which a fill valve is disposed. The fill valve is in fluid communication with the interior of the reservoir cylinder 150. For example, the fill valve may be configured as a Schrader valve, a Presta valve, a Dunlop valve, or some other similar valve. The fill valve, when connected to a source of compressed gas, enables the reservoir cylinder 150 to be filled with compressed gas or refilled with compressed gas in the event of any leakage.

The reservoir cylinder 150 includes a driver cylinder 160 disposed therein. Further, a movable piston 162 is slidably disposed within the driver cylinder 160. The actuator blade 164 is connected to the movable piston 162. As shown, the driver blade 164 includes a proximal end 166 and a distal end 168. The proximal end 166 of the driver blade 164 is connected to the movable piston 162 by a pin 170. When the piston 162 moves to a Top Dead Center (TDC) (i.e., retracted or ready) position within the driver cylinder 160 and the fastener driver 100 is ready to be fired, the distal end 168 of the driver blade 164 is adjacent the nose piece 121. Upon firing, the distal end 168 of the driver blade 164 is moved into the nosepiece 121 to drive the fastener from within the nosepiece 121 and into the workpiece until the piston 162 reaches a Bottom Dead Center (BDC) (i.e., extended or driven) position within the driver cylinder 160.

Fig. 6-9 further indicate that the fastener driver 100 includes a circuit board 172 that controls operation of the fastener driver 100. A user interface 174 is disposed on the circuit board 172 and extends through the housing 102 into an area adjacent the handle portion 110. The user interface 174 provides user controls for the fastener driver 100 and includes, for example, an on/off switch, a mode selector button, a remaining charge indicator, a charge indicator, and other additional buttons and indicators as necessary. The circuit board 172, when engaged with the battery receptacle portion 114 and the battery pack 116, is electrically connected to the battery receptacle portion and the battery pack and provides DC power to a motor 176 (e.g., a brushless direct current (BLDC) motor) that is operatively coupled to the lift mechanism 180. The lift mechanism 180 selectively engages the driver blade 164 and the lift mechanism 180 is driven by the motor 176 to move the driver blade 164 from a driven or BDC position to a ready position (between the BDC position and the TDC position) prior to a subsequent fastener driving operation. In response to initiating a subsequent fastener driving operation, motor 176 is restarted to cause lift mechanism 180 to move driver blade 164 from the ready position to the TDC position, after which lift mechanism 180 is disengaged from driver blade 164, which is then urged toward the driven or BDC position by the force of the compressed gas acting on piston 162. As best shown in fig. 7 and 9, the latch actuator assembly 190 cooperates with the lift mechanism 180 to selectively engage the driver blade 164 and hold the driver blade 164 in the ready position before the latch actuator assembly 190 is actuated by the lift mechanism 180 to release the driver blade 164 into the nose piece 121 to drive a fastener from the fastener driver 100 into a workpiece.

As further depicted in fig. 6-9, the fastener driver 100 further includes a sensor bracket 200 disposed at least partially over the lift mechanism 180. Sensor mount 200 includes a first sensor 202 configured to sense the angular (or rotational) position of lift mechanism 180, a second sensor 204 that senses the linear position of workpiece contact mount 122 slidably disposed on nose piece 121, and a third sensor 206 that senses the position of fastener delivery mechanism 230, described below. For example, the sensors 202, 204, 206 are hall effect sensors configured to sense the presence of a magnet or magnetic field. The workpiece contact mount 122 includes a magnet 212 that is sensed by the second sensor 204 when the workpiece contact mount 122 is engaged with a workpiece and slid over the nose piece 121. When the magnet 212 is sensed, the fastener driver 100 is allowed to fire. If no sensing of the workpiece contacting the magnet 212 on the carriage 122 is made, the fastener driver firing is not allowed. Fastener delivery mechanism 230 also includes magnet 214. If the magnet 214 on the fastener delivery mechanism 230 is not sensed, an indication is made that the fastener delivery mechanism 230 is not properly positioned, possibly due to a stuck fastener, and that the fastener driver 100 is not allowed to fire.

As shown, the fastener driver 100 includes a depth adjuster 220 having a threaded shaft 222 threadably engaged with the workpiece contact mount 122. The depth adjuster 220 is rotatable to change the linear position of the workpiece contact mount 122 relative to the nose piece 121. This changes the depth to which fasteners ejected from the fastener driver 100 are driven into the workpiece.

As shown, the fastener driver 100 also includes a fastener delivery mechanism 230. As best shown in fig. 8-9, fastener delivery mechanism 230 includes a spring-loaded actuator portion 300 slidably disposed within a bracket 302 on nose piece 121. The actuator portion 300 includes a proximal end 304 and a distal end 306. Spring 308 is mounted in a compressed manner adjacent to proximal end 304 of actuator portion 300 to bias actuator portion 300 toward drive channel 310 of nose piece 121. The pusher portion 312 is mounted on the distal end 306 of the actuator portion 300 by a hinge pin 314. In another aspect, the pusher portion 312 and the actuator portion 300 are integrally formed as a single, unitary portion, and the pusher portion 312 is formed on the actuator portion 300 (e.g., the distal end 306 of the actuator portion 300). A torsion spring 316 is provided on the hinge pin 314 to bias the pusher portion 312 about the hinge pin 314 toward the nose piece 121.

