US20210276164A1 - Impact tool - Google Patents
Impact tool Download PDFInfo
- Publication number
- US20210276164A1 US20210276164A1 US17/326,724 US202117326724A US2021276164A1 US 20210276164 A1 US20210276164 A1 US 20210276164A1 US 202117326724 A US202117326724 A US 202117326724A US 2021276164 A1 US2021276164 A1 US 2021276164A1
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- United States
- Prior art keywords
- anvil
- motor housing
- hammer
- length
- impact tool
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25B—TOOLS OR BENCH DEVICES NOT OTHERWISE PROVIDED FOR, FOR FASTENING, CONNECTING, DISENGAGING OR HOLDING
- B25B21/00—Portable power-driven screw or nut setting or loosening tools; Attachments for drilling apparatus serving the same purpose
- B25B21/02—Portable power-driven screw or nut setting or loosening tools; Attachments for drilling apparatus serving the same purpose with means for imparting impact to screwdriver blade or nut socket
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25B—TOOLS OR BENCH DEVICES NOT OTHERWISE PROVIDED FOR, FOR FASTENING, CONNECTING, DISENGAGING OR HOLDING
- B25B21/00—Portable power-driven screw or nut setting or loosening tools; Attachments for drilling apparatus serving the same purpose
- B25B21/02—Portable power-driven screw or nut setting or loosening tools; Attachments for drilling apparatus serving the same purpose with means for imparting impact to screwdriver blade or nut socket
- B25B21/026—Impact clutches
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25F—COMBINATION OR MULTI-PURPOSE TOOLS NOT OTHERWISE PROVIDED FOR; DETAILS OR COMPONENTS OF PORTABLE POWER-DRIVEN TOOLS NOT PARTICULARLY RELATED TO THE OPERATIONS PERFORMED AND NOT OTHERWISE PROVIDED FOR
- B25F5/00—Details or components of portable power-driven tools not particularly related to the operations performed and not otherwise provided for
- B25F5/001—Gearings, speed selectors, clutches or the like specially adapted for rotary tools
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25F—COMBINATION OR MULTI-PURPOSE TOOLS NOT OTHERWISE PROVIDED FOR; DETAILS OR COMPONENTS OF PORTABLE POWER-DRIVEN TOOLS NOT PARTICULARLY RELATED TO THE OPERATIONS PERFORMED AND NOT OTHERWISE PROVIDED FOR
- B25F5/00—Details or components of portable power-driven tools not particularly related to the operations performed and not otherwise provided for
- B25F5/008—Cooling means
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25F—COMBINATION OR MULTI-PURPOSE TOOLS NOT OTHERWISE PROVIDED FOR; DETAILS OR COMPONENTS OF PORTABLE POWER-DRIVEN TOOLS NOT PARTICULARLY RELATED TO THE OPERATIONS PERFORMED AND NOT OTHERWISE PROVIDED FOR
- B25F5/00—Details or components of portable power-driven tools not particularly related to the operations performed and not otherwise provided for
- B25F5/02—Construction of casings, bodies or handles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25B—TOOLS OR BENCH DEVICES NOT OTHERWISE PROVIDED FOR, FOR FASTENING, CONNECTING, DISENGAGING OR HOLDING
- B25B23/00—Details of, or accessories for, spanners, wrenches, screwdrivers
- B25B23/14—Arrangement of torque limiters or torque indicators in wrenches or screwdrivers
- B25B23/1405—Arrangement of torque limiters or torque indicators in wrenches or screwdrivers for impact wrenches or screwdrivers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25D—PERCUSSIVE TOOLS
- B25D11/00—Portable percussive tools with electromotor or other motor drive
- B25D11/04—Portable percussive tools with electromotor or other motor drive in which the tool bit or anvil is hit by an impulse member
Definitions
- the present invention generally relates to hand-held power tools, such as an impact tool or impact driver that is capable of rotary impact operation, and, for example, to an impact tool that has a shorter axial length than certain conventional impact tools.
- An impact driver is known from granted Japanese patent no. 4981345 that uses a motor for rotating a spindle via a speed reducing planetary gear mechanism.
- the rotational force of the motor is converted to rotational impact force via a hammer peripherally provided on a front end part of the spindle.
- the hammer is mounted so that it is urged frontward by a compression spring (i.e., a spring).
- Such a device includes a pin that passes through a rear part of the spindle and that serves as a rotary shaft of a planetary gear of the planetary gear mechanism.
- a washer is provided on the front side of the rear part of the spindle that presses the pin rearward. This washer receives the spring on its front side and is shaped such that the immediate inner side of the portion that receives the spring bulges frontward in order to properly position and/or prevent mispositioning of the spring.
- impact tools whose front-rear length and/or vertical length is (are) shorter than conventional devices while at the same time providing adequate tightening torque. This makes the impact tool easy to handle, e.g., in narrow work spaces.
- a first aspect of the present teachings is an impact tool that comprises: a motor, a motor housing that houses the motor, a grip housing that is integrally provided with the motor housing, a hammer case that is disposed frontward of the motor housing, a spindle that is rotated by the motor, a hammer that is housed inside the hammer case and that is rotated by the spindle, and an anvil that is housed inside the hammer case and is impacted by the hammer.
- the length from a rear end of the motor housing to a front end of the anvil is less than 128 mm. This may make the impact tool easier to handle, especially in tight places, and/or may make the impact tool usable in locations where the use of a larger impact tool is impractical.
- a second aspect of the present teachings is an impact tool according to the abovementioned aspect in which the length from the rear end of the motor housing to the front end of the anvil is less than 125 mm.
- a third aspect of the present teachings is an impact tool according to any of the abovementioned aspects in which the length from the rear end of the motor housing to the front end of the anvil is less than 120 mm.
- a fourth aspect of the present teachings is an impact tool according to any of the abovementioned aspects in which a battery is held (retained) below the grip housing and in which a length from a lower end of the battery to an upper end of the motor housing is less than 300 mm.
- a fifth aspect of the present teachings is an impact tool according to any of the abovementioned aspects in which a battery is held (retained) below the grip housing and in which a length from a lower end of the battery to an upper end of the motor housing is less than 250 mm.
- a sixth aspect of the present teachings is an impact tool according to any of the abovementioned aspects in which a battery is held (retained) below the grip housing and in which a length from a lower end of the battery to an upper end of the motor housing is less than 235 mm.
- Impact tools according to the first to sixth aspects generally provide superior handling properties as compared to larger impact tools capable of generating the same tightening torque.
- a seventh aspect of the present teachings is an impact tool according to any of the abovementioned aspects, wherein the impact tool further includes an engaging part on the spindle and a pin having an engaged part that latches to the engaging part and holds a planetary gear.
- the pin is immovable toward the hammer side because of the interaction of the engaging part and the engaged part.
- An impact tool allows a conventional pin retaining washer to be omitted, thereby shortening the length from the rear end of the motor housing to the front end of the anvil.
- An eighth aspect of the present teachings is an impact tool according to any of the abovementioned aspects that includes a coil spring for urging the hammer.
- the engaging part and the engaged part are disposed at a location at which they do not interfere with the coil spring and the hammer, thereby reducing the effect of the impact and increasing durability.
- a ninth aspect of the present teachings is an impact tool according to any of the abovementioned aspects in which the pin comprises a large diameter part that holds the planetary gear and a small diameter part with a diameter smaller than that of the large diameter part.
- the engaging part is a recessed part to which the small diameter part mates.
- the length from the rear end of the motor housing to the front end of the anvil can be further shortened and the engaging part can be designed in a relatively simple manner.
- a tenth aspect of the present teachings is an impact tool according to any of the abovementioned aspects, wherein the impact tool further includes a spring receiving projection part provided on the spindle for holding (supporting) the coil spring. Furthermore, the location at which the hammer opposes the spring receiving projection part is hollowed (is hollow). Because the spindle directly receives the spring, the length from the rear end of the motor housing to the front end of the anvil can be further shortened without reducing the operational performance of the hammer.
- An eleventh tenth aspect of the present teachings is an impact tool according to any of the abovementioned aspects, wherein the impact tool further includes a bearing that is capable of holding a rotary shaft of the motor.
- the impact tool of this aspect also includes a bearing holding wall that holds the bearing and that is held by the hammer case, a first protruding part on the motor housing, and a second protruding part on the bearing holding wall that is disposed rearward of the first protruding part.
- the second protruding part is a rear part of the bearing holding wall and is disposed on the outer side in the radial direction of the bearing.
- the length from the rear end of the motor housing to the front end of the anvil can be further shortened while fixing the bearing holding wall with adequate strength.
- a twelfth aspect of the present teachings is an impact tool according to any of the abovementioned aspects that includes an internal gear that meshes with the planetary gear.
- a configuration is adopted wherein the internal gear abuts the front side of the hammer case and the internal gear is non-rotatably provided on the bearing holding wall.
- the location at which the internal gear opposes the hammer is hollow or hollowed.
- a thirteenth aspect of the present teachings is an impact tool according to any of the abovementioned aspects, wherein the impact tool further includes a bearing for holding the anvil disposed at a front part of the hammer case.
- a washer is disposed between the anvil and the hammer case, and a projecting part extends from the hammer case to the anvil side on the inner diameter side of the washer. Because the anvil washer, rather than the bearing of the anvil, is attached inside the front part of the hammer case, the front-rear length of the bearing (and, in turn, the length from the rear end of the motor housing to the front end of the anvil) can be shortened.
- anvil washer i.e., the press fitting length
- the front-rear length of the receiving part i.e., the roller
- FIG. 1 is a right side view of an impact driver according to the present teachings.
- FIG. 2 is a rear view of FIG. 1 .
- FIG. 3 is a center longitudinal cross sectional view of FIG. 1 .
- FIG. 4 is an enlarged view of a main body part shown in FIG. 3 .
- FIG. 5 is a cross sectional view taken along the A-A line in FIG. 3 .
- FIG. 6 is a cross sectional view taken along the B-B line in FIG. 4 .
- FIG. 7 is a cross sectional view taken along the C-C line in FIG. 4 .
- FIG. 8 is a cross sectional view taken along the D-D line in FIG. 4 .
- FIG. 9 is a front view of a bearing retainer shown in FIG. 3 .
- FIG. 1 is a right side view of a rechargeable impact driver 1 (i.e., a representative example of a rotary impact tool), which is one example of a power tool for tightening, e.g., a screw according to the present teachings.
- the impact driver 1 comprises a housing 2 , which forms the contour or outer profile of the impact driver 1 .
- the front of the impact driver 1 of FIG. 1 is located at the right side of the figure.
- the impact driver 1 also comprises a tubular main body part 4 with a central axis that extends in a front-rear direction.
- a grip part 6 protrudes or projects from a lower part of the main body part 4 .
- the grip part 6 is configured to be gripped by a user.
- a trigger-type switch relay (or simply a “trigger switch”) 8 is disposed on the grip part 6 and can be pulled by a user using his or her fingertip to operate the impact driver 1 .
- the switch relay 8 protrudes from a switch main body part 8 a.
- the main body part 4 of the impact driver surrounds or encloses, in order from the rear side toward the front side, a motor 10 , for example, an electric motor, more preferably a brushless DC motor, a planetary gear mechanism 12 , a spindle 14 , a coil spring 15 that is an elastic body, a hammer 16 , and an anvil 18 .
- a motor 10 for example, an electric motor, more preferably a brushless DC motor, a planetary gear mechanism 12 , a spindle 14 , a coil spring 15 that is an elastic body, a hammer 16 , and an anvil 18 .
- These elements are coaxially housed in the main body part 4 of the impact driver 1 .
- the motor 10 is a drive source of the impact driver 1 .
- the planetary gear mechanism 12 reduces the rotational speed of the motor 10 , that rotation is transmitted to the spindle 14 .
