Power ratchet tool with multi-piece crankshaft assembly

Abstract

A powered ratchet tool includes a housing, a head of the housing, a drive assembly, a yoke supported within the head, an anvil, a pawl, and a shaft assembly. The drive assembly includes an output member rotatable about a first axis. The yoke is pivotable about a second axis perpendicular to the first axis. An anvil extends from the head and is configured to engage the socket. The pawl is movable between first and second positions to switch the direction of rotation of the anvil. A shaft assembly extends between the output member and the yoke and is formed in a multi-piece configuration, the shaft assembly including a shaft extending along a first axis, a first coupler fixed to a first end of the shaft, a second coupler fixed to a second end of the shaft, and a pin extending from the second coupler to the yoke.

Description

[0001] Cross-reference to related applications

[0002] This application claims priority to U.S. Provisional Application No. 63 / 594,326, filed on October 30, 2023, which is currently under examination and whose entire contents are incorporated herein by reference. Technical Field

[0003] This utility model relates to power tools, and more specifically to powered ratchet tools. Background Technology

[0004] This utility model relates to a powered ratchet wrench for applying torque to fasteners to tighten or loosen them.

[0005] Powered ratchet tools are typically powered by a power source—such as a DC battery, a conventional AC power source—or by compressed air. A powered ratchet wrench consists of components such as a motor, a motor-driven drive assembly, and an output component for applying torque to the fastener. Utility Model Content

[0006] In some aspects, the present invention relates to a powered ratchet tool comprising: a housing including a head; a drive assembly including an output member rotatable about a first axis; a yoke supported within the head and pivotable about a second axis perpendicular to the first axis; an anvil extending from the head and configured to engage a socket; and a pawl movable between a first position and a second position, wherein in the first position the pawl is coupled to the anvil to co-rotate with the yoke in a first direction about the second axis, and in the second position the pawl is coupled to the anvil to co-rotate with the yoke in a second direction about the second axis. The device includes a yoke and a shaft assembly extending between the output of a drive assembly and the yoke. The shaft assembly is configured as a multi-piece structure and includes a shaft, a first coupler, a second coupler, and a pin. The shaft extends along a first axis and has a first end and a second end opposite to the first end. The first coupler is fixed to the first end of the shaft and configured to couple the shaft assembly to co-rotate with the output of the drive assembly about the first axis. The second coupler is fixed to the second end of the shaft. The pin extends from the second coupler to the yoke, wherein the pin is offset from the first axis such that rotation of the shaft assembly about the first axis causes reciprocating motion of the yoke about the second axis.

[0007] In some respects, the technology described in this utility model relates to a powered ratchet tool, wherein the first coupler is made of powdered metal.

[0008] In some respects, the technology described in this utility model relates to a powered ratchet tool, wherein the second coupler is made of powdered metal.

[0009] In some aspects, the technology described in this document relates to power ratchet tools, wherein the drive assembly includes a motor and a planetary transmission, and wherein the output is a carrier of the planetary transmission.

[0010] In some aspects, the technology described in this document relates to power ratchet tools, wherein the first coupler includes a spline, and wherein the spline is received within the carrier of the planetary transmission.

[0011] In some aspects, the technology described in this document relates to power ratchet tools, wherein the shaft is made of chrome-molybdenum steel.

[0012] In some aspects, the technology described in this document relates to power ratchet tools, wherein the yoke receives a bushing, and wherein the bushing receives a pin of the shaft assembly.

[0013] In some aspects, the technology described in this document relates to power ratchet tools, wherein the second coupler includes a recess for receiving the pin, a first wing, and a second wing, wherein the recess is at least partially formed in the second wing, and wherein the first wing and the second wing are different sizes such that the first axis intersects a center of mass of the second coupler.