Fastener delivery mechanism 230 also includes a first rocker arm 318 rotatably mounted on nose piece 121 via a first post 320 (e.g., a threaded fastener). The first rocker arm 318 includes a forked end 322 that fits around a transverse post 324 on the distal end 306 of the actuator portion 300. As shown, fastener delivery mechanism 230 further includes a second rocker 326 rotatably mounted to nose piece 121 via a second post 328 and to first rocker 318 via a third post 330. A spring-loaded actuator 332 is mounted on the free end of the second rocker arm 326. The spring-loaded actuator 332 can rotate in only a single direction toward the delivery end of the fastener driver 100 against the force of a spring returning it to the upright position. When the driver blade 164 returns to the TDC position, teeth on the driver blade 164 engage the spring-loaded actuator 332 to actuate the fastener delivery mechanism 230 and move the fastener into the drive channel 310 of the nose piece 121 to be fired when the trigger is pulled.

Fig. 8 indicates that the first rocker arm 318 includes a pocket 340 in which the magnet 214 is disposed. As the first rocker arm 318 rotates clockwise, the first rocker arm 318 moves the pusher portion 312 in a first direction (e.g., in a downward direction away from the nose piece 121) along the collated fastener strips, the fastener delivery mechanism 230 moves to the fastener-capturing position. In the fastener acquisition position, the magnet 214 moves away from the third sensor 206 and is no longer detected by the third sensor 206. When the first rocker arm 318 rotates clockwise and the pusher portion 312 moves in a second direction (e.g., in an upward direction toward the nose piece 121), when the actuator portion 300 is fully extended, the pusher portion 312 moves the retrieved fastener into the drive channel 310 of the nose piece 121 and the fastener delivery mechanism 230 moves to the fastener delivery position. In the fastener delivery position, the magnet 214 is detected by the third sensor 206 and the fastener driver 100 is allowed to fire. Specifically, when the presence of the magnet 214 is detected, the circuit board 172 (i.e., the electronic control unit) of the fastener driver 100 receives an input from the third sensor 206, which indicates that the fastener is properly loaded into the fastener driving channel 310. Thereafter, the circuit board 172 activates the motor 176 in response to the workpiece contact mount 122 being retracted or depressed onto the workpiece and the trigger being pulled.

If the third sensor 206 does not detect the magnet 214, the fasteners in the pusher portion 312 are not fully delivered and jamming may occur if the fastener driver 100 is allowed to fire. As such, if the magnet 214 on the first rocker arm 318 is not detected, the fastener driver 100 is not permitted to fire. Specifically, when the presence of the magnet 214 is not detected, the circuit board 172 (i.e., the electronic control unit) of the fastener driver 100 receives an input from the third sensor 206, which indicates that the fastener is not properly loaded into the fastener driving channel 310. As such, if the workpiece contact mount 122 is retracted and the trigger is pulled, the circuit board 172 will not activate the motor 176.

Referring to fig. 10-12, details of the sensor mount 200 are shown. As previously described, the sensor holder 200 is configured to hold the first sensor 202, the second sensor 204, and the third sensor 206, as shown in fig. 7. As shown in fig. 10-12, the sensor holder 200 includes an elongate body 402 having a first end 404 and a second end 406. The elongate body 402 of the sensor holder 200 defines a longitudinal axis 408. A first mounting tab 410 extends from the elongate body 402 near the first end 404. A second mounting tab 412 extends from the elongate body 402 near the midpoint of the elongate body 402 between the midpoint and the second end 406. As shown, the first mounting tab 410 defines a longitudinal axis 414 that is parallel to the longitudinal axis 408 of the elongate body 402 of the sensor bracket 200. The second mounting tab 412 defines a longitudinal axis 416 perpendicular to the longitudinal axis 408 of the elongate body 402. As shown, the mounting tabs 410, 412 are formed with apertures 418, 420 to allow fasteners to extend therethrough to mount the sensor mount 200 within the housing 102 of the fastener driver 100.

Fig. 10-12 further illustrate that the sensor mount 200 includes a first sensor pocket 422 formed near a midpoint of the elongate body 402 between the midpoint and the first end 404. The first sensor pocket 422 is configured to receive the first sensor 202 therein. Further, the first sensor pocket 422 is oriented such that the longitudinal axis 424 of the first sensor pocket 422 is at an acute angle a relative to the longitudinal axis 408 of the elongate body 402. Moreover, first sensor pocket 422 and first sensor 202 disposed therein are parallel to first mounting tab 410. In particular aspects, acute angle a is greater than or equal to 5.0 °, such as greater than or equal to 6.0 °, greater than or equal to 7.0 °, greater than or equal to 8.0 °, greater than or equal to 9.0 °, greater than or equal to 10.0 °, greater than or equal to 11.0 °, or greater than or equal to 12.0 °. Further, angle a is less than or equal to 20.0 °, such as less than or equal to 19.0 °, less than or equal to 18.0 °, less than or equal to 17.0 °, less than or equal to 16.0 °, less than or equal to 15.0 °, less than or equal to 14.0 °, or less than or equal to 13.0. It should be understood that angle a may be within a range between and include any of the maximum and minimum values of a disclosed herein.

The sensor bracket 200 also includes a second sensor pocket 426 located near the midpoint of the elongate body 402, between the midpoint and the second end 406, and near the second mounting tab 412. As shown, the second sensor pocket 426 is configured to receive the second sensor 204 therein. Further, the second sensor pocket 426 is oriented such that a longitudinal axis 428 of the second sensor pocket 426 is perpendicular to the longitudinal axis 408 of the elongate body 402. In addition, the second sensor pocket 426 and the second sensor 204 disposed therein are parallel to the longitudinal axis 416 of the second mounting tab 412.

