Electromagnetic Stapler Depth Adjuster Cam Mechanism

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Solution Overview

Problem

Existing electromagnetic staplers lack the ability to easily and repeatably adjust to intermediate depths of drive, limiting their versatility in handling fasteners of different sizes and hardness levels in workpieces.

Innovation Solution

A manually adjustable depth adjuster is integrated into the stapler, featuring a cam with a cam surface interacting with the solenoid core, an adjustment knob, and a detent mechanism, allowing the stapler to be set to multiple predefined positions for precise control of the driver's axial stroke and energy delivery.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a depth adjuster is added to control the axial stroke of the driver, then the ability to control fastener drive depth is improved, but the device complexity increases

Engineering Contradiction:

Improvefastener drive depth controlVSAvoidadjuster mechanism complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The adjuster mechanism transforms a static stapler into a dynamic system where the driver's axial stroke can be varied. The cam mechanism allows the upper position of the core to be adjusted, thereby changing the length of the axial stroke of the driver to control fastener drive depth.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The cam acts as an intermediary element between the adjustment knob and the solenoid core. By rotating the cam, the upper position of the core is defined, which indirectly controls the driver's axial stroke length and thus the fastener drive depth without directly modifying the solenoid structure.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If multiple predefined positions are provided for depth adjustment, then the versatility for different fastener sizes and workpiece hardness is improved, but the device complexity increases

Engineering Contradiction:

Improveadjustment position optionsVSAvoiddetent mechanism complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The continuous adjustment range is segmented into discrete predefined positions using the detent mechanism. This allows the cam to be secured at specific angular positions, providing distinct drive depth settings (maximum, minimum, and intermediate positions) rather than continuous adjustment.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system changes the parameter of driver axial stroke length by adjusting the cam position. Each predefined position corresponds to a specific stroke length, allowing the user to select appropriate parameters for different fastener sizes and workpiece hardness levels.

Inventive Principle:

Principle #35Parameter changes

3Measurement precision

If the cam surface interacts with the solenoid core to define upper position, then the precision of depth control is improved, but the manufacturing precision requirements increase

Engineering Contradiction:

Improvedepth control precisionVSAvoidcam surface precision

Core Design Contradiction:

Measurement precisionVSManufacturing precision

Solution Approach 1:

The cam surface is designed with a curved profile rather than a linear shape. This curved surface interacts with the solenoid core to define precise upper positions at different cam rotation angles, enabling accurate control of the driver's axial stroke length and thus precise depth control.

Inventive Principle:

Principle #14Spheroidality (Curvature)

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

Enables precise control over the depth of fastener penetration, accommodating various fastener sizes and workpiece hardnesses by providing a range of adjustable positions, from maximum to minimum depth, including intermediate settings, enhancing the stapler's versatility and user convenience.

Implementation Method 1

Electromagnetic staplers include a solenoid that is used to convert electricity into an electromagnetic force that is suitable for accelerating a driver to impact the fastener and drive the fastener into the workpiece

Methodology Applied

Scientific EffectElectromagnetic force: Electromagnetic Induction

Implementation Method 2

The depth adjuster includes a cam having a cam surface that interacts with the core of the solenoid so as to define an upper position of the core

Methodology Applied

Scientific EffectCam mechanism: Cam

Data Source

PatentUS8104659B2Electromagnetic stapler with a manually adjustable depth adjuster

Publication Date: 2012.01.31 STANLEY BLACK & DECKER INC

AI summary

An electromagnetic stapler includes a driver for driving fasteners into a workpiece, and a solenoid for providing power to the driver. The solenoid has a coil, and a core that is operatively connected to the driver. The stapler also includes a manually adjustable depth adjuster for adjusting a depth of drive of the fasteners. The depth adjuster is movable between a plurality of predefined positions, including a maximum depth of drive position, a minimum depth of drive position, and at least one intermediate depth of drive position. The depth adjuster includes a cam having a cam surface that interacts with the core so as to define an upper position of the core, an adjustment knob operatively connected to the cam, and a detent mechanism for securing the cam at one of the plurality of predefined positions to thereby define the upper position of the core.