- the rotational force of the spindle 14 is converted into a rotational impact force by the hammer 16 and is transferred to the anvil 18 .
- the spring 15 spans the space between the spindle 14 and the hammer 16 and absorbs shock when necessary.
- the anvil 18 receives the rotational impact force and rotates around an axis.
- the main body part 4 of the housing 2 comprises a motor housing 20 that houses the motor 10 and a hammer case 22 , which is disposed frontward of the motor housing 20 and houses the hammer 16 .
- the motor housing 20 comprises a left motor housing 20 a and a right motor housing 20 b that are shaped as half-split tubes, and a rear motor housing 20 c that constitutes a rear surface.
- An air suction port 20 e is formed both above and below a rear part of the left motor housing 20 a and both above and below a rear part of the right motor housing 20 b .
- a screw boss 20 f is configured to accept a screw 3 from the rear and is provided at the rear between the air suction ports 20 e of the left motor housing 20 a and the air suction ports 20 e of the right motor housing 20 b .
- exhaust ports 20 g are formed on the left and right of the rear motor housing 20 c.
- the hammer case 22 is tubular, and the diameter of its front part is narrower than the diameter of its rear part.
- the hammer case 22 is attached so that a portion of its rear part is inserted into a front part of the motor housing 20 .
- a dish-shaped metal bearing retainer 24 serves as a bearing holding wall and is attached to the inner sides of the motor housing 20 .
- the bearing retainer 24 has a generally concave shape, although portions of it may be planar. It is held in place by the hammer case 22 , because the bearing retainer 24 is interposed between the hammer case 22 and the motor housing 20 .
- the metal bearing retainer is illustrated by itself in FIG. 9 and includes a hole 24 a formed at the center of the bearing retainer 24 .
- a region adjacent to the hole 24 a is formed as a short hexagonal columnar hollow shape that is bottomed with respect to the outer part of that adjacent region.
- the region adjacent to the hole 24 a includes a hollow part 24 b that is hollow to the rear and that is positioned so that its bottom surface is oriented in the vertical direction.
- an outward protruding rib 24 c protrudes in a ring shape outward in the radial directions with respect to the front side, and is provided on an outer edge of a rear end part of the bearing retainer 24 (i.e., on the rear side of the hollow part).
- the motor housing 20 includes an inward protruding rib 20 d (shown in FIGS.
- the housing 2 in the grip part 6 is a grip housing 26 that is integrally provided at a lower part of the motor housing 20 .
- the grip housing 26 comprises a left grip housing 26 a and a right grip housing 26 b , each of which is half-split shaped.
- the left grip housing 26 a and the right grip housing 26 b and the left motor housing 20 a and the right motor housing 20 b , respectively, are aligned by the screws 3 .
- a forward/reverse switching lever 5 is provided rearward of the switch relay 8 at an upper part of the right grip housing 26 b such that it passes laterally through the boundary area between the main body part 4 and the grip part 6 .
- This switching lever 5 is used for selecting a rotational direction of the motor 10 .
- a light 7 is oriented to illuminate frontward, and is provided frontward of the forward/reverse switching lever 5 on the upper side of the switch relay 8 .
- the light 7 is an LED and is provided such that it overlaps the switch relay 8 in the vertical directions. Because the light 7 overlaps the switch relay 8 in the vertical directions, a user's finger should not be positioned in the radiation direction of the light 7 . This arrangment substantially prevents the light from being blocked, thereby ensuring that the visibility of the light 7 is satisfactory when turned on.
- a lower end part of the grip housing 26 is a battery attachment part 26 c that widens principally frontward with respect to an upper part of the grip housing 26 .
- a battery 28 is detachable via a pushbutton 28 a , and is held or retained below the battery attachment part 26 c .
- the battery 28 may comprise, for example, a 14.4 V (volt) lithium ion battery (pack).
- a display part 26 d with a display switch (e.g., a display part comprising an LED) is provided at a front part of an upper part of the battery attachment part 26 c .
- a hook groove 26 e to which a hook (not shown) can be attached, and a screw hole 26 f to which a separate member, such as a hook, having a screw can be attached, are formed on the left and right of the upper part of the battery attachment part 26 c .
- a strap 26 g is provided at a rear part of the battery attachment part 26 c .
- a circuit board 51 ( FIG. 3 ) is housed inside the battery attachment part 26 c . Six switching devices (not shown) are mounted on the circuit board 51 . These switching devices correspond in number to the number of associated drive coils 17 which are discussed below.
- the motor 10 is preferably a brushless DC motor comprising a stator 19 having a stator core 9 , a front insulating member 11 and a rear insulating member 13 at the front and rear of the stator core 9 , respectively, and a plurality of (here, six) drive coils 17 which are wound around the stator core 9 via the front insulating member 11 and the rear insulating member 13 .
- a sensor board 31 is fixed to the front insulating member 11 by screws 21 .
- Magnetic sensors 31 a (illustrated, for example, in FIG. 8 ), are fixed to a rear surface of the sensor board 31 .
- six coil connection parts Ila are provided at a peripheral edge of a front surface of the front insulating member 11 and serve as contacts that electrically connect to each of the drive coils 17 and the sensor board 31 .
- a rotor 29 is disposed inside the stator 19 .
- the rotor 29 comprises: a rotor shaft 30 , which serves as a rotary shaft, a tubular rotor core 23 disposed around the rotor shaft 30 , and permanent magnets 25 disposed on the outer side of the rotor core 23 .
- the permanent magnets 25 are tubular and have polarities that alternate in the circumferential direction.
- the rotor 29 also includes a plurality of sensor permanent magnets 27 that are radially disposed on the front side of the permanent magnets 25 (i.e., on the sensor board 31 side).
- the rotor core 23 , the permanent magnets 25 , and the sensor permanent magnets 27 constitute a rotor assembly 29 a .
- the rotor assembly 29 a is disposed above the switch main body part 8 a , and this arrangement improves the balance of the impact driver 1 , thereby making the impact driver 1 easier to use when gripped.
- a tubular resin sleeve 35 is provided on the rotor shaft 30 on the front side of the rotor core 23 .
- a front bearing 36 of the rotor shaft 30 is provided frontward of the resin sleeve 35 .
- a pinion 37 is fixed to a front end part of the rotor shaft 30 forward of the bearing 36 .
- a fan 32 for cooling is attached via a metal insert bushing 39 rearward of the rotor core 23 of the rotor shaft 30 .
- the insert bushing 39 is press fitted onto the rotor shaft 30 of the fan 32 and exerts a strong fixing force thereagainst.
- the bearing 36 is disposed along a straight line that extends from the center of the screw 3 of an upper part in the main body part 4 and the center of a screw 3 of the lower part in the main body part 4 .
- FIG. 8 in particular, four through holes 41 are formed in a side part of the circumferential edge of the sensor board 31 , and one small recessed part 43 , recessed toward the inner side in the circumferential direction, is provided in an upper part of the circumferential edge of the sensor board 31 .
- five frontward small projections 45 are provided in correspondence with the through holes 41 and the recessed part 43 on a front part of the front insulating member 11 .
- the small projections 45 extend into the through holes 41 and the recessed part 43 .
- two recessed parts 47 which are recessed toward the inner side in the circumferential directions, are provided on the side part of the circumferential edge of the sensor board 31 , and the screws 21 described above extend into the recessed parts 47 .
- the fan 32 is shaped such that an adjacent part (i.e., the inner side) of the rotor shaft 30 bulges frontward with respect to the outer part (i.e., the outer side) of the rotor shaft 30 .
- the fan 32 has a bulging part 32 a that bulges frontward, toward a center part.
- a rear bearing 34 of the rotor shaft 30 is installed on an inner surface of the rear motor housing 20 c so that the bearing 34 is partially disposed within the rear side (i.e., the inner side on the outer part) of the bulging part 32 a .
- the exhaust ports 20 g are disposed in the rear motor housing 20 c and on the outer side of the fan 32 in the radial directions. This allows the airflow produced by the fan 32 to be discharged efficiently.
- the exhaust ports 20 g are disposed above and below each of the screws 3 , which screws 3 are received in the screw bosses 20 f .
- the rear motor housing 20 c is attached, for example, by the screw bosses 20 f , which screw bosses 20 f are regions adjacent to the exhaust ports 20 g , and thereby the post-assembly strength of the rear motor housing 20 c is improved.
- the bearing retainer 24 is disposed at a location at which it overlaps, in the axial direction, two of the screws 21 and four of the small projections 45 (except for the ones on the uppermost side) related to the front insulating member 11 . Consequently, the length of the main body part 4 in the front-rear direction is shorter than would be possible if the bearing retainer 24 were disposed frontward of the screws 21 , the small projections 45 , and the like.
- a front protruding wall 24 d protrudes frontward from an outer edge of a front part of the bearing retainer 24 , and a male thread ridge (not shown) is formed on an outer circumferential surface thereof.
- a female thread groove (not shown) is formed on an inner circumferential surface of a rear end part of the hammer case 22 .
- the bearing retainer 24 is fixed to the hammer case 22 by the meshing of the male thread groove with the female thread groove.
- the hollow part 24 b of a rear part of the bearing retainer 24 has a hexagonal columnar shape, it is easy to rotate the bearing retainer 24 with respect to the hammer case 22 by using a wrench or similar tool.
- the male thread ridge easily advances into the female thread groove making it is easy to attach the bearing retainer 24 to the hammer case 22 .
- the front bearing 36 of the rotor shaft 30 is installed so that it extends into a rear part of the hole 24 a of the bearing retainer 24 .
- a plurality of hollow parts 49 a are formed, arrayed in the circumferential direction, in a rear surface of the hollow part 24 b of the bearing retainer 24 (i.e., outside of the bearing 36 ).
- Ribs 49 b are respectively formed between the hollow parts 49 a .
- a bearing 40 FIGS.
- the bearing retainer 24 suitably dissipates heat by way of the hollow parts 49 a , alone or by a combination of the hollow parts 49 a and the ribs 49 b . Furthermore, because the bearing retainer 24 is made of metal, it is even more suited to dissipating heat.
- a plurality of front protruding parts 24 e which protrude frontward, are formed in stripes along the radial directions at a location on the front side of the bearing 36 in the bearing retainer 24 (i.e., on the outer side of the bearing 36 inside the hollow part 24 b ).
- the front protruding parts 24 e also help the bearing retainer 24 dissipate heat.
- the front protruding parts 24 e extend into the inner diameter side of the bearing 40 and overlap the bearing 40 in the axial direction.
- the spindle 14 comprises a hollow discoidal (disk-shaped) part 14 b , which is the rear part of the spindle 14 and is located on the front side of a rear end part of the spindle 14 .
- the discoidal part 14 b protrudes radially outward (vertically and laterally) with respect to the other portion of the spindle 14 , and the diameter of the discoidal part 14 b is greater than the diameter of the other portion.
- hollow parts 24 f are provided on a portion opposing the discoidal part 14 b . Each of the hollow parts 24 f extends to the outer side of the bearing 40 . These hollow parts 24 f help the bearing retainer 24 dissipate heat.
- the planetary gear mechanism 12 comprises: an internal gear 42 having internal teeth, a plurality of planetary gears 44 having external teeth that mesh with the internal gear 42 , and pins 46 that constitute the shafts of the planetary gears 44 .
- the internal gear 42 is formed such that both the inner and outer diameters of a front part 42 b , located on the front side of a tubular rear part at a rear part of the internal gear 42 , are expanded to be greater than the diameter of the tooth part 42 a . This diameter expansion results in a recessed part 42 c on the inner circumferential side of the front part 42 b.
- each of the protruding parts 42 d extends into a corresponding recessed part 22 c , they are mutually engaged. To ensure an adequate length in the front-rear directions in such engagement, each of the protruding parts 42 d is formed such that it reaches the outer circumferential side of the final retraction position of the hammer 16 .