Sensor holder 200 further includes a third sensor pocket 430 near second end 406 of elongate body 402. Third sensor pocket 430 is configured to receive third sensor 206 therein. Further, third sensor pocket 430 is oriented such that a longitudinal axis 432 of third sensor pocket 430 is perpendicular to longitudinal axis 408 of elongate body 402. In addition, third sensor pocket 430 and third sensor 206 disposed therein are oriented parallel to longitudinal axis 416 of second mounting tab 412.

The sensor holder 200 further includes a curved extension 440 extending from the first end 404 of the elongate body 402. The curved extension 440 extends in a downward direction relative to fig. 11 and 12 and is generally perpendicular to the longitudinal axis 408 of the elongate body 402. The curved extension 440 includes an inner surface 442 and an outer surface 444. The inner surface 442 is shaped to fit around a gusset on one end of the reservoir cylinder 150. The outer surface 444 is curved to match the curvature of the outer surface of the reservoir cylinder 150 adjacent the sensor mount 200.

Referring now to FIG. 13, a method of operating a gas spring powered fastener driver is illustrated and generally designated 500. As shown, the method 500 begins at block 502 and includes monitoring a position of a fastener delivery mechanism by monitoring a position of a magnet within a first rocker arm of the fastener delivery mechanism. The method 500 proceeds to block 504 and includes determining whether the fastener delivery mechanism has moved from the fastener acquisition position to the fastener delivery position by sensing a magnet within the first rocker arm at a third sensor located on the sensor bracket. Thereafter, at step 506, the method 500 includes determining whether a fastener delivery location is detected. If a fastener delivery position is detected, the method 500 proceeds to block 508 and includes allowing the fastener driver to fire when the trigger is actuated. The method 500 then proceeds to step 510 and includes determining whether the power is off. If the power is off, the method 500 ends. Otherwise, if the power supply remains on, the method 500 returns to block 502 and continues as described herein.

Returning to step 506, if a fastener delivery location is not detected, the method 500 moves to block 514 and includes indicating that a jam condition may occur. This may be accomplished by providing a visual indication, an audible indication, or a combination of both. Thereafter, at block 516, the method 500 includes preventing the fastener driver from firing. The method 500 then proceeds to step 510 and includes determining whether the power is off. If the power is off, the method 500 ends. Otherwise, if the power supply remains on, the method 500 returns to block 502 and continues as described herein.

Fig. 14-17 illustrate the internal components of another fastener driver 1000. These internal components may be used with fastener driver 100 in lieu of (and as described in conjunction with) the internal components shown in fig. 6-9. As shown, the fastener driver 1000 includes a nose piece 1020 with a workpiece contact mount 1022 slidably disposed on the nose piece 1020. The front piece 1020 extends from or is attached to the reservoir cylinder 1050. Referring briefly to fig. 1-5, if used in conjunction with the external components of the fastener driver 100 described above, the reservoir cylinder 1050 would be disposed within the head portion 108 of the housing 102. The reservoir cylinder 1050 includes a valve port 1052 in which a fill valve is disposed. The fill valve is in fluid communication with the interior of the reservoir cylinder 1050. For example, the fill valve may be configured as a Schrader valve, a Presta valve, a Dunlop valve, or some other similar valve. When connected to a source of compressed gas, the fill valve enables the reservoir cylinder 1050 to be filled with compressed gas or refilled with compressed gas in the event of any leakage.

The reservoir cylinder 1050 includes a driver cylinder 1060 disposed therein. Further, a movable piston 1062 is slidably disposed within driver cylinder 1060. The driver blade 1064 is connected to a movable piston 1062. As shown, the driver blade 1064 includes a proximal end 1066 and a distal end 1068. The proximal end 1066 of the driver blade 1064 is connected to the movable piston 1062 by a pin 1070. When the piston 1062 moves to a Top Dead Center (TDC) (i.e., retracted or ready) position within the driver cylinder 1060 and the fastener driver 100 is ready to be fired, the distal end 1068 of the driver blade 1064 is adjacent to the nose piece 1020. Upon firing, the distal end 1068 of the driver blade 1064 is moved into the nosepiece 1020 to drive the fastener from within the nosepiece 1020 and into the workpiece until the piston 1062 reaches a Bottom Dead Center (BDC) (i.e., extended or driven) position within the driver cylinder 1060.

Although not shown in fig. 14-17, the fastener driver 1000 can include a circuit board (similar to circuit board 172) that controls operation of the fastener driver 1000. The circuit board, when engaged with the battery receptacle portion and the battery pack, is electrically connected to the battery receptacle portion and the battery pack and provides DC power to a motor 1076 (e.g., a brushless direct current (BLDC) motor) that is operatively coupled to the lift mechanism 1080. The lift mechanism 1080 selectively engages the driver blade 1064 and the lift mechanism 1080 is driven by a motor 1076 to move the driver blade 1064 from the BDC position to the TDC position and in the process move the piston 1062 from the BDC position to the TDC position. The latch actuator assembly 1090 cooperates with the lift mechanism 1080 to selectively engage the driver blade 1064 and hold the driver blade 1064 in a ready position before the latch actuator assembly 1090 is actuated by the lift mechanism 1080 to release the driver blade 1064 into the nosepiece 1020 to drive a fastener from the fastener driver 100 into a workpiece.

