U.S. patent number 3,874,460 [Application Number 05/410,859] was granted by the patent office on 1975-04-01 for impact wrench.
This patent grant is currently assigned to Robert Bosch G.m.b.H.. Invention is credited to Manfred Bleicher, Gernot Hansel, Wolfgang Schmid, Karl Wanner.
United States Patent |
3,874,460 |
Schmid , et al. |
April 1, 1975 |
Impact wrench
Abstract
An electric impact wrench wherein the output shaft of the
electric motor which is installed in a synthetic plastic housing
can rotate the tool holder through the medium of a two-speed
transmission and the output shaft can cause a plunger to repeatedly
strike against the tool holder in response to rotation of a
crankshaft which can receive torque from the output shaft. The
two-speed transmission has several spur gears and the output shaft
can drive the crankshaft by way of two bevel gears. The axes of all
of the gears are located in a common plane which coincides with the
central longitudinal symmetry plane of the housing.
Inventors: |
Schmid; Wolfgang (Plattenhardt,
DT), Bleicher; Manfred (Leinfelden, DT),
Hansel; Gernot (Stuttgart-Plieningen, DT), Wanner;
Karl (Echterdingen, DT) |
Assignee: |
Robert Bosch G.m.b.H.
(Stuttgart, DT)
|
Family
ID: |
5860293 |
Appl.
No.: |
05/410,859 |
Filed: |
October 29, 1973 |
Foreign Application Priority Data
|
|
|
|
|
Oct 28, 1972 [DT] |
|
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2252951 |
|
Current U.S.
Class: |
173/109; 173/48;
173/117; 173/201 |
Current CPC
Class: |
B25D
16/006 (20130101) |
Current International
Class: |
B25D
16/00 (20060101); B25d 011/00 () |
Field of
Search: |
;173/109 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Leppink; James A.
Attorney, Agent or Firm: Striker; Michael S.
Claims
What is claimed as new and desired to be protected by Letters
Patent is set forth in the appended claims:
1. In a portable power tool, particularly in an impact wrench, a
combination comprising a housing; a tool holder rotatably and
axially movably installed in said housing; a prime mover mounted in
said housing and having a rotary output member; means for rotating
said tool holder, including a multi-speed transmission actuatable
to transmit torque from said output member to said tool holder,
said multi-speed transmission including an intermediate shaft
parallel to said output member, a driven shaft parallel to said
intermediate shaft and coaxial with said tool holder, a safety
clutch normally coupling said tool holder with said driven shaft, a
first gear rigid with said output member, a second gear rigid with
said intermediate shaft and meshing with said first gear, third and
fourth gears rigid with said intermediate shaft, and fifth and
sixth gears coaxial with and movable axially of said driven shaft
to and from operative positions in which said fifth and sixth gears
respectively mesh with said first and fourth gears and thereby
transmit torque to said driven shaft, said fifth gear being movable
to said operative position thereof when said sixth gear is out of
its operative position and vice versa; and means for moving said
tool holder lengthwise, including a second transmission actuatable
to transmit to said tool holder axial impulses in response to
rotation of said output member.
2. A combination as defined in claim 1, wherein said second, third
and fourth gears are integral with said intermediate shaft and said
second transmission also comprises a plurality of gears including a
first bevel gear integral with said intermediate shaft and a second
bevel gear meshing with said first bevel gear.
3. A combination as defined in claim 1, wherein said first to sixth
gears are spur gears and the diameter of said second gear exceeds
the diameters of said first, third, fourth, fifth and sixth
gears.
4. A combination as defined in claim 1, wherein said intermediate
shaft is provided with an axial bore at one end thereof and further
comprising an antifriction bearing received in said bore and a
support mounted in said housing and having an extension coaxial
with said intermediate shaft and supporting said bearing, said
second transmission including a further shaft normally receiving
torque from said intermediate shaft and rotatably mounted in said
support.
5. A combination as defined in claim 4, wherein said gears further
include a first bevel bear coaxial with and driven by said
intermediate shaft and a second bevel gear coaxial with said
further shaft and meshing with said first bevel gear, said further
shaft having an eccentric crankpin and said second transmission
further comprising a clutch interposed between said second bevel
gear and said further shaft.
