Power Tool Coupling Mechanism for One-Handed Tool Head Locking
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Solution Overview
Problem
Existing coupling mechanisms for removable tool heads in power tools are cumbersome, difficult to handle, and prone to reliability issues due to their complex design requiring multiple elements, recesses, balls, and springs.
Innovation Solution
A simplified coupling mechanism that uses only one ball or one plane of balls for axial and rotational locking of removable tool heads, allowing for one-handed operation and providing clear haptic and acoustic feedback for proper engagement and disengagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional coupling mechanism with multiple balls, springs, and recesses is used, then the locking reliability is improved, but the device complexity increases and ease of operation deteriorates
Solution Approach 1:
The patent extracts and eliminates unnecessary elements from the traditional coupling mechanism. Specifically, it removes multiple balls, springs, and complex recesses, retaining only one ball and one spring that perform both axial and rotational locking functions. This extraction principle directly resolves the contradiction by reducing device complexity while preserving locking reliability through the optimized single-ball mechanism.
Solution Approach 2:
The patent merges multiple locking functions into a single integrated mechanism. The one ball simultaneously provides axial positioning and rotational locking, while the one spring handles both return force and engagement control. This merging of functions reduces the number of parts and simplifies the overall structure without compromising reliability.
2Reliability
If a traditional coupling mechanism with multiple elements is used, then the locking function is improved, but the ease of operation deteriorates due to requiring two hands
Solution Approach 1:
By removing unnecessary elements like multiple balls and complex spring arrangements, the patent creates a streamlined coupling mechanism that can be operated with one hand. The simplified structure reduces the manual dexterity and two-handed coordination required in traditional mechanisms.
Solution Approach 2:
The coupling mechanism is designed to be self-actuating through the spring-loaded ball that automatically engages and disengages with the tool head's recess during insertion and removal. This self-service mechanism eliminates the need for complex manual manipulation, allowing operators to simply insert or remove tool heads without intricate hand movements.
3Ease of operation
If a simplified coupling mechanism with one ball is used, then the ease of operation is improved, but the device complexity reduction may affect reliability
Solution Approach 1:
The patent optimizes the parameters of the single ball and spring system to ensure reliable performance. The ball's diameter, material properties, and spring constants are carefully selected to provide sufficient locking force and durability. This parameter optimization allows the simplified mechanism to maintain coupling reliability despite having fewer parts.
Solution Approach 2:
The ball and surrounding components are designed with appropriate material selections and composite structures that enhance strength and wear resistance. This ensures that the single-ball mechanism can withstand operational loads and maintain reliable locking performance over time.
4Manufacturing precision
If a traditional coupling mechanism with multiple recesses and balls is used, then the manufacturing precision requirements are increased, but the device complexity increases
Solution Approach 1:
By eliminating multiple recesses and balls, the patent dramatically reduces the number of precision features that must be manufactured and assembled. The single-ball mechanism requires only one precisely positioned recess in the tool head, significantly reducing manufacturing complexity and precision requirements compared to traditional multi-ball 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 simplified coupling mechanism enhances ease of use, reduces assembly complexity, improves reliability, and provides clear feedback for operators, making the power tool safer, easier to handle, and more efficient to manufacture.
Implementation Method 1
a first biasing element arranged at the front end abutting the outer sleeve and the front end
Implementation Method 2
a second biasing element abutting the tool side end of the cavity and the inner sleeve
Implementation Method 3
The outer sleeve comprises an inclined inner surface and an inner projection adjacent to the inclined inner surface
Data Source
AI summary
Disclosed herein is a power tool comprising a motor, a drive shaft connected to the motor, a front end defining a cavity comprising a tool side end and a free end, and a coupling mechanism for releasably connecting a removable tool head to the drive shaft. The coupling mechanism comprising two sleeves, a first and a second biasing element and at least one ball that together either put the coupling mechanism in an open position ready to receive the removable tool head or into a closed position upon manual dislocation of the inner sleeve during insertion of another tool head, so that the at least one ball can glide into at least a partial engagement with a recess on the removable tool head and is locked there via the inner projection of the outer sleeve, which outer sleeve is held in position by the first biasing element.