Offset Impact Mechanism for Compressed-Air-Free Hammer Tools
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Solution Overview
Problem
Conventional powered hammer tools, including air hammers and nail guns, require a continuous supply of compressed air or fail to deliver sufficient impact force for chiseling, cutting, and shaping metal and/or stone, limiting their use and effectiveness.
Innovation Solution
An impact mechanism for a hammer tool powered by electricity via a rechargeable battery, featuring a perpendicular and offset longitudinal axis, includes a hammer with radially protruding impact surfaces that transfer force to an intermediate bit, which then impacts a conventional hammer bit, driven by a gear carrier and motor, allowing for sufficient impact force without compressed air.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If compressed air is used to power the impact mechanism, then sufficient impact force is generated, but the tool requires a continuous supply of compressed air which limits its use in worksites without compressed air infrastructure
Solution Approach 1:
The patent replaces the pneumatic system (compressed air) with an electric motor-driven impact mechanism. The electric motor rotates an eccentric weight to generate centrifugal force that drives the impact piston, eliminating the need for compressed air infrastructure while maintaining sufficient impact force for chiseling and breaking operations
Solution Approach 2:
The patent uses a hybrid approach by incorporating a pneumatic chamber and piston within the electric impact mechanism. The rotating eccentric weight compresses air in the chamber, which then drives the piston to deliver impact forces, combining electric power with pneumatic force multiplication to achieve high impact force without external compressed air supply
2Adaptability or versatility
If an electric motor is used to power the impact mechanism, then the tool can operate without compressed air, but conventional electric impact mechanisms fail to deliver sufficient impact force for chiseling and breaking
Solution Approach 1:
The patent employs periodic impact action through the rotation of an eccentric weight that periodically compresses air in a chamber, driving a piston to deliver repeated impact forces. This periodic conversion of rotational motion to linear impact motion generates sufficient force for breaking operations while maintaining continuous operation capability
Solution Approach 2:
The patent changes the operational parameters by using a high-speed electric motor to rotate the eccentric weight at high RPM, which rapidly compresses air in the chamber to generate high-pressure pulses. This parameter change (high rotational speed) enables the electric mechanism to achieve impact forces comparable to pneumatic systems
3Force
If the hammer bit is positioned close to the impact mechanism, then direct impact is achieved, but the hammer bit cannot move freely and rotational inertia is insufficient to generate large impact force
Solution Approach 1:
The patent introduces an intermediate pneumatic chamber and piston as a mediator between the rotating eccentric weight and the hammer bit. The piston converts rotational motion to linear impact motion through air compression, allowing the hammer bit to be positioned at an optimal distance for both free movement and sufficient rotational inertia while still receiving effective impact forces
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 impact mechanism generates a powerful impact force sufficient for chiseling, cutting, and shaping metal and/or stone, using a rechargeable power source, enhancing the tool's versatility and usability.
Implementation Method 1
a hammer with radially protruding impact surfaces adapted to impact an intermediate bit that is constrained to a small linear motion inside the tool housing
Implementation Method 2
an intermediate bit that is constrained to a small linear motion inside the tool housing. The intermediate bit is then adapted to impact a conventional hammer bit
Implementation Method 3
The hammer and the gear carrier respectively include a ball groove. In an embodiment, the ball groove of the hammer and the ball groove of the gear carrier are limited to use in one rotary direction
Data Source
AI summary
An impact mechanism for an impact tool having a housing with a housing longitudinal axis, wherein the impact mechanism includes an impact mechanism longitudinal axis that is offset and substantially perpendicular to the housing longitudinal axis. The impact mechanism includes a gear carrier adapted to be driven by a motor of the impact tool to rotate about the impact mechanism longitudinal axis, a hammer slidably coupled to the gear carrier and rotatable about the impact mechanism longitudinal axis, the hammer includes a radial surface with a hammer lug extending therefrom, and an intermediate bit adapted to receive impact force from the hammer lug and transfer impact force to a tool bit.