As further depicted in fig. 14-17, the fastener driver 1000 further includes a sensor mount 1100 disposed at least partially over the lifting mechanism 1080. The sensor mount 1100 includes a first sensor 1102 configured to sense an angular (or rotational) position of the lift mechanism 1080, a second sensor 1104 that senses a linear position of a workpiece contact mount 1022 slidably disposed on the nose piece 1020, and a third sensor 1106 that senses a position of the fastener delivery mechanism 1130 or one or more links within the fastener delivery mechanism 1130 described below. For example, the first sensor 1102 is a hall effect sensor configured to sense the presence of a nearby magnet or nearby magnetic field. The second sensor 1104 and the third sensor 1106 are inductive sensors configured to output signals based on movement of one or more metal targets mounted on the fastener driver 1000 moving in proximity to the sensors 1104, 1106.

As shown, the lift mechanism 1080 includes a magnet 1110 that is sensed by the first sensor 1102 to determine the angle (or rotation) of the lift mechanism 1080 as the lift mechanism 1080 or a portion thereof rotates to move the driver blade 1064 from the BDC position to the TDC position. The workpiece contact mount 1022 includes a workpiece contact mount (WCB) target 1112, which is a metal target, such as an iron-containing target. Further, WCB target 1112 is a steel target, such as a carbon steel target. The WCB target 1112 is sensed by the second sensor 1104 to determine the position of the workpiece contact mount 1022 as it slides over the nosepiece 1020 between an extended position in which the fastener driver 100 is prevented from firing and a retracted or depressed position in which the fastener driver 100 is engaged with the workpiece and the fastener driver 100 is permitted to fire and drive fasteners into the workpiece.

Fig. 14-17 further indicate that the fastener driver 100 includes a depth adjuster 1120 having a threaded shaft 1122 in threaded engagement with the workpiece contact mount 1022. The depth adjuster 1120 is rotatable to change the linear position of the workpiece contact mount 1022 relative to the nosepiece 1020. This changes the depth to which fasteners ejected from the fastener driver 100 are driven into the workpiece.

As best shown in fig. 16 and 17, the fastener driver 100 further includes a fastener delivery mechanism 1130. Fastener delivery mechanism 1130 includes a spring-loaded actuator portion 1200 slidably disposed within a bracket 1202 on nosepiece 1020. The actuator portion 1200 includes a proximal end 1204 and a distal end 1206. A spring 1208 is mounted in a compressed manner adjacent the proximal end 1204 of the actuator portion 1200 to bias the actuator portion 1200 toward the drive channel 1210 of the nose piece 1020. The pusher 1212 is mounted to the distal end 1206 of the actuator portion 1200 by a hinge pin 1214. A torsion spring 1216 is provided on the hinge pin 1214 to bias the pusher 1212 around the hinge pin 1214 toward the nose piece 1020.

The fastener delivery mechanism 1130 also includes a first rocker arm 1218 rotatably mounted to the nose piece 1020 via a first post 1220 (e.g., a threaded fastener). The first rocker arm 1218 includes a fork end 1222 that mates around a transverse post 1224 on the distal end 1206 of the actuator portion 1200. As shown, the fastener delivery mechanism 1130 also includes a second rocker arm 1226 rotatably mounted to the nose piece 1020 via a second post 1228 and to the first rocker arm 1218 via a third post 1230. A spring-loaded actuator 1232 is mounted on the free end of the second rocker arm 1226. The spring-loaded actuator 1232 can be rotated in only a single direction toward the delivery end of the fastener driver 1000 against the force of a spring returning it to the upright position. When the driver blade 1064 returns to the TDC position, teeth on the driver blade 1064 engage a spring-loaded actuator 1232 to actuate the fastener delivery mechanism 1130 and move the fastener into the drive channel 1210 of the nose piece 1020 to be fired when the trigger is pulled.

Fig. 16 indicates that the fastener delivery mechanism 1130 of the fastener driver 1000 includes a first actuator target 1240 on the forked end 1222 of the first rocker arm 1218 above the transverse post 1224 on the distal end 1206 of the actuator portion 1200. In addition, the fastener delivery mechanism 1130 of the fastener driver 1000 includes a second actuator target 1242 on the forked end 1222 of the first rocker arm 1218, below the transverse post 1224 on the distal end 1206 of the actuator portion 1200, opposite the first actuator target 1240. In a particular aspect, the actuator targets 1240, 1242 are metal targets, such as ferrous targets. Further, the actuator targets 1240, 1242 are steel targets, such as carbon steel targets. In one embodiment, actuator targets 1240, 1242 are the same size and shape. In another embodiment, actuator targets 1240, 1242 are different in size and shape. For example, the first actuator target 1240 may be larger than the second actuator target 1242. Further, the first actuator target 1240 may be smaller than the second actuator target 1242. In another embodiment, the actuator targets 1240, 1242 may have the same mass. In yet another embodiment, the actuator targets 1240, 1242 may have different masses. For example, the mass of the first actuator target 1240 may be greater than the mass of the actuator target 1242. Alternatively, the mass of the first actuator target 1240 may be less than

The actuator targets 1240, 1242 are sensed by the second sensor 1104 to determine the position of the first rocker arm 1218 and the position of the fastener delivery mechanism 1130 as it delivers fasteners, one at a time, to the drive channel 1210 of the nose piece 1020. For example, as the first rocker arm 1218 rotates clockwise and moves the pusher 1212 in a first direction (e.g., in a downward direction away from the nosepiece 1020) along the collated fastener strips, the fastener delivery mechanism 1130 moves to the fastener-capturing position. In the fastener acquisition position, the magnet 1114 is moved away from the third sensor 1106 and is no longer detected by the third sensor 1106. When the first rocker arm 1218 is rotated clockwise and the pusher 1212 is moved in a second direction (e.g., in an upward direction toward the nosepiece 1020), when the actuator portion 1200 is fully extended, the pusher 1212 moves the retrieved fastener into the drive channel 1210 of the nosepiece 1020 and the fastener delivery mechanism 1130 is moved to the fastener delivery position. In the fastener delivery position, the magnet 1114 is detected by the third sensor 1106 and the fastener driver 100 is allowed to fire. Specifically, when the presence of the magnet 1114 is detected, the circuit board (i.e., the electronic control unit) of the fastener driver 100 receives input from the third sensor 1106, which indicates that the fastener is properly loaded into the fastener driving channel 1210. Thereafter, the circuit board activates the motor 1076 in response to the workpiece contact support 1022 being retracted or depressed onto the workpiece and the trigger being pulled.

