Power Tool Casing Engagement Feature for Vibration Control
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Solution Overview
Problem
Pneumatic drills for cutting masonry face issues with vibration, wear, and increased weight due to the structural casing and alignment requirements of the hydraulic ram, leading to inefficiencies in impact force delivery and operator discomfort.
Innovation Solution
A power tool design featuring a tool carrier with a casing engagement feature that prevents rotation and allows movement along the operational axis, combined with an actuator module and elastic ropes for efficient energy transfer, reducing vibration and wear while maintaining high impact force per unit weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the moving platform slides on the exterior surface of the ram cylinder, then the device can be constructed with a structural casing, but this introduces extra loads and wear on the ram cylinder and creates unwanted vibration
Solution Approach 1:
The tool carrier is nested within the casing module, with the casing engagement feature providing internal support surfaces. This nested arrangement allows the structural casing to provide strength while the internal tool carrier bearing surfaces carry the operational loads, preventing excessive wear on the ram cylinder.
Solution Approach 2:
The tool carrier acts as an intermediary component between the ram cylinder and the chisel. It provides bearing surfaces that interface with the ram piston, absorbing and distributing the loads and wear away from the ram cylinder's exterior surface, thereby reducing unwanted vibration and wear.
2Ease of manufacture
If the moving platform is not aligned correctly on the ram, then construction is easier, but its movement along the ram cylinder creates unwanted vibration
Solution Approach 1:
The tool carrier is designed with dynamic alignment features including the casing engagement feature with fin and groove geometry. This allows the tool carrier to maintain correct alignment during movement along the operational axis while accommodating manufacturing tolerances, preventing unwanted vibration without requiring extremely tight manufacturing tolerances.
Solution Approach 2:
The casing engagement feature uses asymmetric fin and groove geometry to provide directional guidance and alignment. The fin on the tool carrier fits into the groove of the casing module, creating a keyed arrangement that prevents rotation and ensures correct alignment during movement, reducing vibration while maintaining ease of manufacture.
3Strength
If the casing is made robust and heavy for structural support, then the device can handle high loads, but the overall weight of the power tool increases significantly
Solution Approach 1:
The casing is segmented into a modular casing module with distinct functional zones. The casing engagement feature is integrated as a separate component within the casing module, allowing the structural casing to provide strength while the segmented engagement feature provides precise alignment and load-bearing surfaces, reducing the need for excessive casing weight.
Solution Approach 2:
The casing engagement feature serves multiple functions: it provides structural support, ensures precise alignment of the tool carrier, reduces vibration, and facilitates easy assembly and disassembly. This multi-functionality allows the casing to be optimized for strength without excessive weight, as the engagement feature handles alignment and load distribution.
4Productivity
If the tool carrier can move freely along the operational axis, then impact energy transfer is improved, but rotation around the operational axis must be prevented
Solution Approach 1:
The casing engagement feature provides dynamic constraints that allow linear movement along the operational axis while preventing rotation. The fin-and-groove geometry creates a sliding fit that permits axial motion for impact energy transfer but restricts rotational movement, maintaining stability during operation.
Solution Approach 2:
The casing engagement feature acts as an intermediary constraint mechanism between the tool carrier and casing module. It mediates the motion by allowing necessary linear movement for productivity while imposing rotational stability through its geometric constraints, balancing both requirements.
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 design enhances impact force efficiency, reduces noise and vibration, and improves handling by minimizing misfire forces, resulting in a more effective and operator-friendly power tool for masonry cutting.
Implementation Method 1
array of elastic ropes, one end of which is coupled to the body and the other end of which is coupled to the coupling member
Implementation Method 2
actuator, operable to move the body along the operational axis of the power tool from an impact position to a retracted position
Implementation Method 3
actuator, operable to move the body along the operational axis of the power tool from an impact position to a retracted position
Implementation Method 4
clutch mechanism, selectively coupleable to the body, arranged such that, at the impact position the clutch mechanism is operable to couple the body to the piston
Data Source
AI summary
A power tool is provided that includes a tool carrier for mounting an impact tool. The tool carrier has a base member aligned with an operational axis. The base member has a head end for receiving impact energy, a foot end provided with a tool mount configured to transmit the impact energy to the impact tool, and a casing engagement feature between the head end and foot end. A first casing module is provided with a tool carrier engagement feature complementary in shape to, and for interlocking engagement with, the tool carrier casing engagement feature to prevent rotation of the tool carrier relative to the first casing module around the operational axis, and permits relative movement between the tool carrier and the first casing module along the operational axis.