[0014] In some aspects, the technology described in this document relates to power ratchet tools, comprising: a housing including a head; a drive assembly; a yoke supported within the head; and a shaft assembly extending between an output of the drive assembly and the yoke, the shaft assembly including a shaft, a first coupler, and a second coupler, the shaft extending along a first axis and having a first end and a second end opposite the first end, the shaft being formed by a first manufacturing process, the first coupler being fixed to the first end of the shaft, the first coupler being configured to couple to the shaft assembly for co-rotation with the output of the drive assembly, the first coupler being formed by a second manufacturing process, the second coupler being fixed to the second end of the shaft, the second coupler being formed by a third manufacturing process, wherein at least one of the second manufacturing process and the third manufacturing process is different than the first manufacturing process.

[0015] In some aspects, the technology described in this document relates to power ratchet tools, wherein the shaft assembly includes a pin extending from the second coupler, wherein the pin is offset from the first axis, which causes rotation of the shaft assembly about the first axis to result in reciprocating motion of the yoke about a second axis.

[0016] In some aspects, the technology described in this document relates to power ratchet tools, wherein at least one of the second manufacturing process and the third manufacturing process is a powder metal manufacturing process.

[0017] In some aspects, the technology described in this document relates to power ratchet tools, wherein the second manufacturing process and the third manufacturing process are the same manufacturing process.

[0018] In some aspects, the technology described in this document relates to power ratchet tools, wherein the first coupler and the second coupler have a different hardness than the shaft.

[0019] In some aspects, the technology described in this document relates to power ratchet tools, wherein the first manufacturing process comprises machining.

[0020] In some aspects, the technology described in this document relates to power ratchet tools, wherein the shaft is made of chrome-molybdenum steel.

[0021] In some aspects, the technology described in this document relates to power ratchet tools, comprising: a housing comprising a head; a drive assembly comprising an output rotatable about a first axis; a yoke supported within the head and pivotable about a second axis perpendicular to the first axis; an anvil extending from the head and configured to engage a socket; a pawl movable between a first position in which the pawl couples the anvil for co-rotation with the yoke about the second axis in a first direction and a second position in which the pawl couples the anvil for co-rotation with the yoke about the second axis in a second direction; and a shaft assembly extending between the output of the drive assembly and the yoke, the shaft assembly formed in a multi-piece configuration, the shaft assembly comprising: a shaft extending along the first axis and having a first end and a second end opposite the first end, a first coupler configured to couple the shaft assembly for co-rotation with the output of the drive assembly about the first axis, and a pin extending from the second coupler to the yoke, wherein the pin is offset from the first axis, which causes rotation of the shaft assembly about the first axis to result in reciprocal motion of the yoke about the second axis, wherein the shaft is made of a first material, and wherein at least one of the first coupler or the second coupler is made of a second material different from the first material.

[0022] In some aspects, the technology described in this document relates to power ratchet tools, wherein the shaft is made of forged steel.

[0023] In some aspects, the technology described in this document relates to power ratchet tools, wherein the first coupler and the second coupler are made of the second material.

[0024] In some aspects, the technology described in this document relates to power ratchet tools, wherein the pin is made of forged steel.

[0025] In some aspects, the technology described in this document relates to power ratchet tools, wherein the drive assembly comprises a motor and a planetary transmission, wherein the output is a carrier of the planetary transmission, wherein the first coupler comprises a spline, wherein the spline is received within the carrier of the planetary transmission, and wherein the shaft is pressed into a recess of the first coupler.

[0026] Other features and aspects of this utility model will become apparent from a careful reading of the following detailed description and accompanying drawings. Attached Figure Description

[0027] Figure 1 This is a perspective view of a power ratchet tool that embodies various aspects of this utility model.

[0028] Figure 2 It is along Figure 1 The AA line in the middle is cut off Figure 1 A cross-sectional view of a power ratchet tool.

[0029] Figure 3 It is along Figure 1 BB line cut Figure 2 A cross-sectional view of a power ratchet tool.

[0030] Figure 4 yes Figure 1 A perspective view of the crankshaft assembly of a power ratchet tool.