If the third sensor 1106 does not detect the magnet 1114, the fasteners in the pusher 1212 are not fully delivered and jamming may occur if the fastener driver 100 is allowed to fire. As such, if the magnet 1114 on the first rocker arm 1218 is not detected, the fastener driver 100 is not permitted to fire. Specifically, when the presence of the magnet 1114 is not detected, the circuit board (i.e., the electronic control unit) of the fastener driver 100 receives an input from the third sensor 1106, which indicates that the fastener is not properly loaded into the fastener driving channel 1210. As such, if the workpiece contact mount 1022 is retracted and the trigger is pulled, the circuit board will not activate the motor 1076.

Referring to fig. 18-20, details of a sensor holder 1100 are shown. As previously described, the sensor holder 1100 is configured to hold the first sensor 1102, the second sensor 1104, and the third sensor 1106, as shown in fig. 15. As shown in fig. 18-20, sensor holder 1100 includes an elongate body 1302 having a first end 1304 and a second end 1306. The elongate body 1302 of the sensor holder 1100 defines a longitudinal axis 1308. A first mounting tab 1310 extends from the elongate body 1302 adjacent the first end 1304. The second mounting tab 1312 extends from the elongate body 1302 near a midpoint of the elongate body 1302 between the midpoint and the second end 1306. As shown, the first mounting tab 1310 defines a longitudinal axis 1314 that is parallel to the longitudinal axis 1308 of the elongate body 1302 of the sensor holder 1100. The second mounting tab 1312 defines a longitudinal axis 1316 perpendicular to the longitudinal axis 1308 of the elongate body 1302. As shown, the mounting tabs 1310, 1312 are formed with apertures 1318, 1320 to allow fasteners to extend therethrough to mount the sensor bracket 1100 within the housing 102 of the fastener driver 100.

Fig. 18-20 further illustrate that the sensor mount 1100 includes a first sensor pocket 1322 formed near a midpoint of the elongate body 1302 between the midpoint and the first end 1304. The first sensor pocket 1322 is configured to receive the first sensor 1102 therein. Further, the first sensor pocket 1322 is oriented such that a longitudinal axis 1324 of the first sensor pocket 1322 is at an acute angle AA relative to the longitudinal axis 1308 of the elongate body 1302. Also, the first sensor pocket 1322 and the first sensor 1102 disposed therein are parallel to the first mounting tab 1310. In particular aspects, acute angle AA is greater than or equal to 5.0 °, such as greater than or equal to 6.0 °, greater than or equal to 7.0 °, greater than or equal to 8.0 °, greater than or equal to 9.0 °, greater than or equal to 10.0 °, greater than or equal to 11.0 °, or greater than or equal to 12.0 °. Further, the angle AA is less than or equal to 110.0 °, such as less than or equal to 109.0 °, less than or equal to 108.0 °, less than or equal to 107.0 °, less than or equal to 106.0 °, less than or equal to 105.0 °, less than or equal to 14.0 °, or less than or equal to 13.0. It should be understood that angle AA may be within a range between and include any of the maximum and minimum values of AA disclosed herein.

The sensor bracket 1100 also includes a second sensor pocket 1326 located near the midpoint of the elongate body 1302, between the midpoint and the second end 1306, and near the second mounting tab 1312. As shown, the second sensor pocket 1326 is configured to receive the second sensor 1104 therein. Further, the second sensor pocket 1326 is oriented such that a longitudinal axis 1328 of the second sensor pocket 1326 is parallel to the longitudinal axis 1308 of the elongate body 1302. In addition, the second sensor pocket 1326 and the second sensor 1104 disposed therein are perpendicular to the longitudinal axis 1316 of the second mounting tab 1312.

As shown in fig. 18, the second sensor pocket 1326 has a pocket length PL that extends at least partially along the overall length L of the sensor mount 1100. In one aspect, pocket length PL is less than or equal to forty percent (40%) of total length L, such as less than or equal to thirty-five percent (35%) of total length L, less than or equal to forty percent (30%) of total length L, or less than or equal to twenty-five percent (25%) of total length L. Further, pocket length PL is greater than or equal to five percent (5%) of total length L, such as greater than or equal to ten percent (10%) of total length, greater than or equal to fifteen percent (15%) of total length, or greater than or equal to twenty percent (20%) of total length. In another aspect, the pocket length PL is within a range between and including any of a maximum value and a minimum value of the pocket length PL disclosed herein.

The sensor holder 1100 further includes a third sensor pocket 1330 near the second end 1306 of the elongate body 1302. The third sensor pocket 1330 is configured to receive the third sensor 1106 therein. Further, the third sensor pocket 1330 is oriented such that a longitudinal axis 1332 of the third sensor pocket 1330 is perpendicular to the longitudinal axis 1308 of the elongate body 1302 and the longitudinal axis 1328 of the second sensor pocket 1326. In addition, the third sensor pocket 1330 and the third sensor 1106 disposed therein are oriented parallel to the longitudinal axis 1316 of the second mounting tab 1312.

