Modular Torque Screwdriver with Interchangeable Shanks
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Solution Overview
Problem
Current screwdrivers lack consistency in applying the precise torque required for different screw types, leading to potential safety issues in industries like aerospace and machining, as the torque application varies with operator strength and experience, and existing solutions are either uneconomical or prone to incorrect torque settings.
Innovation Solution
A pre-calibrated manual torque screwdriver with a handle containing modular torque modules and interchangeable shanks, where each shank is machined to fit specific screw types, ensuring exact torque without operator adjustment, and manufactured using plastic molding for cost-effectiveness and simplicity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If a fixed torque screwdriver with interchangeable blade is used, then the blade can be replaced when worn, but there is a risk of accidental swapping with blades of similar dimensions but different technical characteristics leading to incorrect torque
Solution Approach 1:
The handle is divided into multiple calibrated chambers, each containing a calibration element with specific torque characteristics. Each shank is designed to engage with specific chambers based on its geometry, ensuring that only the correct torque calibration is activated for each screw type, eliminating the risk of incorrect torque application while maintaining blade interchangeability.
2Adaptability or versatility
If an adjustable torque device with split conical cam is used, then torque can be adjusted by turning the handle, but the operator must know the various torques for individual screws and manually adjust the handle, requiring experience and knowledge
Solution Approach 1:
The torque calibrations are pre-configured in the handle during manufacturing, with each chamber containing calibration elements set to specific torque values. The shanks are pre-designed with geometries that automatically engage with the appropriate chambers, so the operator simply selects the correct shank for the screw type and the correct torque is automatically applied, eliminating the need for manual adjustment and operator knowledge of torque values.
3Device complexity
If a monolithic fixed torque screwdriver is used, then the structure is simple, but once the blade is worn it is necessary to throw away the entire handle containing the mechanism, which is uneconomical
Solution Approach 1:
The screwdriver is designed as a segmented system with a reusable handle containing multiple calibration chambers and interchangeable shanks with integrated blades. When a blade wears out, only the shank needs to be replaced, not the entire handle, significantly improving cost-effectiveness while maintaining structural simplicity through the modular design.
4Reliability
If multiple calibrated chambers with multiple balls and springs are used, then pre-calibrated torque is achieved without operator adjustment, but the manufacturing complexity increases
Solution Approach 1:
Multiple calibration elements (balls and springs) are nested within compact cylindrical chambers inside the handle. Each chamber contains a complete calibration system for a specific torque value, with elements arranged concentrically and axially to maximize space utilization. This nested arrangement achieves reliable pre-calibrated torque for multiple screw types while keeping the overall handle size manageable and the structure organized.
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
Ensures consistent and precise torque application for various screw types, enhancing safety and reducing manufacturing complexity, while being easy to use and cost-effective, with the ability to provide higher torque during unscrewing.
Implementation Method 1
each containing an elastic spring (11) acting on a cylindrical roller (10) to provide a predetermined torque
Implementation Method 2
The rollers (10) are arranged so as to act on the peripheral surface of the bush (9)
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The present invention relates to a pre-calibrated manual torque screwdriver, containing within the handle (1) the pre-calibrated torque device composed of multiple individual modules which can be arranged side by side and are modular, the central part (9) acting as a female mating seat, said modules cooperating in coordination with a plurality of shanks (2), which are interchangeable with tangs which can be inserted from the front part of said handle and have, at the other end, the tip or shape of the screwdriver, while the tangs or the part that can be inserted are provided with the male seat or seats ( 2.1 - 2.8) of various length suitable for mating with one or more of said torque modules, each module cooperating in the central part with a respective bush which has an internal coaxial seat with female mating which is suitable to mate with a corresponding male seat provided on the tangs of said interchangeable shanks which can be inserted longitudinally within the handle, wherein the mating between the male seats of the tangs of the shanks and the female seats of the internal bushes of each pre-calibrated torque module contained-within the handle produces a- torque which corresponds to the sum of the individual torques of the individual modules involved in the tang-bush mating.