Battery-Operated Stud Punch Head with Movable Arms
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Solution Overview
Problem
Manual stud punches are cumbersome, expensive, and difficult to maneuver in confined spaces, limiting their effectiveness and causing user fatigue and repetitive stress injuries due to the need for significant physical exertion and limited leverage, as well as being restricted to punching single studs from a single direction.
Innovation Solution
A battery-operated stud punch with a power tool housing and a stud punch head featuring movable arms supported by a drive mechanism, allowing for adjustable orientation and reduced user effort, capable of punching holes in multiple studs without crushing flanges, and accommodating various stud sizes and orientations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a manual stud punch is used, then the tool can punch holes in steel studs, but the user experiences significant physical exertion and repetitive stress injury
Solution Approach 1:
The patent replaces the purely manual mechanical punching system with a powered system that uses an electric motor to drive the punching mechanism. The motor provides the force needed to punch through steel studs, eliminating the need for the user to apply significant manual strength while maintaining high punching speed and productivity.
Solution Approach 2:
The patent employs movable arms that can adjust their position and orientation dynamically. The first arm holds the punch and the second arm holds the die, and both arms can move to accommodate different stud orientations and positions. This dynamic capability allows the tool to adapt to various working conditions without requiring the user to reposition or reorient the entire tool, reducing physical exertion while maintaining operational efficiency.
2Adaptability or versatility
If a manual stud punch is used, then the tool can punch holes in studs, but the user has limited leverage and can only punch from one direction
Solution Approach 1:
The patent employs movable arms that can adjust their position and orientation dynamically. The first arm holds the punch and the second arm holds the die, and both arms can move to accommodate different stud orientations and positions. This dynamic capability allows the tool to adapt to various working conditions without requiring the user to reposition or reorient the entire tool, reducing physical exertion while maintaining operational efficiency.
Solution Approach 2:
The powered stud punch is designed to perform multiple functions: it can punch holes in studs oriented in different directions, accommodate various stud sizes and gauges, and operate in confined spaces. The movable arms and powered mechanism provide universal applicability across different punching scenarios, eliminating the limitations of single-direction punching while maintaining ease of operation.
3Productivity
If a manual stud punch is used, then the tool can punch holes in studs, but the user becomes susceptible to repetitive stress injury when punching many holes
Solution Approach 1:
The patent replaces the purely manual mechanical punching system with a powered system that uses an electric motor to drive the punching mechanism. The motor provides the force needed to punch through steel studs, eliminating the need for the user to apply significant manual strength while maintaining high punching speed and productivity. This substitution directly addresses the issue of user fatigue when punching multiple holes.
4Ease of operation
If a typical manual stud punch is used, then the tool can punch holes in studs, but the tool is bulky and difficult to manipulate in confined areas
Solution Approach 1:
The patent employs movable arms that can adjust their position and orientation dynamically. The first arm holds the punch and the second arm holds the die, and both arms can move to accommodate different stud orientations and positions. This dynamic capability allows the tool to adapt to various working conditions without requiring the user to reposition or reorient the entire tool, reducing physical exertion while maintaining operational efficiency.
Data Source
AI summary
A stud punch head for a power tool includes a head housing and a first arm movably coupled to the head housing. The first arm supports a punch. The stud punch head also includes a second arm movably coupled to the head housing and relative to the first arm. The second arm supports a die opposite the punch. The stud punch head also includes a drive mechanism positioned at least partially within the head housing and operatively coupled to a motor of the power tool. The drive mechanism is operable to move the first arm and the second arm toward and away from each other.