Flywheel Nailer Solenoid Trigger Safety Mechanism
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Solution Overview
Problem
Existing power-assisted fastener driving devices face challenges such as high costs, limited portability, safety risks due to complex mechanical switches, and inefficiencies in delivering consistent impact force, particularly when using compressed air, fuel cells, or electrical solenoids.
Innovation Solution
A device utilizing a flywheel pivotably connected to a solenoid and motor, with a trigger mechanism and work contact element assembly that engages and disengages to control the flywheel's contact with the drive mechanism, allowing for controlled energy storage and release to impact fasteners using low voltage energy without continuous rotation, thereby enhancing safety and maneuverability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If compressed air is used to power the fastener driving device, then the device can achieve sufficient impact force, but the system cost increases and portability is limited due to requiring an air compressor and air-lines
Solution Approach 1:
The patent extracts and eliminates the external air compressor and air-line system from the fastener driving device. Instead, it incorporates an integrated rechargeable battery-powered motor that directly drives the impact mechanism, removing the complexity of compressed air storage and delivery systems while maintaining portability and sufficient impact force.
Solution Approach 2:
The patent implements a multi-functional integrated power system where a single rechargeable battery unit serves multiple functions: powering the motor, controlling the solenoid, and providing the control circuitry. This replaces the separate air compressor, air storage tanks, and control systems traditionally required in pneumatic fastener drivers.
2Force
If a continuously rotating flywheel is used to drive the fastener, then sufficient energy can be delivered, but the device size and weight increase and reliability decreases due to additional complexity
Solution Approach 1:
The patent transitions from a continuously rotating flywheel to a dynamically controlled system where the flywheel is accelerated only when needed by an electric motor. The flywheel can be rapidly spun up to the required speed, used to deliver the impact, and then stopped. This dynamic operation reduces the need for large continuous rotation mechanisms and associated safety guards.
Solution Approach 2:
The patent replaces the traditional mechanically continuous flywheel-drive system with an electromechanical system. An electric motor accelerates the flywheel to the required speed, and a solenoid-controlled release mechanism transfers the flywheel's energy to the impactor. This substitution eliminates the need for complex continuous mechanical drive trains and constant rotation safety mechanisms.
3Ease of operation
If mechanical switches are used to control the impact mechanism, then the device can be actuated, but safety risks increase due to accidental activation and the switches are subject to wear
Solution Approach 1:
The patent replaces mechanical switches with electronic sensors and control circuitry. Optical sensors or capacitive sensors detect the user's intent to activate the device and trigger the impact sequence through electronic control of the motor and solenoid. This eliminates mechanical wear and reduces the risk of accidental activation since electronic sensors can be designed with higher activation thresholds and multiple confirmation requirements.
Solution Approach 2:
The patent implements feedback control where sensors continuously monitor the device state, flywheel speed, and trigger position. The control circuit processes this feedback information and adjusts the motor and solenoid operation accordingly. This feedback mechanism prevents accidental activation by requiring specific sensor signal patterns and ensures reliable operation by monitoring system parameters throughout the impact cycle.
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 provides reliable and safe delivery of impacting force, reducing the risk of accidental activation and wear, while using low voltage energy sources and eliminating the need for complex mechanical switches and continuously rotating flywheels, thus improving user safety and tool portability.
Implementation Method 1
a motor operably connected to the flywheel
Implementation Method 2
A flywheel is pivotally connected to a solenoid and a motor. The motor is configured to store energy in the flywheel.
Implementation Method 3
A solenoid is connected to a lever arm. The solenoid is configured to rotate the lever arm between a first position whereat the flywheel is spaced apart from a drive mechanism and a second position whereat the flywheel can contact the drive mechanism.
Data Source
AI summary
A device for impacting a fastener in one embodiment includes a drive mechanism, a flywheel pivotable between a first flywheel position whereat the flywheel is not in contact with the drive mechanism and a second flywheel position whereat the flywheel contacts the drive mechanism, a motor operably connected to the flywheel, a trigger movable between a first trigger position and a second trigger position, and a WCE assembly movable between a first WCE position and a second WCE position, the WCE assembly configured such that (i) when the trigger is in the first trigger position and the WCE assembly is in the first WCE position, the WCE assembly mechanically engages the trigger to preclude movement of the trigger out of the first position, and (ii) when the WCE assembly is in the second WCE assembly position, the WCE assembly does not mechanically engage the trigger.