Impacting Apparatus

Abstract

An impacting apparatus comprises a motor to actuate a spring striker assembly that includes a gas spring piston that is coupled to a striker. After a sufficient movement of the piston, the piston commences movement and accelerates the spring striker assembly to impact a substrate or object. The motor is coupled to the spring striker assembly through an interrupted drive mechanism such as a chain and sprockets configuration for providing for continuous impacting/driving. The drive mechanism alternatively actuates the piston of the spring striker assembly and decouples from the spring striker assembly to allow pressure or other force to act on the spring piston. The gas spring is replaceable and becomes slightly energized when installed in the apparatus by a gas spring preload means.

Claims

1. An impacting apparatus, the apparatus comprising a power source, a control circuit, a motor, said motor capable of rotational motion, a striker cup, a spring striker assembly, said spring striker assembly comprising a gas spring and an striker, said gas spring comprising a chamber and a piston and said striker comprising at least one lifting surface, a chain assembly, said chain assembly comprising a plurality of sprockets, said sprockets being operatively coupled to said motor, a chain operatively coupled to said plurality of sprockets, said chain comprising a plurality of lifter links disposed along said chain and said sprockets capable of causing the chain to translate, and a clutch, wherein when said chain assembly translates, at least one lifter link of said plurality of lifter links engages at least one lifting surface of said striker for a portion of said translation of said chain to increase potential energy in said gas spring and after said chain assembly disengages said spring striker assembly, potential energy from said gas spring decreases while accelerating the striker to impact said striker cup, wherein the impact force from said striker is transmitted to said striker cup, wherein said chain assembly thereafter again engages said spring striker assembly, and wherein said clutch prevents reverse rotation of the motor when the apparatus is not operating.

2. The apparatus of claim 1, wherein each lifter link of said plurality of lifter links comprises a lifting roller.

3. The apparatus of claim 1, wherein said at least a portion of said at least one lifting surface of said striker inclines toward said striker.

4. The apparatus of claim 1, wherein said apparatus further comprises a gas spring preload means.

5. The apparatus of claim 1, wherein said gas spring comprises at least one cup seal.

6. An impacting apparatus, the apparatus comprising a power source, a control circuit, a motor, said motor capable of rotational motion, a striker cup, a spring striker assembly, said spring striker assembly comprising a gas spring and a striker, said gas spring comprising a chamber and a piston and said striker comprising at least one lifting surface, a chain assembly, said chain assembly comprising a plurality of sprockets, said sprockets being operatively coupled to said motor, a chain operatively coupled to said plurality of sprockets, said chain comprising a plurality of lifter links disposed along said chain and said sprockets capable of causing the chain to translate, and a sensor, said sensor being operatively coupled to said control circuit and capable of determining the location of at least one of said striker and said striker cup, wherein when said chain assembly translates, at least one lifter link of said plurality of lifter links engages at least one lifting surface of said striker for a portion of said translation of said chain to increase potential energy in said gas spring and after said chain assembly disengages said spring striker assembly, potential energy from said gas spring decreases while accelerating the striker to impact said striker cup, wherein the impact force of said striker is transmitted to said striker cup, wherein said sensor causes said motor to cease operation after said sensor detects that an impact of said striker cup has occurred.

7. The apparatus of claim 6, wherein each lifter link of said plurality of lifter links comprises a lifting roller for facilitating disengagement of said chain assembly from said spring striker assembly.

8. The apparatus of claim 6, wherein said at a portion of said least one lifting surface of said striker inclines toward said striker.

9. The apparatus of claim 6, wherein said apparatus further comprises a gas spring preload means.

10. The apparatus of claim 6, wherein said gas spring comprises at least one cup seal.

11. An impacting apparatus, the apparatus comprising a power source, a control circuit, a motor, said motor capable of rotational motion, a striker cup, a spring striker assembly, said spring striker assembly comprising a gas spring and an striker, said gas spring comprising a chamber and a piston and said striker comprising at least one lifting surface, a chain assembly, said chain assembly comprising a plurality of sprockets, said sprockets being operatively coupled to said motor, a chain operatively coupled to said plurality of sprockets, said chain comprising a plurality of lifter links disposed along said chain and said sprockets capable of causing the chain to translate, a gas spring preload means for installing the gas spring in the apparatus, wherein said gas spring preload means energizes the gas spring slightly during installation in the apparatus, wherein when said chain assembly translates, at least one lifter link of said plurality of lifter links engages at least one lifting surface of said striker for a portion of said translation of said chain to increase potential energy in said gas spring and after said chain assembly disengages said spring striker assembly, potential energy from said gas spring decreases while accelerating the striker to impact said striker cup, wherein the impact force from said striker is transmitted to said striker cup.

