Supercapacitor Rail-Driven Nailer Using Lorentz Force
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Solution Overview
Problem
Existing powered fastener-driving tools are costly, heavy, and difficult to maintain due to reliance on compressed air, fuel cells, or large electric motors, which increases operational and maintenance expenses and complexity.
Innovation Solution
A battery-charged supercapacitor-powered fastener-driving tool using conductive rails and a partially conductive piston, where electrical current induces magnetic fields to generate a Lorentz force for driving fasteners, eliminating the need for compressed air, fuel cells, or heavy motors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If pneumatic fastener-driving tools use compressed air as a power source, then fastener-driving power is achieved, but tool cost and maintenance complexity increase due to requiring air compressors and hoses
Solution Approach 1:
The patent replaces the pneumatic mechanical system (compressor, hoses, air supply) with an electromagnetic system consisting of a battery-powered motor that directly drives the piston through a reduction gear mechanism. This substitution eliminates the need for external air compressors and hoses, reducing device complexity while maintaining fastener-driving power.
Solution Approach 2:
The patent extracts and removes the air compressor and hose components from the fastener-driving tool system. By integrating a self-contained battery-powered motor directly into the tool, the design eliminates the need for external air supply equipment, thereby reducing both device complexity and maintenance requirements while preserving the necessary driving power.
2Power
If combustion fastener-driving tools use fuel cells as a power source, then fastener-driving power is achieved, but operational cost increases due to replaceable fuel cells
Solution Approach 1:
The patent replaces the combustion fuel cell system with an electric motor system powered by a rechargeable battery. This substitution eliminates the need for replaceable fuel cells and their associated combustion components, reducing operational costs while maintaining the necessary fastener-driving power through electromagnetic conversion and mechanical transmission.
3Power
If electric fastener-driving tools use large electric motors as a power source, then sufficient fastener-driving power is achieved, but tool weight increases
Solution Approach 1:
The patent segments the power transmission system into multiple stages: a compact electric motor generates rotational power, which is then transmitted through a reduction gear mechanism to amplify torque at lower speeds. This segmentation allows the use of a smaller, lighter motor while achieving the necessary fastener-driving power through mechanical advantage, thereby reducing overall tool weight.
Solution Approach 2:
The patent implements a dynamic power transmission system with a reduction gear mechanism that adjusts the rotational speed and torque characteristics during operation. The motor operates at higher speeds with the reduction gear converting this to high-torque low-speed output at the piston, allowing the use of a lighter motor while maintaining sufficient driving power throughout the fastener-driving cycle.
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 solution provides a lightweight, cost-effective, and easier-to-maintain fastener-driving tool that reduces operational costs and complexity by leveraging supercapacitor technology to drive fasteners without the need for traditional power sources, enhancing user experience and tool efficiency.
Implementation Method 1
The electrical current induces magnetic fields in the rails and the piston
Implementation Method 2
the combination of the electrical current and the magnetic fields induce a Lorentz force that acts on the piston to move the piston
Data Source
AI summary
The present disclosure provides various embodiments of a fastener-driving tool that includes a battery-charged supercapacitor as a power source. The fastener-driving tool includes first and second spaced-apart, conductive rails and a partially conductive piston slidably mounted on the rails. The rails and the piston are electrically connected to one another. The supercapacitor is electrically connected to the first rail. When the supercapacitor discharges electrical current, the electrical current flows from the supercapacitor, into the first rail, through the piston into the second rail, and from the second rail. The electrical current induces magnetic fields in the rails and the piston, and the combination of the electrical current and the magnetic fields induce a Lorentz force that acts on the piston to move the piston toward a nosepiece to drive a fastener.