Brushless Impact Wrench High Torque Motor Design
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Solution Overview
Problem
Existing impact wrenches lack the capability to achieve high maximum fastening torque, which is essential for efficiently tightening bolts and screws, particularly in industrial applications where higher torque values are required.
Innovation Solution
The design incorporates a brushless motor with a stator and rotor, an impact mechanism, and battery-mounting parts, allowing for a higher torque output by optimizing the motor output, impact rate, and speed-reduction ratio, with configurations capable of achieving maximum fastening torques of 3,200 N·m or more.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If conventional motor and impact mechanism designs are used, then the device complexity remains manageable, but the maximum fastening torque is insufficient for industrial applications
Solution Approach 1:
The patent applies parameter changes by optimizing the motor output (increasing to 1,250 W or more), adjusting the impact rate (600-3,200 ipm), and configuring the speed-reduction ratio (1/60 to 1/15) to achieve maximum fastening torque of 3,200 N·m or more. These parameter modifications resolve the contradiction by systematically tuning the system to deliver high torque while maintaining reasonable device complexity through coordinated optimization of multiple components.
2Productivity
If higher motor output and optimized impact rate are implemented, then the productivity increases, but the use of energy increases
Solution Approach 1:
The impact mechanism operates through periodic impact actions at controlled rates (600-3,200 ipm), converting continuous motor rotation into discrete high-torque impacts. This periodic action enables high productivity by delivering concentrated torque pulses for rapid fastening while managing energy consumption through the intermittent nature of the impact cycles rather than continuous high-power delivery.
Solution Approach 2:
The patent replaces conventional brushed motor systems with a brushless motor, eliminating mechanical brushes and commutators. This substitution improves productivity through more reliable continuous operation and reduced maintenance, while simultaneously reducing energy loss from brush friction and electrical arcing, thereby improving overall energy efficiency.
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 solution enables the impact wrench to deliver significantly higher fastening torque, effectively addressing the limitations of existing tools by providing configurations that achieve torques up to 10,000 N·m, enhancing the efficiency and capability in industrial fastening tasks.
Implementation Method 1
a brushless motor comprising a stator and a rotor, which rotates relative to the stator
Implementation Method 2
an impact mechanism (e.g., a hammer), which is rotated by the rotor; an anvil, which is impacted by the impact mechanism
Data Source
AI summary
An impact wrench includes: a brushless motor comprising a stator and a rotor, which rotates relative to the stator, an impact mechanism, which is rotated by the rotor, an anvil, which is impacted by the impact mechanism; and one or more battery-mounting parts, on which one or more battery packs is (are respectively) mounted. The maximum fastening torque of the anvil is 3,200 N·m or more.