Patent Grant
8196674
1. Field of the Invention
The present invention relates to a vibration reducing technique of an impact tool such as a hammer and a hammer drill.
2. Description of the Related Art
(1st Known Art)
Japanese non-examined laid-open Patent Publication No. 2003-11073 discloses an electric hammer having a vibration reducing mechanism. This known electric hammer has a dynamic vibration reducer to reduce vibration caused in the axial direction of the hammer bit during hammering operation. The dynamic vibration reducer has a weight that can linearly move under a biasing force of a coil spring, and the dynamic vibration reducer reduces vibration of the hammer during hammering operation by the movement of the weight in the axial direction of the tool bit.
In the known electric hammer, the weight and the coil spring are disposed within a space having an annular section between a cylinder and a barrel part that houses the cylinder.
In the above-described arrangement and construction, component parts of the dynamic vibration reducer such as the weight and the coil spring need to be individually mounted to the cylinder or the barrel part. Thus, in the known electric hammer, further improvement is required in ease of assembly of the vibration reducing mechanism.
(2nd Known Art)
As another known art, a conventional electric hammer has a motor which linearly drives a hammer bit in the axial direction of the hammer bit. In a motor having a brush holder which is arranged on one end side of the motor along its axis of rotation and holds carbon brushes for supplying electric current, a motor cover is removably mounted for replacement of the carbon brushes which are consumables. A construction in which a motor housing for housing a motor is covered with a motor cover on the side of one axial end of the motor is disclosed, for example, in Japanese non-examined laid-open Patent Publication No. 2007-44869.
The known motor cover is designed and provided to cover the motor, particularly the brush holder and its surrounding region, and serves only as a cover.
(3rd Known Art)
As further another known art, Japanese non-examined laid-open Patent Publication No. 2004-174710 discloses a motor-driven power tool. In this known power tool, a controller is electrically connected to a driving motor by a plurality of lead wires, and power is supplied from a power source to the controller and then to a driving motor via the lead wires. In design of a power tool of this type, however, a further technique for improving ease of mounting electrical components such as a controller is required.
Accordingly, it is an object of the invention to provide a technique that contributes to further improvement of an impact tool.
Particularly, the object of the invention specifically reflects the following aspects:
Above-described object (1) can be solved by an invention as claimed. A representative impact tool according to the present invention performs a predetermined hammering operation on a workpiece by a striking movement of a tool bit in an axial direction of the tool bit. The impact tool includes a motor, a tool body, a dynamic vibration reducer and a driving mechanism part. The motor drives the tool bit. The tool body houses the motor. The dynamic vibration reducer reduces vibration of the tool body during hammering operation. The driving mechanism part is driven by the motor and forcibly drives the dynamic vibration reducer by applying an external force other than vibration of the tool body to the dynamic vibration reducer, during hammering operation. The “predetermined hammering operation” in this invention suitably includes not only a hammering operation in which the tool bit performs only a linear striking movement, but an electrical hammering operation in which the tool bit performs a linear striking movement and a circumferential rotation.
In this invention, when using a hand-held impact tool, in relation to the technique of forcibly driving the dynamic vibration reducer by applying an external force other than vibration of the tool body to the dynamic vibration reducer, a design vibration value of the impact tool, or a theoretically estimated value of vibration which may be caused in the impact tool during operation, may be actually outputted as a lower value than the estimate due to the user's pressing operation by hand. Therefore, the dynamic vibration reducer is forcibly and steadily driven by application of a predetermined external force other than vibration of the tool body to the dynamic vibration reducer. In a state in which the apparent vibration value of the tool body is lower or in which the user's hand receives a substantial amount of vibration caused in the tool body, the dynamic vibration reducer is provided with a vibration reducing function which is adaptable to vibrations of higher values substantially corresponding to design vibration value, so that the user's hand is prevented from unnecessarily receiving vibration of the tool body.
According to the preferred embodiment of this invention, at least one of the dynamic vibration reducer and the driving mechanism part is mounted to the tool body in a form of an assembly into which at least one of a plurality of component parts forming the dynamic vibration reducer and a plurality of component parts forming the driving mechanism part are assembled in advance.
Therefore, according to this invention, at least one of the dynamic vibration reducer forming a vibration reducing mechanism and the driving mechanism part is provided in the form of an assembly so that it can be handled as one part. Therefore, mounting operation to the tool body can be facilitated and ease of assembly is increased. Further, the assembly can be removed as one part so that ease of repair is increased.
According to a further embodiment of the present invention, the impact tool further includes a barrel part connected to the tool body, and a cylinder disposed within the barrel part. The dynamic vibration reducer includes a weight that can linearly move in the axial direction of the tool bit and an elastic element that applies a biasing force to the weight in the axial direction of the tool bit. Further, the weight and the elastic element are mounted to either one of the cylinder and the barrel part in order to form an assembly.