6. A combination as defined in claim 4, wherein said housing
consists at least in part of a synthetic plastic material and said
support consists of a metallic material, such as cast aluminum.
7. A combination as defined in claim 1, wherein said second
transmission comprises a pneumatic impeller assembly having a
cylinder reciprocable with respect to and being coaxial with said
tool holder and a plunger reciprocable in said cylinder and
arranged to repeatedly strike against said tool holder in response
to reciprocation of said cylinder.
8. A combination as defined in claim 7, wherein said second
transmission further comprises a crankshaft rotatably mounted in
said housing and means for reciprocating said cylinder in response
to rotation of said crankshaft, said gears including a first gear
receiving torque from said output member and a second gear mating
with said first gear and arranged to normally rotate said
crankshaft in response to rotation of said first gear.
9. In a portable power tool, particularly an impact wrench, a
combination comprising a housing; a tool holder rotatably and
axially movably installed in said housing; a prime mover mounted in
said housing and having a rotary output member; means for rotating
said tool holder, including a multi-speed transmission actuatable
to transmit torque from said output member to said tool holder and
comprising an intermediate shaft parallel to said output member, a
driven shaft parallel with said intermediate shaft and coaxial with
said tool holder, said tool holder having a shank axially movably
installed in said driven shaft, a gear train arranged to transmit
motion from said output member to said intermediate shaft and from
said intermediate shaft to said driven shaft, and a safety clutch
interposed between said shank and said driven shaft, said safety
clutch comprising a sleeve interposed between said driven shaft and
said shank and having internal teeth mating with external teeth
provided on said shank so that the shank is movable axially of said
sleeve while its external teeth remain in mesh with said internal
teeth, said safety clutch further comprising means for normally
transmitting torque from said driven shaft to said sleeve; and
means for moving said tool holder lengthwise, including a second
transmission actuatable to transmit to said tool holder axial
impulses in response to rotation of said output member.
10. A combination as defined in claim 8, wherein the length of said
external teeth, as considered in the axial direction of said shank,
is between 30 and 60 percent of the length of said internal
teeth.
11. A combination as defined in claim 8, wherein said shank
includes a first portion which is provided with said external teeth
and a cylindrical second portion having a diameter equal to or
closely approximating the root diameters of said internal
teeth.
12. A combination as defined in claim 11, wherein said second
portion of said shank has a polished peripheral surface.
13. A combination as defined in claim 8, wherein said internal
teeth and said external teeth are involute teeth.
14. A combination as defined in claim 8, wherein said internal
teeth have top lands provided with chamfers.
15. In a portable power tool, particularly in an impact wrench, a
combination comprising a housing; a tool holder rotatably and
axially movably installed in said housing; a prime mover mounted in
said housing and having a rotary output member; means for rotating
said tool holder, including a multi-speed transmission comprising
an intermediate shaft driven by said output member, a driven shaft
co-axial with said tool holder and rotatable by said intermediate
shaft at a plurality of speeds, and a safety clutch between said
tool holder and said driven shaft, said safety clutch comprising a
sleeve axially movably receiving a portion of said tool holder and
rotatably mounted in said driven shaft, at least one
torque-transmitting element having a first portion received in a
radial opening of said driven shaft and a second portion normally
extending into an external axially parallel groove of said sleeve,
and means for yieldably holding said torque-transmitting element
against radial movement away from the axis of said driven shaft to
thereby maintain said second portion of said element in said
groove; and means for moving said tool holder lengthwise, including
a second transmission actuatable to transmit to said tool holder
axial impulses in response to rotation of said output member.
16. A combination as defined in claim 15, wherein said
torque-transmitting element is a sphere.
17. A combination as defined in claim 15, wherein said
torque-transmitting element is a roller.
18. A combination as defined in claim 15, wherein said
torque-transmitting element further comprises a third portion which
normally extends radially outwardly beyond said opening and said
means for yieldably holding comprises at least one ring surrounding
said driven shaft and means for biasing said ring against said
third portion of said element.
19. A combination as defined in claim 18, wherein said means for
yieldably holding comprises two rings flanking said third portion
of said torque-transmitting element and having conical surface
portions abutting against said third portion.