12. The apparatus of claim 11, wherein each lifter link of said plurality of lifter links comprises a lifting roller.

13. The apparatus of claim 11, wherein said at least a portion of said at least one lifting surface of said striker inclines toward said striker.

14. The apparatus of claim 11, wherein said apparatus further comprises a gas spring mount and wherein said gas spring mount comprises at least one degree of freedom.

15. The apparatus of claim 11, wherein said apparatus comprises a threaded region and said gas spring comprises a threaded member for engagement with said threaded region.

16. The apparatus of claim 11, wherein said gas spring preload means is one of an extended thread, a camming mechanism, a mechanical advantage and a toggle clamp.

17. The apparatus of claim 11, wherein said apparatus further comprises a sensor, said sensor being operatively coupled to said control circuit and capable of determining the position of the drive mechanism prior to removal of the gas spring from the apparatus.

18. The apparatus of claim 17, wherein said apparatus further comprises a one-way clutch, said one-way clutch operatively coupled to said motor and said sensor to prevent reverse rotation of said motor prior to and during removal of the gas spring from the apparatus.

19. The apparatus of claim 11, wherein said apparatus further comprises a handle that is operatively coupled to said control circuit and wherein pressure on said handle initiates rotation of said motor and a lack of pressure on said handle terminates rotation of said motor.

Description

DESCRIPTION OF THE DRAWINGS

[0030] The advantages and features of the present disclosure will become better understood with reference to the following detailed description and claims taken in conjunction with the accompanying drawings, wherein like elements are identified with like symbols, and in which reference numerals refer to like parts throughout the description of several views of the drawings, in which

[0031] FIG. 1 shows a cross-sectional view of an impacting apparatus, in accordance with an exemplary embodiment of the present disclosure;

[0032] FIG. 2 shows another cross-sectional view of an impacting apparatus, in accordance with an exemplary embodiment of the present disclosure;

[0033] FIG. 3 shows a disassembled view of an impacting apparatus, in accordance with an exemplary embodiment of the present disclosure;

[0034] FIG. 4 shows another disassembled view an impacting apparatus, in accordance with an exemplary embodiment of the present disclosure;

[0035] FIG. 5 shows a cutaway view of an impacting apparatus, in accordance with an exemplary embodiment of the present disclosure;

[0036] FIG. 6 shows another cutaway view of an impacting apparatus, in accordance with an exemplary embodiment of the present disclosure;

[0037] FIG. 7 shows another cutaway view of an impacting apparatus, in accordance with an exemplary embodiment of the present disclosure;

[0038] FIG. 8 shows another cutaway view of an impacting apparatus, in accordance with an exemplary embodiment of the present disclosure;

[0039] FIG. 9 shows another cutaway view of an impacting apparatus, in accordance with an exemplary embodiment of the present disclosure;

[0040] FIG. 10 shows another cutaway view of an impacting apparatus, in accordance with an exemplary embodiment of the present disclosure;

[0041] FIG. 11 shows another cutaway view of an impacting apparatus, in accordance with an exemplary embodiment of the present disclosure;

[0042] FIG. 12 shows a view of an operating cycle of an impacting apparatus, in accordance with an exemplary embodiment of the present disclosure;

[0043] FIG. 13 shows a view of an operating cycle of an impacting apparatus, in accordance with an exemplary embodiment of the present disclosure;

[0044] FIG. 14 shows a view of an operating cycle of an impacting apparatus, in accordance with an exemplary embodiment of the present disclosure;

[0045] FIG. 15 shows a view of an operating cycle of an impacting apparatus, in accordance with an exemplary embodiment of the present disclosure;

[0046] FIG. 16 shows a view of an operating cycle of an impacting apparatus, in accordance with an exemplary embodiment of the present disclosure;

[0047] FIG. 17 shows a view of an operating cycle of an impacting apparatus, in accordance with an exemplary embodiment of the present disclosure;

[0048] FIG. 18 shows a view of an operating cycle of an impacting apparatus, in accordance with an exemplary embodiment of the present disclosure;

[0049] FIG. 19 shows a view of an operating cycle of an impacting apparatus, in accordance with an exemplary embodiment of the present disclosure;

[0050] FIG. 20 shows components of a drive mechanism of an impacting apparatus, in accordance with an exemplary embodiment of the present disclosure;

[0051] FIG. 21 shows a cutaway view of an impacting apparatus, in accordance with an exemplary embodiment of the present disclosure;

[0052] FIG. 22 shows striker rollers and a striker cup of an impacting apparatus, in accordance with an exemplary embodiment of the present disclosure; and

[0053] FIG. 23 shows a cutaway view of an impacting apparatus, in accordance with an exemplary embodiment of the present disclosure.

