Magnetic Coil Setting Tool Pump Piston Air Compression
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Solution Overview
Problem
Existing setting tools for fasteners, such as nails and rivets, face inefficiencies in air compression and energy transfer, leading to suboptimal performance and increased weight due to additional pressure chambers and loss channels.
Innovation Solution
A setting tool utilizing a magnetic coil and magnetizable components to efficiently compress air, where the magnetic coil drives a pump piston within a cylinder, generating compressed air stored in a pressure chamber, which then accelerates a ram to drive the fastener, eliminating the need for direct air-driven rams and reducing weight by optimizing energy conversion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a conventional air-driven ram is used, then the setting tool can drive fasteners, but the tool weight increases and energy transfer efficiency decreases due to additional pressure chambers and loss channels
Solution Approach 1:
The patent removes the pressure chamber and intermediate air storage from the system. Instead of using a separate pressure chamber to store compressed air before driving the ram, the invention directly couples the pump piston to the ram, eliminating unnecessary components and reducing tool weight while maintaining functionality
Solution Approach 2:
The patent combines the pump piston and ram into a single integrated component. The pump piston directly drives the ram without an intermediate pressure chamber, merging two functions into one component and reducing the number of parts and overall device complexity
2Productivity
If compressed air is stored in a pressure chamber for one setting process, then the setting process can be completed, but loss channels increase and energy efficiency decreases
Solution Approach 1:
The patent implements continuous action by having the pump piston directly drive the ram in a continuous motion. The magnetic coil continuously acts on the pump piston during the driving process, eliminating the need to store compressed air and reducing energy losses associated with pressure chamber containment and release
Solution Approach 2:
The patent removes the pressure chamber from the system entirely. By eliminating this component, the invention removes the associated loss channels and energy inefficiencies related to storing and releasing compressed air in an intermediate chamber
3Use of energy by moving object
If the magnetic coil is positioned to overlap the pump piston, then energy transfer efficiency increases, but the device complexity increases
Solution Approach 1:
The magnetic coil serves multiple functions: it acts as both the actuator for the pump piston and the guide for the piston's linear motion. This multi-functionality improves energy transfer efficiency while avoiding the need for additional guiding mechanisms that would increase device complexity
Solution Approach 2:
The patent combines the magnetic actuation function and the mechanical guidance function into a single integrated magnetic coil structure. The coil both generates the magnetic field to move the piston and provides the structural framework that guides the piston's motion, reducing the need for separate components
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 enhances energy efficiency, reduces tool weight, and minimizes loss channels by converting electrical energy into kinetic energy of the ram through efficient air compression, allowing for more precise and efficient fastening processes.
Implementation Method 1
generating compressed air by feeding a current pulse into a magnetic coil and the generated magnetic field moves a magnetizable pump piston within the magnetic coil in a pump cylinder
Implementation Method 2
The pump piston is movable along an axis in the pump cylinder. An axial closure of the pump cylinder closes off a pump volume within the pump cylinder with the pump piston. The annular magnet arrangement has a magnet coil which encloses the pump cylinder and which at least partially overlaps the magnetizable closure and partially overlaps the magnetizable pump piston along the axis
Implementation Method 3
The compressed air generated by the pump device and held in the pressure chamber accelerates the drive piston in the guide cylinder
Implementation Method 4
The setting tool converts electrical energy into a magnetic field, into a compression of air and then into the kinetic energy of the ram
Data Source
Figure 1
Figure 2~4
AI summary
The setting device 1 according to the invention has a plunger 3 which, driven by compressed air, drives in the fastening element 2. A pump unit 5 generates the compressed air. The pump unit 5 has a pump cylinder 23, a pump piston 22, and an annular magnet arrangement 28, 46 surrounding the pump cylinder 23. The pump piston 22 is movable within the pump cylinder 23 along an axis 11. An axial closure 25 of the pump cylinder 23 seals off a pumping volume 27 within the pump cylinder 23 together with the pump piston 22. The annular magnet arrangement 28, 46 has a magnetic coil 28 that surrounds the pump cylinder 23 and overlaps at least partially with the magnetizable closure 25 and partially with the magnetizable pump piston 22 along the axis 11.