Powered Ratcheting Wrench Structure for High Torque in a Compact Body
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Solution Overview
Problem
Existing battery-powered tools, such as wrenches, lack an improved construction that balances compactness with high torque and structural rigidity, and efficient power management.
Innovation Solution
A compact ratcheting wrench design featuring a hollow cylindrical steel support tube surrounding a motor and battery assembly, a semi-rigid plastic handle, and a brushless DC motor with a compact outer diameter, along with a user-actuated crown and hall effect sensor for activation, enhancing structural integrity and power delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a battery-powered wrench uses a larger motor and battery assembly to provide high torque, then the torque output is improved, but the overall size and weight of the tool increases
Solution Approach 1:
The support tube is positioned inside the handle, creating a nested configuration where the support tube surrounds the motor and battery assembly. This nested arrangement allows the motor and battery to be compactly housed within the handle structure, providing high torque output while maintaining a compact overall tool size.
Solution Approach 2:
The support tube provides structural reinforcement in a radial dimension, allowing the motor and battery assembly to be compact in the axial dimension. By distributing structural support throughout the handle via the support tube, the design achieves high torque capability without increasing the length or diameter of the tool.
2Volume of moving object
If the wrench uses a compact motor design to reduce size, then the tool compactness is improved, but the structural rigidity and torque delivery capability deteriorates
Solution Approach 1:
The support tube provides localized structural reinforcement at critical positions within the handle, specifically surrounding the motor and battery assembly. This localized support enhances structural rigidity and torque delivery capability precisely where needed, without requiring the entire tool to be larger or heavier.
Solution Approach 2:
The combination of the support tube structure with the motor and battery assembly creates a composite construction that provides both structural rigidity and compactness. The support tube acts as a structural framework that maintains rigidity while allowing the motor and battery to be compactly arranged within the available space.
3Power
If the battery assembly is designed for efficient power delivery, then the power output is improved, but the heat generation increases requiring better thermal management
Solution Approach 1:
The support tube extracts and isolates the motor and battery assembly within a dedicated structural framework. This separation allows for independent thermal management of the power delivery components, facilitating heat dissipation pathways that do not interfere with the compact overall tool design.
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 provides significant torque while maintaining a compact shape, allowing manual and motor-powered operation, with efficient power management and heat dissipation, ensuring durability and ease of use.
Implementation Method 1
A magnet may be affixed to an end of the rod opposite the crown. A rear end of the housing tube may be closed by a cap. A spring may be housed in the housing tube and bias the rod in a forward direction. The wrench may further comprise a hall effect sensor to sense the magnet.
Data Source
AI summary
A wrench including a tool head including a tool output member. The wrench also includes a motor configured to selectively drive the output member and a battery assembly. The battery assembly includes a battery cell and the battery cell provides power to the motor. A support tube surrounds at least a portion of the motor and a portion of the battery assembly. A handle surrounds the support tube.