DETAILED DESCRIPTION OF THE DISCLOSURE

[0054] The best mode for carrying out the present disclosure is presented in terms of its preferred embodiment, herein depicted in the accompanying figures. The preferred embodiments described herein detail for illustrative purposes are subject to many variations. It is understood that various omissions and substitutions of equivalents are contemplated as circumstances may suggest or render expedient but are intended to cover the application or implementation without departing from the spirit or scope of the present disclosure. Furthermore, although the following relates substantially to one embodiment of the design, it will be understood by those familiar with the art that changes to materials, part descriptions and geometries can be made without departing from the spirit of the disclosure. It is further understood that references such as front, back, top dead center, or bottom dead center do not refer to exact positions, but approximate positions as understood in the context of the geometry in the attached figures.

[0055] The terms a and an herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items.

[0056] The present disclosure provides for an impacting apparatus 1000. In an embodiment, the apparatus comprises a power source 30, a control circuit 20, a motor 10, a gas spring 70, a drive mechanism 15, a spring striker assembly 40, a striker 50, a striker cup 55 and at least one bumper 60. The apparatus also comprises a handle 100 and a start switch 170. The gas spring includes a piston 72 that is at least partially disposed within the spring striker assembly, and which spring striker assembly is operatively coupled to the drive mechanism.

[0057] The gas spring of the present disclosure also includes a cylinder 80 and one or more cup seals 82. The cup seals make a rod seal around the spring piston 72. The configuration is highly advantageous because it allows for a long stroke, a small increase in cylinder pressure and a small size.

[0058] In an embodiment, the gas spring has a threaded member 76 adjacent to the gas spring piston. This threaded member allows the user to change out gas springs on the impacting device. Impacting devices require a long lifecycle that involves hundreds of thousands of impact cycles. Traditional gas springs cannot meet this requirement, therefore it is critical to change out the gas springs quickly and safely during service intervals. One method for doing this is to screw the gas springs into the impacting apparatus, which method will be discussed in detail below.

[0059] Additionally, it is important that the gas spring piston stays in alignment as it is being compressed. If the gas spring piston and the gas spring cylinder are not co-linear, unnecessary stress may be placed on the gas spring seal and the life of the gas spring may be shortened. Accordingly, in an embodiment, the apparatus comprises a gas spring mount with at least one degree of freedom, on which mount the gas spring is disposed. If the mount is allowed to roll, yaw or move laterally, the gas spring piston can stay co-linear with the gas spring cylinder.

[0060] In another embodiment, the gas spring is replaceable and becomes slightly energized when installed in the apparatus. In such an embodiment, the apparatus comprises a gas spring preload means for installing the gas spring in the apparatus. The gas spring preload means also facilitates the quick and safe replacement of a gas spring 70 of the apparatus. In an embodiment, the apparatus comprises a cavity 78 in which the gas spring is installed for operation. The cavity may be accessed by removing screws from a portion of the housing of the apparatus that is proximate to the striker cup and/or bumper of the apparatus and that is secured to the apparatus by screws or other suitable fastener. When the housing portion is removed, the striker cup 55 and/or bumper 60 may thereafter be removed to gain access to the gas spring cavity 78 (and gas spring, if a gas spring is being replaced). The new gas spring is placed in the cavity 78, and the bumper and/or striker cup are reinstalled. In an embodiment, and as shown in FIG. 3 the housing portion is replaced, and the screws are of sufficient length that the housing portion can be fastened and drawn toward the gas spring sufficiently that the housing can abut and slightly compress and energizes the gas spring while the gas spring is a position where the spring striker assembly is not being acted on by the drive assembly. This prevents the gas spring piston from bottoming out in the gas spring cylinder.

