Impact Power Tool Housing Layout for Compact Strength
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Solution Overview
Problem
Conventional rotary power tools, such as hydraulic torque wrenches, face challenges in achieving greater compactness, reduced material usage, and improved protection for internal components while maintaining strength and ease of handling.
Innovation Solution
The design incorporates a motor, pinion, planet gears, internal gear, and an output part, with the internal gear comprising a gear part and a retaining part for holding the gear part, and a bearing disposed frontward of the internal gear part. The tool case is made of resin, and a cover is provided to protect the internal components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the outer casing part is formed of metal to provide strength, then the strength and durability are improved, but the weight increases and the ease of manufacture decreases
Solution Approach 1:
The patent changes the material parameter from metal to resin, fundamentally altering the properties of the outer casing part. This substitution reduces weight while maintaining sufficient strength through optimized resin formulation and structural design, and significantly improves ease of manufacture through injection molding processes.
Solution Approach 2:
The patent employs composite material strategies by combining resin with strategic metal components only where absolutely necessary for structural integrity. This hybrid approach allows the majority of the casing to be made from lightweight, easy-to-manufacture resin while maintaining overall strength requirements through selective metal reinforcement.
2Volume of moving object
If the small diameter part of the cylinder overlaps the bearing in the circumferential direction to make the tool compact, then the volume is reduced, but the complexity of the structure increases
Solution Approach 1:
The patent applies nesting by placing the small diameter part of the cylinder within the bearing's circumferential space, allowing one component to occupy the space of another without interference. This nested arrangement achieves compact volume while maintaining structural simplicity through clear hierarchical positioning of components.
Solution Approach 2:
The patent resolves spatial conflicts by utilizing the circumferential dimension for overlapping components rather than arranging them linearly along the tool's length. This dimensional reorganization allows the small diameter cylinder part and bearing to coexist in the same axial space by occupying different circumferential zones, achieving compactness without increasing complexity.
Data Source
AI summary
An impact power tool includes a front housing connected to a rear housing. A motor is disposed at least partially in the rear housing. An impulse case is disposed at least partially in the front housing. The impulse case is operably coupled to the motor to receive torque therefrom and be rotated thereby. A first protrusion is provided on an interior surface of the impulse case. A first blade is provided inside the impulse unit and is configured to be impacted by the first protrusion. An output shaft is partially disposed within the impulse unit and partially projects out of the impulse unit. The output shaft is configured to be rotated in response to the first protrusion impacting the first blade.