20. A combination as defined in claim 19, wherein said means for
biasing comprises a single spring arranged to react against one of
said rings and to bear against the other ring to thereby urge both
said rings against said third portion of said torque-transmitting
element.
21. A combination as defined in claim 20, wherein one of said rings
has a tubular extension axially movably surrounding the other of
said rings, said single spring reacting against said extension and
bearing against said other ring.
22. A combination as defined in claim 19, wherein the mass of one
of said rings equals or closely approximates the mass of the other
of said rings.
Description
BACKGROUND OF THE INVENTION
The present invention relates to portable power tools in general,
and more particularly to improvements in portable power tools of
the type known as impact wrenches wherein a tool holder is
rotatable in and is also movable axially with respect to the
housing in response to repeated impulses against its shank. Such
power tools can be used for chipping of rock, concrete or the like,
for drilling or holes in wood, rock or other material, for the
application or removal of screws, bolts, nuts or the like, and/or
for other purposes wherein the working end of the tool is to rotate
with or relative to and/or penetrate into a workpiece. The prime
mover of the power tool is preferably an electric motor which can
rotate the tool holder at one or more speeds, preferably at several
speeds.
It is already known to construct an electric impact wrench in such
a way that the tool holder can be rotated at several speeds and
that the tool holder can receive axial impulses which drive its
working end into a workpiece while the tool holder rotates or while
the torque transmitting connection between the motor and the tool
holder is interrupted. A drawback of presently known impact
wrenches of the just outlined character is that their parts occupy
a substantial amount of space so that the power tool must be
provided with a relatively large, bulky and heavy housing. This is
undesirable because the manipulation of such power tools is
tiresome and the likelihood of injury or accident is more
pronounced than if the impact wrench comprises a relatively small,
lightweight and handy housing. Another drawback of presently known
impact wrenches is that they comprise an excessive number of
discrete parts, such as differently configurated and/or dimensioned
gears, especially if the tool holder is to be rotated at several
speeds.
SUMMARY OF THE INVENTION
An object of the invention is to provide a portable power tool,
especially an electric impact wrench, which is smaller, lighter and
handier than but just as versatile as presently known power
tools.
A further object of the invention is to provide an impact wrench
wherein the tool holder can be rotated and/or propelled axially in
a novel and improved way.
An additional object of the invention is to provide the impact
wrench with novel and improved transmissions which serve to rotate
and to propel the tool holder into a workpiece.
Still another object of the invention is to provide a novel and
improved multi-speed transmission for use in the above outlined
impact wrench.
A further object of the invention is to provide a novel arrangement
of gears in an electrically powered impact wrench.
The invention is embodied in a portable power tool, particularly in
an impact wrench, which comprises a housing preferably consisting
of synthetic plastic material, a tool holder which is rotatably and
axially movably installed in the housing, a prime mover (preferably
an electric motor) which is mounted in the housing and has a rotary
output member, means for rotating the tool holder, and means for
transmitting axial impulses to the tool holder. The means for
rotating the tool holder preferably comprises a multi-speed
transmission which is actuatable to transmit torque from the output
member to the tool holder, and the means for transmitting axial
impulses comprises a second transmission which is actuatable to
transmit to the tool holder axial impulses in response to rotation
of the output member. At least one of the two transmissions
comprises a plurality of gears (for example, the multi-speed
transmission may comprise several spur gears and the second
transmission may comprise several bevel gears) and, in accordance
with a feature of the invention, the axes of all of the gears are
located in a single plane. Such plane preferably coincides with the
central longitudinal symmetry plane of the housing.
In accordance with a presently preferred embodiment of the
invention, the multi-speed transmission has an intermediate shaft
which is parallel to the tool holder and to the output member and
is integral with several gears, for example, with three gears which
serve to transmit torque from the output member to the tool holder,
and with a gear which serves to transmit torque to a crankshaft of
the second transmission.
