Compact Impact Tool Layout for Tight-Space Tightening
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Solution Overview
Problem
Existing impact tools face challenges in performing tightening operations in cramped or cornered locations due to their bulkiness, limiting their usability in such spaces.
Innovation Solution
The impact tool design includes a compact configuration with a maximum overall length of 100 mm, a center height of 29 mm or less, and a maximum tightening torque of 140 N·m, allowing for easy operation in confined areas by minimizing the tool's dimensions and maintaining sufficient torque.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the impact tool is designed with conventional dimensions, then it can provide sufficient tightening torque, but it becomes too bulky to operate in cramped locations
Solution Approach 1:
The motor is disposed in the interior of the stator, creating a nested configuration where the rotor rotates within the stator housing. This nested arrangement significantly reduces the overall length of the impact tool while maintaining the necessary torque output for effective tightening operations in confined spaces.
Solution Approach 2:
The patent reconfigures the traditional linear arrangement of impact tool components into a compact multi-dimensional layout. The motor, stator, rotor, spindle, and anvil are arranged in a space-efficient configuration that minimizes the overall length while preserving the hammer's rotational impact capability.
2Length of moving object
If the impact tool is made more compact, then it can fit in cramped locations, but the tightening torque may be compromised
Solution Approach 1:
The hammer is designed to rotate about the rotational axis during operation, creating a dynamic impact mechanism. This rotational movement of the hammer allows the compact tool to generate sufficient tightening torque through the rotational impact force, maintaining effectiveness despite the reduced overall length.
Solution Approach 2:
The patent optimizes the parameters of the hammer and anvil interaction to maintain high torque output. The hammer's mass, the anvil's position, and the rotational speed are carefully tuned to ensure that the compact configuration still delivers the necessary tightening force for effective fastening operations.
3Length of moving object
If the motor is positioned with conventional spacing from the anvil, then it can provide adequate power transmission, but it increases the overall length
Solution Approach 1:
The power transmission path is segmented into distinct functional zones: the motor generates rotational force, the stator and rotor transmit this force through electromagnetic interaction, the spindle converts it to linear motion, and the hammer delivers the final impact. This segmentation allows for optimized spacing that maintains power transmission efficiency while minimizing overall length.
Solution Approach 2:
The spindle acts as an intermediary element between the motor and the hammer, converting rotational motion to linear motion and transmitting force efficiently over the compact distance. This intermediary mechanism ensures adequate power transmission despite the reduced spacing between motor and anvil components.
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 compact design enables efficient tightening operations in cramped locations, enhancing usability and accessibility in tight spaces without compromising torque performance.
Implementation Method 1
a motor comprising a stator and a rotor, at least a portion of which is disposed in the interior of the stator and which rotates about a rotational axis
Implementation Method 2
a hammer, which impacts the anvil in a rotational direction
Data Source
AI summary
An impact tool (1) includes: a motor (6) having a rotor (27) that is rotatable about a rotational axis (AX); a spindle (8) disposed forward of the stator and rotating when the rotor rotates; an anvil (10) having at least a portion disposed forward of the spindle and mounting a bit (300); a hammer (47), which rotatably impacts the anvil; and a housing (2), which has a motor-housing part (21) that houses the motor. The maximum tightening torque is 140 N·m or more. Overall length (La), which is the distance—in the front-rear direction parallel to the rotational axis—between a rear-end portion of the motor-housing part and a front-end portion of the anvil, is 100 mm or less. The hammer has a base portion, a front-side ring portion protruding forward from the base portion, and hammer projection portions protruding radially inward from the front ring portion.