According to this invention, the dynamic vibration reducer is mounted to either the cylinder or the barrel part so that it can be handled as one part integrated with the cylinder or the barrel part. Therefore, the dynamic vibration reducer can be mounted to the tool body simply by mounting the cylinder or the barrel part to the tool body.
According to a further embodiment of the present invention, the driving mechanism part includes a cam shaft that is rotationally driven by the motor, an eccentric cam that is integrally formed or fixedly connected with the cam shaft, a bearing that rotatably supports at least one axial end of the cam shaft, and a bearing housing that houses the bearing, all of which are assembled into the driving mechanism part. The driving mechanism part further includes two pins disposed in series in the axial direction of the tool bit. The pins are caused to linearly move in the axial direction of the hammer bit by rotation of the eccentric cam in order to forcibly drive the dynamic vibration reducer. One of the pins which is adjacent to the eccentric cam is mounted to the bearing housing transversely to the axis of the cam shaft. As a result, the driving mechanism part forms an assembly.
Thus, according to this invention, the cam shaft with which the eccentric cam is integrally formed or fixedly connected is mounted to the bearing housing via the bearing, and the pin adjacent to the eccentric cam is further mounted to the bearing housing, so that an assembly is formed. Therefore, the assembly can be easily mounted to the tool body by inserting the bearing housing into the tool body in the axial direction of the cam shaft, for example, through an opening formed in the tool body for mounting the driving mechanism and then fixing it to the tool body.
Two pins disposed in series in the axial direction of the tool bit are provided which convert rotation of the eccentric cam into linear motion and transmit it to the weight, as a driving force acting in the axial direction of the tool bit, via the elastic element of the dynamic vibration reducer. The pin adjacent to the eccentric cam is required to have some large diameter in order to ensure stability of movement.
The barrel part is fitted onto a cylindrical portion formed in the tool body. In a construction in which the pin remote from the eccentric cam is mounted, for example, to the cylindrical portion, if the pin has a large diameter, the cylindrical portion is required to have a greater thickness. Accordingly, the diameter of the cylindrical portion is increased. In this invention, the power transmitting pin consists of two pins, and the pin adjacent to the eccentric cam is incorporated into the assembly. Therefore, the pin remote from the eccentric cam can be designed to have the smallest possible diameter to the extent that adequate strength is ensured. As a result, the diameter of the cylindrical portion for mounting the barrel part and thus the diameter of the barrel part can be reduced.
According to a further embodiment of the present invention, the impact tool further includes a driving mechanism that converts a rotating output of the motor into linear motion and drives the tool bit, and an enclosed housing space that houses the driving mechanism. The air bleeding mechanism and the filler port cap are mounted to the bearing housing after the bearing housing is mounted to the tool body, so that an assembly of the driving mechanism part is formed. The air bleeding mechanism provides communication between the inside and the outside of the housing space and regulates pressure of the housing space and the filler port cap closes an oil filler port from which lubricating oil is supplied into the housing space. Typically, the “air bleeding mechanism” in this invention mainly includes a cylindrical member that has an air passage for communicating the inside and the outside of the housing space of the driving mechanism and houses a filter for absorbing lubricating oil in the air passage. The air bleeding mechanism is mounted to the bearing housing, for example, by fitting into an opening formed in a bearing housing part of the bearing housing in the axial direction of the cam shaft
Thus, according to this invention, an assembly is formed by mounting the air bleeding mechanism and the filler port cap to the bearing housing, so that ease of assembly can be further improved.
Particularly, above-described object (2) can be solved by the other representative impact tool according to the invention which includes a tool body, a plurality of internal mechanisms housed within the tool body, a motor as one of the internal mechanisms, and a motor shaft as one of the internal mechanisms. The motor shaft is rotationally driven when the motor is driven, and the motor shaft is arranged to cross an axis of the tool bit. The impact tool further includes a covering member which is mounted to the tool body on the side of one axial end of the motor shaft and covers the end of the motor shaft, and the covering member retains at least part of the internal mechanisms. According to the invention, the covering member has not only a function of covering internal mechanisms, but a function of retaining internal mechanisms, so that it is not necessary to provide an additional mechanism for retaining the internal mechanisms which are retained by the covering member.