[0031] Before explaining any embodiment of this utility model in detail, it should be understood that this utility model is not limited to the application of the details of the construction and arrangement of the components described in the following description or shown in the drawings. This utility model can have other embodiments and can be implemented or realized in various ways. Furthermore, it should be understood that the wording and terminology used in this utility model are for illustrative purposes and should not be considered restrictive. Detailed Implementation

[0032] Figure 1 A powered ratchet tool 10 is shown, including a housing 12 defining a longitudinal central axis A. In the illustrated embodiment, the housing 12 includes a handle portion 13, a drive housing 14 coupled to and supported by the handle portion 13, and a head 18 extending from the drive housing 14. In some embodiments, the head 18 may include an elongated tubular segment 19 to provide extended reach to the powered ratchet tool 10 (e.g., Figure 2 In other embodiments, the elongated tubular section 19 may be omitted or shortened to provide a ratchet tool 10 with a more compact form (e.g., Figure 1 The handle portion 13 shown includes a pair of clamshell halves 30. The handle portion 13 also includes a handle 34 formed of an elastic material such as rubber or silicone and molded onto the clamshell halves 30. The handle portion 13 is configured to be gripped by the user during use of the ratchet tool 10.

[0033] See also Figure 1In the illustrated embodiment, the battery pack 26 is removably coupled to the housing 12 and is received by the handle portion 13. Specifically, the battery pack 26 can be inserted into and removed from a cavity in the handle portion 13 in a direction along the axis A. An indicator 38 supported by the handle portion 13 displays a charge level of the battery pack 26. The battery pack 26 includes a latch 42 that retains the battery pack 26 within the cavity and can be actuated (e.g., depressed) to release the battery pack 26 from the ratchet tool 10. The illustrated battery pack 26 is a removable and rechargeable 12-volt battery pack and includes three (3) lithium-ion battery cells. In other constructions, the battery pack 26 can include fewer or more battery cells, a different chemical composition, and / or a different output voltage.

[0034] Referring to Figure 1 and Figure 2 The ratchet tool 10 includes a motor 44 having a motor shaft 48 that is rotatable about the axis A when the motor 44 is energized, and a switch 56 for selectively connecting the motor 44 to the battery pack 26 (e.g., through a circuit of the switch 56 or through a control system that receives input from the switch 56). A switch paddle 60 is coupled to the handle portion 13 for manipulation by a user. When the switch paddle 60 is depressed toward the body of the housing portion 13, the switch 56 is compressed to energize the motor 44. The switch paddle 60 is pivotable about a stem 64. A resilient member 68 is engaged with the switch paddle 60 to bias the switch paddle 60 away from the switch 56. In some embodiments, the switch 56 is a variable speed switch that is configured to control a speed of operation of the motor 44. In some embodiments, other types of actuators (e.g., triggers, buttons, etc.) can be provided for actuating the switch 56.

[0035] Referring to Figure 2 The drive housing 14 at least partially encloses and supports a drive assembly 52 that is operably coupled to the motor shaft 48. In some embodiments, the drive housing 14 can be an integral part of the handle portion 13 of the housing 12. In other embodiments, the drive housing 14 can be a separate component, optionally made of a different material (e.g., steel) than the material (e.g., plastic) of the handle portion 13. The illustrated drive assembly 52 is a planetary gear arrangement that includes a pinion gear 50 (which can be integrally formed with the motor shaft 48), a plurality of planet gears 54 that mesh with the pinion gear 50, and a ring gear 58 that meshes with the planet gears 54 such that rotation of the pinion gear 50 causes the planet gears 54 to orbit about an inner periphery of the ring gear 58. The drive assembly 52 includes an output 62, which in the illustrated embodiment is a planet carrier that is coupled to the planet gears 54 (e.g., by a pin). However, other types of drive assemblies can be used, and in some embodiments, the motor shaft 48 itself can define the output 62 of the drive assembly 52.