As shown in fig. 19, the third sensor pocket 1330 has a pocket height PH that extends at least partially along the overall height H of the sensor mount 1100. In one aspect, pocket height PH is less than or equal to seventy percent (70%) of total height H, such as less than or equal to sixty-five percent (65%) of total height H, less than or equal to sixty percent (60%) of total height H, or less than or equal to fifty-five percent (55%) of total height H. Further, pocket height PH is greater than or equal to thirty-five percent (35%) of total height H, such as greater than or equal to forty percent (40%) of total height, greater than or equal to forty-five percent (45%) of total height, or greater than or equal to fifty percent (50%) of total height. In another aspect, the pocket height PH is within a range between and including any of a maximum value and a minimum value of the pocket heights PH disclosed herein.

Sensor holder 1100 further includes a curved extension 1340 extending from first end 1304 of elongate body 1302. The curved extension 1340 extends in a downward direction relative to fig. 11 and 12 and is generally perpendicular to the longitudinal axis 1308 of the elongate body 1302. The curved extension 1340 includes an inner surface 1342 and an outer surface 1344. The inner surface 1342 is shaped to fit around a gusset on one end of the reservoir cylinder 1050. The outer surface 1344 is curved to match the curvature of the outer surface of the reservoir cylinder 1050 adjacent the sensor bracket 1100.

Fig. 21 is a block diagram showing a gas spring powered fastener driver 1400. As shown, the gas spring powered fastener driver 1400 includes a controller 1402, i.e., an electronic control unit. The motor 1404 and battery 1406 are operatively coupled to the controller 1402. Further, a trigger 1408 is operatively coupled to the controller 1402 and the motor 1404. The first sensor 1410, the second sensor 1412, the third sensor 1414, and the fourth sensor 1416 are operably coupled to the controller 1402. The controller 1402 uses signals from the sensors 1410, 1412, 1414, 1416 to control the operation of the motor 1404 and the gas spring fastener driver 1400. The sensors 1410, 1412, 1414, 1416 include hall sensors, inductive sensors, micro switches, optical sensors, acoustic sensors, or any combination thereof.

As shown, a first sensor 1410 is positioned within the gas spring powered fastener driver 1400 to sense a fastener 1420, such as a nail, within a fastener driving channel 1422 of a nose piece 1424 of the gas spring powered fastener driver 1400. For example, the first sensor 1410 may be placed adjacent to the fastener driving channel 1422. Alternatively, the first sensor 1410 may be disposed partially or entirely within the fastener driving channel 1422, such as in a sidewall thereof. If the first sensor 1410 senses a fastener 1420 within the fastener driving channel 1422, the controller 1402 sends a signal to the trigger 1408 to allow the motor 1404 to be actuated. If no fastener 1420 is sensed within the fastener driving channel 1422, the controller 1402 prevents the motor 1404 from being actuated when the trigger 1408 is depressed or otherwise switched.

The second sensor 1412 is positioned to sense a workpiece contact mount (WCB) target 1430, such as a ferrous target, that is slidably disposed on a workpiece contact mount 1432 on the nose piece 1424. When the WCB target 1430 is sensed, indicating that the workpiece contact support 1432 is engaged with a workpiece, the controller 1402 sends a signal to the trigger 1408 to allow the motor 1404 to be actuated to drive a fastener into the workpiece. If no WCB target 1430 is detected, the controller 1402 prevents the motor 1404 from being actuated when the trigger 1408 is depressed or otherwise switched.

Fig. 21 further illustrates that third sensor 1414 and fourth sensor 1416 are positioned to detect first actuator target 1440 and second actuator target 1442 on actuator 1444 within fastener delivery mechanism 1446 to determine the position of actuator 1444 and fastener delivery mechanism 1446 when fastener delivery mechanism 1446 is moving or attempting to move fastener 1420 into fastener driving channel 1422 of nose piece 1424. The position of the fastener delivery mechanism 1446 may indicate whether the fastener 1420 is properly delivered or whether jamming has occurred. If the position of the fastener delivery mechanism 1446 indicates that the fastener 1420 is properly delivered, the controller 1402 sends a signal to the trigger 1408 to allow the motor 1404 to be actuated to drive the fastener into the workpiece. If the position of the fastener delivery mechanism 1446 indicates that a jam has occurred, the controller 1402 prevents the motor 1404 from being actuated when the trigger 1408 is depressed or otherwise switched. It should be appreciated that other portions of the fastener delivery mechanism 1446 can include targets that can be detected by the third sensor 1414 and the fourth sensor 1416 to determine the position of the fastener delivery mechanism 1446.

Referring now to FIG. 22, a method of operating a gas spring powered fastener driver is illustrated and generally designated 1500. As shown, the method 1500 begins at block 1502 and includes monitoring a position of a fastener delivery mechanism by monitoring positions of a first metal target and a second metal target disposed on or molded into a first rocker arm of the fastener delivery mechanism. The method 1500 proceeds to block 1504 and includes determining whether the fastener delivery mechanism has moved from the fastener acquisition position to the fastener delivery position by sensing the first metal target and the second metal target within the first rocker arm at a third sensor located on the sensor bracket. Thereafter, at step 1506, the method 1500 includes determining whether a fastener delivery location is detected. If a fastener delivery position is detected, the method 1500 proceeds to block 1508 and includes allowing the fastener driver to fire when the trigger is actuated. The method 1500 then proceeds to step 1510 and includes determining whether the power is off. If the power is turned off, the method 1500 ends. Otherwise, if the power supply remains on, the method 1500 returns to block 1502 and continues as described herein.