Further, the motor may include a rotor that rotates together with the motor shaft, a bearing that supports an axial end of the motor shaft, and a brush holder unit that is disposed between the rotor and the bearing and holds carbon brushes for supplying electric current to the rotor. The internal mechanism to be retained by the covering member may be a bearing housing part that houses the bearing, and the covering member retains the bearing housing part by pressing in a radial direction of the motor shaft while pressing from the side of the axial end of the motor shaft. The “bearing housing part” in this invention is typically provided integrally as a part of the motor housing on the one end side of the motor housing in the direction of the axis of the motor. Therefore, in the construction in which the brush holder unit is disposed between the rotor and the bearing, the brush holder unit is arranged in a connecting region between a body region for housing the rotor and the bearing housing part for housing the bearing. Therefore, no reinforcing rib can be provided in the connecting region between the body region and the bearing housing part located on the end in the direction of the axis of the motor, and an opening is formed in the connecting region in order to allow the brush holder for holding at least the carbon brushes to protrude to the motor shaft (commutator) side through the opening. For such reasons, the connecting region may be reduced in strength and cause runout during driving of the motor.
However, according to the invention, the construction in which the covering member presses the bearing housing part in the radial direction of the motor shaft while pressing it from the side of the axial end of the motor shaft, can compensate for strength reduction of the connecting region between the body region and the bearing housing part which is caused by providing the brush holder unit.
Further, the impact tool may further include a driving shaft as one of the internal mechanisms which is rotationally driven by the motor shaft, and a driving mechanism as one of the internal mechanisms which converts a rotating output of the driving shaft into linear motion and linearly drives the tool bit. The tool body may have an enclosed housing space that houses the driving shaft and the driving mechanism. The internal mechanism to be retained by the covering member is an air bleeding mechanism that provides communication between the inside and the outside of the housing space and regulates pressure of the housing space. Further, the covering member retains the air bleeding mechanism by pressing from the side of the axial end of the motor shaft. Typically, the “air bleeding mechanism” mainly includes a cylindrical member that has an air passage for communicating the inside and the outside of the housing space and houses a filter for absorbing lubricating oil in the air passage. The air bleeding mechanism may be mounted, for example, by fitting into an opening formed in the tool body that houses the driving mechanism, along the direction of the axis of the motor shaft. Further, as the filter, felt, sponge, cloth, etc. can be suitably used, but materials which can absorb and catch lubricant can also be appropriately used.
With the construction in which the covering member retains the air bleeding mechanism by pressing from the side of the axial end of the motor shaft, the air bleeding mechanism can be reliably prevented from falling out due to the internal pressure of the housing space.
Further, the impact tool may further include a driving shaft as one of the internal mechanisms which is rotationally driven by the motor shaft, and a driving mechanism as one of the internal mechanisms which converts a rotating output of the driving shaft into linear motion and linearly drives the tool bit. The tool body includes an enclosed housing space that houses the driving shaft and the driving mechanism. The internal mechanism to be retained by the covering member is a filler port cap that closes an oil filler port from which lubricating oil is supplied into the housing space, and the covering member retains the filler port cap by pressing from the side of the axial end of the motor shaft. As a result, the filler port cap can be reliably prevented from falling out due to the internal pressure of the housing space.
According to the invention, a technique of providing an additional function is provided for a covering member for covering internal mechanisms housed within a tool body in an impact tool.
Particularly, above-described object (3) can be solved by the other representative impact tool according to the invention which includes at least a driving motor, a tool body, a brush holder unit, a connecting terminal, a power terminal, a power switch and a control unit. The driving motor is designed to drive the tool bit. In this case, a motor shaft that is caused to rotate by driving of the driving motor may be arranged to cross an axis of the tool bit, or it may be arranged such that its extension crosses the axis of the tool bit, but the motor shaft itself does not cross the axis of the tool bit. Further, the tool bit which is driven by the driving motor may be a component part of the impact tool according to this invention, or it may be a separate part from the impact tool. The tool body is designed as a housing part that houses the driving motor. The brush holder unit is designed as a holding part that holds a plurality of motor brushes for supplying electric power to the driving motor. The connecting terminal can be connected to a connected terminal of the brush holder unit by plugging in. The manner of “plugging in” may typically represent a manner of plugging a male terminal in a female terminal for terminal connection and include the manner in which a connecting terminal in the form of a male terminal is plugged in a connected terminal in the form of a female terminal. The power terminal is designed as a terminal to which a power cord is connected. The power switch can switch between a state in which the driving motor is energized and a state in which the driving motor is de-energized. The control unit has a function of performing controls relating to power supply to the driving motor.
Particularly, electrical components including the connecting terminal, the power terminal, the power switch and the control unit are integrally mounted to a housing and thus form an electrical component assembly. Thus, the electrical component assembly is mounted to the body side by connecting the connecting terminal to the connected terminal by plugging in. Therefore, with such a construction, various electrical components installed in the housing can be handled as one part in the form of the electrical component assembly. Further, the electrical components can be easily mounted to the tool body side in one operation by plug-in terminal connection between the connecting terminal and the connected terminal. Therefore, ease of mounting the electrical components can be improved. Further, the electrical component assembly can be removed as one part so that ease of repair is increased.