- the recessed part 42 c is disposed at the same position as an outer circumferential part of the hammer 16 in the radial direction. Furthermore, because of the presence of the recessed part 42 c , the location at which the internal gear 42 opposes the hammer 16 is hollowed; in other words, the inner diameter of the front part 42 b of the internal gear 42 is greater than the outer diameter of the hammer 16 , and the front part 42 b of the internal gear 42 is formed such that it does not interfere with the hammer 16 . A portion of the hammer 16 can thus partially overlap a portion of the internal gear 42 and extend into the recessed part 42 c .
- the internal gear 42 is non-rotatably attached to the inner side of a region at which the front part of the bearing retainer 24 and a rear end edge of the hammer case 22 overlap.
- a front surface of the internal gear 42 contacts a step part 22 a formed by the slight diametric expansion of a rear part of the hammer case 22 at the rear end edge over the front part, and therefore, the internal gear 42 abuts the hammer case 22 on the front side.
- the front protruding wall 24 d of the bearing retainer 24 extends into the inner side of the motor housing 20 , which is the outer side of the tooth part 42 a.
- Each of the pins 46 and the majority of each of the planetary gears 44 are disposed inward of the discoidal part 14 b of the spindle 14 .
- Each of the pins 46 is formed such that the diameter of its front end part is narrower than its rear portion, namely, large diameter parts 46 b are respectively located on the rear sides of small diameter parts 46 a .
- a plurality of pin holes 14 c corresponding to the small diameter parts 46 a of the pins 46 , are provided (the same number as the pins 46 ) in a front surface of the discoidal part 14 b of the spindle 14 .
- a plurality of pin holes 14 d corresponding to rear end parts of the large diameter parts 46 b of the pins 46 , are provided in a rear surface of the discoidal part 14 b . Furthermore, each of the pins 46 is provided inside the discoidal part 14 b so that the small diameter parts 46 a respectively enter the pin holes 14 c and the rear end parts of the large diameter parts 46 b respectively enter the pin holes 14 d .
- the small diameter part 46 a is aligned with its corresponding pin hole 14 c , and thereby a step or shoulder between the small diameter part 46 a and the large diameter part 46 b contacts an inner surface of the discoidal part 14 b (i.e., an inner circumferential edge of the pin hole 14 c ).
- the pin 46 is thus in a state in which it cannot move toward the hammer 16 .
- Each of the planetary gears 44 is fixedly mounted to its corresponding pin 46 so that it cannot rotate relative to the pin 46 .
- Each of the planetary gears 44 is disposed such that some of the external teeth protrude outward from the discoidal part 14 b.
- a spindle hole is provided at the front and rear of the discoidal part 14 b .
- the spindle hole is an inner part of (i.e. defined within) the spindle 14 and extends frontward from a rear surface of the spindle 14 .
- the spindle hole has: a front side hole 14 e , which is a front part of the spindle hole, and a rear side hole 14 f , which is provided rearward of the front side hole 14 e .
- the diameter of the rear side hole 14 f is larger than the diameter of the front side hole 14 e .
- the pinion 37 tends not to contact the rear side hole 14 f when the pinion 37 enters those holes to mesh with the planetary gears 44 .
- the spindle 14 is sufficiently durable in view of the torque that will be applied thereto.
- Teeth are formed in the pinion 37 inwardly of a rear part of the spindle hole (i.e., inward of the rear side hole 14 f and of a rear part of the front side hole 14 e ) and are shared and mesh with all the planetary gears 44 .
- the pinion 37 is located at a tip part of the rotor shaft 30 of the motor 10 , and the tip part of the rotor shaft 30 extends into the pinion.
- the diameter of the rear side hole 14 f is larger than the external diameter of the bearing 36 of the rotor shaft 30 .
- a short spring receiving projection part 14 g is oriented in the front-rear direction and is provided integrally with the discoidal part 14 b of the spindle 14 at an outer edge of the front surface of the discoidal part 14 b.
- the spring receiving projection part 14 g is ring shaped (i.e. annular), and a ring shaped (annular) rear end part of the spring 15 is disposed on the inner side of the spring receiving projection part 14 g .
- the spring receiving projection part 14 g is a spring receiving structure that receives (supports) the spring 15 . Furthermore, the pin holes 14 d are disposed on the inner side of the spring 15 , and the small diameter parts 46 a of the pins 46 are disposed rearward of the spring 15 .
- the spring receiving projection part 14 g enters the inner side of the internal gear 42 . Furthermore, the spring receiving projection part 14 g , the rear end part of the spring 15 and the internal gear 42 overlap in the front-rear direction.
- a front end of the pinion 37 is disposed rearward of a front end of the spring receiving projection part 14 g . This allows a shorter pinion 37 to be used, and the cost of materials related to the pinion 37 can be reduced.
- the front end of the pinion 37 is disposed rearward of a front end of the internal gear 42 . The pinion 37 can thus be made shorter, and the cost of materials related to the pinion 37 can be reduced.
- the inner diameter of the bearing 40 receives the rear end part 14 a of the spindle 14 and is larger than the external diameter of the bearing 36 , which is held by the bearing retainer 24 .
- a rear surface of the bearing 40 is disposed so that it is located frontward of a front surface of the bearing 36 and so that the bearing 40 and the bearing 36 are shifted or displaced from one another in the front-rear direction. The force transmitted from the spindle 14 to the bearing 40 thus tends not to be transmitted to the bearing 36 . Therefore, the service life of the bearing 36 , the bearing retainer 24 , etc. can be increased.
- the hammer 16 has a hollow or a hollow interior 16 a , which is formed in a tubular manner frontward of a rear surface of the hammer 16 .
- a front part of the spring 15 extends into the hollow 16 a .
- a ring-shaped front end part of the spring 15 is located near the bottom or front end of the hollow 16 and is spaced therefrom by a plurality of balls 50 and a hammer washer 52 at the bottom of the hollow 16 a.
- a spring receiving release part 16 b is provided that widens from the rear end edge toward the outer side with respect to the outer side surface at the front side.
- the spring receiving release part 16 b and the spring receiving projection part 14 g of the spindle 14 are disposed at the same position in the inner-outer directions (i.e., the radial directions) of the tubular main body part 4 .
- the spring receiving release part 16 b avoids the spring receiving projection part 14 g , the hammer 16 and the spindle 14 do not interfere with one another even if, for example, the hammer 16 moves rearward and comes into proximal contact with the front side of the discoidal part 14 b.
- the hollow 16 a is disposed at the same position as the pin holes 14 d and the small diameter parts 46 a of the pins 46 , in the radial directions.
- the pin holes 14 d and the small diameter parts 46 a are disposed at locations at which they do not interfere with the hammer 16 even if, for example, the hammer 16 moves rearward and comes into proximal contact with the front side of the discoidal part 14 b .
- balls 54 are interposed between the hammer 16 and a front part of the spindle 14 and guide the hammer 16 principally in the front-rear directions during impact.
- the anvil 18 on the front side of the hammer 16 comprises, at its rear end part, a pair of extension parts 18 a , each of which extends in the radial directions.
- An anvil bearing 60 is provided on the front side of the extension parts 18 a , 18 a .
- the anvil bearing 60 rotatably supports the anvil 18 around its axis and fixedly supports the anvil 18 in the axial direction.
- the anvil bearing 60 is attached to an inner wall of a front end part of the hammer case 22 .
- a rear hole 18 b extends frontward from a rear surface of the anvil 18 and is formed in the center of a rear part of the anvil 18 .
- a front end part of the spindle 14 extends into the rear hole 18 b so that a rotational impact force cannot be transmitted.
- a chuck part (or simply “a chuck”) 18 c which accepts and holds a not-shown tool bit (i.e., a tip tool), is provided at a front part of the anvil 18 .
- An anvil washer 62 receives the anvil 18 and is made of a synthetic resin (e.g., nylon).
- the anvil washer 62 is disposed between the outer edges of the extension parts 18 a of the anvil 18 and a front inner wall of the hammer case 22 .
- a washer holding part 22 b protrudes frontward in a ring shape from the front inner wall of the hammer case 22 and is provided on the immediate inner side of an inner wall of the ring shaped anvil washer 62 .
- the anvil washer 62 is press fitted into or otherwise held by the washer holding part 22 b.
- a front end of the switch relay 8 is disposed rearward of the rear surface of the anvil 18 . This makes the impact driver 1 easy to handle because of the advantageous positional relationship between the portion of the tool that receives the impact and the switch relay 8 operated by the user.
- the grip part 6 i.e., the grip housing 26
- the motor causes the rotor shaft 30 to rotate.
- the fan 32 is rotated by the rotor shaft 30 and creates a flow of air from the air suction ports 20 e to the exhaust ports 20 g .
- the flow of the air first cools the outer circumference of the stator core 9 .
- the entire surface of the sensor board 31 is cooled.
- the rotor core 23 and the inner circumferences of the drive coils 17 and the stator core 9 are also cooled.
- the rotational force of the rotor shaft 30 is reduced by the planetary gears 44 which run while spinning inside the internal gear 42 , and the rotational force of the rotor shaft 30 is transmitted to the spindle 14 via the pins 46 .
- the spindle 14 both rotates the anvil 18 and guides the hammer 16 such that the hammer 16 oscillates to the front and rear (i.e., impacts) when torque above a prescribed threshold is received at the anvil 18 .
- the cushioning effect provided by the spring 15 acts on the hammer 16 (and on the spindle 14 and the like).
- the length from a rear end of the motor housing 20 to a front end of the anvil 18 (hereinbelow, called the “front-rear length of the main body part 4 ”) can be shortened by employing the following types of independently-usable configurations described below, or by employing one or more combinations thereof.
- the length of the main body part 4 in the front-rear direction can be made shorter than that of the prior art (129 mm) (i.e., can be made less than 128 mm, preferably less than 125 mm, or more preferably less than 120 mm by employing a combination of preferred configurations).
- the front-rear length of the main body part 4 in the impact driver 1 shown in FIGS. 1-4 is 119.7 mm.
- the pin holes 14 c are provided in the discoidal part 14 b of the spindle 14 .
- the pins 46 i.e., “engaged parts”
- the pins 46 have the small diameter parts 46 a , engage with the pin holes 14 c and hold the planetary gears 44 .
- the pin holes 14 c and the small diameter parts 46 a make the pins 46 immovable toward the hammer 16 side.
- This configuration makes it possible both to suppress (prevent) the movement of the pins 46 toward the hammer 16 , even if a conventional washer is not separately provided in front of the pins 46 , and to omit the conventional washer, thus making it possible to reduce the number of parts and to commensurately shorten the front-rear length of the main body part 4 .
- the pins 46 comprise the large diameter parts 46 b , which hold the planetary gears 44 , and the small diameter parts 46 a , whose diameters are smaller than those of the large diameter parts 46 b .
- the pin holes 14 c are recessed parts that mate with the small diameter parts 46 a . This configuration makes it possible to suppress (prevent) the movement of the pins 46 in a simple manner, even if a conventional washer is omitted, in order to, for example, shorten the front-rear length of the main body part 4 .
- the spring receiving projection part 14 g which holds (supports) the spring 15 , is provided on the spindle 14 , and the location at which the hammer 16 opposes the spring receiving projection part 14 g is hollow from the spring receiving release part 16 b of the hollow 16 a .
- This configuration makes it possible to adequately hold the spring 15 and to prevent the spring 15 and the spring receiving projection part 14 g from interfering with one another, thereby protecting them.
- the impact driver 1 includes the bearing 36 , which is capable of holding (rotatably supporting) the rotor shaft 30 of the motor 10 , and the bearing retainer 24 , which holds the bearing 36 and serves as the bearing holding wall that is held by the hammer case 22 .