[0036] Referring to Figures 1 to 3 , the head 18 supports an output assembly 120 configured to receive a bit (such as a socket) for engagement with a workpiece (such as a fastener). The output assembly 120 includes a yoke 124 having a plurality of yoke teeth 150 Figure 2 ), an anvil 128 (such as a square head for engaging a socket) having an output member 144 Figure 3 ), a pawl 132 Figure 2 , and a forward reverse switch 136 having a grip actuator 140 accessible through the head 18. The anvil 128 is rotatable about a second axis B that is perpendicular to the first axis A. The grip actuator 140 can be used to rotate the forward reverse switch 136 between a first position and a second position.

[0037] The yoke 124 is selectively engageable with the pawl 132 via a first set of pawl teeth 151 or a second set of pawl teeth 152. The pawl 132 is movable about, and more particularly pivotable about, a pawl pin 130. When the forward reverse switch 136 is in the first position, the pawl 132 is configured to engage the first set of pawl teeth 151 with the yoke teeth 150 to couple the anvil 128 for co-rotation with the yoke 124 in a first direction, but to allow the yoke 124 to rotate relative to the anvil 128 in a second / opposite direction. When the forward reverse switch 136 is in the second position, the pawl 132 is configured to engage the second set of pawl teeth 152 with the yoke teeth 150 to couple the anvil 128 for co-rotation with the yoke 124 in the second direction, but to allow the yoke 124 to rotate relative to the anvil 128 in the first direction.

[0038] Referring to Figures 2-4 , the ratchet tool 10 includes a shaft assembly 74 that extends coupled for co-rotation with the output 62 of the drive assembly 52. The illustrated shaft assembly 74 is a multi-piece assembly that includes a shaft 76 having a first end 184 and a second end 188 opposite the first end 184, a first coupler 72 secured to the first end 184 of the shaft 76, a second coupler 84 secured to the second end 188 of the shaft 76, and a pin 116 secured to the second coupler 84. As explained in greater detail below, the shaft assembly 74 transmits torque from the drive assembly 52 to the yoke 124 to cause the yoke 124 to pivot reciprocally about the axis B. In some embodiments, the shaft 76 is made of a relatively high strength material, such as chrome molybdenum steel (e.g., 42CrMo steel), and is machined to the shape and dimensions required for the power ratchet tool 10.

[0039] As Figure 4As best shown, the illustrated first coupler 72 includes an interlocking feature, such as a spline 80 or another geometric feature such as a key, square, or hexagonal geometry, as illustrated, that mates with a corresponding interlocking feature (e.g., an internal spline) formed in the output 62 of the drive assembly 52( Figure 2 ). The first coupler 72 further includes a cylindrical portion 88 that extends from the spline 80 and has a recess 90 opposite the spline 80. Because the first coupler 72 is formed separately from the shaft 76, the first coupler 72 can be made from a different material, by a different manufacturing process, and / or have different material properties than the shaft 76. For example, the first coupler in the illustrated embodiment is made from a powder metal via a suitable powder metal manufacturing process, such as compaction and sintering. This can allow the relatively complex geometric features of the first coupler 72 (e.g., including the spline 80) to be made more cheaply than by machining or forging. In other embodiments, the second coupler 84 can be made by conventional machining, casting, or some combination of casting and power metallurgy.

[0040] Referring to Figure 2 , the recess 90 receives the first end 184 of the shaft 76 in a press fit. However, the first coupler 72 can be coupled to the shaft 76 in other ways, such as welding, brazing, mechanical fasteners, etc. In this way, the first coupler 72 couples the shaft 76 to the output 62 for co-rotation therewith about the axis A. The cylindrical portion 88 of the first coupler 72 is supported for rotation about the axis A by a bearing 92.

