Impact Hammer Swing Arm Spring Energy Storage
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Solution Overview
Problem
Existing impact tools, such as pneumatic, hydraulic, gasoline, and electric driven tools, face inefficiencies due to energy loss and structural requirements, leading to reduced performance and shorter tool life, particularly in the use of compressed air and hydraulic systems which result in noise pollution and increased energy consumption.
Innovation Solution
The design incorporates a spindle with a multiple roller 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 optimized spring deflection and reduced spring free length, integrated into a gear reducer for enhanced efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If hydraulic fluid is used to stroke the hydraulic cylinder and compress a gaseous spring, 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 that consumes stored energy and reduces efficiency
Solution Approach 1:
The patent removes the hydraulic valve and fluid evacuation system from the impact tool, replacing it with a direct mechanical spring compression mechanism. The swing arm directly compresses the spring during the upward stroke without requiring valve actuation or fluid management, eliminating the parasitic energy losses associated with hydraulic systems while maintaining the ability to generate high impact forces.
Solution Approach 2:
The patent replaces the hydraulic system (fluid pressure, valves, cylinders) with a purely mechanical system consisting of a swing arm and spring assembly. This substitution eliminates the need for hydraulic fluid evacuation and valve actuation, directly addressing the energy efficiency problem while preserving the impact generation capability through mechanical energy storage and release.
2Force
If higher reactive forces or hydraulic pressures are used to counter energy losses, then impact force is maintained, but greater energy input, structurally stronger equipment, and increased maintenance are required, resulting in shorter tool life
Solution Approach 1:
The patent employs a dynamic spring compression system where the spring is compressed during the swing arm's upward motion and then releases energy to propel the piston downward for impact. This dynamic energy storage and release mechanism allows the system to maintain high impact forces without requiring continuously high hydraulic pressures, thereby reducing stress on structural components and extending tool life.
Solution Approach 2:
The spring is compressed in advance during the upward swing arm motion, storing energy before the impact event. This preliminary energy storage allows the system to deliver high impact forces without requiring high pressures during the actual impact moment, reducing overall system stress and maintenance requirements while extending tool life.
3Force
If pneumatic hammers use large quantities of compressed air to accelerate the piston, then impact force is achieved, but energy intensive compressors are required and noise pollution increases
Solution Approach 1:
The patent replaces the pneumatic system (compressed air, large volume gas storage) with a mechanical spring-based energy storage system. The spring is compressed by the swing arm during the upward stroke and then releases energy to accelerate the piston for impact, achieving the same force generation without requiring energy-intensive compressors or large quantities of compressed air, thereby significantly reducing energy consumption.
Solution Approach 2:
The patent removes the compressed air system and large-volume air storage requirements from the impact tool, replacing it with a compact mechanical spring assembly. This extraction of the pneumatic system eliminates the need for energy-intensive compressors while maintaining impact force capability, directly addressing the energy consumption problem.
4Speed
If pneumatic hammers release large quantities of compressed air, then piston acceleration is achieved, but noise pollution associated with air release and compressor operation increases
Solution Approach 1:
The patent replaces the pneumatic acceleration system with a mechanical spring propulsion system. The compressed spring directly propels the piston for impact without releasing large quantities of compressed air, thereby eliminating the noise pollution associated with air release and compressor operation while maintaining effective piston acceleration and 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 achieves significant energy savings and extended tool life by minimizing energy wastage and reducing the need for high hydraulic pressures, while also decreasing noise pollution and operational costs.
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 compound spring assembly with a plurality of spring stacks including a plurality of offset and counter sunk springs stacked in series allowing for maximum use of spring deflection while minimizing spring free length
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.