- the inward protruding rib 20 d which serves as a first protruding part, is provided on the motor housing 20 ;
- the outward protruding rib 24 c which serves as a second protruding part, is provided on the bearing retainer 24 ;
- the outward protruding rib 24 c is disposed rearward of the inward protruding rib 20 d ;
- the outward protruding rib 24 c is the rear part of the bearing retainer 24 and is disposed on the outer side in the radial directions of the bearing 36 .
- This configuration makes it possible to shorten the front-rear length of the bearing retainer 24 as compared to the case in which the bearing 36 is disposed rearward of the outward protruding rib 24 c , and thus shortens the front-rear length of the main body part 4 .
- the outward protruding rib 24 c which contacts the inward protruding rib 20 d , is still provided, strength can be maintained even though the front-rear length of the main body part 4 is shortened.
- the internal gear 42 meshes with the planetary gears 44 and is configured such that it abuts the hammer case 22 on the front side.
- the internal gear 42 is non-rotatably provided on the bearing retainer 24 , and the location at which the internal gear 42 opposes the hammer 16 is hollow (i.e., the internal gear 42 includes the recessed part 42 c ).
- This configuration makes it possible for the hammer 16 to move to a location at which it overlaps with the internal gear 42 in the front-rear direction (i.e., to a location at which a rear end part of the hammer 16 extends into the inner side of the front part 42 b of the internal gear 42 ), without interfering with the internal gear 42 .
- This configuration can, while maintaining the distance over which the hammer 16 is moved, narrow the front-rear spacing between the internal gear 42 and the hammer 16 and commensurately shorten the front-rear length of the main body part 4 as compared to a device in which no recessed part 42 c is provided in the internal gear 42 .
- the bearing 60 for holding the anvil 18 is disposed in a front part of the hammer case 22
- the anvil washer 62 is disposed between the anvil 18 and the hammer case 22
- the washer holding part 22 b which serves as a projecting part, is provided such that it extends from the hammer case 22 to the anvil 18 side and such that it is disposed on the inner diameter side of the anvil washer 62 .
- This configuration makes it possible to attach the anvil washer 62 even without providing the projecting part on the bearing 60 and to shorten the front-rear length of the bearing 60 while securing an adequate attachment length (i.e., a press fitting length) for the washer holding part 22 b .
- This also makes it possible to shorten the front-rear length of the main body part 4 .
- the hollow parts 49 a are provided inside the outward protruding rib 24 c of the bearing retainer 24 . This configuration makes it possible to effectively absorb the shock of the rotary impact in the radial directions and of the axial impact in the axial directions induced by the front-rear movement and the rotation of the hammer 16 and received from the bearing retainer 24 .
- the motor housing 20 comprises the rear motor housing 20 c , which constitutes a rear surface of the motor housing 20 .
- the rear motor housing 20 c is formed independently of other portions of the motor housing 20 (i.e., portions other than the rear part). This configuration makes it possible to suppress or minimize the rearward bulging of the motor housing 20 , while still maintaining the size of the internal space of the motor housing 20 , and to shorten the front-rear length of the main body part 4 .
- the fan 32 is shaped such that its inner side in the radial directions bulges frontward with respect to its outer side and is disposed such that the bearing 34 , which is adjacent to the fan 32 , projects into the inner side of the bulging part 32 a of the fan 32 .
- This configuration makes it possible for the bearing 34 to approach (i.e. to be disposed closer to) the fan 32 as compared with a configuration in which the bearing 34 is disposed rearward of a (conventional) flat or planar fan. This also makes it possible to shorten the front-rear length of the main body part 4 .
- the diameter of the rear side hole 14 f is made larger than the outer diameter of the bearing 36 of the rotor shaft 30 .
- This configuration makes it possible to assemble the motor 10 , including the bearing 36 , by appropriately using the space of the rear side hole 14 f , even after the assembly of the spindle 14 and the bearing retainer 24 .
- This arrangement produces a motor 10 , the front-rear length of which is short, thereby making it possible to easily assemble the impact driver 1 so that the front-rear length of the main body part 4 is short.
- the screw bosses 20 f are provided on the left motor housing 20 a and also on the right motor housing 20 b .
- Each of the screw bosses 20 f extends in the front-rear directions.
- the rear motor housing 20 c is fixed by two of the screws 3 to two of the screw bosses 20 f and thereby the length of the main body part 4 in the front-rear directions is shortened.
- the bearing 34 , the fan 32 , the rear insulating member 13 , the stator core 9 , the rotor shaft 30 , and the permanent magnets 25 are disposed such that they are interposed between two of the screws 3 . This configuration also makes it possible to shorten the length of the main body part 4 in the front-rear directions.
- the appropriate selection and adoption (usage) of one or more such configurations makes it possible to configure the impact driver 1 , comprising: the motor 10 , the motor housing 20 which houses the motor 10 , the grip housing 26 which is integrally provided with the motor housing 20 , the hammer case 22 which is disposed frontward of the motor housing 20 , the spindle 14 which is rotated by the motor 10 , the hammer 16 , which is housed inside the hammer case 22 and is rotated by the spindle 14 , and the anvil 18 which is housed inside the hammer case 22 and is impacted by the hammer 16 .
- the length from the rear end of the motor housing 20 to the front end of the anvil 18 is less than 128 mm (or 125 mm or 120 mm). Furthermore, the practical lower limit of the front-rear length of the main body part 4 is preferably 115 mm (or 110 mm).
- shortening the front-rear length of the main body part 4 makes it possible to adequately support the main body part 4 even though the vertical length of the grip housing 26 is short.
- This makes it possible to configure the impact driver 1 so that the battery 28 is held below the grip housing 26 and so that the length from a lower end of the battery 28 to an upper end of the motor housing 20 is less than 300 mm (or 250 mm, or 235 mm).
- the practical lower limit of that length is preferably 230 mm (or 200 mm).
- the weight of the impact driver 1 is preferably less than 2.0 kilograms (kg), and more preferably less than 1.5 kg or less than 1.4 kg.
- the impact driver 1 can output a torque of at least 150 Newton-meters (Nm), and more preferably a torque of 160 Nm or greater, and yet more preferably a torque of 170 Nm or greater.
- the rear end of the battery attachment part 26 c and the rear end of the motor housing 20 are disposed on the front side of a rear surface of the battery 28 .
- the rear end of the motor housing 20 is disposed on the front side of the rear end of the battery attachment part 26 c .
- shortening the front-rear length and/or the vertical length of the impact driver 1 makes it possible to provide an impact driver 1 that it is easy to handle and that reduces incidences of impingements (blockages) in narrow places and that reduces the likelihood of having to perform work (power tool operations) in an unreasonable (e.g., uncomfortable or awkward) posture.
- pin small diameter parts may be inserted into small holes, or in combination therewith, small projections may be inserted into small holes or tabs may be latched together, and the like.
- pin holes instead of forming the pin holes as through openings or bottomless, it is also possible to form the pinholes as blind openings or with bottoms.
- the spindle 14 may be held on the inner diameter side of the coil spring 15 , or the spindle 14 may be held by being press fitted to the outer diameter side or the inner diameter side of the coil spring 15 , or the spindle 14 may be held by using a screw to screw the coil spring 15 to the spindle 14 , or the coil spring 15 and the spindle 14 may be welded together.
- the spindle 14 may be held on the inner diameter side of the coil spring 15 , or the spindle 14 may be held by being press fitted to the outer diameter side or the inner diameter side of the coil spring 15 , or the spindle 14 may be held by using a screw to screw the coil spring 15 to the spindle 14 , or the coil spring 15 and the spindle 14 may be welded together.
- Various combinations of these configurations may also be adopted.
- the spring receiving release part 16 b of the hammer 16 may be formed into a shape other than a shape in which its diameter expands rearward.
- a configuration may be adopted in which the external gear is not held in the bearing retainer 24 , but rather is held by a separate housing.
- a configuration may be adopted wherein, instead of the anvil washer 62 being attached by press fitting, the anvil washer 62 is latched by a tab and a latching part thereof, or wherein the anvil washer 62 is welded, or the like.
- a configuration is adopted wherein six switching devices are disposed on the circuit board 51 , which in turn is disposed inside the battery attachment part 26 c .
- the six switching devices are disposed on the sensor board 31 .
- the battery 28 may be any (arbitrary) lithium ion battery (pack) of 18 V (20 V maximum), or in the range of 18-36 V, such as 18 V, 25.2 V, 28 V, or 36 V.
- a lithium ion battery (pack) having a voltage that is less than 14.4 V or greater than 36 V may be used.
- Other types of batteries may also be used, such as, e.g., nickel-cadmium or nickel-metal hydride.
- the permanent magnets 25 and the sensor permanent magnets 27 in the rotor assembly 29 a can also be integrally configured as four plate shaped permanent magnets.
- the present teachings can also be readily adapted to a rechargeable driver drill or a hammer (vibration) driver drill by utilizing a gear case in place of the hammer case 22 , by omitting the hammer 16 and the anvil 18 , and further including a speed reducing mechanism part such as, for example, a two-stage planetary gear mechanism, thereby making the output shaft of the speed reducing mechanism part protrude frontward from the gear case, and fixing the tip tool holding part, which holds the tip tool, to the front part of the output shaft.
- a speed reducing mechanism part such as, for example, a two-stage planetary gear mechanism
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Abstract
Description
- The present application claims priority to Japanese patent application serial number 2012-285063 filed on Dec. 27, 2012, the contents of which are incorporated fully herein.
- The present invention generally relates to hand-held power tools, such as an impact tool or impact driver that is capable of rotary impact operation, and, for example, to an impact tool that has a shorter axial length than certain conventional impact tools.
- An impact driver is known from granted Japanese patent no. 4981345 that uses a motor for rotating a spindle via a speed reducing planetary gear mechanism. The rotational force of the motor is converted to rotational impact force via a hammer peripherally provided on a front end part of the spindle. The hammer is mounted so that it is urged frontward by a compression spring (i.e., a spring).
- Such a device includes a pin that passes through a rear part of the spindle and that serves as a rotary shaft of a planetary gear of the planetary gear mechanism. In order to retain this pin, a washer is provided on the front side of the rear part of the spindle that presses the pin rearward. This washer receives the spring on its front side and is shaped such that the immediate inner side of the portion that receives the spring bulges frontward in order to properly position and/or prevent mispositioning of the spring.
- Disclosed herein are impact tools whose front-rear length and/or vertical length is (are) shorter than conventional devices while at the same time providing adequate tightening torque. This makes the impact tool easy to handle, e.g., in narrow work spaces.
- A first aspect of the present teachings is an impact tool that comprises: a motor, a motor housing that houses the motor, a grip housing that is integrally provided with the motor housing, a hammer case that is disposed frontward of the motor housing, a spindle that is rotated by the motor, a hammer that is housed inside the hammer case and that is rotated by the spindle, and an anvil that is housed inside the hammer case and is impacted by the hammer. In this tool, the length from a rear end of the motor housing to a front end of the anvil is less than 128 mm. This may make the impact tool easier to handle, especially in tight places, and/or may make the impact tool usable in locations where the use of a larger impact tool is impractical.
- A second aspect of the present teachings is an impact tool according to the abovementioned aspect in which the length from the rear end of the motor housing to the front end of the anvil is less than 125 mm.
- A third aspect of the present teachings is an impact tool according to any of the abovementioned aspects in which the length from the rear end of the motor housing to the front end of the anvil is less than 120 mm.
- A fourth aspect of the present teachings is an impact tool according to any of the abovementioned aspects in which a battery is held (retained) below the grip housing and in which a length from a lower end of the battery to an upper end of the motor housing is less than 300 mm.
- A fifth aspect of the present teachings is an impact tool according to any of the abovementioned aspects in which a battery is held (retained) below the grip housing and in which a length from a lower end of the battery to an upper end of the motor housing is less than 250 mm.
- A sixth aspect of the present teachings is an impact tool according to any of the abovementioned aspects in which a battery is held (retained) below the grip housing and in which a length from a lower end of the battery to an upper end of the motor housing is less than 235 mm.
