Two-Stage Locking Electric Screwdriver with Internal Gear Clutch
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Solution Overview
Problem
Conventional electric screwdrivers face challenges in achieving accurate torque modulation, power efficiency, and minimizing parts for effective two-stage locking, leading to incomplete bolt installation and increased power consumption.
Innovation Solution
A two-stage locking electric screwdriver design featuring an internal gear clutch with staggered internal teeth and interlaced cams, a motor unit, clutch unit, screwdriver head unit, trigger unit, and a micro-controller unit, which allows for precise torque modulation and reduced part count, enhancing locking accuracy and power efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional electric screwdrivers use single-stage locking, then the device complexity is reduced, but the manufacturing precision and locking quality are insufficient
Solution Approach 1:
The locking process is divided into two distinct stages: a first locking stage and a second locking stage. The clutch unit is correspondingly segmented into first and second clutches that engage at different rotational positions, enabling precise torque control at each stage while maintaining manageable device complexity through modular design
Solution Approach 2:
The clutch unit dynamically transitions between first and second clutch engagement based on rotational position, with the cam mechanism automatically shifting from first clutch to second clutch after a predetermined rotation angle, enabling adaptive torque modulation without complex external control systems
2Ease of operation
If external torque modulation is used, then the ease of operation is improved, but the use of energy increases due to motor current being affected by clutch torque
Solution Approach 1:
The torque modulation is performed preliminarily by pre-setting the clutch engagement characteristics and cam profile geometry before operation. This allows the motor to operate at optimal current levels without real-time torque adjustment, reducing power consumption while maintaining ease of operation through pre-configured torque stages
Solution Approach 2:
The patent replaces electrical torque control with a mechanical cam-and-clutch system that automatically modulates torque based on rotational position. This mechanical substitution eliminates the need for electronic torque sensing and adjustment, reducing power consumption while maintaining operational simplicity
3Adaptability or versatility
If multiple separate units (gear unit, clutch unit, screwdriver head unit) are used, then the adaptability is improved, but the device complexity and part count increase
Solution Approach 1:
The gear unit and clutch unit are merged into a single integrated clutch unit that performs both gear reduction and clutch engagement functions. The screwdriver head unit is integrated with the clutch output shaft, reducing the number of separate components while maintaining the adaptability to handle various screwdriver bit configurations
4Use of energy by moving object
If internal torque modulation is used, then the use of energy is reduced, but the ease of operation deteriorates as torque adjustment requires special tools
Solution Approach 1:
The clutch unit is designed to be self-servicing through automatic engagement and disengagement based on rotational position. The cam mechanism automatically transitions between first and second clutch engagement without requiring external tools or manual intervention, achieving both low power consumption and ease of operation
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 design achieves precise torque modulation, reduces power consumption, and minimizes part count, resulting in improved locking quality and reduced manufacturing costs, ensuring complete and secure bolt installation.
Implementation Method 1
a torsion spring, going through the torque tube; and a torque sheath, covering the torque tube
Implementation Method 2
an internal gear clutch, in the form of a planetary gear... configured with a pair of interlaced (inner and outer ring) planetary orbits, and with design of cam surface on the planetary orbits formed by interlaced projecting portions
Implementation Method 3
an internal gear clutch, in the form of a planetary gear, with one side bound with a gear and a gear disc
Implementation Method 4
The cam surfaces of the lower clutch and the internal gear clutch contact each other
Data Source
AI summary
A two-stage locking electric screwdriver, with its main improved features as follow: the electric screwdriver has pre-locking and locking functions; the torque settings of the electric screwdriver can be easily modulated, and meanwhile the torque accuracy and energy efficiency can be improved; the torque modulation type is external modulation, so that the torque modulation can be carried out externally and even the torsion spring can be replaced. Meanwhile, the component structures inside the electric screwdriver is improved through a design that the motor directly drives the clutch and then drive the screwdriver head unit, and that an internal gear clutch is used to replaced the gear unit and clutch unit, so that the number of parts is dramatically reduced to save production cost. During general rotation, the electric screwdriver will not drive the clutch unit, and when the torque jumps to the set value, the internal gear clutch rotates and generates a torque.