Multi-Motor Rotary Impact Tool for High Torque in Compact Space
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Solution Overview
Problem
Existing power-driven tools with rotary impact mechanisms struggle to achieve high torque output efficiently, particularly in tightening and loosening threaded fasteners, and often have bulky designs that hinder portability and efficiency.
Innovation Solution
A powered rotary impact tool equipped with a multi-motor drive unit and a rotary impact mechanism, where a plurality of motors cooperatively drive the impact mechanism, enabling high torque output through a combination of continuous and intermittent rotational impacts, with a compact design that allows for fastening torques of up to 5400 ft-lbs within 10 seconds and loosening torques of 4000 ft-lbs, while maintaining a compact size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a single motor is used to drive the impact mechanism, then the device complexity is reduced, but the torque output and productivity are insufficient
Solution Approach 1:
The drive system is segmented into multiple independent motors (first motor and second motor) that cooperatively drive the impact mechanism. This segmentation allows each motor to contribute to the overall torque output, achieving high torque (5400 ft-lbs fastening, 4000 ft-lbs loosening) while maintaining a compact form factor that would be difficult with a single motor of equivalent power.
2Power
If the tool size is increased to accommodate high torque components, then the torque output is improved, but the portability and ease of operation deteriorate
Solution Approach 1:
The patent employs a compact spatial arrangement where the multi-motor drive unit and impact mechanism are integrated in a vertically stacked configuration along the longitudinal axis. This dimensional optimization allows the tool to achieve high torque output (5400 ft-lbs fastening torque) while maintaining a compact length of less than 70 mm, significantly improving portability and ease of operation compared to conventional impact tools.
3Ease of operation
If the tool size is reduced for portability, then the ease of operation is improved, but the torque output capability deteriorates
Solution Approach 1:
The patent merges the first motor, second motor, and impact mechanism into a tightly integrated multi-motor drive unit with a compact form factor (length <70 mm, cross-sectional area <130 cm²). This merging of components enables the tool to deliver exceptional torque output (5400 ft-lbs fastening, 4000 ft-lbs loosening) within a portable size, achieving both ease of operation and high power capability simultaneously.
4Productivity
If conventional single-motor design is used, then the manufacturing cost is reduced, but the productivity and torque efficiency deteriorate
Solution Approach 1:
The patent implements a dynamic control system that coordinates the operation of multiple motors and the impact mechanism to deliver high torque (5400 ft-lbs) within 10 seconds for fastening and 4000 ft-lbs within 5 seconds for loosening. This dynamic multi-motor configuration significantly improves productivity compared to conventional single-motor designs, achieving high torque output in half the time while maintaining a compact form factor.
Data Source
AI summary
A power-driven impact tool is provided. The impact tool includes a motor, a transmission, and a rotary impact mechanism received in a housing. The transmission may be a planetary transmission that reduces a speed of a rotary force output by the motor. The impact tool may be a cordless impact tool, receiving power from a battery back that is removably coupled in a battery receptacle of the housing. First and second handles on the housing may provide for user stability and control during operation of the impact tool. A plurality of user selection devices, including a trigger, a forward/reverse switch, and a mode selector, may be provided on one of the handles for user control of the impact tool.