BLDC Lifter Control in a Gas Spring-Powered Fastener Driver
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Solution Overview
Problem
Existing fastener drivers face power, size, and cost constraints, with many designs relying on external sources like air compressors or electrical energy, which can be inefficient and bulky.
Innovation Solution
A gas spring-powered fastener driver with a brushless direct current (BLDC) motor, a cylinder and piston mechanism, and a driver blade that operates on a gas spring principle, utilizing a battery pack for power and a lifter mechanism to drive fasteners into a workpiece.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If external air compressors or electrical energy sources are used to power fastener drivers, then sufficient driving power can be achieved, but the device size increases and portability decreases
Solution Approach 1:
The patent extracts and eliminates the external air compressor and electrical energy source from the fastener driver system. Instead, it incorporates a self-contained gas spring mechanism that stores mechanical energy internally within the driver body, allowing the tool to operate without bulky external power supplies while maintaining sufficient driving power.
Solution Approach 2:
The patent employs a gas spring mechanism that utilizes compressed gas to provide the driving force for the fastener. The gas spring is pre-charged and stores potential energy that is converted to kinetic energy during operation, delivering the necessary power to drive fasteners into the workpiece without requiring external pneumatic or hydraulic systems.
2Reliability
If traditional fastener driver mechanisms are used, then reliable fastener driving can be achieved, but the device complexity and cost increase
Solution Approach 1:
The gas spring mechanism is designed to be self-contained and self-regulating. It automatically stores and releases energy without requiring complex control systems, sensors, or multiple actuators. The mechanical design ensures reliable fastener driving through inherent energy storage and release characteristics of the gas spring, reducing overall system complexity.
3Use of energy by moving object
If battery packs are integrated into the handle portion, then portable power supply is achieved, but the center of gravity shifts and handling balance deteriorates
Solution Approach 1:
The patent positions the battery pack in the handle portion, utilizing the vertical dimension and the natural grip area of the user's hand. This placement leverages the user's hand as a support structure, allowing the battery's weight to be counterbalanced by the user's grip rather than creating an unfavorable torque that would affect handling balance.
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 design provides a compact, efficient, and cost-effective solution for driving fasteners without external air pressure, utilizing a gas spring mechanism for power and a BLDC motor for control, enhancing operational efficiency and reducing tool size.
Implementation Method 1
A gas spring-powered fastener driver with a brushless direct current (BLDC) motor, a cylinder and piston mechanism, and a driver blade that operates on a gas spring principle
Implementation Method 2
The drive unit including a brushless direct current (BLDC) motor
Data Source
AI summary
A powered fastener driver including a housing defining a cylinder support portion, a drive unit support portion, and a handle portion that is spaced apart from the drive unit support portion. The powered fastener driver includes a cylinder, a piston movable within the cylinder from a top-dead-center (TDC) position to a bottom-dead-center (BDC) position, a driver blade attached to the piston for movement therewith along a driving axis from the TDC position toward the BDC position, a lifter operable to move the piston and driver blade, in unison, from the BDC position toward the TDC position, and a drive unit supported by the drive unit support portion and operably coupled to the lifter. The powered fastener driver further includes a user interface supported by the housing, and a printed circuit board positioned within the housing and positioned between the drive unit support portion and the handle portion.