[0061] In another embodiment, the gas spring 70 comprises a threaded member 76 for threadable engagement with the apparatus. In this embodiment, the apparatus also comprises threads 79 for receiving the gas spring in a threaded region 79b. In such an embodiment, the threads of the gas spring must be long enough to start screwing into the device without the gas spring piston engaging the striker. Once the threads have been engaged with the threaded region, the gas spring piston can engage the striker and continued rotation of the gas spring can energize or preload the gas spring. It is important to note that the gas spring piston should not touch the inside of the cylinder as damage would occur during each impact. Other methods such as a quick release may also be used. The gas spring attachment means may also comprise a camming mechanism, a mechanical advantage or mechanism, and the like.

[0062] An alternate method for gas spring replacement involves the use of a toggle clamp 79a to compress and energize the gas spring. In such an embodiment a toggle clamp 79a is affixed to the top of the apparatus 1000 and engages with a flange 70a that is welded to the gas spring. Moving the handle of the toggle clamp downward engages and energizes the gas spring. Moving the handle of the toggle clamp upward releases the gas spring and allows it to be removed from the top of the apparatus for easy replacement. The toggle clamp can have a locking mechanism (not shown) that prevents it from releasing the gas spring when the apparatus is in use.

[0063] It is important to note that the gas spring 70 should never be removed from the apparatus when it is under load from the drive mechanism 15. If it is engaged with the drive mechanism, the stored energy in the gas spring may be released upon spring removal, which poses an injury threat to the user. To ensure that the gas spring is not under load from the drive mechanism, the drive mechanism must be in a known specific position. This can be accomplished by stopping the drive mechanism with a sensor 210 in a specified location or allowing the mechanism to back drive to allow the gas spring to de-energize.

[0064] The drive mechanism 15 may comprise, in an embodiment, a chain 130 and sprockets 120 as shown in the figures. The chain has two or more lifter links 150 spaced equidistant along the chain. In such an embodiment, it will be apparent that the drive mechanism is configured to permit effectively instantaneous transition from when the lifter links are engaged with the spring striker assembly to when there is no engagement. The drive mechanism 15 is operatively coupled to the spring striker assembly 40, such that the drive mechanism may alternate in actuating the spring striker assembly, thereby actuating the piston 72 (when the lifter link is engaged, for example) and in withholding a drive force on the spring striker assembly such as for a portion of the operational cycle of the apparatus.

[0065] In an embodiment, the drive mechanism 15 engages the spring striker assembly 40 and actuates the piston by pushing upwards by the striker to store potential energy within the gas spring 70. In an embodiment, the initial pressure (before the drive mechanism actuates the piston) within the gas spring is at least 40 psia. In an embodiment, the present disclosure utilizes a pressure of 1500 psi on an 8 mm spring piston. The configuration and design of the gas spring are such that the pressure increase during the piston movement is less than 30% of the initial pressure, thus yielding a more constant torque to the motor that improves the motor efficiency. The drive mechanism thereafter disengages the spring striker assembly, allowing pressure or other forces to act on the piston causing the piston and striker to move away from the cylinder 80 and towards the striker cup 55. The drive mechanism is tuned to prevent further engagement until after the spring striker assembly has returned to an approximate starting position. The drive mechanism may thereafter again act on the spring striker assembly to again store potential energy within the gas spring and may thereafter again temporarily cease to act on the spring striker assembly to allow potential energy to instead act on the piston to rapidly move the striker to impact the striker cup. The drive mechanism is preferably configured to allow for continuous impacting, by way of sprockets 120 and a chain assembly (such as chain 130, for example (as shown in the figures), for such continuous impacting.

[0066] The drive mechanism 15 of the present disclosure may also include a one-way clutch 160 to prevent back rotation of the motor when the device is at rest. The one-way clutch can be disposed anywhere in the drive mechanism from the output sprockets to the motor shaft.

[0067] The spring striker assembly 40 is operatively coupled to the gas spring 70 (such as to the piston 72 or nose portion 74 thereof) such that when the spring striker assembly is released under pressure the force from the piston is imparted onto the striker, causing the piston and striker to move in a direction away from the cylinder 80 and impact a striker cup 55 of the apparatus, which striker cup transmits the force of the impact to an impact target 110, such as a post, nail, grounding rod, rivet, concrete surface, or ground surface, for example. The striker cup facilitates positioning of the impact target so that the impact target can receive the force of the striker and so that the impact target can remain in a position to receive such force when the apparatus is providing multiple or continuous impacts. It was discovered during the course of development that the ratio of the tool mass to the moving mass (i.e., the mass of the spring piston and striker) was important to the efficiency of the apparatus. It is preferred to have the moving mass be less than 20% of the total mass of the tool and more preferable to have the moving mass be less than 10% of the total mass. This allows the present disclosure to have increased efficiency in transferring the potential energy into driving energy on the object or substrate. The smaller the moving mass in relation to the total mass of the tool, the smaller the reaction force that drives the tool off of the impact target. Reaction force is a major loss of efficiency in existing impacting tools. In an embodiment, the spring striker assembly has a mass of 1.3 pounds and the tool has a total mass of 16 pounds. This represents an 8% ratio. The spring striker assembly may be operatively coupled to striker rollers 200 and roller channels 202, or other structure that limits its range of motion. Another unexpected discovery was that increasing the speed of the spring striker assembly during impact reduced the reaction force on the tool user.