- Impact tools according to the first to sixth aspects generally provide superior handling properties as compared to larger impact tools capable of generating the same tightening torque.
- A seventh aspect of the present teachings is an impact tool according to any of the abovementioned aspects, wherein the impact tool further includes an engaging part on the spindle and a pin having an engaged part that latches to the engaging part and holds a planetary gear. The pin is immovable toward the hammer side because of the interaction of the engaging part and the engaged part.
- An impact tool according to the seventh aspect allows a conventional pin retaining washer to be omitted, thereby shortening the length from the rear end of the motor housing to the front end of the anvil.
- An eighth aspect of the present teachings is an impact tool according to any of the abovementioned aspects that includes a coil spring for urging the hammer. The engaging part and the engaged part are disposed at a location at which they do not interfere with the coil spring and the hammer, thereby reducing the effect of the impact and increasing durability.
- A ninth aspect of the present teachings is an impact tool according to any of the abovementioned aspects in which the pin comprises a large diameter part that holds the planetary gear and a small diameter part with a diameter smaller than that of the large diameter part. In this aspect, the engaging part is a recessed part to which the small diameter part mates. In this aspect, the length from the rear end of the motor housing to the front end of the anvil can be further shortened and the engaging part can be designed in a relatively simple manner.
- A tenth aspect of the present teachings is an impact tool according to any of the abovementioned aspects, wherein the impact tool further includes a spring receiving projection part provided on the spindle for holding (supporting) the coil spring. Furthermore, the location at which the hammer opposes the spring receiving projection part is hollowed (is hollow). Because the spindle directly receives the spring, the length from the rear end of the motor housing to the front end of the anvil can be further shortened without reducing the operational performance of the hammer.
- An eleventh tenth aspect of the present teachings is an impact tool according to any of the abovementioned aspects, wherein the impact tool further includes a bearing that is capable of holding a rotary shaft of the motor. The impact tool of this aspect also includes a bearing holding wall that holds the bearing and that is held by the hammer case, a first protruding part on the motor housing, and a second protruding part on the bearing holding wall that is disposed rearward of the first protruding part. The second protruding part is a rear part of the bearing holding wall and is disposed on the outer side in the radial direction of the bearing. In this aspect, the length from the rear end of the motor housing to the front end of the anvil can be further shortened while fixing the bearing holding wall with adequate strength.
- A twelfth aspect of the present teachings is an impact tool according to any of the abovementioned aspects that includes an internal gear that meshes with the planetary gear. A configuration is adopted wherein the internal gear abuts the front side of the hammer case and the internal gear is non-rotatably provided on the bearing holding wall. In addition, the location at which the internal gear opposes the hammer is hollow or hollowed. By bringing the hammer closer to the internal gear, the length from the rear end of the motor housing to the front end of the anvil can be further shortened without reducing the operational performance of the hammer.
- A thirteenth aspect of the present teachings is an impact tool according to any of the abovementioned aspects, wherein the impact tool further includes a bearing for holding the anvil disposed at a front part of the hammer case. A washer is disposed between the anvil and the hammer case, and a projecting part extends from the hammer case to the anvil side on the inner diameter side of the washer. Because the anvil washer, rather than the bearing of the anvil, is attached inside the front part of the hammer case, the front-rear length of the bearing (and, in turn, the length from the rear end of the motor housing to the front end of the anvil) can be shortened. Furthermore, a sufficient length for attaching the anvil washer (i.e., the press fitting length) can be ensured while adequately maintaining the front-rear length of the receiving part (i.e., the roller) of the bearing of the anvil and adequately holding the anvil.
- Further objects, embodiments, advantages, effects and designs of the present teachings will be explained in the following, or will become apparent to the skilled person, with the assistance of the exemplary embodiments and the appended Figures.
-
FIG. 1 is a right side view of an impact driver according to the present teachings. -
FIG. 2 is a rear view ofFIG. 1 . -
FIG. 3 is a center longitudinal cross sectional view ofFIG. 1 . -
FIG. 4 is an enlarged view of a main body part shown inFIG. 3 . -
FIG. 5 is a cross sectional view taken along the A-A line inFIG. 3 . -
FIG. 6 is a cross sectional view taken along the B-B line inFIG. 4 . -
FIG. 7 is a cross sectional view taken along the C-C line inFIG. 4 . -
FIG. 8 is a cross sectional view taken along the D-D line inFIG. 4 . -
FIG. 9 is a front view of a bearing retainer shown inFIG. 3 . -
FIG. 1 is a right side view of a rechargeable impact driver 1 (i.e., a representative example of a rotary impact tool), which is one example of a power tool for tightening, e.g., a screw according to the present teachings. Theimpact driver 1 comprises ahousing 2, which forms the contour or outer profile of theimpact driver 1. The front of theimpact driver 1 ofFIG. 1 is located at the right side of the figure. Theimpact driver 1 also comprises a tubularmain body part 4 with a central axis that extends in a front-rear direction. Agrip part 6 protrudes or projects from a lower part of themain body part 4. Thegrip part 6 is configured to be gripped by a user. A trigger-type switch relay (or simply a “trigger switch”) 8 is disposed on thegrip part 6 and can be pulled by a user using his or her fingertip to operate theimpact driver 1. Theswitch relay 8 protrudes from a switchmain body part 8 a. - As shown in
FIGS. 3-5 , themain body part 4 of the impact driver surrounds or encloses, in order from the rear side toward the front side, amotor 10, for example, an electric motor, more preferably a brushless DC motor, a planetary gear mechanism 12, aspindle 14, acoil spring 15 that is an elastic body, ahammer 16, and ananvil 18. These elements are coaxially housed in themain body part 4 of theimpact driver 1. - The
motor 10 is a drive source of theimpact driver 1. After the planetary gear mechanism 12 reduces the rotational speed of themotor 10, that rotation is transmitted to thespindle 14. Furthermore, the rotational force of thespindle 14 is converted into a rotational impact force by thehammer 16 and is transferred to theanvil 18. Thespring 15 spans the space between thespindle 14 and thehammer 16 and absorbs shock when necessary. Theanvil 18 receives the rotational impact force and rotates around an axis. - Referring again to
FIGS. 1-2 , themain body part 4 of thehousing 2 comprises amotor housing 20 that houses themotor 10 and ahammer case 22, which is disposed frontward of themotor housing 20 and houses thehammer 16. - The
motor housing 20 comprises aleft motor housing 20 a and aright motor housing 20 b that are shaped as half-split tubes, and arear motor housing 20 c that constitutes a rear surface. Anair suction port 20 e is formed both above and below a rear part of theleft motor housing 20 a and both above and below a rear part of theright motor housing 20 b. Furthermore, ascrew boss 20 f is configured to accept ascrew 3 from the rear and is provided at the rear between theair suction ports 20 e of theleft motor housing 20 a and theair suction ports 20 e of theright motor housing 20 b. In addition,exhaust ports 20 g are formed on the left and right of therear motor housing 20 c. - The
hammer case 22 is tubular, and the diameter of its front part is narrower than the diameter of its rear part. Thehammer case 22 is attached so that a portion of its rear part is inserted into a front part of themotor housing 20. - Referring again to
FIGS. 3-5 , a dish-shapedmetal bearing retainer 24 serves as a bearing holding wall and is attached to the inner sides of themotor housing 20. The bearingretainer 24 has a generally concave shape, although portions of it may be planar. It is held in place by thehammer case 22, because the bearingretainer 24 is interposed between thehammer case 22 and themotor housing 20. The metal bearing retainer is illustrated by itself inFIG. 9 and includes ahole 24 a formed at the center of the bearingretainer 24. In addition, a region adjacent to thehole 24 a is formed as a short hexagonal columnar hollow shape that is bottomed with respect to the outer part of that adjacent region. In other words, the region adjacent to thehole 24 a includes ahollow part 24 b that is hollow to the rear and that is positioned so that its bottom surface is oriented in the vertical direction. In addition, an outward protrudingrib 24 c protrudes in a ring shape outward in the radial directions with respect to the front side, and is provided on an outer edge of a rear end part of the bearing retainer 24 (i.e., on the rear side of the hollow part). Furthermore themotor housing 20 includes an inward protrudingrib 20 d (shown inFIGS. 3-5 ) that protrudes inward from an inner surface of themotor housing 20 at a position adjacent (i.e., on the front side of) the outward protrudingrib 24 c. This configuration of thehammer case 22 and the bearingretainer 24 substantially seals the planetary gear mechanism 12, thehammer case 22 and the bearingretainer 24 from the outside. - Referring again to
FIGS. 1 and 2 , thehousing 2 in thegrip part 6 is agrip housing 26 that is integrally provided at a lower part of themotor housing 20. Thegrip housing 26 comprises aleft grip housing 26 a and aright grip housing 26 b, each of which is half-split shaped. Theleft grip housing 26 a and theright grip housing 26 b and theleft motor housing 20 a and theright motor housing 20 b, respectively, are aligned by thescrews 3. - A forward/
reverse switching lever 5 is provided rearward of theswitch relay 8 at an upper part of theright grip housing 26 b such that it passes laterally through the boundary area between themain body part 4 and thegrip part 6. This switchinglever 5 is used for selecting a rotational direction of themotor 10. In addition, alight 7 is oriented to illuminate frontward, and is provided frontward of the forward/reverse switching lever 5 on the upper side of theswitch relay 8. In this embodiment, thelight 7 is an LED and is provided such that it overlaps theswitch relay 8 in the vertical directions. Because thelight 7 overlaps theswitch relay 8 in the vertical directions, a user's finger should not be positioned in the radiation direction of thelight 7. This arrangment substantially prevents the light from being blocked, thereby ensuring that the visibility of thelight 7 is satisfactory when turned on. - A lower end part of the
grip housing 26 is abattery attachment part 26 c that widens principally frontward with respect to an upper part of thegrip housing 26. Abattery 28 is detachable via apushbutton 28 a, and is held or retained below thebattery attachment part 26 c. Thebattery 28 may comprise, for example, a 14.4 V (volt) lithium ion battery (pack). - A
display part 26 d with a display switch (e.g., a display part comprising an LED) is provided at a front part of an upper part of thebattery attachment part 26 c. In addition, ahook groove 26 e, to which a hook (not shown) can be attached, and ascrew hole 26 f to which a separate member, such as a hook, having a screw can be attached, are formed on the left and right of the upper part of thebattery attachment part 26 c. Furthermore, astrap 26 g is provided at a rear part of thebattery attachment part 26 c. In addition, a circuit board 51 (FIG. 3 ) is housed inside thebattery attachment part 26 c. Six switching devices (not shown) are mounted on thecircuit board 51. These switching devices correspond in number to the number of associated drive coils 17 which are discussed below. - Referring again to
FIGS. 3-5 , themotor 10 is preferably a brushless DC motor comprising astator 19 having astator core 9, a front insulatingmember 11 and a rear insulatingmember 13 at the front and rear of thestator core 9, respectively, and a plurality of (here, six) drive coils 17 which are wound around thestator core 9 via the front insulatingmember 11 and the rear insulatingmember 13. In addition, asensor board 31 is fixed to the front insulatingmember 11 byscrews 21.Magnetic sensors 31 a (illustrated, for example, inFIG. 8 ), are fixed to a rear surface of thesensor board 31. Furthermore, in total, six coil connection parts Ila are provided at a peripheral edge of a front surface of the front insulatingmember 11 and serve as contacts that electrically connect to each of the drive coils 17 and thesensor board 31. - A
rotor 29 is disposed inside thestator 19. Therotor 29 comprises: arotor shaft 30, which serves as a rotary shaft, atubular rotor core 23 disposed around therotor shaft 30, andpermanent magnets 25 disposed on the outer side of therotor core 23. Thepermanent magnets 25 are tubular and have polarities that alternate in the circumferential direction. Therotor 29 also includes a plurality of sensorpermanent magnets 27 that are radially disposed on the front side of the permanent magnets 25 (i.e., on thesensor board 31 side). Therotor core 23, thepermanent magnets 25, and the sensorpermanent magnets 27 constitute a rotor assembly 29 a. The rotor assembly 29 a is disposed above the switchmain body part 8 a, and this arrangement improves the balance of theimpact driver 1, thereby making theimpact driver 1 easier to use when gripped. - A
