Battery-Powered Handheld Punch Tool for Pilot-Hole Sheet Cutting
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Solution Overview
Problem
Existing handheld reciprocating punch tools, or nibblers, generate numerous small, sharp fragments during cutting operations, are limited by the need for AC power or compressed air, and cannot initiate cuts in the middle of a sheet or on closed ducts.
Innovation Solution
A handheld punch tool with a housing, motor, transmission, bit holder, die holder, and punch, where the motor is powered by a rechargeable battery pack, allowing for efficient cutting with reduced fragment generation and enabling cuts to start anywhere on a sheet.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a typical nibbler is used to cut sheet metal, then cutting efficiency is improved, but numerous small sharp fragments are generated that are difficult to clean up
Solution Approach 1:
The cutting process is segmented into two distinct phases: first a pilot hole is drilled to create an opening, then the punch tool enters the hole to complete the cut. This segmentation allows the cutting action to occur within the confines of the pilot hole, containing fragments rather than scattering them across the work surface.
Solution Approach 2:
The pilot hole acts as an intermediary structure that mediates between the cutting tool and the workpiece. By creating this intermediate opening first, the subsequent punching action is confined to the hole space, and fragments are contained within or near the hole rather than being ejected across the entire work surface.
2Power
If AC power or compressed air is used to power the nibbler, then sufficient power is provided for cutting, but access and maneuverability are limited by power cords or air hoses
Solution Approach 1:
The power source (battery pack) is extracted from the fixed infrastructure (AC outlet or compressed air system) and integrated directly into the portable tool. This extraction eliminates the need for power cords or air hoses, allowing the tool to operate independently and be maneuvered freely throughout the work area.
Solution Approach 2:
The power delivery system transitions from a static, fixed connection (power cord plugged into outlet) to a dynamic, mobile system (rechargeable battery pack). This dynamic power source enables the tool to move freely while maintaining sufficient power delivery for cutting operations.
3Productivity
If a typical nibbler is used for cutting, then edge cuts are achieved efficiently, but cuts cannot be initiated in the middle of a sheet or on closed ducts
Solution Approach 1:
A preliminary action (drilling a pilot hole) is performed before the main cutting action. This preliminary hole creation enables the punch tool to access the workpiece at any location, not just at edges, by providing an entry point for the punch to engage and begin the cutting process.
Solution Approach 2:
The tool system becomes multi-functional by combining a drilling function (for creating pilot holes) with a punching function (for completing cuts). This universality allows the same tool to perform both edge cuts and internal cuts, adapting to various cutting scenarios regardless of workpiece geometry.
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
The tool effectively reduces fragment generation, enhances maneuverability with a battery-powered design, and allows for initiating cuts anywhere on a sheet, improving operational efficiency and safety.
Implementation Method 1
The motor includes a motor shaft. The transmission is supported in the housing and is configured to be driven by the motor shaft.
Data Source
AI summary
A handheld punch tool including a housing, a motor, and a transmission configured to be driven by a motor shaft. The transmission has a crankshaft and a reciprocating shaft mounted to the crankshaft. The handheld punch tool further includes a bit holder configured to be driven by the crankshaft and to retain a tool bit to form a pilot hole in a workpiece to be cut in response to rotation of the crankshaft and the bit holder. Moreover, the handheld punch tool includes a die holder, a die, and a punch. The die and the die holder define a feed slot therebetween for receiving the workpiece to be cut. The punch is configured to be driven by the reciprocating shaft to reciprocate within the die holder such that at least a portion of each of the die holder, the die, and the punch is insertable into the pilot hole.