Adjustable Auxiliary Handle for High Torque Impact Wrench

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Solution Overview

Problem

High torque impact wrenches face challenges in providing ergonomic and adjustable handling options, which limits operator comfort and control, especially when dealing with large and stuck fasteners.

Innovation Solution

The impact tool features a housing with a motor housing portion, an anvil, and an impact mechanism driven by a motor, along with a battery receptacle, trigger switch, and an auxiliary handle assembly with an adjustable mount and band clamp, allowing for various rotational and positional adjustments for improved ergonomics and control.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If a fixed handle configuration is used, then the device structure is simple, but operator comfort and control are limited

Engineering Contradiction:

Improveoperator comfort and controlVSAvoidhandle adjustment mechanism

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The handle assembly is made adjustable rather than fixed, allowing dynamic reconfiguration. The auxiliary handle can be rotated to different angular positions and secured at selected orientations, enabling the operator to customize the handle configuration for different working conditions and personal comfort preferences.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The handle system is divided into separate components: a primary handle and an auxiliary handle that can be independently positioned. The auxiliary handle is mounted on a rotation mechanism that allows it to be decoupled from a fixed configuration and repositioned relative to the primary handle, creating modular handle segments.

Inventive Principle:

Principle #1Segmentation

2Force

If high torque is delivered to loosen stuck fasteners, then the fastener can be removed, but the tool requires excessive current draw

Engineering Contradiction:

Improvetorque outputVSAvoidcurrent draw

Core Design Contradiction:

ForceVSUse of energy by moving object

Solution Approach 1:

The impact mechanism delivers torque in periodic rotational impacts rather than continuous force. The camshaft and hammer assembly create intermittent striking motions that apply high torque in discrete impacts, allowing the motor to draw current in controlled pulses rather than sustaining excessive continuous current while maintaining effective fastener loosening capability.

Inventive Principle:

Principle #19Periodic action

Data Source

PatentUS11597061B2High torque impact tool

Publication Date: 2023.03.07 MILWAUKEE ELECTRIC TOOL CORP

AI summary

An impact tool includes a housing extending along a longitudinal axis. The housing includes a motor housing portion, a first handle extending from the motor housing portion, and a front housing coupled to the motor housing portion opposite the first handle. The impact tool also includes a motor supported within the motor housing portion, an anvil extending from the front housing, an impact mechanism supported within the front housing, and an auxiliary handle assembly. The auxiliary handle assembly includes a mount coupled to the housing, an auxiliary handle coupled to the mount and spaced from the first handle, and an adjustment mechanism. Loosening the adjustment mechanism permits rotation of the auxiliary handle assembly about the longitudinal axis relative to the housing, and tightening the adjustment mechanism secures the auxiliary handle assembly in a selected rotational position.