Impact Hammer Swing Arm Mechanism for Energy Efficiency
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Solution Overview
Problem
Existing impact tools, such as pneumatic, hydraulic, gasoline, diesel, and electric driven tools, face inefficiencies due to energy loss, high energy requirements, structural challenges, and environmental concerns like noise and air pollution, primarily because of the need for high-pressure fluids or large volumes of compressed air, which reduces their performance and tool life.
Innovation Solution
The design incorporates a spindle with a swing arm that transfers rotational motion to a piston, interacting with a compound spring assembly for energy storage, allowing efficient energy transfer and minimizing energy loss through the use of a multiple roller swing arm and gear reducer, which reduces the need for extensive rotational motion to reset, thereby enhancing energy efficiency and tool performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If high pressure fluids or large volumes of compressed air are used to power impact tools, then the tools can generate sufficient impact force, but the tools become heavy, bulky, expensive, and energy intensive
Solution Approach 1:
The impact tool is divided into separate functional components: a motor that generates rotational energy, a swing arm that converts rotational motion to linear motion, and a piston that delivers the impact. This segmentation allows each component to be optimized independently, eliminating the need for heavy pressure vessels while maintaining impact force.
Solution Approach 2:
The patent replaces the traditional pneumatic or hydraulic mechanical system with an electric motor-driven system. The motor generates rotational energy that is converted to linear impact through the swing arm and piston mechanism, eliminating the need for compressed air tanks and high-pressure fluid systems.
2Force
If hydraulic fluid is used to stroke the hydraulic cylinder in hydraulic breakers, then the piston can be lifted and propelled for impact, but a valve must be actuated and oil evacuated with each stroke, resulting in parasitic load and reduced efficiency
Solution Approach 1:
The patent extracts and eliminates the valve and hydraulic fluid evacuation system from the breaker mechanism. Instead of using hydraulic fluid that requires valve actuation and evacuation, the invention uses a solid piston driven directly by the swing arm's rotational motion, removing the parasitic energy losses associated with valve operation.
Solution Approach 2:
The swing arm mechanism automatically converts rotational motion to linear piston motion without requiring external valve control. The piston is propelled by the direct mechanical action of the swing arm, eliminating the need for separate valve actuation systems and reducing energy losses.
3Stability of the object's composition
If the piston is decelerated as the oil cushions the movement and the valve begins to actuate, then the next lift cycle can be prepared, but the impact of the piston is diminished
Solution Approach 1:
The patent removes the oil cushioning system and valve actuation mechanism that cause piston deceleration. The swing arm mechanism provides a direct mechanical connection that maintains piston acceleration throughout the stroke, eliminating the energy losses and impact force reduction caused by oil cushioning and valve preparation.
4Force
If higher reactive forces or hydraulic pressures are used to counter energy losses, then the impact force can be maintained, but greater energy input, structurally stronger equipment, and increased maintenance are required, resulting in shorter tool life
Solution Approach 1:
The patent replaces the hydraulic system requiring high reactive forces with an electric motor-driven swing arm mechanism. This substitution eliminates the need for structurally stronger components to handle high hydraulic pressures, reducing mechanical stress on the system and extending tool life while maintaining impact 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
This solution leads to significant energy savings, reduced emissions, and extended tool life by optimizing energy transfer and minimizing non-productive motion, resulting in improved performance and environmental benefits.
Implementation Method 1
The piston is adapted to interact with an energy storage medium when the swing arm moves the piston in the first direction, thereby causing energy to be stored in the energy storage medium. The energy storage medium may be a compound spring assembly with a plurality of spring stacks including a plurality of offset and counter sunk springs stacked in series
Implementation Method 2
A swing arm is coupled to the spindle such that the rotational motion of the spindle is transferred to the swing arm. The swing arm makes contact with a contact surface of a piston such that the rotational motion of the swing arm causes the piston to move in a first direction along a linear path
Implementation Method 3
As the swing arm continues to rotate, the swing arm may lose contact with the contact surface of the piston, thus allowing the plurality of offset and counter sunk springs of the compound spring assembly to urge the piston in a second direction opposite the first direction allowing the piston to strike an anvil impact surface
Data Source
AI summary
A hydraulic, pneumatic, gasoline, diesel, or electric tool may include a spindle that is adapted for rotational movement. A swing arm may be coupled to the spindle such that rotational motion of the spindle is transferred to the swing arm. The swing arm makes contact with a piston such that the rotational motion causes the piston to move along a linear path. The piston may interact with an energy storage medium when the swing arm moves the piston in the first direction, causing energy to be stored in the energy storage medium. As the swing arm continues to rotate, the swing arm may lose contact with the piston, thus allowing the energy storage medium to urge the piston in a second direction opposite the first direction to strike an anvil. The swing arm may be a multiple roller swing arm. The energy storage medium may be a compound spring assembly.