Slip Clutch Mounting Tool for Insulation Board Assembly
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Solution Overview
Problem
Existing assembly tools for driving plate screws into screw dowels for fastening insulation boards to substructures often result in high braking torque, causing work-physiological issues and damage to the insulation board, with the potential for excessive release of insulating material.
Innovation Solution
Incorporation of a slip clutch between the drive shaft and the tool housing, which automatically reduces torque below the braking torque of the stop disk, reducing forces on the work machine and minimizing damage to the insulation board, while maintaining a compact and easy-to-handle design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a stop disc is used to ensure flush mounting of the anchor plate, then the anchor plate sits flush with the insulation surface, but high braking torque is generated causing work-physiological issues and potential damage to the insulation board
Solution Approach 1:
A slip clutch is introduced as an intermediary mechanism between the drive shaft and the stop disc. This slip clutch allows controlled slippage when a predetermined torque threshold is exceeded, thereby mediating between the need for precise flush mounting and the need to prevent damage from excessive braking torque. The slip clutch absorbs the harmful braking torque through controlled frictional slippage while still allowing the stop disc to function for precision positioning.
Solution Approach 2:
The slip clutch acts as a beforehand cushioning mechanism by being pre-configured with a predetermined torque threshold. Before the harmful braking torque can damage the insulation board or cause work-physiological issues, the slip clutch preemptively slips to reduce the torque transmission. This prior cushioning prevents the harmful effects before they occur, while still allowing normal operation for achieving flush mounting precision.
2Reliability
If high braking torque is transmitted to the drive motor when the stop plate contacts the insulation board surface, then the anchor plate is securely positioned, but this causes occupational health issues and can damage softer insulation materials
Solution Approach 1:
The slip clutch serves as a mediator between the reliable positioning function of the stop disc and the ease of operation concern. It allows the stop disc to reliably position the anchor plate flush with the surface, while simultaneously protecting the operator from harmful braking torque through controlled slippage. This maintains positioning reliability while improving ease of operation by eliminating shock loads.
Solution Approach 2:
The slip clutch provides beforehand cushioning by being pre-set with a torque threshold that is lower than the damaging threshold. When the stop disc approaches the surface and braking torque begins to build, the slip clutch preemptively slips to cushion the operator from the full impact, while still allowing the positioning function to complete reliably.
3Manufacturing precision
If the stop plate is significantly larger in diameter than the plate screw and washer, then flush mounting is ensured, but high braking torque is generated causing insulation material to be released and polluting the environment
Solution Approach 1:
The slip clutch acts as an intermediary that decouples the relationship between the large-diameter stop disc and the drive motor. The large stop disc can continue to provide precise flush mounting, while the slip clutch mediates the torque transmission to prevent excessive force that would cause insulation material to be released and pollute the environment.
Solution Approach 2:
The slip clutch provides beforehand cushioning by limiting the maximum braking torque to a predetermined level. This prevents the high braking torque that would otherwise cause insulation material to be ripped from the board and released into the environment, while still allowing the large stop disc to function for precise positioning.
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 slip clutch effectively reduces torque transmission, minimizing damage to the insulation board and reducing the release of insulating material during assembly, enhancing work physiology and tool usability.
Implementation Method 1
a slip clutch (7) arranged between the drive shaft (6) and the tool housing (2), which automatically reduces torque below the braking torque of the stop disk (3)
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
To create an assembly tool for driving a countersunk screw into a screw anchor for fastening an insulation board to a substructure, which is ergonomically advantageous, avoids damage to the surface of the insulation board, and releases less insulation material during assembly, the invention proposes an assembly tool with a slip clutch that disengages reproducibly at a defined torque, which is lower than the braking torque that would bring a stop disc of the assembly tool to a halt upon full contact with the insulation board without the slip clutch. The defined torque of the slip clutch reduces the forces on the machine connected to the assembly tool during its operation. The consistently constant torque of the slip clutch also reduces damage to the surface of the insulation board and the removal of insulation material.