Dual Clutch Mechanism for Impact Tool Load Distribution
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Solution Overview
Problem
Existing impact tools experience high load on clutch mechanisms when shifting from a disengaged to an engaged state, leading to potential wear and reduced efficiency in power transmission.
Innovation Solution
The impact tool employs a dual clutch mechanism system where the first clutch mechanism starts transmission as the tool moves from the front end to an intermediate position and the second clutch mechanism begins transmission from the intermediate to the separate position, distributing the load and ensuring smooth engagement, with the first mechanism using frictional engagement and the second using positive engagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single clutch mechanism is used to transmit power from the first rotary body to the second rotary body, then the structure is simple, but the load on the clutch teeth becomes excessively large when shifting from disengaged to engaged state
Solution Approach 1:
The single clutch mechanism is divided into two separate clutch mechanisms (first and second clutch mechanisms) with different engagement characteristics. The first clutch mechanism uses frictional engagement to provide smooth initial power transmission, while the second clutch mechanism uses positive engagement for reliable torque transmission. This segmentation distributes the load across two mechanisms, preventing excessive stress on individual clutch teeth during engagement transitions.
2Productivity
If clutch teeth are abruptly engaged to transmit power quickly, then power transmission efficiency is high, but the load on clutch teeth becomes excessively large causing wear and potential failure
Solution Approach 1:
The first clutch mechanism performs preliminary power transmission through frictional engagement before the second clutch mechanism fully engages. This preliminary action allows the rotational speeds of the first and second rotary bodies to synchronize gradually, reducing the speed differential and minimizing impact loads when the second clutch mechanism's positive engagement teeth connect. This two-stage engagement process maintains high power transmission efficiency while protecting clutch teeth from excessive wear.
3Speed
If the clutch mechanism allows rapid engagement to respond quickly to loading conditions, then the operational response is fast, but the abrupt engagement creates harmful loads on the clutch teeth
Solution Approach 1:
The first clutch mechanism acts as an intermediary between the motor and the second clutch mechanism during the engagement process. It provides a buffer zone that gradually transfers power through frictional engagement, mediating the speed synchronization between the first and second rotary bodies. This intermediary action enables relatively fast engagement response while preventing harmful shock loads from being transmitted directly to the second clutch mechanism's positive engagement teeth.
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 reduces the load on individual clutch mechanisms, prolongs their lifespan, and ensures reliable power transmission by synchronizing rotation speeds, thereby enhancing the tool's operational efficiency and durability.
Implementation Method 1
the first clutch mechanism being a friction clutch mechanism configured to start transmission while the movable unit moves from the front end position to an intermediate position
Implementation Method 2
the second clutch mechanism being a positive clutch mechanism configured to start transmission while the movable unit moves from the intermediate position to the rearmost position
Data Source
AI summary
An impact tool includes a tool body, a tool holder, a cylindrical member, a reciprocating member, a motor, a first rotary body, a second rotary body, a swinging member, and clutch mechanisms. The clutch mechanisms are disposed between the first rotary body and the second rotary body on a power transmission path from the motor to the swinging member. The tool holder and the cylindrical member move together as a movable unit with respect to the tool body between a front end position and a separate position, according to a pressing force applied to the tool holder. The clutch mechanisms are each configured to start transmission of the first rotary body to the second rotary body while the movable unit moves from the front end position to the separate position and to interrupt transmission while the movable unit moves from the separate position to the front end position.