[0068] At least one bumper 60 is disposed on the apparatus for absorbing a portion of the force of impact of the striker cup 55 when the striker 50 imparts its energy to drive or to strike the impact target 110. This is used to reduce wear and tear on the components of the apparatus. The at least one bumper may be of an elastic material and may be disposed on the apparatus at any position where it is capable of absorbing a portion of the force of impact of the striker.

[0069] In an embodiment, the drive mechanism 15 comprises a plurality of sprockets 120 (and, in a preferred embodiment, a first sprocket 120a and a second sprocket 120b), a chain 130 and a plurality of lifter links 150 that act on the striker 50 to engage the spring striker assembly 40 and to energize the gas spring upon translation of the chain assembly. Two or more lifter links (also referred to herein as lifting links) can be used and are preferably spaced equidistantly apart along the chain. An unexpected discovery was that keeping the lifting links inline with the line of force improved the reliability of the engagement of the device. To improve the wear characteristics of the device, lifting rollers 140 may be provided to create a rolling release of the lifter link from the striker lifting surface or surfaces 180 of the striker 50. This dramatically reduces wear and improves the useful life of the device. It is also advantageous to angle the striker lifting surfaces at an incline towards the striker to lock the striker on the lifting link during its engagement. Using three or more lifting links can also improve the life of the device by reducing the wear per cycle of each link.

[0070] In an embodiment, the striker 50 in the spring striker assembly comprises striker rollers 200 and roller channels 202. The rollers are utilized to reduce the resistance and to counteract the offset force of the drive mechanism. This significantly increases the efficiency of the device. The channels are disposed along the exterior length of the striker. The striker rollers are captured and roll in the channels of the striker.

[0071] In an embodiment, the electronics of the apparatus comprise at least one sensor 210 that detects the location of either the striker 50 or the striker cup 55 to determine when to turn the motor 10 off after impacting is completed.

[0072] In another embodiment, a sensor is not provided. As an alternative, the one-way clutch 160 prevents the motor 10 from driving backward, when the motor stops anywhere in the cycle. This constitutes a simple mechanical method that maintains the safety of the device.

[0073] In another embodiment, neither a one-way clutch nor a sensor is provided. After impacting is completed, the energized spring back drives the mechanism and the spring is de energized leaving the device in a safe state.

[0074] In another embodiment of the apparatus 1000, movement of the handle 100 toward the impact target 110 may initiate the switching on of the motor 10. One or more of the handles can be spring-loaded or otherwise biased away from the impacting end of the apparatus to allow pressing down on the handle(s) to initiate motor rotation and to stop the motor on release of the handle.

[0075] The present disclosure offers the following advantages: the gas spring is capable of generating a relatively high amount of force in a small amount of space such that the size of the apparatus may be smaller than other impacting apparatuses. Further, because of the relatively small increase from the initial pressure in the gas spring to the maximum pressure, the motor of the apparatus is not significantly overworked or overtorqued, thus leading to a longer useful life of the apparatus. Furthermore, the apparatus disclosed herein has an improved safety profile over prior art impacting devices. For example, the apparatus disclosed herein has an improved recoil force as opposed to the prior art. This was an unexpected discovery as the striker assembly of the present disclosure is low mass and, as such, during the driving of an object or striking a substrate, therefore does not put a reactionary force on the operator. In contrast, with conventional tools, a larger moving mass can result in significant recoil to the operator.

[0076] The foregoing descriptions of specific embodiments of the present disclosure have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present disclosure to the precise forms disclosed, and many modifications and variations are possible in light of the above teaching. The exemplary embodiment was chosen and described in order to best explain the principles of the present disclosure and its practical application, to thereby enable others skilled in the art to best utilize the disclosure and various embodiments with various modifications as are suited to the particular use contemplated.