Rotary Impact Tool Rib-Integrated Gear Case Support
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Solution Overview
Problem
Existing power tools, such as impact drivers, face challenges in efficiently transmitting torque while maintaining a compact design, often requiring separate gear boxes or cases that increase size and weight.
Innovation Solution
The power tool design incorporates an outer housing with ribs that rotationally fix a gear case and directly support a ring gear, eliminating the need for a separate gear box and reducing the tool's size and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate gear box or case is used to support the gear assembly, then the gear assembly is properly supported and torque is transmitted, but the power tool's size and weight increase
Solution Approach 1:
The patent combines the gear case support function with the outer housing by integrating ribs that extend from the outer housing into the gear case. This merging eliminates the need for a separate gear box structure, reducing overall tool weight while maintaining proper gear assembly support through the integrated rib structures.
2Reliability
If a separate gear box or case is used to support the gear assembly, then the gear assembly is properly supported and torque is transmitted, but the power tool's size increases
Solution Approach 1:
The outer housing and gear case are merged into a single integrated structure where ribs extend from the outer housing to provide structural support for the gear assembly. This eliminates the need for a separate gear box, reducing the overall size and length of the power tool while maintaining reliable gear support.
3Weight of moving object
If the ring gear is directly supported by the outer housing, then the tool's size and weight are reduced, but torque transmission efficiency must be maintained
Solution Approach 1:
The patent applies local quality by providing targeted structural reinforcement through ribs at specific locations where the ring gear interfaces with the outer housing. These localized rib structures provide adequate torque transmission support without requiring a complete separate gear box, thus maintaining torque efficiency while reducing overall weight.
Data Source
AI summary
A power tool includes an outer housing, a drive mechanism positioned within the outer housing, a gear case positioned within the outer housing, a gear assembly positioned within the gear case, and an output mechanism configured to receive torque from the drive mechanism via the gear assembly to rotate about a rotational axis. The outer housing includes a rib extending from an inner surface of the outer housing, and the rib is received in an aperture of the gear case to rotationally fix the gear case to the outer housing.