Electromagnetic Impact Driver Using Inductor and Internal Mass
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Solution Overview
Problem
Existing compact angle impact wrenches face issues with small parts breaking, contamination, and reduced lubrication over time, leading to inhibited impact power, and their size can make them inconvenient for use in tight spaces.
Innovation Solution
An impact driver system utilizing a rotatable shaft and a rotating driver mechanism, where a first mass is accelerated by an inductor to induce rotation, with a computer-controlled method to repeatedly activate the inductor for efficient energy transfer and torque generation, allowing for bidirectional operation and compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional impact wrench designs with small moving parts are used, then compact size is achieved, but reliability deteriorates due to parts breaking, contamination, and lubrication loss
Solution Approach 1:
The patent extracts and eliminates the complex multi-part clutch mechanism from traditional impact wrenches. Instead, it uses a single rotating driver mechanism with simplified internal mass and inductor components, removing the problematic small moving parts that break and require lubrication while maintaining the impact function.
Solution Approach 2:
The patent replaces the mechanical clutch system with an electromagnetic inductor system. The inductor uses electromagnetic fields to accelerate the internal mass, substituting complex mechanical engagement parts with a more reliable electromagnetic field-based acceleration mechanism that has fewer moving parts.
2Force
If larger parts are used to generate impact power, then impact force is improved, but the tool size increases making it inconvenient for tight spaces
Solution Approach 1:
The patent changes the dimensional approach by using a long, slender tool design rather than a compact short design. The inductor is positioned along the length of the housing, allowing the internal mass to travel a longer distance in one dimension (length) to generate sufficient impact force without increasing the tool's width or height, making it suitable for tight spaces.
Solution Approach 2:
The patent changes the physical parameters of the system by using electromagnetic field strength and acceleration distance as the primary determinants of impact force rather than part size. The inductor's electromagnetic field parameters and the internal mass's travel distance are optimized to generate high impact force within a compact tool envelope.
3Power
If more moving parts are used in the impact mechanism, then impact power is improved, but maintenance requirements increase due to lubrication loss and contamination
Solution Approach 1:
The patent implements a self-lubricating design by eliminating the need for external lubrication systems. The simplified rotating driver mechanism and inductor system require no lubrication, and the internal mass operates in a sealed environment without requiring maintenance for lubrication replenishment or contamination removal.
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 system provides reliable and efficient impact force within a small space, enhancing durability and convenience by determining torque strength based on the tool's length rather than width, enabling effective loosening and tightening in tight locations.
Implementation Method 1
A first inductor is positioned to accelerate the first mass toward the rotating driver mechanism
Data Source
AI summary
An impact driver, in accordance with one embodiment, includes a rotatable shaft, and a rotating driver mechanism configured to rotate the shaft. A first mass is positioned to selectively strike the rotating driver mechanism for inducing a rotation of the shaft in a first direction. A first inductor is positioned to accelerate the first mass toward the rotating driver mechanism. A computer-implemented method, in accordance with one embodiment, includes repeatedly activating a first inductor for repeatedly accelerating a first mass toward a rotating driver mechanism to selectively strike the rotating driver mechanism for inducing a rotation of a shaft in a first direction. In response to receiving an indication that rotation of the shaft is detected, the repeated activation is terminated.