[0041] Referring to Figure 2 and Figure 4The second coupler 84 shown includes a cylindrical portion 100 having a recess 102, a first wing portion 104 and a second wing portion 108 extending from the cylindrical portion 100, and an eccentric recess 111 defining a third axis C that is parallel to the first axis A. A pin 116 is press fit (or otherwise secured) within the eccentric recess 111 such that the pin 116 extends along the third axis C. A drive bushing 156 is coupled to the pin 116 and is received within a drive recess 164 formed in the yoke 124. The recess 102 receives the second end 188 of the shaft 76 in a press fit. However, the second coupler 84 can be coupled to the shaft 76 in other ways, such as welding, brazing, mechanical fasteners, etc. The cylindrical portion 100 of the second coupler 84 is supported for rotation about the axis A by a bearing 112. Due to the eccentric location of the pin 116 (i.e., offset from the first axis A), rotation of the shaft 76 about the first axis A causes the yoke 124 to pivotally reciprocate about the second axis B. The wing portion 104 provides additional material thickness to the eccentric recess 111 to accommodate the pin 116, and the wing portion 108 is sized to balance the second coupler 84 and minimize vibration. In particular, the wing portion 108 is sized and shaped to ensure that the center of mass of the second coupler 84 intersects the first axis A1 to minimize vibration during rotation of the shaft assembly 74. Similar to the first coupler 72, the second coupler 84 can be made from powder metal by a suitable powder metal process. In other embodiments, the second coupler 84 can be manufactured by traditional machining, casting, or some combination of machining, casting, and powder metallurgy.

[0042] In operation, the shaft assembly 74 rotates about the first axis A and transmits torque from the motor 44 (via the drive assembly 52) to the yoke 124 to cause the yoke 124 to reciprocate about the second axis B. Depending on the position of the pawl 132 and the forward / reverse switch 136, the anvil 128 will be driven in a first rotational direction or a second rotational direction. The multi-piece construction of the shaft assembly 74 advantageously allows the components of the shaft assembly 74 to be made from different materials and / or by different manufacturing processes. For example, instead of the shaft assembly 74 being forged as a single piece of steel (which can be difficult and expensive due to the complex geometry of the shaft assembly 74), the first coupler 72 and the second coupler 84 can be made from powder metal, or other ways to provide higher manufacturing efficiency for complex shapes. The remaining shaft 76 and pin 116 can then have simple cylindrical shapes formed in various ways and using solid steel. In some embodiments, the couplers 72, 84 can have different durometers than the shaft 76 and the pin 116. For example, one or both of the couplers 72, 84 can have a lower durometer than the shaft 76 and the pin 116.

[0043] Although the present application 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 application.

[0044] The various features of the present application are recited in the claims.

Claims

1. A power ratchet tool characterized by, Comprising: a housing including a head; a drive assembly including an output rotatable about a first axis; a yoke supported within the head and pivotable about a second axis perpendicular to the first axis; an anvil extending from the head and configured to engage a socket; a pawl movable between a first position in which the pawl couples the anvil for co-rotation with the yoke in a first direction about the second axis and a second position in which the pawl couples the anvil for co-rotation with the yoke in a second direction about the second axis; and a shaft assembly extending between the output of the drive assembly and the yoke, the shaft assembly formed in a multi-piece configuration, the shaft assembly including: a shaft extending along the first axis and having a first end and a second end opposite the first end; a first coupler fixed to the first end of the shaft, the first coupler configured to couple the shaft assembly for co-rotation with the output of the drive assembly about the first axis; a second coupler fixed to the second end of the shaft; and a pin extending from the second coupler to the yoke, wherein the pin is offset from the first axis such that rotation of the shaft assembly about the first axis causes reciprocal movement of the yoke about the second axis. The first coupler is made of a powder metal.

2. The power ratchet tool of claim 1, wherein, The second coupler is made of a powder metal.

3. The power ratchet tool of claim 1, wherein, The drive assembly includes a motor and a planetary transmission, and wherein the output is a carrier of the planetary transmission.