The novel features which are considered as characteristic of the
invention are set forth in particular in the appended claims. The
improved impact wrench itself, however, both as to its construction
and its mode of operation, together with additional features and
advantages thereof, will be best understood upon perusal of the
following detailed description of certain specific embodiments with
reference to the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a fragmentary longitudinal vertical sectional view of an
electric impact wrench which embodies one form of the
invention;
FIG. 2 is a sectional view as seen in the direction of arrows from
the line II--II of FIG. 1;
FIG. 3 is an enlarged fragmentary sectional view as seen in the
direction of arrows from the line III--III of FIG. 1;
FIG. 4 is a fragmentary longitudinal vertical sectional view of a
second impact wrench; and
FIG. 5 is a similar fragmentary longitudinal vertical sectional
view of a third impact wrench.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring first to FIG. 1, there is shown an electric impact wrench
which comprises a combined motor and gear housing including a front
section 1, a median section 2 and a rear section 3. The rear
section 3 is made integral with or is separably connected with a
spade handle 3a. The sections 1-3 preferably consist of a suitable
synthetic plastic material. The prime mover of the impact wrench is
an electric motor 4 which is mounted in the central region of the
lower part of the median housing section 2. The motor 4 has a rotor
5 which drives an output shaft 6; the latter extends beyond both
ends of the motor casing and its left-hand end portions carries a
customary flywheel 8. The leftmost part of the shaft 6 rotates in
an antifriction roller bearing 7 which is installed in the front
section 1 of the housing. The right-hand portion of the output
shaft 6 rotates in an antifriction ball bearing 9 which is
installed in a partition 2a of the median housing section 2. The
rightmost part of the output shaft 6 constitutes a small spur gear
or pinion 10 which meshes with a larger spur gear 12 on an
intermediate shaft 11 mounted in the housing in parallelism with
and at a level above the output shaft 6. The spur gear 12
constitutes an integral part of the intermediate shaft 11 the front
end portion of which is mounted in an antifriction roller bearing
13 installed in the partition 2a. The rear end portion of the
intermediate shaft 11 rotates on an antifriction ball bearing 14.
The latter is installed in an axial bore 15 of the intermediate
shaft 11 and its inner race surrounds a centering member 18 and is
secured thereto by a screw 19 or an analogous fastener. The
centering member 18 has a smaller-diameter front end portion or
extension 16 which extends into the inner race of the bearing 14.
The rear portion of the centering member 18 is mounted on a fixed
bracket or support 17 which is installed in the housing section 3
in front of the handle 3a.
In addition to the aforementioned spur gear 12, the intermediate
shaft is formed with spur gears 20, 21 and a bevel gear 22. The
diameter of the spur gear 12 exceeds the diameters of the gears 20,
21 and 22, and this spur gear is located behind the gears 20, 21
but in front of the bevel gear 22. The gear 20 is smaller than the
gear 21 and these gears respectively mesh with spur gears 24, 25
which are freely rotatable on but can be coupled to a hollow driven
shaft 23 which is parallel to the shafts 6, 11 and is mounted in
the housing at a level above the intermediate shaft 11. The gear 24
is rotatable relative to the gear 25, and vice versa. The
arrangement is such that the gear 24 drives the shaft 23 when it is
caused to move in a direction to the right, as viewed in FIG. 1,
and that the gear 25 drives the shaft 23 when it is caused to move
in a direction to the left, as viewed in FIG. 1. The shifter means
for moving the gears 24, 25 axially of the driven shaft 23
comprises a manually operable actuating member in the form of a
rotary knob 30 shown in FIG. 2. This knob is adjacent to one side
of the median housing section 2 so that it can be grasped by one
hand while the other hand grips the handle 3a. The axial lengths of
the gears 20, 24 and 21, 25 are selected in such a way that the
gears 24, 25 respectively remain in mesh with the gears 20, 21 even
if they are shifted from the neutral positions shown in FIG. 1. The
gear 24 can drive the shaft 23 when the latter can rotate with
respect to the gear 25, and vice versa.
