Torque Amplifying Screw Connector Tool with Radial Counter-Holding
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Solution Overview
Problem
Existing tools for tightening screw connectors on electric cables are inconvenient, require significant operator effort, and can lead to accidents due to lack of radial counter-holding, limited adaptability, and potential deformation of cables, especially when used in tight spaces.
Innovation Solution
A tool with a reduction gear and extendable hand crank that amplifies torque, featuring a socket wrench with rungs that lie laterally on the connector or cable to counteract torque, allowing for safe and efficient tightening without deforming cables, and compatible with various cable diameters through interchangeable rungs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If impact wrenches are used to tighten screws on screw connectors, then high torque is achieved, but the predetermined torque value is falsified due to impact effect
Solution Approach 1:
The patent replaces impact wrenches with a cordless screwdriver that uses a reduction gear mechanism (planetary gear system) to mechanically amplify torque. This substitution eliminates the impact effect while achieving the required high torque through gear multiplication, ensuring accurate and controlled tightening without falsifying torque values.
Solution Approach 2:
The patent changes the torque delivery mechanism from impulsive (impact wrench) to continuous and controlled (reduction gear system). The planetary gear system provides a gradual increase in torque with a maximum overrun slip, allowing precise torque control and preventing overs tightening while maintaining high torque output.
2Force
If torque multipliers are used to tighten large bolts, then high torque is achieved, but they are not suitable for screw connectors due to lack of radial counter-holding means
Solution Approach 1:
The patent merges the torque multiplication function with the counter-holding function into a single integrated tool. The reduction gear mechanism provides both torque amplification and radial counter-holding through its structural design, eliminating the need for separate torque multipliers and making the tool directly applicable to screw connectors on cylindrical cables.
Solution Approach 2:
The patent creates a multi-functional tool that combines cordless screwdriver capabilities, torque multiplication through planetary gears, and radial counter-holding features. This universal tool can be applied to various cable diameters and screw connector types without requiring separate specialized equipment.
3Ease of manufacture
If conventional tightening devices are used, then screws can be tightened, but considerable operator effort is required and working position is uncomfortable
Solution Approach 1:
The patent replaces manual tightening devices with a cordless screwdriver powered by an electric motor. The motor-driven system with planetary gear reduction eliminates the need for operator leverage and manual effort, allowing comfortable operation in various positions without requiring the operator to exert considerable physical force.
Solution Approach 2:
The patent changes the power source from manual mechanical input to electric motor power. This parameter change transforms the operation from labor-intensive to automated, reducing operator effort to simple trigger activation while maintaining the ability to achieve required tightening torques.
4Ease of manufacture
If conventional tightening devices are used, then screws can be tightened, but accidents occur due to sudden release of resistance when unscrewing
Solution Approach 1:
The patent replaces manual tightening devices with a cordless screwdriver that provides controlled torque application and release. The electric motor with electronic control and mechanical overload protection prevents sudden releases of resistance, eliminating the safety hazard of hands being violently moved when screw resistance suddenly ceases.
Solution Approach 2:
The patent incorporates mechanical overload protection and controlled torque delivery through the planetary gear system that provides maximum overrun slip. This beforehand cushioning prevents sudden torque releases by allowing controlled slippage before complete disengagement, protecting the operator from injury.
5Stability of the object's composition
If counter-holding devices are used, then cables can be held steady, but they are limited to a specific range of outer diameters or require adapters
Solution Approach 1:
The patent integrates multiple counter-holding mechanisms into a single tool design that can accommodate various cable diameters. The combination of radial counter-holding from the reduction gear structure and the ability to adjust the tool's grip allows it to securely hold cables of different sizes without requiring separate adapters for each diameter range.
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 convenient, safe, and efficient tightening of screw connectors with high torque, preventing cable deformation and accommodating different cable sizes, facilitating single-person operation in tight spaces without accidents.
Implementation Method 1
a reduction gear, e.g. a planetary gear 2, which is driven 3r by a hand crank 3, 3b to a interchangeable socket wrench 4
Implementation Method 2
a reduction gear, e.g. a planetary gear 2
Implementation Method 3
the rungs or the rungs lie laterally on the connector and/or on the cable to be connected, with twisting of the handle being prevented and the torque on the screw is transferred
Data Source
Figure 1~2
AI summary
The tool for mounting a screw connector (6) on electrode cable (5, 5a), comprises a handle (1), which has two rungs (1b) on the side of the rungs turned to the screw connector, and a reduction gear. The rungs are arranged parallel to the axis of the handle, are distanced to each other as large external diameter of the screw connector and/or the cable to be connected and have a longitudinal stretching, which is equal or smaller than the large external diameter of the screw connector. The reduction gear is secured against bending, is arranged in the interior of the handle. The tool for mounting a screw connector (6) on electrode cable (5, 5a), comprises a handle (1), which has two rungs (1b) on the side of the rungs turned to the screw connector, and a reduction gear. The rungs are arranged parallel to the axis of the handle, are distanced to each other as large external diameter of the screw connector and/or the cable to be connected and have a longitudinal stretching, which is equal or smaller than the large external diameter of the screw connector. The reduction gear is secured against bending, is arranged in the interior of the handle and is actuated on the side of the input shaft by crank handle (3, 3b) in order to influence on the side of the output shaft over interchangeable stuck key or insert on the head of the screw connector with a torque, which is larger than the torque influencing on the hand crank. The reduction gear is a planetary gear in which the input shaft is arranged coaxial to the output shaft and in insert position. The drive is arranged together with the shafts coaxial in the interior of the handle. The rungs are mounted by a collar with the handle and are arranged in a position. The rungs are screwed or connected in different positions in order to adjust the intermediate distance of the external diameter of the screw connector and/or the cable to be connected. The rungs have a cylindrical elongated strand form or a flat or bent form. The handle together with the collar and the rungs is produced from electrical-insulating plastic or metal with complete plastic covering. The lever of the crank handle is renewable and a cordless screwdriver, a lever or a key equipped with a ratcheting mechanism is mounted on the input shaft of the reduction gear on the location of the crank handle.