Returning to step 1506, if a fastener delivery location is not detected, the method 1500 moves to block 1514 and includes indicating that a jam condition may or has occurred. This may be accomplished by providing a visual indication, an audible indication, a tactile feedback, or a combination thereof. Thereafter, at block 1516, the method 1500 includes preventing the fastener driver from firing. The method 1500 then proceeds to step 1510 and includes determining whether the power is off. If the power is turned off, the method 1500 ends. Otherwise, if the power supply remains on, the method 1500 returns to block 1502 and continues as described herein.

FIG. 23 depicts another method of illustrating operation of a gas spring powered fastener driver. This method is generally designated 1600. As shown, the method 1600 begins at block 1602 and includes monitoring a position of a fastener delivery mechanism by monitoring positions of a first metal target and a second metal target disposed on or molded into a first rocker arm of the fastener delivery mechanism. The method 1600 proceeds to block 1604 and includes determining a position of the fastener delivery mechanism by sensing a first metal target and a second metal target within the first rocker arm at a third sensor located on the sensor holder. Thereafter, at step 1606, method 1600 includes determining if an error location is detected. For example, the error location may include a location where the fastener delivery mechanism does not return properly to a location where a nail is (or should be) loaded into the fastener-driving channel of the nose piece of the powered fastener driver. If no false position is detected, the method 1600 proceeds to block 1608 and includes allowing the fastener driver to fire when the trigger is actuated. The method 1600 then proceeds to step 1610 and includes determining whether the power is turned off. If the power is off, method 1600 ends. Otherwise, if the power supply remains on, the method 1600 returns to block 1602 and continues as described herein.

Returning to step 1606, if an error location is detected, method 1600 moves to block 1614 and includes indicating that a stuck condition may occur or has occurred. This may be accomplished by providing a visual indication, an audible indication, a tactile feedback, or a combination thereof. Thereafter, at block 1616, method 1600 includes preventing the fastener driver from firing. The method 1600 then proceeds to step 1610 and includes determining whether the power is turned off. If the power is off, method 1600 ends. Otherwise, if the power supply remains on, the method 1600 returns to block 1602 and continues as described herein.

FIG. 24 illustrates yet another method of operating a gas spring powered fastener driver. The method is generally designated 1700. As shown, the method 1700 begins at block 1702 and includes monitoring the position of a fastener within a powered fastener driver, for example, by monitoring a fastener driving channel. The method 1700 proceeds to block 1704 and includes determining a position of a fastener by sensing/not sensing the fastener using a sensor positioned adjacent to the fastener driving channel. Thereafter, at step 1706, method 1700 includes determining whether a fastener is detected within a fastener driving channel. If a fastener is detected within the fastener driving channel, the method 1700 proceeds to block 1708 and includes allowing the fastener driver to fire when the trigger is actuated. The method 1700 then proceeds to step 1710 and includes determining whether the power is off. If the power is off, the method 1700 ends. Otherwise, if the power supply remains on, the method 1700 returns to block 1702 and continues as described herein.

Returning to step 1706, if no fasteners are detected within the fastener driving channel, the method 1700 moves to block 1714 and includes indicating that a jam condition may occur or has occurred. This may be accomplished by providing a visual indication, an audible indication, a tactile feedback, or a combination thereof. Thereafter, at block 1716, the method 1700 includes preventing the fastener driver from firing. The method 1700 then proceeds to step 1710 and includes determining whether the power is off. If the power is off, the method 1700 ends. Otherwise, if the power supply remains on, the method 1700 returns to block 1702 and continues as described herein.

Although the disclosure has been described in detail with reference to certain preferred embodiments, variations and modifications exist within the scope and spirit of one or more independent aspects of the disclosure as described.

Various features of the utility model are set forth in the appended claims.

Claims (33)

1. A powered fastener driver, the powered fastener driver comprising:

a housing;

a nose piece extending from the housing;

a driver blade movable within the nose piece;

a piston coupled to the driver blade to move with the driver blade;

An actuator cylinder within which the piston is movable from a top dead center position and a bottom dead center position;

A magazine coupled to the nosepiece, the aligned fasteners being receivable in the magazine;

A fastener delivery mechanism coupled to the nosepiece for individually delivering the aligned fasteners in the magazine to the fastener-driving channels in the nosepiece, the fastener delivery mechanism movable between a fastener-acquisition position and a fastener-delivery position, and

A sensor for determining the position of the fastener delivery mechanism.

2. The powered fastener driver of claim 1 wherein the powered fastener driver is permitted to fire a fastener and drive the fastener into a workpiece when the fastener delivery mechanism is in a fastener delivery position.

3. The powered fastener driver of claim 1 wherein the powered fastener driver is prevented from firing when the fastener delivery mechanism is in the wrong position.

4. The powered fastener driver of claim 1 wherein the powered fastener driver is not permitted to fire a fastener and drive the fastener into a workpiece when the fastener delivery mechanism is not in the fastener delivery position.

5. The powered fastener driver of claim 1 wherein the fastener delivery mechanism includes an actuator portion coupled to the driver, and wherein when the fastener delivery mechanism is in the fastener-accessing position, the actuator portion moves the driver in a first direction to access a fastener.

6. The powered fastener driver of claim 5 wherein the actuator portion moves the driver in a second direction to move a fastener into the fastener driving channel when the fastener delivery mechanism is in the fastener delivery position.