The shaft 23 is provided with a set of four equidistant external
torque receiving teeth or claws 26 (see also FIG. 2) which are
disposed in the internal recesses or grooves 27 of the gears 24, 25
when these gears assume the neutral positions of FIG. 1. The gear
24 has internal torque-transmitting teeth or claws 28a separated
from each other by axially parallel grooves 28 which receive the
claws 26 when the knob 30 is rotated in a direction to move the
gear 24 to the right, as viewed in FIG. 1. The intermediate shaft
11 then rotates the shaft 23 through the medium of gears 20, 24 at
the lower of two speeds. The gear 25 has internal axially parallel
teeth or claws 29a separated from each other by axially parallel
grooves 29 which receive the claws 26 when the knob 30 is rotated
to move the gears 24, 25 in a direction to the left, as viewed in
FIG. 1, whereby the shaft 23 is driven at the higher of two
speeds.
The shaft 23 can rotate in a front antifriction (ball) bearing 31
and a rear antifriction (roller) bearing 32, both installed in the
median housing section 2. The bearing 32 is located in front of and
is spaced apart from the spur gears 24, 25. The outer race of the
front bearing 31 for the shaft 23 is received in a metallic sleeve
33 which is embedded into the plastic material of the median
housing section 2. A similar metallic sleeve 34, which is also
embedded in the plastic material of the housing section 2, receives
the outer race of the rear bearing 32 for the shaft 23. That
portion of the shaft 23 which is located behind the front bearing
31 is formed with one or more radial openings or bores 35 for the
median portions of spherical torque transmitting elements 36 each
of which has an inner portion normally extending into an axially
parallel external groove 40 machined into the external surface of a
sleeve 41 for the shank 42 of a tool holder 43. A third or outer
portion of each element 36 invariably extends outwardly beyond the
periphery of the driven shaft 23 and abuts against the front end
face of a ring 37 which is movable axially of the shaft 23 and is
biased against the elements 35 by a strong helical spring 38. The
rearmost convolution of the spring 38 reacts against a ring-shaped
retainer 39 which abuts against an external shoulder of the shaft
23 in front of the bearing 32. The innermost portion 37a of the
front end face of the ring 37 is of conical shape and diverges
forwardly, i.e., away from the rear bearing 32. This conical
portion 37a abuts against the spherical elements 36. The parts
35-41 constitute a simple but reliable safety clutch which is
normally engaged (as long as the inner portions of the elements 36
extend into the grooves 40 and of the sleeve 41) so that the shaft
23 can rotate the tool holder 43. The safety clutch is disengaged
when the tool holder 43 causes the sleeve 41 to offer a
predetermined resistance to rotation with the shaft 23; the inner
portions of the spherical elements 36 are then expelled from the
respective grooves 40 and travel outwardly along the conical
portion 37a of the front end face of the ring 37 (against the
opposition of the spring 38) so that the shaft 23 can rotate with
respect to the sleeve 41 and tool holder 43.
The sleeve 41 is installed in the front portion of and extends
forwardly beyond the driven shaft 23. The axial bore of the sleeve
41 receives the shank 42 of the tool holder 43. The shank 42
constitutes an anvil which can receive impacts from an impeller
assembly including a pneumatic cylinder 65 and a plunger 66 which
is reciprocable in the cylinder 65. An intermediate portion 45a of
the shank 42 of the tool holder 43 is provided with external
involute teeth 45 which mate with complementary internal teeth 44
of the sleeve 41. The length of the teeth 45, as considered in the
axial direction of the tool holder 43, is preferably between 30 and
60 percent of the length of internal teeth 44.
The maximum diameter of the shank portion 45a exceeds the diameters
of the remaining cylindrical portion of the shank 42, and such
cylindrical portion of the shank 42 is a tight sliding fit in the
sleeve 41. The diameter of the cylindrical portion of the shank 42
in front of and behind the portion 45a equals or approximates the
root diameters of teeth 45. The shank 42 preferably consists of a
high-quality metal and its external surface is preferably finished
to a high degree of polish to insure that it can move axially and
rotate in the sleeve 41 with a minimum of play. The top lands of
internal teeth 44 in the sleeve 41 are preferably chamfered, as at
46 (see FIG. 3). The sleeve 41 is preferably produced by extrusion
molding. Its teeth 44 are polished and cooperate with the teeth 45
to enable the shank 42 (and hence the entire tool holder 43) to
move axially in response to impacts which are being transmitted by
the plunger 66 while the tool holder rotates with the sleeve 41
(provided that the safety clutch including the parts 35-41 is
engaged). The shank 42 cannot rotate relative to the sleeve 41, or
vice versa.
