Zero-Distance Fastener Tool With Gear Drive for Tight Wall Clearance
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Solution Overview
Problem
Conventional torque wrenches are limited in their ability to turn fasteners that are separated from an adjacent wall by a very small distance, such as less than 2 mm, due to the thickness of the sockets, which restricts their application in tight spaces like large diameter or underwater pipes where multiple fasteners are used, increasing the time required for attachment or removal.
Innovation Solution
A zero distance tool comprising a driver, an adapter, and a housing with a main gear and sector gear configuration that allows for rotational input to be applied to fasteners even in close proximity to walls, enabling rotation of fasteners by a predetermined angle in each cycle and repositioning without removing the tool, thereby accommodating smaller spacings than conventional sockets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a conventional hexagonal socket is used to turn a fastener, then the fastener can be engaged and rotated, but the socket cannot be placed over fasteners separated from walls by less than 2 mm due to socket wall thickness
Solution Approach 1:
The socket is divided into multiple thin-walled segments or lobes that can flex independently. This segmentation allows the overall socket structure to bend and conform to tight spaces while maintaining engagement with the fastener, enabling operation in spaces where conventional rigid sockets cannot fit.
Solution Approach 2:
The socket transitions from a rigid, fixed-geometry structure to a dynamic, flexible structure that can change its shape during operation. The flexible walls allow the socket to adapt its geometry to accommodate varying distances between fasteners and walls, enabling engagement in previously inaccessible tight spaces.
2Ease of operation
If a conventional hexagonal socket is used, then fasteners can be turned, but the rotation angle per cycle is limited to about 30° due to proximity of adjacent fasteners or walls
Solution Approach 1:
The flexible socket enables larger rotation angles (up to 60° per cycle) by allowing the fastener to rotate through a greater arc without collision with adjacent fasteners or walls. The flexibility compensates for the limited space, maintaining engagement while permitting extended rotation that reduces the number of cycles needed.
Solution Approach 2:
The socket's physical parameters (wall thickness, flexibility, geometry) are changed to enable larger rotation angles. By modifying the structural parameters of the socket to be more flexible and adaptive, the system achieves greater rotational movement per cycle, directly reducing the time required for fastener operations.
3Ease of operation
If conventional sockets are used in applications with multiple fasteners close to each other, then fasteners can be engaged, but the thick socket walls prevent insertion between adjacent fasteners
Solution Approach 1:
The socket structure is segmented into multiple thin-walled sections that can flex and compress independently. This segmentation reduces the effective thickness of the socket walls, allowing the tool to be inserted between closely spaced fasteners while maintaining sufficient structural integrity for engagement.
Solution Approach 2:
The socket employs flexible wall construction with thin film-like structures that can compress and deform to fit into tight spaces between adjacent fasteners. These flexible shells maintain their engagement function while reducing the overall thickness barrier that prevents insertion in crowded configurations.
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 zero distance tool enables efficient turning of fasteners in tight spaces by allowing up to 60° rotation in each cycle, significantly reducing the time needed for attachment or removal compared to conventional wrenches, which typically limit rotation to about 30° per cycle.
Implementation Method 1
The zero distance tool may include a main gear configured to receive a torsional input from the wrench. The sector gear may be configured to engage with a fastener.
Data Source
AI summary
A zero distance tool for turning a fastener is disclosed. The tool may have a driver configured to receive a torsional input. The tool may also have an adapter rotatably coupled to the driver. The adapter may be configured to engage with a fastener. The tool may have a housing configured to enclose the driver and the adapter.