Anvil-Socket Dynamics for Impact Wrench Energy Transfer
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Solution Overview
Problem
Existing impact wrenches suffer from inefficiencies due to looseness in the socket-anvil connection, leading to reduced energy transfer and performance, as a result of manufacturing variations and spring effects, which affect torque application and overall efficiency.
Innovation Solution
The impact wrench is designed with dynamically tuned drive components, where the anvil and socket are optimized to have a combined stiffness between 1.15 and 1.45 times the stiffness of the fastener, and their combined inertia is equal to the inertia of the hammer, ensuring maximum output with minimal weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the socket-anvil connection uses standard manufacturing tolerances, then ease of manufacture and assembly is improved, but energy transfer efficiency deteriorates due to looseness and spring effects
Solution Approach 1:
The patent applies parameter changes by precisely controlling the stiffness of the anvil and socket components. The anvil stiffness is tuned to be between 1.15 and 1.45 times the fastener stiffness, and the socket stiffness is optimized to achieve a combined stiffness that eliminates spring effects. This parameter optimization resolves the contradiction by achieving both manufacturability and maximum energy transfer efficiency through controlled stiffness values.
Solution Approach 2:
The patent applies dynamics by tuning the natural frequency of the anvil-fastener system to match the impact frequency of the hammer. This dynamic tuning ensures that the system operates at resonance, maximizing energy transfer from the hammer impacts to the fastener. The dynamic approach resolves the contradiction by optimizing energy transfer through frequency matching while maintaining standard manufacturing practices.
2Loss of energy
If the combined stiffness of anvil and socket is increased to reduce looseness, then energy transfer is improved, but device complexity and manufacturing difficulty worsen
Solution Approach 1:
The patent resolves this contradiction by changing the stiffness parameters of existing components rather than adding new components or complex mechanisms. The anvil stiffness is tuned to be between 1.15 and 1.45 times the fastener stiffness, and the socket stiffness is optimized to achieve a combined stiffness that eliminates spring effects. This parameter optimization achieves maximum energy transfer while maintaining simple, manufacturable components.
3Productivity
If the combined inertia of anvil and socket is optimized to match the hammer inertia, then productivity and torque output are improved, but weight of components increases
Solution Approach 1:
The patent applies parameter changes by optimizing the inertia of the anvil and socket components to match the hammer inertia. This inertia tuning maximizes the torque output and productivity of the impact wrench by ensuring that the drive components are neither too light (which would reduce torque) nor too heavy (which would increase weight unnecessarily). The parameter optimization achieves maximum productivity with minimal weight.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This tuning enhances energy transfer and torque application, resulting in improved performance by minimizing energy loss and maximizing the amount of energy delivered to the fastener.
Implementation Method 1
the anvil and socket are tuned and configured so that their combined stiffness, when removably coupled together including the interface between the two, is optimized so as to be between 1.15 and 1.45 times the stiffness of the fastener
Implementation Method 2
their combined inertia, when removably coupled together, is equal to the inertia of the hammer, thereby facilitating a hammer velocity of zero when the socket exerts peak force upon the fastener
Data Source
AI summary
The present invention provides methods and systems an impact wrench having dynamically tuned drive components, such as an anvil/socket combination, and related methodology for dynamically tuning the drive components in view of inertia displacement, as well as stiffness between coupled components, and with regard to impact timing associated with clearance gaps between the component parts.