The front section 1 of the housing contains two annular sealing
elements 47, 48 which prevent entry of dust or other foreign matter
into the driven shaft 23 and/or into the space between the races of
the front bearing 31.
The bevel gear 22 of the intermediate shaft 11 meshes with a bevel
gear 50. The latter is rotatable about the axis of a hollow
crankshaft 49 forming part of a second safety clutch which is
installed in the motion transmitting connection between the bevel
gear 22 of the intermediate shaft 11 and the cylinder 65 of the
impeller assembly for the shank 42 of the tool holder 43. The
crankshaft 49 is normal to the intermediate shaft 11. A plane which
is common to the axes of the shafts 6, 11 and 23 also includes the
axis of the crankshaft 49, i.e., the axes of gears 10, 12, 20-22,
24-25 and 50 are located in a common plane which is preferably the
central longitudinal vertical symmetry plane of the housing 1-3.
The hollow crankshaft 49 is mounted in two antifriction roller
bearings 51, 52 which are installed in the aforementioned bracket
or support 17. The latter is an aluminum casting, i.e., the
rigidity of its material greatly exceeds the rigidity of the
plastic material of housing sections 1, 2 and 3. As shown in FIG.
2, the support 17 is provided with four bores 53 for reception of
screws or analogous fasteners (not shown) by means of which the
support is mounted in the rear housing section 3.
The lower portion of the crankshaft 49 is provided with one or more
radially extending openings or bores 54 for spherical torque
transmitting elements 55 which extend outwardly beyond the
peripheral surface of the crankshaft and into axially parallel
internal flutes or grooves 56 of the bevel gear 50. The innermost
portions of the spherical torque transmitting elements 55 normally
abut against the adjacent intermediate portion of an axially
movable plug 58 which is installed in the crankshaft 49 and serves
to normally hold the outer portions of the elements 55 in the
adjacent internal grooves 56. When the plug 58 is moved upwardly,
as viewed in FIG. 1, against the opposition of a helical spring 57
which reacts against an internal surface 49a of the crankshaft 49,
the neck portion 58a of the plug 58 allows the elements 55 to move
radially inwardly so that the bevel gear 50 is free to rotate with
respect to the crankshaft. This interrupts the transmission of
motion from the intermediate shaft 11 to the cylinder 65.
The spring 57 in the axial bore of the crankshaft 49 biases the
lower end portion or follower 58b of the plug 58 against an
eccentric pin 60 which is mounted on a rotary actuating member 59.
The latter is accessible from without the housing of the impact
wrench so that it can be rotated by hand between a first position
which is shown in FIG. 1 and a second position (e.g., in response
to rotation through an angle of substantially 180.degree.. In the
illustrated first position of the actuating member 59, the
eccentric pin 60 allow the spring 57 to expand and to maintain a
conical portion 58c of the plug 58 in engagement with the spherical
elements 55 so that the elements 55 couple the bevel gear 50 with
the crankshaft 49. When the actuating member 59 is rotated through
180 degrees to its second position, the pin 60 lifts the follower
58b of the plug 58 so that a conical surface 61 of the follower 58b
bears against the spherical elements 55 and positively prevents the
outer portions of such spherical elements from leaving the
respective flutes 56 of the bevel gear 50. The safety clutch
between the crankshaft 49 and bevel gear 50 is then inoperative
because the crankshaft 49 is rotated whenever the motor 4 rotates
the intermediate shaft 11.
The actuating member 59 is further movable to one or two third
positions (clockwise or counterclockwise through 90.degree. with
respect to the first position shown in FIG. 1) whereby the
spherical elements 55 are adjacent to the neck portion 58a of the
plug 58 and are free to leave the flutes 56 so that the bevel gear
50 can rotate relative to the crankshaft 49. When the plug 58
dwells in the position of FIG. 1 and the crankshaft 49 offers a
predetermined resistance to rotation with the bevel gear 50, the
plug 58 moves upwardly and allows the elements 55 to leave the
flutes 56 so that the bevel gear 50 can rotate relative to the
crankshaft.
