Fastening Tool Timed Ready-to-Fire Flywheel Control
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Solution Overview
Problem
Existing cordless fastening tools are often cumbersome due to their size and weight, require expensive and non-refillable fuel cartridges, and have complex designs that do not reliably set fasteners in a consistent manner, with sequential operation speeds being less than desirable due to delays in kinetic energy storage and discharge.
Innovation Solution
A fastening tool with a contact trip switch, trigger switch, motor assembly, and controller that includes a mode selector switch for selecting between sequential and rapid sequential modes, allowing the flywheel to reach firing speed without user input after a firing sequence, reducing operational delays and improving efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the tool operates in full sequential mode to ensure safe and controlled fastener discharge, then operational safety is improved, but the speed of operation deteriorates due to delays in creating and storing kinetic energy
Solution Approach 1:
The system dynamically adjusts its operational mode based on user input. The controller monitors switch states and automatically transitions between sequential mode (safe, controlled operation) and bump mode (rapid, continuous operation), allowing the tool to adapt its speed and safety characteristics to the specific task requirements
Solution Approach 2:
The controller changes the operational parameters of the motor assembly and flywheel system based on detected switch states. In sequential mode, the system waits for proper switch sequencing before energizing the flywheel. In bump mode, the flywheel is energized immediately upon trigger activation, fundamentally changing the timing and energy delivery parameters to eliminate delays
2Ease of operation
If the tool uses complex fuel cartridges to power the fastening mechanism, then portability and cordless operation are improved, but the cost of operation deteriorates due to expensive non-refillable cartridges
Solution Approach 1:
The patent replaces the chemical energy storage system (fuel cartridges) with an electrical energy storage system (battery-powered motor assembly). The motor drives the flywheel to store kinetic energy, substituting the mechanical-chemical energy delivery mechanism with an electro-mechanical one, thereby eliminating the need for expensive disposable fuel cartridges
Solution Approach 2:
Instead of discarding expensive fuel cartridges after use, the system recovers and stores kinetic energy in a reusable flywheel that can be rapidly re-energized by the motor. The battery-powered system allows for repeated energy storage and release cycles without consumable costs
3Weight of moving object
If the tool is designed to be compact and lightweight for ease of use, then portability is improved, but the power output deteriorates due to limitations in motor size and energy storage capacity
Solution Approach 1:
The system uses periodic energy storage and release cycles. The motor assembly periodically energizes the flywheel to store kinetic energy, which is then released in controlled bursts to drive fasteners. This periodic operation allows a small, lightweight motor to deliver high power impulses without requiring continuous high power output, maintaining compact size while achieving sufficient driving force
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 tool enables faster and more consistent fastener installation by allowing the flywheel to maintain firing speed for a predetermined time in rapid sequential mode, reducing downtime and improving user flexibility without the need for complex fuel cartridges.
Implementation Method 1
the controller can bring the flywheel to firing speed without input from the operator after a completed firing sequence
Implementation Method 2
a motor assembly and a controller. The motor assembly can have a flywheel, which can be driven by a motor
Data Source
AI summary
A fastening tool and method of operating a fastening tool can include a driver, a motor, a flywheel driven by the motor, an actuator, and a controller. The actuator can cause the driver to engage with the flywheel to cause the driver to move along an axis. The controller can selectively operate the motor and selectively operate the actuator. In a first state, the controller will not operate the actuator unless the contact trip switch and the trigger switch are both actuated, the contact trip switch being actuated prior to actuation of the trigger switch, and the flywheel is rotating at a first predetermined speed. When the controller is in the first state, the controller can operate the motor to rotate the flywheel at a second predetermined speed until the earlier of a second predetermined period of time after operation of the actuator, or a subsequent operation of the actuator.