Impact Tool Hammer-Anvil Mechanism for Torque Control
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Solution Overview
Problem
Existing impact tools face challenges in efficiently imparting striking rotational force to fasteners, particularly when high torque is required, and lack a seamless transition between powered and non-powered operation modes.
Innovation Solution
The impact tool design incorporates a motor-driven transmission system with an impact mechanism featuring a hammer, anvil, and spring washer, allowing for incremental torque application and a locking mechanism that enables conversion between powered impact driver and non-powered torque wrench modes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a motor-driven impact mechanism is used to impart striking rotational force, then productivity and power are improved, but device complexity increases
Solution Approach 1:
The impact mechanism is segmented into distinct functional components: a motor assembly for power generation, a transmission assembly for torque transfer, and an impact assembly with hammer and anvil for striking action. This segmentation allows each component to be optimized independently while maintaining overall system functionality.
Solution Approach 2:
The impact tool is designed with multi-functionality, serving both as a powered impact driver for loosening fasteners and as a manual torque wrench for tightening operations. The locking mechanism enables the same device to perform different functions based on operational mode, reducing the need for separate tools.
2Adaptability or versatility
If a locking mechanism is added to enable torque wrench mode, then adaptability is improved, but device complexity increases
Solution Approach 1:
The locking mechanism is designed to be dynamically controllable, allowing the user to switch between locked and unlocked states based on operational requirements. The mechanism responds to user input through a actuator that engages or disengages the locking element, providing flexible adaptation between impact driver and torque wrench modes.
Solution Approach 2:
An intermediary locking element is introduced between the drive shaft and housing, serving as a mediator that enables or disables torque transmission to the anvil. This intermediary component allows clean separation of functions by physically blocking or allowing power flow based on operational mode.
3Power
If high torque is required for stuck fasteners, then power is improved, but loss of energy increases
Solution Approach 1:
The impact mechanism employs periodic action through the hammer-anvil striking cycle, where rotational force is applied in intermittent impacts rather than continuous rotation. This periodic striking action delivers high peak forces to the fastener while allowing the drive shaft to recover between impacts, improving power delivery efficiency.
Solution Approach 2:
The transmission mechanism maintains continuous torque transmission from the motor to the drive shaft through properly engaged gears and bearings, minimizing energy loss. The seamless power flow ensures that motor power is continuously converted to mechanical torque without interruption or significant energy dissipation.
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 design effectively imparts rotational force to fasteners, ensuring efficient loosening or tightening, and allows for manual operation as a torque wrench, enhancing versatility and operational flexibility.
Implementation Method 1
a spring washer (250) that exerts a preload force on the pinion (74) to maintain the pinion (74) meshed with the drive shaft gear (86)
Implementation Method 2
an impact mechanism (30) coupled between the motor and the drive shaft and operable to impart a striking rotational force to the drive shaft (22)
Data Source
AI summary
The invention provides, in another aspect, an impact tool comprising a housing, a motor having an output shaft defining a first axis, a drive shaft rotatably supported by the housing about a second axis oriented substantially normal to the first axis, a gear coupled for co-rotation with the drive shaft, an impact mechanism coupled between the motor and the drive shaft and operable to impart a striking rotational force to the drive shaft, the impact mechanism including, an anvil rotatably supported by the housing and coupled to the drive shaft, the anvil including a pinion engaged with the drive shaft gear, a hammer coupled to the motor to receive torque from the motor and impart the striking rotational force to the anvil, and a spring washer exerting a preload force on the pinion to maintain the pinion meshed with the drive shaft gear.