The upper end portion of the crankshaft 49 is rigid with a
disk-shaped crank arm 62 having an eccentric crank pin 63 which is
coupled to the rear end of a connecting rod 64. The front end of
the connecting rod 64 is coupled to a pin 63a in the rear end wall
of the cylinder 65. Thus, when the crankshaft 49 is rotated by the
intermediate shaft 11 through the medium of bevel gears 22, 50 and
spherical elements 55, the connecting rod 64 moves the cylinder 65
forwardly and rearwardly whereby the plunger 66 strikes against the
rear end face of the shank 42 whenever the cylinder 65 performs a
forward stroke. The space between the plunger 66 and the rear end
wall of the cylinder 65 contains a cushion of gas (e.g., air) which
is compressed when the cylinder 65 moves forwardly relative to the
plunger 66 (which is slidable in the cylinder) whereby the
compressed cushion causes the plunger to strike against the shank
42 so as to propel a tool (not shown) which is connected to the
holder 43 into a workpiece, e.g., a concrete wall, rock, wooden
panel or the like. The cylinder 65 is slidably guided by the
internal surface of the gear portion of the driven shaft 23.
When the spur gears 24, 25 assume the axial positions of FIG. 1,
the multi-speed transmission between the output shaft 6 and the
driven shaft 23 is ineffective. Thus, when the motor 4 is started
(for example, in response to depression of a customary trigger, not
shown, in the handle 3a), the output shaft 6 drives the
intermediate shaft 11 and the latter drives the crankshaft 49 so
that the cylinder 65 of the impeller assembly moves back and forth
and causes the plunger 66 to repeatedly strike against the shank 42
so that the tool holder 43 drives the tool into a workpiece, e.g.,
a concrete wall or the like. For example, the tool can be used for
chipping or to make a hole in a concrete wall.
If the user decides to rotate the knob 30 in a direction to engage
the claws 26 of the driven shaft 23 with the claws 28a or 29a of
the spur gear 24 or 25, the motor 4 can rotate the shaft 23 through
the medium of the gear 24 or 25 so that the shaft 23 rotates the
sleeve 41 by way of spherical elements 36. If the nature of the
workpiece into which the tool is caused to penetrate is such that
the sleeve 41 offers a predetermined resistance to rotation with
the shaft 23, the spherical elements 36 are expelled radially
outwardly by the ribs which separate the grooves 40 of the sleeve
41 from each other. The elements 36 shift the ring 37 against the
opposition of the spring 38 and allow the shaft 23 to rotate with
respect to the sleeve 41 and tool holder 43. The spring 38 expands
immediately and causes the spherical elements 36 to reenter the
adjacent grooves 40 as soon as the tool is disengaged from the
workpiece or as soon as the resistance which the sleeve 41 offers
to rotation with the shaft 23 decreases sufficiently to allow the
spring 38 to move the ring 37 forwardly.
If the operator wishes to use the wrench exclusively for drilling,
i.e., to disengage the bevel gear 50 from the crankshaft 49 while
the motor 4 is on and the intermediate shaft 11 drives the shaft 23
by way of the spur gear 24 or 25, the handle 3a is employed to push
the housing including the sections 1-3 forwardly while the tip of
the tool bears against the workpiece. This causes the inclined rear
edge faces 45b of teeth 45 to bear against the sleeve 41
(immediately behind the teeth 44) so that the operator supplies a
force which urges the rotating tool into the workpiece. The edge
faces 45b then abut against the inclined surfaces at the rear ends
of the spaces between the teeth 44 of the sleeve 41. Such
engagement of the edge faces 45b with the just mentioned inclined
surfaces prevents the tool holder 43 from moving axially of the
shaft 23 as long as the force which tends to move the tool holder
toward the gears 24, 25 does not exceed the force with which the
operator pushes the housing 1-3 of the impact wrench toward the
workpiece. The sleeve 41 is held against axial movement with
respect to the drive shaft 23 by a distancing ring 41A which
engages the inner race of the antifriction bearing 31 and a nut 23A
at the front end of the shaft 23.
The chamfers 46 on the teeth 44 of the sleeve 41 insure that burrs,
ridges or fins which can develop on the teeth 44, especially if the
impact wrench is used to remove material from or to penetrate into
very hard workpieces (such as concrete or rock), do not reach and
damage the precision-finished external surface of the cylindrical
portion of the shank 42 in front of and/or behind the teeth 45.