tubular resin sleeve 35 is provided on therotor shaft 30 on the front side of therotor core 23. Afront bearing 36 of therotor shaft 30 is provided frontward of theresin sleeve 35. In addition, apinion 37 is fixed to a front end part of therotor shaft 30 forward of thebearing 36. Afan 32 for cooling is attached via ametal insert bushing 39 rearward of therotor core 23 of therotor shaft 30. Theinsert bushing 39 is press fitted onto therotor shaft 30 of thefan 32 and exerts a strong fixing force thereagainst. Thebearing 36 is disposed along a straight line that extends from the center of thescrew 3 of an upper part in themain body part 4 and the center of ascrew 3 of the lower part in themain body part 4. With this configuration, vibration of therotor shaft 30 can be effectively suppressed. - As shown in
FIG. 8 in particular, four throughholes 41 are formed in a side part of the circumferential edge of thesensor board 31, and one small recessedpart 43, recessed toward the inner side in the circumferential direction, is provided in an upper part of the circumferential edge of thesensor board 31. Moreover, five frontwardsmall projections 45 are provided in correspondence with the throughholes 41 and the recessedpart 43 on a front part of the front insulatingmember 11. Furthermore, thesmall projections 45 extend into the throughholes 41 and the recessedpart 43. In addition, two recessedparts 47, which are recessed toward the inner side in the circumferential directions, are provided on the side part of the circumferential edge of thesensor board 31, and thescrews 21 described above extend into the recessedparts 47. - As shown in
FIG. 5 , thefan 32 is shaped such that an adjacent part (i.e., the inner side) of therotor shaft 30 bulges frontward with respect to the outer part (i.e., the outer side) of therotor shaft 30. In other words, thefan 32 has a bulgingpart 32 a that bulges frontward, toward a center part. Furthermore, arear bearing 34 of therotor shaft 30 is installed on an inner surface of therear motor housing 20 c so that thebearing 34 is partially disposed within the rear side (i.e., the inner side on the outer part) of the bulgingpart 32 a. Theexhaust ports 20 g are disposed in therear motor housing 20 c and on the outer side of thefan 32 in the radial directions. This allows the airflow produced by thefan 32 to be discharged efficiently. In addition, theexhaust ports 20 g are disposed above and below each of thescrews 3, which screws 3 are received in thescrew bosses 20 f. In this manner therear motor housing 20 c is attached, for example, by thescrew bosses 20 f, which screwbosses 20 f are regions adjacent to theexhaust ports 20 g, and thereby the post-assembly strength of therear motor housing 20 c is improved. - In addition, as shown principally in
FIG. 7 andFIG. 9 , the bearingretainer 24 is disposed at a location at which it overlaps, in the axial direction, two of thescrews 21 and four of the small projections 45 (except for the ones on the uppermost side) related to the front insulatingmember 11. Consequently, the length of themain body part 4 in the front-rear direction is shorter than would be possible if the bearingretainer 24 were disposed frontward of thescrews 21, thesmall projections 45, and the like. - Furthermore, referring again to
FIGS. 3-5 , afront protruding wall 24 d protrudes frontward from an outer edge of a front part of the bearingretainer 24, and a male thread ridge (not shown) is formed on an outer circumferential surface thereof. Moreover, a female thread groove (not shown) is formed on an inner circumferential surface of a rear end part of thehammer case 22. The bearingretainer 24 is fixed to thehammer case 22 by the meshing of the male thread groove with the female thread groove. Furthermore, because thehollow part 24 b of a rear part of the bearingretainer 24 has a hexagonal columnar shape, it is easy to rotate the bearingretainer 24 with respect to thehammer case 22 by using a wrench or similar tool. The male thread ridge easily advances into the female thread groove making it is easy to attach the bearingretainer 24 to thehammer case 22. - In addition, the front bearing 36 of the
rotor shaft 30 is installed so that it extends into a rear part of thehole 24 a of the bearingretainer 24. Referring back toFIGS. 7 and 9 , a plurality ofhollow parts 49 a are formed, arrayed in the circumferential direction, in a rear surface of thehollow part 24 b of the bearing retainer 24 (i.e., outside of the bearing 36).Ribs 49 b, each of which is shaped as a small rear-facing wall, are respectively formed between thehollow parts 49 a. In addition, a bearing 40 (FIGS. 3-5 ), which receives arear end part 14 a of thespindle 14, is installed on the inner side of thehollow part 24 b of the bearingretainer 24. Thehollow parts 49 a are positioned in the direction of thebearing 40. The bearingretainer 24 suitably dissipates heat by way of thehollow parts 49 a, alone or by a combination of thehollow parts 49 a and theribs 49 b. Furthermore, because the bearingretainer 24 is made of metal, it is even more suited to dissipating heat. - In addition, a plurality of front protruding
parts 24 e which protrude frontward, are formed in stripes along the radial directions at a location on the front side of the bearing 36 in the bearing retainer 24 (i.e., on the outer side of thebearing 36 inside thehollow part 24 b). The front protrudingparts 24 e also help the bearingretainer 24 dissipate heat. The front protrudingparts 24 e extend into the inner diameter side of thebearing 40 and overlap the bearing 40 in the axial direction. - As shown in
FIGS. 3-5 , thespindle 14 comprises a hollow discoidal (disk-shaped)part 14 b, which is the rear part of thespindle 14 and is located on the front side of a rear end part of thespindle 14. Thediscoidal part 14 b protrudes radially outward (vertically and laterally) with respect to the other portion of thespindle 14, and the diameter of thediscoidal part 14 b is greater than the diameter of the other portion. - In the bearing
retainer 24,hollow parts 24 f are provided on a portion opposing thediscoidal part 14 b. Each of thehollow parts 24 f extends to the outer side of thebearing 40. Thesehollow parts 24 f help the bearingretainer 24 dissipate heat. - Part of the planetary gear mechanism 12 is disposed inside the
discoidal part 14 b of thespindle 14. The planetary gear mechanism 12 comprises: aninternal gear 42 having internal teeth, a plurality ofplanetary gears 44 having external teeth that mesh with theinternal gear 42, and pins 46 that constitute the shafts of the planetary gears 44. - The
internal gear 42 is formed such that both the inner and outer diameters of afront part 42 b, located on the front side of a tubular rear part at a rear part of theinternal gear 42, are expanded to be greater than the diameter of the tooth part 42 a. This diameter expansion results in a recessedpart 42 c on the inner circumferential side of thefront part 42 b. - As shown in
FIG. 6 in particular, four protruding parts (protrusions) 42 d are provided in thefront part 42 b, and four corresponding recessed parts (recesses) 22 c are provided on the inner side of thehammer case 22. Because each of the protrudingparts 42 d extends into a corresponding recessedpart 22 c, they are mutually engaged. To ensure an adequate length in the front-rear directions in such engagement, each of the protrudingparts 42 d is formed such that it reaches the outer circumferential side of the final retraction position of thehammer 16. - Referring back to
FIGS. 3-5 , the recessedpart 42 c is disposed at the same position as an outer circumferential part of thehammer 16 in the radial direction. Furthermore, because of the presence of the recessedpart 42 c, the location at which theinternal gear 42 opposes thehammer 16 is hollowed; in other words, the inner diameter of thefront part 42 b of theinternal gear 42 is greater than the outer diameter of thehammer 16, and thefront part 42 b of theinternal gear 42 is formed such that it does not interfere with thehammer 16. A portion of thehammer 16 can thus partially overlap a portion of theinternal gear 42 and extend into the recessedpart 42 c. Theinternal gear 42 is non-rotatably attached to the inner side of a region at which the front part of the bearingretainer 24 and a rear end edge of thehammer case 22 overlap. A front surface of theinternal gear 42 contacts astep part 22 a formed by the slight diametric expansion of a rear part of thehammer case 22 at the rear end edge over the front part, and therefore, theinternal gear 42 abuts thehammer case 22 on the front side. Furthermore, thefront protruding wall 24 d of the bearingretainer 24 extends into the inner side of themotor housing 20, which is the outer side of the tooth part 42 a. - Each of the
pins 46 and the majority of each of theplanetary gears 44 are disposed inward of thediscoidal part 14 b of thespindle 14. Each of thepins 46 is formed such that the diameter of its front end part is narrower than its rear portion, namely,large diameter parts 46 b are respectively located on the rear sides ofsmall diameter parts 46 a. Moreover, a plurality of pin holes 14 c, corresponding to thesmall diameter parts 46 a of thepins 46, are provided (the same number as the pins 46) in a front surface of thediscoidal part 14 b of thespindle 14. In addition, a plurality of pin holes 14 d, corresponding to rear end parts of thelarge diameter parts 46 b of thepins 46, are provided in a rear surface of thediscoidal part 14 b. Furthermore, each of thepins 46 is provided inside thediscoidal part 14 b so that thesmall diameter parts 46 a respectively enter the pin holes 14 c and the rear end parts of thelarge diameter parts 46 b respectively enter the pin holes 14 d. In each of thepins 46, thesmall diameter part 46 a is aligned with itscorresponding pin hole 14 c, and thereby a step or shoulder between thesmall diameter part 46 a and thelarge diameter part 46 b contacts an inner surface of thediscoidal part 14 b (i.e., an inner circumferential edge of thepin hole 14 c). Thepin 46 is thus in a state in which it cannot move toward thehammer 16. - Each of the
planetary gears 44 is fixedly mounted to its correspondingpin 46 so that it cannot rotate relative to thepin 46. Each of theplanetary gears 44 is disposed such that some of the external teeth protrude outward from thediscoidal part 14 b. - A spindle hole is provided at the front and rear of the
discoidal part 14 b. The spindle hole is an inner part of (i.e. defined within) thespindle 14 and extends frontward from a rear surface of thespindle 14. The spindle hole has: afront side hole 14 e, which is a front part of the spindle hole, and arear side hole 14 f, which is provided rearward of thefront side hole 14 e. The diameter of therear side hole 14 f is larger than the diameter of thefront side hole 14 e. Because the diameter of therear side hole 14 f is larger than the diameter of thefront side hole 14 e, thepinion 37 tends not to contact therear side hole 14 f when thepinion 37 enters those holes to mesh with the planetary gears 44. In addition, because the diameter of thefront side hole 14 e is smaller than the diameter of therear side hole 14 f, thespindle 14 is sufficiently durable in view of the torque that will be applied thereto. - Teeth are formed in the
pinion 37 inwardly of a rear part of the spindle hole (i.e., inward of therear side hole 14 f and of a rear part of thefront side hole 14 e) and are shared and mesh with all theplanetary gears 44. Thepinion 37 is located at a tip part of therotor shaft 30 of themotor 10, and the tip part of therotor shaft 30 extends into the pinion. The diameter of therear side hole 14 f is larger than the external diameter of the bearing 36 of therotor shaft 30. In addition, a short spring receivingprojection part 14 g is oriented in the front-rear direction and is provided integrally with thediscoidal part 14 b of thespindle 14 at an outer edge of the front surface of thediscoidal part 14 b. - The spring receiving
projection part 14 g is ring shaped (i.e. annular), and a ring shaped (annular) rear end part of thespring 15 is disposed on the inner side of the spring receivingprojection part 14 g. The spring receivingprojection part 14 g is a spring receiving structure that receives (supports) thespring 15. Furthermore, the pin holes 14 d are disposed on the inner side of thespring 15, and thesmall diameter parts 46 a of thepins 46 are disposed rearward of thespring 15. - The spring receiving
projection part 14 g enters the inner side of theinternal gear 42. Furthermore, the spring receivingprojection part 14 g, the rear end part of thespring 15 and theinternal gear 42 overlap in the front-rear direction. - A front end of the
pinion 37 is disposed rearward of a front end of the spring receivingprojection part 14 g. This allows ashorter pinion 37 to be used, and the cost of materials related to thepinion 37 can be reduced. In addition, the front end of thepinion 37 is disposed rearward of a front end of theinternal gear 42. Thepinion 37 can thus be made shorter, and the cost of materials related to thepinion 37 can be reduced. - The inner diameter of the
bearing 40 receives therear end part 14 a of thespindle 14 and is larger than the external diameter of thebearing 36, which is held by the bearingretainer 24. In addition, a rear surface of thebearing 40 is disposed so that it is located frontward of a front surface of thebearing 36 and so that thebearing 40 and thebearing 36 are shifted or displaced from one another in the front-rear direction. The force transmitted from thespindle 14 to thebearing 40 thus tends not to be transmitted to thebearing 36. Therefore, the service life of thebearing 36, the bearingretainer 24, etc. can be increased. - Moreover, the
hammer 16 has a hollow or a hollow interior 16 a, which is formed in a tubular manner frontward of a rear surface of thehammer 16. A front part of thespring 15 extends into the hollow 16 a. A ring-shaped front end part of thespring 15 is located near the bottom or front end of the hollow 16 and is spaced therefrom by a plurality ofballs 50 and ahammer washer 52 at the bottom of the hollow 16 a. - On the outer side of a rear end edge of the hollow 16 a (i.e., on the outer side of the opening), a spring receiving
