Rack and Pinion Adapter for Fastener Installation Stroke Extension
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Solution Overview
Problem
Standard fastener installation tools have insufficient stroke length to install blind fasteners with long grips, leading to incomplete installation, breakage, and inefficiency, especially with cordless tools which are slower than air-driven tools, posing a need for an adapter to increase stroke length and improve installation speed.
Innovation Solution
An adapter assembly comprising a tension member with a rack gear, a compression member with a matching rack gear, and a pinion gear housing that engages these gears to double the stroke length of standard fastener installation tools, allowing single-stroke installation of blind fasteners with longer grips and enhancing installation speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If a standard installation tool is used, then the tool is compact and easy to handle, but the stroke length is insufficient to install fasteners with long grips
Solution Approach 1:
The adapter assembly nests multiple functional components within a compact structure. The tension member with rack gear, compression member with rack gear, and pinion gears are arranged concentrically and sequentially along the tool's stroke path, allowing the stroke multiplication mechanism to be integrated without significantly increasing the overall tool footprint or complexity.
Solution Approach 2:
The adapter assembly acts as an intermediary device between the standard installation tool and the fastener. It receives the limited stroke input from the tool and transforms it into the extended stroke required for installing fasteners with long grips, effectively mediating between the tool's capabilities and the fastener's requirements.
2Length of moving object
If multiple tool strokes are used to install fasteners, then the stroke length limitation is overcome, but the stem breaks off with too short a length
Solution Approach 1:
The adapter assembly enables continuous, uninterrupted pulling action throughout the entire installation process. By multiplying the tool stroke to provide sufficient total displacement, the fastener stem is pulled continuously through the workpiece and into the sleeve without interruption, preventing the stem from breaking off at an unacceptable length.
Solution Approach 2:
The adapter pre-configures the mechanical advantage and stroke multiplication before installation begins. The rack and pinion gear arrangement is预先 set to provide the necessary mechanical advantage, ensuring that when the tool operates, the full required stroke is delivered in a single continuous action rather than requiring multiple interrupted strokes.
3Object-affected harmful factors
If cordless installation tools are used, then the tripping hazard from air hoses is eliminated, but the installation speed is reduced
Solution Approach 1:
The adapter assembly is designed to work with standard installation tools regardless of power source. It provides the mechanical stroke multiplication function that works equally well with both cordless and air-driven tools, allowing cordless tools to achieve the same installation speed and efficiency as air-driven tools when paired with the adapter.
4Length of moving object
If special long stroke tools are used, then fasteners with long grips can be installed, but the tools are larger, heavier, and more expensive
Solution Approach 1:
The solution segments the stroke extension function from the main tool body. Instead of designing a completely new long-stroke tool, the invention creates a separate adapter assembly that attaches to the standard tool. This adapter contains the stroke multiplication mechanism in modular components that can be added only when needed, avoiding the weight penalty of a permanently extended tool design.
Solution Approach 2:
The adapter assembly provides universal compatibility with standard installation tools while adding the specialized long-stroke capability. The same adapter can be attached to any standard tool to extend its capability, meaning the weight addition is minimal compared to purchasing entirely different specialized tools for each application.
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 adapter doubles the stroke length of standard fastener installation tools, enabling single-stroke installation of fasteners with longer grips and significantly reducing installation time, matching the productivity of air-driven tools with cordless tools, thus improving efficiency and safety.
Implementation Method 1
a first rack gear formed in its outer surface. The adapter further comprises a compression member having an opening therethrough with an inner surface and is disposed around the tension member. The opening is sized to accommodate relative axial sliding of the tension member relative to the compression member. The compression member has a second rack gear formed in the inner surface.
Implementation Method 2
The adapter is operative to increase a stroke length provided by the installation tool
Data Source
AI summary
Adapter for increasing the stroke length of a fastener installation tool. The adapter includes a tensile member with a first rack gear, a compressive member with a second rack gear, and a plurality of pinion gears retained within a pinion gear housing. The tensile member is mateable with the puller shaft of the installation tool and with the tensile member of an installation head. The pinion gear housing is mateable with the body of the installation tool. The distal end of the compressive member is mateable with a reducing member, which in turn mates with the outer sleeve of the installation head. Operation of the pulling tool moves the tensile member axially toward the tool body and engages the pinion gears, which in turn move the compressive member axially away from the tool body.