Such surface cooperates with the internal surface of the sleeve 41
to properly guide the tool holder 43 during rotation and/or axial
movement with respect to the housing.
As mentioned above, the axes of the shafts 6, 11, 23 and 49 are
located in a common plane which is preferably the central
longitudinal vertical symmetry plane of the power tool.
Consequently, the axes of all gears (10, 12, 20, 21, 22, 24, 25,
50) are also located in a common plane. This contributes to
compactness of the tool, especially as considered in a direction at
right angles to such plane. Additional savings in space are
achieved because the gears 12, 20, 21 and 22 constitute integral
parts of the intermediate shaft 11. The mating teeth 44 and 45 of
the sleeve 41 and shank 42 reduce the play of the tool holder 43 in
the sleeve 41 and shaft 23 to a minimum. The extent to which the
shank 43 is movable axially of the sleeve 41 is shown as being
equal or nearly equal to the extent to which the plunger 66 is
movable axially in the cylinder 65. This is desirable because it
enables the tool holder 43 to receive and to reliably transmit to
the tool substantial boring or drilling moments.
FIG. 4 shows a portion of a modified impact wrench wherein the
sleeve 41 in the hollow driven shaft 23 forms part of a modified
safety clutch. The innermost portions of spherical elements 36 in
the radial openings 35 of the driven shaft 23 normally extend into
the grooves 40 of the sleeve 41 and the elements 36 are then held
in such positions by two cooperating rings 77, 78 which replace the
ring 37 of FIG. 1. The front end face of the ring 78 has a conical
portion 78a and the rear end face of the ring 77 has a conical
portion 77a which defines the conical portion 78a a
circumferentially complete recess for the outermost portions of
spherical elements 36. When the resistance which the sleeve 41
offers to rotation with the driven shaft 23 reaches a predetermined
value, the ribs between the grooves 40 of the sleeve 41 expel the
spherical elements 36 radially outwardly and these elements move
the rings 77, 78 away from each other to stress a helical clutch
spring 81. The latter bears against the rear end face of the ring
78 and reacts against a retainer 80 which is affixed to the rear
end of a tubular extension or skirt 79 forming part of or being
rigidly connected to the ring 77 and surrounding the ring 78.
An advantage of the safety clutch of FIG. 4 is that the bias of the
spring 81 can constitute only one-half of the bias of the spring 38
of FIG. 1 but the rings 77, 78 will offer the same resistance to
radially outward movement of the spherical elements 36 as the ring
37 of FIG. 1. If the mass of the ring 77 and its extension or skirt
79 matches the mass of the ring 78, the noise which the tool
produces when the safety clutch including the parts 35, 36, 41,
77-81 is disengaged is surprisingly small. Also, the conical
surfaces 77a, 78a insure a smooth and gradual shifting of spherical
elements 36 to and from the positions shown in FIG. 4.
FIG. 5 illustrates a third safety clutch which uses roller-shaped,
rather than spherical, torque-transmitting elements 86. Each of
these elements normally extends into a discrete groove 40 of the
sleeve 41 and into and through an opening 23D of the driver shaft
23. The roller-shaped elements 86 have conical front and rear
facets which normally abut against the conical portions of adjacent
end faces on two rings 87, 88 respectively corresponding to the
rings 77, 78 of FIG. 4. The ring 87 has a tubular extension or
skirt 89 which surrounds the ring 88 and the spring 81. The latter
reacts against a retainer 90 in the rear end portion of the skirt
89. An advantage of the roller-shaped torque transmitting elements
86 is that they cannot perform any other but radial movements with
respect to the shank 42 and sleeve 41. This enhances the safety and
reliability of the clutch.
Without further analysis, the foregoing will so fully reveal the
gist of the present invention that others can, by applying current
knowledge, readily adapt it for various applications without
omitting features which fairly constitute essential characteristics
of the generic and specific aspects of our contribution to the art
and, therefore, such adaptations should and are intended to be
comprehended within the meaning and range of equivalence of the
claims.
* * * * *