release part 16 b is provided that widens from the rear end edge toward the outer side with respect to the outer side surface at the front side. The spring receivingrelease part 16 b and the spring receivingprojection part 14 g of thespindle 14 are disposed at the same position in the inner-outer directions (i.e., the radial directions) of the tubularmain body part 4. Because the spring receivingrelease part 16 b avoids the spring receivingprojection part 14 g, thehammer 16 and thespindle 14 do not interfere with one another even if, for example, thehammer 16 moves rearward and comes into proximal contact with the front side of thediscoidal part 14 b. - In addition, the hollow 16 a is disposed at the same position as the pin holes 14 d and the
small diameter parts 46 a of thepins 46, in the radial directions. The pin holes 14 d and thesmall diameter parts 46 a are disposed at locations at which they do not interfere with thehammer 16 even if, for example, thehammer 16 moves rearward and comes into proximal contact with the front side of thediscoidal part 14 b. Furthermore,balls 54 are interposed between thehammer 16 and a front part of thespindle 14 and guide thehammer 16 principally in the front-rear directions during impact. - The
anvil 18 on the front side of thehammer 16 comprises, at its rear end part, a pair ofextension parts 18 a, each of which extends in the radial directions. An anvil bearing 60 is provided on the front side of theextension parts anvil bearing 60 rotatably supports theanvil 18 around its axis and fixedly supports theanvil 18 in the axial direction. Theanvil bearing 60 is attached to an inner wall of a front end part of thehammer case 22. - In addition, a
rear hole 18 b extends frontward from a rear surface of theanvil 18 and is formed in the center of a rear part of theanvil 18. A front end part of thespindle 14 extends into therear hole 18 b so that a rotational impact force cannot be transmitted. In addition, a chuck part (or simply “a chuck”) 18 c, which accepts and holds a not-shown tool bit (i.e., a tip tool), is provided at a front part of theanvil 18. - An
anvil washer 62 receives theanvil 18 and is made of a synthetic resin (e.g., nylon). Theanvil washer 62 is disposed between the outer edges of theextension parts 18 a of theanvil 18 and a front inner wall of thehammer case 22. Awasher holding part 22 b protrudes frontward in a ring shape from the front inner wall of thehammer case 22 and is provided on the immediate inner side of an inner wall of the ring shapedanvil washer 62. Theanvil washer 62 is press fitted into or otherwise held by thewasher holding part 22 b. - A front end of the
switch relay 8 is disposed rearward of the rear surface of theanvil 18. This makes theimpact driver 1 easy to handle because of the advantageous positional relationship between the portion of the tool that receives the impact and theswitch relay 8 operated by the user. - An example of the operation of such an
impact driver 1 will now be explained. - When a user or worker grips the grip part 6 (i.e., the grip housing 26) and pulls the
switch relay 8, power is supplied from thebattery 28 to themotor 10, and the motor causes therotor shaft 30 to rotate. Thefan 32 is rotated by therotor shaft 30 and creates a flow of air from theair suction ports 20 e to theexhaust ports 20 g. At this time, the flow of the air first cools the outer circumference of thestator core 9. Subsequently, the entire surface of thesensor board 31 is cooled. Therotor core 23 and the inner circumferences of the drive coils 17 and thestator core 9 are also cooled. - In addition, the rotational force of the
rotor shaft 30 is reduced by theplanetary gears 44 which run while spinning inside theinternal gear 42, and the rotational force of therotor shaft 30 is transmitted to thespindle 14 via thepins 46. Thespindle 14 both rotates theanvil 18 and guides thehammer 16 such that thehammer 16 oscillates to the front and rear (i.e., impacts) when torque above a prescribed threshold is received at theanvil 18. At the time of impact, the cushioning effect provided by thespring 15 acts on the hammer 16 (and on thespindle 14 and the like). - In the above-described
impact driver 1, the length from a rear end of themotor housing 20 to a front end of the anvil 18 (hereinbelow, called the “front-rear length of themain body part 4”) can be shortened by employing the following types of independently-usable configurations described below, or by employing one or more combinations thereof. As a result, the length of themain body part 4 in the front-rear direction can be made shorter than that of the prior art (129 mm) (i.e., can be made less than 128 mm, preferably less than 125 mm, or more preferably less than 120 mm by employing a combination of preferred configurations). For example, the front-rear length of themain body part 4 in theimpact driver 1 shown inFIGS. 1-4 is 119.7 mm. - First, the pin holes 14 c (i.e., “engaging parts”) are provided in the
discoidal part 14 b of thespindle 14. The pins 46 (i.e., “engaged parts”) have thesmall diameter parts 46 a, engage with the pin holes 14 c and hold the planetary gears 44. In addition, the pin holes 14 c and thesmall diameter parts 46 a make thepins 46 immovable toward thehammer 16 side. This configuration makes it possible both to suppress (prevent) the movement of thepins 46 toward thehammer 16, even if a conventional washer is not separately provided in front of thepins 46, and to omit the conventional washer, thus making it possible to reduce the number of parts and to commensurately shorten the front-rear length of themain body part 4. - Furthermore, the
pins 46 comprise thelarge diameter parts 46 b, which hold theplanetary gears 44, and thesmall diameter parts 46 a, whose diameters are smaller than those of thelarge diameter parts 46 b. The pin holes 14 c are recessed parts that mate with thesmall diameter parts 46 a. This configuration makes it possible to suppress (prevent) the movement of thepins 46 in a simple manner, even if a conventional washer is omitted, in order to, for example, shorten the front-rear length of themain body part 4. - In addition, the spring receiving
projection part 14 g, which holds (supports) thespring 15, is provided on thespindle 14, and the location at which thehammer 16 opposes the spring receivingprojection part 14 g is hollow from the spring receivingrelease part 16 b of the hollow 16 a. This configuration makes it possible to adequately hold thespring 15 and to prevent thespring 15 and the spring receivingprojection part 14 g from interfering with one another, thereby protecting them. - The
impact driver 1 includes thebearing 36, which is capable of holding (rotatably supporting) therotor shaft 30 of themotor 10, and the bearingretainer 24, which holds thebearing 36 and serves as the bearing holding wall that is held by thehammer case 22. Furthermore, the inward protrudingrib 20 d, which serves as a first protruding part, is provided on themotor housing 20; the outward protrudingrib 24 c, which serves as a second protruding part, is provided on the bearingretainer 24; the outward protrudingrib 24 c is disposed rearward of the inward protrudingrib 20 d; finally, the outward protrudingrib 24 c is the rear part of the bearingretainer 24 and is disposed on the outer side in the radial directions of thebearing 36. This configuration makes it possible to shorten the front-rear length of the bearingretainer 24 as compared to the case in which thebearing 36 is disposed rearward of the outward protrudingrib 24 c, and thus shortens the front-rear length of themain body part 4. In addition, because the outward protrudingrib 24 c, which contacts the inward protrudingrib 20 d, is still provided, strength can be maintained even though the front-rear length of themain body part 4 is shortened. - Furthermore, the
internal gear 42 meshes with theplanetary gears 44 and is configured such that it abuts thehammer case 22 on the front side. Theinternal gear 42 is non-rotatably provided on the bearingretainer 24, and the location at which theinternal gear 42 opposes thehammer 16 is hollow (i.e., theinternal gear 42 includes the recessedpart 42 c). This configuration makes it possible for thehammer 16 to move to a location at which it overlaps with theinternal gear 42 in the front-rear direction (i.e., to a location at which a rear end part of thehammer 16 extends into the inner side of thefront part 42 b of the internal gear 42), without interfering with theinternal gear 42. This configuration can, while maintaining the distance over which thehammer 16 is moved, narrow the front-rear spacing between theinternal gear 42 and thehammer 16 and commensurately shorten the front-rear length of themain body part 4 as compared to a device in which no recessedpart 42 c is provided in theinternal gear 42. - Furthermore, the bearing 60 for holding the
anvil 18 is disposed in a front part of thehammer case 22, theanvil washer 62 is disposed between theanvil 18 and thehammer case 22, and thewasher holding part 22 b, which serves as a projecting part, is provided such that it extends from thehammer case 22 to theanvil 18 side and such that it is disposed on the inner diameter side of theanvil washer 62. This configuration makes it possible to attach theanvil washer 62 even without providing the projecting part on thebearing 60 and to shorten the front-rear length of thebearing 60 while securing an adequate attachment length (i.e., a press fitting length) for thewasher holding part 22 b. This also makes it possible to shorten the front-rear length of themain body part 4. - In addition, the
hollow parts 49 a are provided inside the outward protrudingrib 24 c of the bearingretainer 24. This configuration makes it possible to effectively absorb the shock of the rotary impact in the radial directions and of the axial impact in the axial directions induced by the front-rear movement and the rotation of thehammer 16 and received from the bearingretainer 24. - The
motor housing 20 comprises therear motor housing 20 c, which constitutes a rear surface of themotor housing 20. Therear motor housing 20 c is formed independently of other portions of the motor housing 20 (i.e., portions other than the rear part). This configuration makes it possible to suppress or minimize the rearward bulging of themotor housing 20, while still maintaining the size of the internal space of themotor housing 20, and to shorten the front-rear length of themain body part 4. - In addition, the
fan 32 is shaped such that its inner side in the radial directions bulges frontward with respect to its outer side and is disposed such that thebearing 34, which is adjacent to thefan 32, projects into the inner side of the bulgingpart 32 a of thefan 32. This configuration makes it possible for thebearing 34 to approach (i.e. to be disposed closer to) thefan 32 as compared with a configuration in which thebearing 34 is disposed rearward of a (conventional) flat or planar fan. This also makes it possible to shorten the front-rear length of themain body part 4. - In addition, the diameter of the
rear side hole 14 f is made larger than the outer diameter of the bearing 36 of therotor shaft 30. This configuration makes it possible to assemble themotor 10, including thebearing 36, by appropriately using the space of therear side hole 14 f, even after the assembly of thespindle 14 and the bearingretainer 24. This arrangement produces amotor 10, the front-rear length of which is short, thereby making it possible to easily assemble theimpact driver 1 so that the front-rear length of themain body part 4 is short. - In addition, as shown in
FIG. 4 andFIG. 5 in particular, thescrew bosses 20 f are provided on theleft motor housing 20 a and also on theright motor housing 20 b. Each of thescrew bosses 20 f extends in the front-rear directions. Therear motor housing 20 c is fixed by two of thescrews 3 to two of thescrew bosses 20 f and thereby the length of themain body part 4 in the front-rear directions is shortened. Furthermore, thebearing 34, thefan 32, the rear insulatingmember 13, thestator core 9, therotor shaft 30, and thepermanent magnets 25 are disposed such that they are interposed between two of thescrews 3. This configuration also makes it possible to shorten the length of themain body part 4 in the front-rear directions. - Furthermore, the appropriate selection and adoption (usage) of one or more such configurations makes it possible to configure the
impact driver 1, comprising: themotor 10, themotor housing 20 which houses themotor 10, thegrip housing 26 which is integrally provided with themotor housing 20, thehammer case 22 which is disposed frontward of themotor housing 20, thespindle 14 which is rotated by themotor 10, thehammer 16, which is housed inside thehammer case 22 and is rotated by thespindle 14, and theanvil 18 which is housed inside thehammer case 22 and is impacted by thehammer 16. In such animpact driver 1, the length from the rear end of themotor housing 20 to the front end of the anvil 18 (i.e., the front-rear length of the main body part 4) is less than 128 mm (or 125 mm or 120 mm). Furthermore, the practical lower limit of the front-rear length of themain body part 4 is preferably 115 mm (or 110 mm). - In addition, shortening the front-rear length of the
main body part 4 makes it possible to adequately support themain body part 4 even though the vertical length of thegrip housing 26 is short. This makes it possible to configure theimpact driver 1 so that thebattery 28 is held below thegrip housing 26 and so that the length from a lower end of thebattery 28 to an upper end of themotor housing 20 is less than 300 mm (or 250 mm, or 235 mm). Furthermore, the practical lower limit of that length is preferably 230 mm (or 200 mm). - Furthermore, it is possible to adopt a configuration wherein the weight of the impact driver 1 (including the battery) is preferably less than 2.0 kilograms (kg), and more preferably less than 1.5 kg or less than 1.4 kg.
