External Stator Generator for Pneumatic Tools
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Solution Overview
Problem
Conventional pneumatic tools with integrated electricity generators face challenges such as exposure of internal components to compressed air and fluids, leading to the need for hermetic sealing and labor-intensive lead wire placement, as well as difficulties in providing a secure environment for sensitive electronic components and conditioning high-frequency, alternating current for use with logic processing devices.
Innovation Solution
An integrated electricity generator with a stator positioned externally to the pneumatic tool housing, featuring an inductor core and coil configured to maintain a magnetic circuit and a power conditioner to condition the generated current for compatibility with logic processing devices and USB protocols.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the stator is positioned inside the pneumatic tool housing, then the integrated electricity generator can be compact, but the internal components are exposed to compressed air and fluids requiring hermetic sealing and labor-intensive lead wire placement
Solution Approach 1:
The patent extracts the stator from the internal housing environment and positions it externally on the pneumatic tool housing. This extraction removes the stator from the harmful compressed air and fluid environment, eliminating the need for hermetic sealing and complex lead wire placement through the housing, while still maintaining integration with the pneumatic tool's power source.
Solution Approach 2:
The patent introduces a magnetic coupling mechanism as an intermediary between the internal rotor and external stator. This magnetic field mediator allows electrical generation across the housing boundary without physical penetration, eliminating the need for hermetic seals and complex wiring through the housing while maintaining efficient energy transfer.
2Device complexity
If the stator is positioned inside the pneumatic tool housing, then integration is tighter, but providing a secure environment for sensitive electronic components becomes difficult
Solution Approach 1:
The patent extracts sensitive electronic components (stator, power conditioner, USB interface) from the harsh internal pneumatic environment and relocates them to the external housing. This physical separation provides a secure, protected environment for electronics while maintaining functional integration through magnetic coupling and external wiring.
3Power
If the generator produces high-frequency alternating current directly, then power generation efficiency is high, but the current must be conditioned for use with logic processing devices and USB protocols
Solution Approach 1:
The patent implements a self-contained power conditioning system that automatically converts the high-frequency AC generated by the stator into regulated DC power suitable for USB devices and logic processing. The power conditioner circuitry self-regulates the conversion process, maintaining efficient power generation while providing compatible output without external intervention.
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 solution eliminates the need for hermetic sealing and lead wire placement, reduces circuit resistance, simplifies tool construction, and enables the pneumatic tool to power devices like cycle counters and LCD screens, increasing compatibility with advanced electronics by conditioning AC power to 5 volts DC.
Implementation Method 1
Magnetic means are affixed to the tool rotor, and thereby cooperate during rotation with a stator mounted in the tool housing, motor cylinder or bearing end plate(s) to induce electrical current in the coils of the stator
Implementation Method 2
an inductor core having opposing ends connected by a middle portion; a coil wound around the middle portion and having leads for supplying current to a load external to the tool housing
Data Source
AI summary
A tool cover for receiving a tool housing of a pneumatic tool is disclosed. The tool cover supports and aligns an inductor element of a stator with magnets of a rotor within the tool housing. The tool cover also supports a circuit to which the inductor element is electrically connected, where the circuit comprises a power conditioner for receiving current from the inductor element and conditioning the current to be acceptable for supply to a load that comprises one or more logic processing devices.