Impact Tool with Brushless Drive and Integrated Hammer-Case Lighting
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Solution Overview
Problem
Existing impact tools lack ergonomic design and efficient work performance, particularly in terms of weight, torque, and illumination in the work environment.
Innovation Solution
Incorporation of a brushless motor, a spindle, a hammer, an anvil, and a resin housing with a light unit comprising multiple light-emitting devices, which provides improved ergonomics and work efficiency by enhancing illumination and reducing weight within specified torque ranges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a light unit with multiple light-emitting devices is added to the impact tool, then the illumination intensity in the work environment is improved, but the weight of the tool increases
Solution Approach 1:
The light-emitting devices are integrated into the existing hammer case structure, merging the illumination function with the housing rather than adding separate components. This reduces overall weight by utilizing existing structural space for dual purposes.
Solution Approach 2:
The hammer case is designed to serve multiple functions: it houses the hammer mechanism and simultaneously supports the light unit. This multi-functionality eliminates the need for additional dedicated housing structures, reducing weight while providing illumination.
2Productivity
If the maximum tightening torque is increased to 1,000-2,500 N·m, then the work efficiency is improved, but the weight and size of the tool increase
Solution Approach 1:
A brushless motor replaces traditional motor types to achieve high torque output with reduced weight. The brushless design eliminates heavy commutators and brushes, providing a more efficient power-to-weight ratio necessary for high torque applications.
Solution Approach 2:
The housing incorporates resin (polymer) materials combined with metal components, creating a composite structure that reduces weight while maintaining the structural strength required to handle 1,000-2,500 N·m torque levels.
3Weight of moving object
If a resin (polymer) housing is used instead of traditional metal housing, then the weight is reduced, but the strength and durability may be compromised
Solution Approach 1:
The housing uses composite construction combining resin (polymer) materials with reinforced metal components or inserts. This composite approach maintains the weight reduction benefits of polymers while restoring structural strength through material combination.
Solution Approach 2:
Different portions of the housing have different material properties - resin is used where weight reduction is prioritized, while metal reinforcements are strategically placed in areas requiring high strength and durability, such as mounting points and stress-bearing sections.
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 impact tool achieves improved ergonomics and work efficiency through bright illumination and reduced weight, with a maximum tightening torque of 1,000 N·m to 2,500 N·m, and a weight of 2 kg to 9 kg, while maintaining a compact design.
Implementation Method 1
a light unit, which is held on the hammer case and comprises a plurality of light-emitting devices
Data Source
AI summary
An impact tool includes: a brushless motor; a spindle, which is rotated by the brushless motor; a hammer, which is held on the spindle; an anvil, which is impacted in a rotational direction by the hammer, a polymer housing, which houses the brushless motor; a hammer case, which is connected to the polymer housing and houses the hammer and the spindle; and a light unit, which is held on the hammer case and comprises a plurality of light-emitting devices. The maximum tightening torque of the anvil is 1,000 N·m or more and 2,500 N·m or less.