- In addition, it is also possible to configure the
impact driver 1 such that it can output a torque of at least 150 Newton-meters (Nm), and more preferably a torque of 160 Nm or greater, and yet more preferably a torque of 170 Nm or greater. - Furthermore, the rear end of the
battery attachment part 26 c and the rear end of themotor housing 20 are disposed on the front side of a rear surface of thebattery 28. In addition, the rear end of themotor housing 20 is disposed on the front side of the rear end of thebattery attachment part 26 c. With this configuration, the rear end of thebattery attachment part 26 c, the rear end of themotor housing 20, and the like tend not to hinder work (power tool operations). - Thus, shortening the front-rear length and/or the vertical length of the
impact driver 1 makes it possible to provide animpact driver 1 that it is easy to handle and that reduces incidences of impingements (blockages) in narrow places and that reduces the likelihood of having to perform work (power tool operations) in an unreasonable (e.g., uncomfortable or awkward) posture. - Furthermore, the present invention is not limited to the above embodiments; for example, the following exemplary types of modifications can be implemented where appropriate.
- With regard to the engaging of the planetary gear mechanism 12 and the
spindle 14, instead of the pin small diameter parts being inserted into the pin holes, or in combination therewith, small projections may be inserted into small holes or tabs may be latched together, and the like. In addition, instead of forming the pin holes as through openings or bottomless, it is also possible to form the pinholes as blind openings or with bottoms. - With regard to the spring receiving structure of the
spindle 14, instead of the configuration wherein thespindle 14 is held by being supported on the outer diameter side of thecoil spring 15, thespindle 14 may be held on the inner diameter side of thecoil spring 15, or thespindle 14 may be held by being press fitted to the outer diameter side or the inner diameter side of thecoil spring 15, or thespindle 14 may be held by using a screw to screw thecoil spring 15 to thespindle 14, or thecoil spring 15 and thespindle 14 may be welded together. Various combinations of these configurations may also be adopted. - The spring receiving
release part 16 b of thehammer 16 may be formed into a shape other than a shape in which its diameter expands rearward. - A configuration may be adopted in which the external gear is not held in the bearing
retainer 24, but rather is held by a separate housing. - A configuration may be adopted wherein, instead of the
anvil washer 62 being attached by press fitting, theanvil washer 62 is latched by a tab and a latching part thereof, or wherein theanvil washer 62 is welded, or the like. - In the disclosed embodiment, a configuration is adopted wherein six switching devices are disposed on the
circuit board 51, which in turn is disposed inside thebattery attachment part 26 c. However, it is also possible to adopt a configuration in which the six switching devices are disposed on thesensor board 31. In addition, it is also possible to dispose thefan 32 frontward of the front insulatingmember 11 and to screw thesensor board 31 to the rear insulatingmember 13 so that thesensor board 31 is disposed rearward of the rear insulatingmember 13. - The
battery 28 may be any (arbitrary) lithium ion battery (pack) of 18 V (20 V maximum), or in the range of 18-36 V, such as 18 V, 25.2 V, 28 V, or 36 V. In addition, a lithium ion battery (pack) having a voltage that is less than 14.4 V or greater than 36 V may be used. Other types of batteries may also be used, such as, e.g., nickel-cadmium or nickel-metal hydride. - The
permanent magnets 25 and the sensorpermanent magnets 27 in the rotor assembly 29 a can also be integrally configured as four plate shaped permanent magnets. - The present teachings can also be readily adapted to a rechargeable driver drill or a hammer (vibration) driver drill by utilizing a gear case in place of the
hammer case 22, by omitting thehammer 16 and theanvil 18, and further including a speed reducing mechanism part such as, for example, a two-stage planetary gear mechanism, thereby making the output shaft of the speed reducing mechanism part protrude frontward from the gear case, and fixing the tip tool holding part, which holds the tip tool, to the front part of the output shaft. - It is understood that other variations and modifications to the disclosed embodiments may be effected by appropriately changing the number, arrangement, material, size, form, and the like of the various members, for example, changing the number of partitions of the housing, increasing or decreasing the number of the external gears installed, positioning the spring receiving projection parts more on the inner side, and changing the form of the switch of the switch relay. It is intended that all such variations and modifications form a part of the present invention to the extent they fall within the scope of the several claims appended hereto.
- Representative, non-limiting examples of the present invention were described above in detail with reference to the attached drawings. This detailed description is merely intended to teach a person of skill in the art further details for practicing preferred aspects of the present teachings and is not intended to limit the scope of the invention. Furthermore, each of the additional features and teachings disclosed above may be utilized separately or in conjunction with other features and teachings to provide improved impact tools (drivers), as well as methods for manufacturing and using the same.
- Moreover, combinations of features and steps disclosed in the above detailed description may not be necessary to practice the invention in the broadest sense, and are instead taught merely to particularly describe representative examples of the invention. Furthermore, various features of the above-described representative examples, as well as the various independent and dependent claims below, may be combined in ways that are not specifically and explicitly enumerated in order to provide additional useful embodiments of the present teachings.
- All features disclosed in the description and/or the claims are intended to be disclosed separately and independently from each other for the purpose of original written disclosure, as well as for the purpose of restricting the claimed subject matter, independent of the compositions of the features in the embodiments and/or the claims. In addition, all value ranges or indications of groups of entities are intended to disclose every possible intermediate value or intermediate entity for the purpose of original written disclosure, as well as for the purpose of restricting the claimed subject matter.
-
- 1 Impact driver (impact tool)
- 10 Motor
- 14 Spindle
- 14 c Pin hole (engaging part recessed part)
- 14 g Spring receiving projection part
- 15 Spring (coil spring)
- 16 Hammer
- 16 b Spring receiving release part
- 18 Anvil
- 20 Motor housing
- 20 d Inward protruding rib (first protruding part)
- 22 Hammer case
- 22 b Washer holding part (projecting part)
- 24 Bearing retainer (bearing holding wall)
- 24 c Outward protruding rib (second protruding part)
- 26 Grip housing
- 28 Battery
- 30 Rotor shaft (rotary shaft) (of motor)
- 36 Bearing (of rotor shaft)
- 42 Internal gear
- 44 Planetary gear
- 46 Pin
- 46 a Small diameter part (engaged part)
- 46 b Large diameter part
- 60 Bearing (of anvil)
- 62 Anvil washer
Claims (19)
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
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US17/326,724 US20210276164A1 (en) | 2012-12-27 | 2021-05-21 | Impact tool |
US18/409,099 US20240139915A1 (en) | 2012-12-27 | 2024-01-10 | Impact tool |
Applications Claiming Priority (6)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP2012285063A JP6050110B2 (en) | 2012-12-27 | 2012-12-27 | Impact tools |
JP2012285063 | 2012-12-27 | ||
US14/064,278 US9643300B2 (en) | 2012-12-27 | 2013-10-28 | Impact tool |
US15/477,388 US10213907B2 (en) | 2012-12-27 | 2017-04-03 | Impact tool |
US16/244,356 US11045926B2 (en) | 2012-12-27 | 2019-01-10 | Impact tool |
US17/326,724 US20210276164A1 (en) | 2012-12-27 | 2021-05-21 | Impact tool |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
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US16/244,356 Continuation US11045926B2 (en) | 2012-12-27 | 2019-01-10 | Impact tool |
Related Child Applications (1)
Application Number | Title | Priority Date | Filing Date |
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US18/409,099 Division US20240139915A1 (en) | 2012-12-27 | 2024-01-10 | Impact tool |
Publications (1)
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US20210276164A1 true US20210276164A1 (en) | 2021-09-09 |
Family
ID=50928515
Family Applications (5)
Application Number | Title | Priority Date | Filing Date |
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US15/477,388 Active 2033-12-04 US10213907B2 (en) | 2012-12-27 | 2017-04-03 | Impact tool |
US16/244,356 Active 2034-09-11 US11045926B2 (en) | 2012-12-27 | 2019-01-10 | Impact tool |
US17/326,724 Abandoned US20210276164A1 (en) | 2012-12-27 | 2021-05-21 | Impact tool |
US18/409,099 Pending US20240139915A1 (en) | 2012-12-27 | 2024-01-10 | Impact tool |
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US14/064,278 Active 2035-10-25 US9643300B2 (en) | 2012-12-27 | 2013-10-28 | Impact tool |
US15/477,388 Active 2033-12-04 US10213907B2 (en) | 2012-12-27 | 2017-04-03 | Impact tool |
US16/244,356 Active 2034-09-11 US11045926B2 (en) | 2012-12-27 | 2019-01-10 | Impact tool |
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Application Number | Title | Priority Date | Filing Date |
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US18/409,099 Pending US20240139915A1 (en) | 2012-12-27 | 2024-01-10 | Impact tool |
Country Status (4)
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US (5) | US9643300B2 (en) |
JP (1) | JP6050110B2 (en) |
CN (1) | CN103894650B (en) |
DE (1) | DE102013021202B4 (en) |
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Also Published As
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US11045926B2 (en) | 2021-06-29 |
CN103894650B (en) | 2016-06-29 |
DE102013021202A1 (en) | 2014-07-03 |
US20240139915A1 (en) | 2024-05-02 |
DE102013021202B4 (en) | 2023-03-16 |
US9643300B2 (en) | 2017-05-09 |
US20190143491A1 (en) | 2019-05-16 |
US20170203418A1 (en) | 2017-07-20 |
US10213907B2 (en) | 2019-02-26 |
CN103894650A (en) | 2014-07-02 |
US20140182869A1 (en) | 2014-07-03 |
JP6050110B2 (en) | 2016-12-21 |
JP2014124751A (en) | 2014-07-07 |
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