Hybrid Impact Tool Mode Collar Mechanism
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Solution Overview
Problem
Existing hybrid impact tools lack an efficient mechanism to switch between drill and impact modes, leading to suboptimal performance in terms of torque transmission and tool efficiency.
Innovation Solution
The implementation of a mode change mechanism with a mode collar and cam mechanism that allows for axial movement of the hammer relative to the spindle, enabling the tool to switch between direct and indirect rotary power transmission based on torque thresholds, thereby optimizing drill and impact operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a mode change mechanism is added to switch between drill and impact modes, then the tool's adaptability to varying torque conditions is improved, but the device complexity increases
Solution Approach 1:
The mode collar is made axially movable between first and second positions, allowing the transmission path to dynamically change based on operational requirements. This dynamic reconfiguration enables the tool to switch between direct power transmission (drill mode) and cam-mediated power transmission (impact mode), resolving the contradiction by making the system adaptable without requiring multiple separate tools.
Solution Approach 2:
The single power tool is designed to perform multiple functions (drilling and impacting) through one mode change mechanism. The cam mechanism serves dual purposes: it transmits power during impact operations and also enables mode switching. This multi-functionality approach allows the tool to adapt to different torque conditions while avoiding the need for separate specialized tools.
2Power
If the mode collar is positioned to enable impact mode with cam mechanism, then the torque transmission effectiveness is improved, but the device complexity increases
Solution Approach 1:
The cam mechanism acts as an intermediary element between the drive shaft and the output spindle during impact mode. It mediates the power transmission by converting rotational motion into the characteristic impact motion through its cam profile, while the mode collar serves as an intermediary switching element that routes power through or bypasses the cam mechanism based on the selected mode.
Solution Approach 2:
The transmission system is segmented into two distinct power transmission paths: a direct path for drill mode and a cam-mediated path for impact mode. The mode collar segments the control function by having separate engagement features for each mode, allowing independent optimization of each transmission path without compromising the other.
3Stability of the object's composition
If the hammer is constrained to co-rotate with the spindle in drill mode, then the rotational stability is improved, but the ease of operation decreases
Solution Approach 1:
The mode change mechanism is designed to be self-actuating through the operator's existing actions. The mode collar can be positioned by the operator during normal operation, and the engagement features automatically lock into place without requiring additional complex control systems. The spring-loaded cam follower automatically adapts to the cam profile when in impact mode, eliminating the need for separate control mechanisms.
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 enhances the tool's ability to adapt to varying torque conditions, ensuring efficient drill mode operation at low torque and effective impact mode operation at higher torque levels, improving overall performance and efficiency.
Implementation Method 1
The cam mechanism couples the hammer to the spindle in a manner that permits limited rotational and axial movement of the hammer relative to the spindle
Implementation Method 2
The spring biases the hammer toward the anvil such that the hammer teeth engage the anvil teeth
Data Source
AI summary
A power tool having a rotary impact mechanism and a mode change mechanism. The impact mechanism is driven by an output member of a transmission and includes a hammer and an anvil. The mode change mechanism includes a mode collar that is movable between a first position, in which the mode collar directly couples the hammer to the transmission output member to inhibit movement of the hammer relative to the spindle, and a second position in which the mode collar does not inhibit movement of the hammer relative to the spindle.