4. The power ratchet tool of claim 1, wherein, The first coupler includes a spline, and wherein the spline is received within the carrier of the planetary transmission.

5. The power ratchet tool of claim 4, wherein, The shaft is made of a chromium-molybdenum steel.

6. The power ratchet tool of any of claims 1-5, wherein, The yoke receives a bushing, and wherein the bushing receives the pin of the shaft assembly.

7. The power ratchet tool of any of claims 1-5, wherein, The second coupler includes a recess for receiving the pin, a first wing, and a second wing, wherein the recess is at least partially formed in the second wing, and wherein the first wing and the second wing are differently sized such that the first axis intersects a center of mass of the second coupler.

8. The power ratchet tool of any one of claims 1-5, wherein, Comprising:

9. A power ratchet tool characterized by, a housing including a head; a drive assembly; a yoke supported within the head; and a shaft assembly extending between an output of the drive assembly and the yoke, the shaft assembly including: a shaft extending along a first axis and having a first end and a second end opposite the first end, the shaft formed by a first manufacturing process; a first coupler fixed to the first end of the shaft, the first coupler configured to couple to the shaft assembly for co-rotation with the output of the drive assembly, the first coupler formed by a second manufacturing process; and a second coupler fixed to the second end of the shaft, the second coupler formed by a third manufacturing process; wherein at least one of the second manufacturing process and the third manufacturing process is different than the first manufacturing process. ​ 10. The power ratchet tool of claim 9, wherein, The shaft assembly includes a pin extending from the second coupler, wherein the pin is offset from the first axis, which causes rotation of the shaft assembly about the first axis to result in reciprocating motion of the yoke about the second axis.

11. The power ratchet tool of claim 9, wherein, At least one of the second manufacturing process and the third manufacturing process is a powder metal manufacturing process.

12. The power ratchet tool of any of claims 9-11, wherein, The second manufacturing process and the third manufacturing process are the same manufacturing process.

13. The power ratchet tool of any of claims 9-11, wherein, The first coupler and the second coupler have a different hardness than the shaft.

14. The power ratchet tool of any of claims 9-11, wherein, The first manufacturing process includes machining.

15. The power ratchet tool of any of claims 9-11, wherein, The shaft is made of chrome-molybdenum steel.

16. A power ratchet tool characterized in that, Comprising: a housing including a head; a drive assembly including an output rotatable about a first axis; a yoke supported within the head and pivotable about a second axis perpendicular to the first axis; an anvil extending from the head and configured to engage a socket; a pawl movable between a first position in which the pawl couples the anvil for co-rotation with the yoke about the second axis in a first direction and a second position in which the pawl couples the anvil for co-rotation with the yoke about the second axis in a second direction; and a shaft assembly extending between the output of the drive assembly and the yoke, the shaft assembly formed in a multi-piece configuration, the shaft assembly including: a shaft extending along the first axis and having a first end and a second end opposite the first end; a first coupler configured to couple the shaft assembly for co-rotation with the output of the drive assembly about the first axis; a second coupler; and a pin extending from the second coupler to the yoke, wherein the pin is offset from the first axis, which causes rotation of the shaft assembly about the first axis to result in reciprocating motion of the yoke about the second axis; wherein the shaft is made of a first material; and wherein at least one of the first coupler or the second coupler is made of a second material different than the first material.

17. The power ratchet tool of claim 16, wherein, The shaft is made of forged steel.

18. The power ratchet tool of claim 16, wherein, The first coupler and the second coupler are made of the second material.

19. The power ratchet tool of any of claims 16-18, wherein, The pin is made of forged steel.

20. The power ratchet tool of any of claims 16-18, wherein, the drive assembly includes a motor and a planetary transmission; the output is a carrier of the planetary transmission; the first coupler includes a spline; the spline is received within the carrier of the planetary transmission; and the shaft is pressed into a recess of the first coupler.

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