Pneumatic Tool Pressure Regulator with Load Reducing Mechanism
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Solution Overview
Problem
Pneumatic tools face challenges in maintaining constant secondary pressure due to fluctuations in primary pressure, leading to variations in the driven amount of fasteners, and have large size and high operating loads due to existing pressure regulation mechanisms.
Innovation Solution
A pressure regulator with a valve body, elastic body, and pressure receiving member that adjusts pressure and reduces operating load, featuring a load reducing mechanism to switch the urging force between normal and reduced states, and a primary pressure balance mechanism to stabilize secondary pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a valve mechanism for pressure regulation is provided, then the pressure of compressed air can be adjusted, but the size of the driving tool increases
Solution Approach 1:
The pressure regulator is nested within the grip structure of the pneumatic tool. The regulator housing is arranged within the grip, and the air chamber is positioned inside the grip structure, utilizing the existing internal space. This nesting approach allows the pressure regulation function to be integrated without significantly increasing the overall tool size.
Solution Approach 2:
The patent arranges components in a compact three-dimensional layout within the grip. The valve body, piston, spring, and air chamber are positioned in a space-efficient configuration that utilizes radial and axial dimensions effectively, reducing the tool's full length while maintaining pressure adjustment functionality.
2Ease of manufacture
If the valve mechanism is arranged in the end of the grip, then the layout space is improved, but the full length of the driving tool becomes large
Solution Approach 1:
The pressure regulator components are arranged in a compact three-dimensional layout within the grip. The valve body, piston, spring, and air chamber are positioned in a space-efficient configuration that utilizes radial and axial dimensions effectively, reducing the tool's full length while maintaining pressure adjustment functionality.
3Stress or pressure
If the spring load of the pressure adjusting mechanism is increased to maintain higher set pressure, then the pressure regulation capability is improved, but the operating load increases making it difficult for users to operate
Solution Approach 1:
A cam mechanism acts as an intermediary between the user's operating force and the spring-loaded piston. The cam profile transforms the user's rotational input motion into axial motion of the piston, providing mechanical advantage that reduces the operating load required to adjust the spring pressure while maintaining the desired pressure regulation capability.
Solution Approach 2:
The cam mechanism provides dynamic mechanical advantage during operation. As the user rotates the cam, the contact point between the cam profile and the piston changes, creating a varying leverage ratio that optimizes the force required at different stages of the adjustment process, making operation easier despite the high spring load.
4Device complexity
If a direct-acting pressure adjusting mechanism is used, then the device complexity is reduced, but the secondary pressure fluctuates when primary pressure changes
Solution Approach 1:
The pressure regulator employs a feedback mechanism where the downstream pressure (secondary pressure) acts on the piston to balance against the spring force. When downstream pressure fluctuates, the piston position adjusts automatically to maintain equilibrium, stabilizing the secondary pressure despite variations in primary pressure. This inherent feedback loop provides pressure stability without requiring complex external control systems.
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 solution enables a compact pneumatic tool with reduced operating load and stable secondary pressure, independent of primary pressure fluctuations, allowing for consistent fastener driving performance and improved user experience.
Implementation Method 1
an elastic body configured to exert an urging force to the valve body in a direction of opening the flow path
Implementation Method 2
a pressure receiving member configured to receive air pressure in the air chamber and press the elastic body in a direction of closing the flow path
Data Source
AI summary
A pneumatic tool includes an air chamber; and a pressure adjusting mechanism which adjusts a pressure of a compressed air in the air chamber. The pressure adjusting mechanism includes a valve body which opens and closes a flow path that communicates the air intake and the air chamber; an elastic body which exerts an urging force to the valve body; a support part which supports an end of the elastic body; a pressure receiving member which receives air pressure in the air chamber and presses the elastic body in a direction of closing the flow path; and a load reducing mechanism capable of switching the urging force of the elastic body acting on the valve body between a normal state and a load reduction state in which the urging force smaller than the normal state is exerted.