Multistage Solenoid Magnetic Driver for Compact Fastener Force
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Solution Overview
Problem
Traditional fastener devices face inefficiencies in battery life and bulkiness due to pneumatic or motor-driven systems, and corded tools require large energy consumption.
Innovation Solution
A battery-powered fastener device utilizing a multistage solenoid with a magnetic driver, where the solenoid stages generate alternating electromagnetic fields to efficiently drive fasteners by combining with the magnetic field of the driver, minimizing energy consumption and maximizing force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a pneumatic system is used to drive fasteners, then the fastener device can achieve sufficient driving force, but the device becomes bulky and requires hoses and compressors
Solution Approach 1:
The patent replaces the pneumatic system with an electromagnetic system consisting of a solenoid and magnetic driver. The solenoid generates electromagnetic fields that interact with the magnetic driver to produce linear motion and driving force, eliminating the need for compressors, hoses, and heavy pneumatic components while maintaining sufficient fastener driving capability
Solution Approach 2:
The invention extracts and removes the external pneumatic system components (compressor, hoses, reservoirs) from the fastener device, retaining only the essential electromagnetic components (solenoid, magnetic driver, battery) that can be integrated into a compact handheld tool configuration
2Force
If a motor and transmission are used in battery-powered fastener devices, then the device can drive fasteners, but battery life is limited due to inefficiencies
Solution Approach 1:
The patent eliminates the motor and transmission mechanical system and replaces it with a direct electromagnetic actuation system. The solenoid converts electrical energy directly into linear motion of the magnetic driver, which then drives the fastener. This direct conversion removes the inefficiencies of mechanical transmission components and extends battery life
Solution Approach 2:
The solenoid is divided into multiple stages that can be selectively energized. This segmentation allows the system to use only the necessary number of stages for each specific fastener driving task, optimizing energy consumption and extending battery life by avoiding unnecessary energy expenditure
3Force
If a solenoid is used to drive small fasteners with multiple impacts, then the device can achieve sufficient force, but the operation time and battery consumption increase
Solution Approach 1:
The magnetic driver is pre-positioned and held in readiness within the solenoid assembly before operation. When a fastener needs to be driven, the system can immediately actuate the appropriate solenoid stage without requiring multiple sequential impacts or repositioning actions, thereby reducing operation time and battery consumption
Solution Approach 2:
The system dynamically selects and activates only the specific solenoid stage(s) needed for the current fastener driving task. This dynamic control allows the system to achieve sufficient driving force in a single or minimal number of strokes rather than requiring multiple impacts, thus reducing operation time and energy consumption
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 multistage solenoid system enhances battery life and reduces energy requirements, providing efficient and compact fastener driving capabilities.
Implementation Method 1
Each stage of the multistage solenoid is configured to be selectively energized to generate a first electromagnetic field and a second electromagnetic field
Implementation Method 2
The magnetic driver has a magnetic field. The controller is contained within the tool housing and is configured to adjust an amount of force the multistage solenoid imparts on the magnetic driver by combining the magnetic field of the magnetic driver with at least a portion of the first electromagnetic field
Data Source
AI summary
A fastener device includes a tool housing, a multistage solenoid, a magnetic driver, and a controller. The magnetic driver is configured to travel through the multistage solenoid between a retracted condition and an extended condition. The controller is contained within the tool housing and is configured to adjust an amount of force the multistage solenoid imparts on the magnetic driver while the magnetic driver travels between a first stage and a second stage of the at least two stages that are adjacent to each other, by combining a magnetic field of the magnetic driver with at least a portion of a first electromagnetic field of the first stage of the at least two stages of the multistage solenoid and at least a portion of a second electromagnetic field of the second stage of the at least two stages of the multistage solenoid.