7. The powered fastener driver of claim 1 wherein the fastener delivery mechanism includes at least one magnet and the at least one magnet is sensed by the sensor to determine when the fastener delivery mechanism is in the fastener delivery position.

8. The powered fastener driver of claim 7 wherein the sensor is a hall effect sensor.

9. The powered fastener driver of claim 1 wherein the fastener delivery mechanism includes at least one metal target and the at least one metal target is sensed by the sensor to determine when the fastener delivery mechanism is in the fastener delivery position.

10. The powered fastener driver of claim 9 wherein the sensor is an inductive sensor.

11. The powered fastener driver of claim 1, wherein the powered fastener driver further comprises:

A workpiece contact mount disposed on the nose piece, the workpiece contact mount including a workpiece contact mount target, and

And a second sensor for detecting a position of the workpiece contacting the carrier target.

12. A powered fastener driver, the powered fastener driver comprising:

a housing;

a nose piece extending from the housing;

a workpiece contact mount slidably disposed on the nose piece, the workpiece contact mount comprising at least one workpiece contact mount target;

a driver blade movable within the nose piece;

A piston coupled to the driver blade to move therewith;

An actuator cylinder within which the piston is movable between a top dead center position and a bottom dead center position;

A magazine coupled to the nosepiece, the aligned fasteners being receivable in the magazine;

A fastener delivery mechanism coupled to the nosepiece for individually delivering the aligned fasteners in the magazine to the fastener driving channels in the nosepiece, the fastener delivery mechanism including at least one actuator target;

A first sensor for detecting movement of the at least one workpiece contact mount target and the workpiece contact mount, and

A second sensor for detecting movement of the at least one actuator target and movement of the fastener delivery mechanism.

13. The powered fastener driver of claim 12 wherein the at least one workpiece contact mount target and the at least one actuator target comprise metal targets.

14. The powered fastener driver of claim 13 wherein the metal targets are ferrous targets.

15. The powered fastener driver of claim 14 wherein the ferrous targets are steel targets.

16. The powered fastener driver of claim 12 wherein the first sensor and the second sensor comprise inductive sensors.

17. The powered fastener driver of claim 12 wherein the at least one workpiece contact mount target is sensed by the second sensor to determine the position of the workpiece contact mount as the workpiece contact mount slides on the nose piece between the extended position and the retracted position.

18. The powered fastener driver of claim 17 wherein in the extended position the powered fastener driver is prevented from firing.

19. The powered fastener driver of claim 18 wherein in the retracted position the powered fastener driver is engaged with a workpiece and the powered fastener driver is permitted to fire.

20. The powered fastener driver of claim 12 wherein the fastener delivery mechanism includes a first rocker arm coupled to the driver and at least one actuator target is sensed by the second sensor to determine a position of the fastener delivery mechanism when the fastener delivery mechanism delivers fasteners one at a time to the fastener driving channel of the nose piece.

21. The powered fastener driver of claim 20 wherein the fastener delivery mechanism moves to the fastener-accessing position as the first rocker arm rotates clockwise and moves the pusher in a downward direction away from the nose piece.

22. The powered fastener driver of claim 21 wherein when the first rocker arm rotates clockwise, the pusher moves in an upward direction toward the nosepiece and moves a captured fastener into the fastener-driving channel of the nosepiece and the fastener delivery mechanism moves to a fastener delivery position.

23. The powered fastener driver of claim 22 wherein in the fastener delivery position the powered fastener driver is permitted to fire.

24. A powered fastener driver, the powered fastener driver comprising:

a housing;

a nose piece extending from the housing;

a driver blade movable within the nose piece;

A piston coupled to the driver blade to move therewith;

An actuator cylinder within which the piston is movable between a top dead center position and a bottom dead center position;

A magazine coupled to the nosepiece, the aligned fasteners being receivable in the magazine;

A fastener delivery mechanism coupled to the nosepiece for individually delivering the aligned fasteners in the magazine to the fastener-driving channels in the nosepiece, the fastener delivery mechanism movable between a fastener-acquisition position and a fastener-delivery position, and

A sensor for detecting whether the fastener is in the fastener driving channel.

25. The powered fastener driver of claim 24 wherein the powered fastener driver is permitted to fire when a fastener is detected within the fastener driving channel.

26. The powered fastener driver of claim 24 wherein the powered fastener driver is prevented from firing when no fastener is detected in the fastener driving channel.

27. The powered fastener driver of claim 24 wherein the sensor is an inductive sensor adjacent the fastener driving channel.

28. The powered fastener driver of claim 24 wherein the sensor is a microswitch in the fastener driving channel.

29. The powered fastener driver of claim 24 wherein the sensor is an optical sensor adjacent the fastener driving channel.

30. The powered fastener driver of claim 24 wherein the sensor is an acoustic sensor adjacent the fastener driving channel.

31. The powered fastener driver of claim 24 wherein the fastener delivery mechanism includes an actuator, and wherein the actuator includes an actuator target that is sensed to determine when the fastener delivery mechanism is in the fastener acquisition position and the fastener delivery position.

32. The powered fastener driver of claim 31 further comprising a motor and a lifter mechanism operable to return the driver blade within the driver cylinder toward the top dead center position, wherein the motor is capable of being activated to drive a fastener into a workpiece when the fastener delivery mechanism is in the fastener delivery position.

33. The powered fastener driver of claim 32 wherein the motor cannot be activated when the fastener delivery mechanism is not in the fastener delivery position.