Brushless Motor Fastener Driver With Flywheel Energy Transfer
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Solution Overview
Problem
Existing fastener driving tools, such as nailers, lack an efficient mechanism for transferring kinetic energy directly to fasteners, leading to reduced driving performance and precision.
Innovation Solution
A fastener driving tool equipped with a brushless electric motor having a central stator and an external rotor with a flywheel, where an energy transfer member, acting as a driver, directly contacts the rotor to propel fasteners into a workpiece, utilizing a mechanism of grooves and ridges for enhanced frictional engagement and stabilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a traditional impact tool with flywheels is used, then the tool can drive fasteners, but the kinetic energy transfer efficiency is reduced and driving precision is compromised
Solution Approach 1:
The patent extracts the essential function of kinetic energy transfer by using a simplified driver mechanism that directly contacts the rotating rotor, eliminating the need for complex flywheel assemblies while maintaining efficient energy transfer to the fastener
Solution Approach 2:
The driver acts as an intermediary element between the rotating rotor and the fastener, converting rotational kinetic energy into linear impact force through direct contact, thereby improving energy transfer efficiency
2Power
If a brushless electric motor with external rotor is used, then the motor efficiency is improved, but the device complexity increases
Solution Approach 1:
The patent replaces traditional brushed motor mechanisms with a brushless electric motor design, using electromagnetic fields instead of mechanical brushes and commutators to control current flow, thereby improving power efficiency while managing structural complexity through integrated motor design
3Force
If the driver directly contacts the rotor with grooves and ridges, then the frictional engagement is enhanced, but the manufacturing precision requirements increase
Solution Approach 1:
The driver features localized grooves and ridges at specific contact points with the rotor, concentrating frictional engagement forces at these strategic locations rather than requiring precision throughout the entire driver surface, thereby reducing overall manufacturing precision requirements while maintaining effective force transmission
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 configuration enables improved kinetic energy transfer, enhancing the driving efficiency and precision of fasteners into a workpiece, with the use of brushless motors and a flywheel-driven energy transfer mechanism providing consistent and controlled propulsion.
Implementation Method 1
an energy transfer member arranged to transfer kinetic energy from the rotor directly or indirectly to a fastener held in the tool
Implementation Method 2
the rotor including a flywheel, the tool including a driver arranged to contact the flywheel and to be propelled by the flywheel
Implementation Method 3
utilizing a mechanism of grooves and ridges for enhanced frictional engagement and stabilization
Implementation Method 4
at least one brushless electric motor and an energy transfer member arranged to transfer kinetic energy from the motor
Data Source
AI summary
A fastener driving tool arranged to drive fasteners into a workpiece includes at least one electric motor having a central stator and an external rotor arranged to rotate around the stator. The rotor may be in the form of a flywheel. The tool includes an energy transfer member such as a driver arranged to transfer kinetic energy from the rotor to a fastener held in the tool, thereby to drive the fastener from the tool into a workpiece. The electric motor may be a brushless motor. The tool may include two such motors, arranged such that both of their rotors propel the driver simultaneously.