Further, in the electrical component assembly, a motor speed sensor for detecting information relating to rotation speed of the driving motor may preferably be integrally mounted to the housing, and the control unit outputs control signals relating to rotation speed control to the driving motor based on the information detected by the motor speed sensor. The “information relating to rotation speed of the driving motor” may typically include rotation speed itself and various information relating to the rotation speed. Further, the “rotation speed control” may typically include the manner of controlling to match actual rotation speed with a rotation speed setting which is freely set by the user. Further, in the control unit, an output part that outputs control signals relating to motor speed control to the driving motor may also have a function as an output part that outputs control signals relating other than motor speed control, or the output parts may be separately independently provided. With such a construction, the electrical component assembly is provided in which, in addition to the electrical components including the connecting terminal, the power terminal, the power switch and the control unit, a mechanism for controlling rotation speed of the driving motor is integrally mounted to the housing.
Preferably, the electrical component assembly may be disposed at the rear of the tool body between the tool body and a handle to be held by a user, and terminal connection between the connected terminal and the connecting terminal is made by inserting the connecting terminal into the connected terminal provided in the rear of the tool body, in a direction transverse to a motor shaft which is caused to rotate by driving of the driving motor. Typically, the connected terminal can be designed as a female terminal and the connecting terminal as a male terminal which can be plugged in the connected terminal. The rear side of the tool body here is the side of the tool body which is remote from the tool bit, provided that the tool bit side of the tool body is taken as the front side. With such a construction, mounting of the electrical component assembly and terminal connection can be achieved by inserting the connecting terminal provided on the electrical component assembly into the connected terminal provided in the rear of the tool body, in a direction transverse to the motor shaft of the driving motor.
Further, the motor shaft caused to rotate by driving of the driving motor may be arranged to cross an axis of the tool bit. With this construction, in the impact tool in which the motor shaft is arranged to cross an axis of the tool bit, ease of mounting electrical components can be improved.
Preferably, the power cord itself connected to the power terminal may be retained on the housing. As for retaining of the power cord itself, the power cord may be directly retained on the housing, or it may be indirectly retained on the housing via an intervening member such as a cord guard disposed between the power cord and the housing. With such a construction, the electrical component assembly is provided in which, in addition to the electrical components including the connecting terminal, the power terminal, the power switch and the control unit, the power cord itself is integrally mounted to the housing.
According to the invention, ease of mounting electrical components relating to power supply to a driving motor for driving the tool bit can be improved.
Other objects, features and advantages of the present invention will be readily understood after reading the following detailed description together with the accompanying drawings and the claims.
Each of the additional features and method steps disclosed above and below may be utilized separately or in conjunction with other features and method steps to provide and manufacture improved impact tools and method for using such impact tools and devices utilized therein. Representative examples of the present invention, which examples utilized many of these additional features and method steps in conjunction, will now be described in detail with reference to the drawings. This detailed description is merely intended to teach a person skilled in the art further details for practicing preferred aspects of the present teachings and is not intended to limit the scope of the invention. Only the claims define the scope of the claimed invention. Therefore, combinations of features and steps disclosed within the following detailed description may not be necessary to practice the invention in the broadest sense, and are instead taught merely to particularly describe some representative examples of the invention, which detailed description will now be given with reference to the accompanying drawings.
As shown in
The body 103 mainly includes a motor housing 105 that houses a driving motor 111, and a gear housing 107 that is connected to the motor housing 105 and houses a motion converting mechanism 113. A barrel part 108 is disposed at the front of the gear housing 107 and houses a striking mechanism 115. The gear housing 107 is disposed in front and upper regions around the motor housing 105. The barrel part 108 is connected to the front end of the gear housing 107 and extends forward along the axis of the hammer bit 119. The handgrip 109 is generally U-shaped having an open front and connected to the rear of the motor housing 105. A power switch 131 for electrically driving the driving motor 111 and an actuating member 133 for actuating the power switch 131 between on and off positions are disposed in the upper region of the handgrip 109. The actuating member 133 is mounted to the handgrip 109 such that it can slide in a horizontal direction (lateral direction) transverse to the axial direction of the hammer bit. When the actuating member 133 is actuated or slid into the on position by the user's finger, the driving motor 111 is electrically driven.
The rotating output of the driving motor 111 is appropriately converted into linear motion via the motion converting mechanism 113 and transmitted to the striking element 115. As a result, an impact force is generated in the axial direction of the hammer bit 119 via the striking element 115. The driving motor 111 is arranged such that the axis of a motor shaft 112 crosses the axis of the hammer bit 119. The motion converting mechanism 113, which serves to convert the rotating output of the driving motor 111 into linear motion and transmit it to the striking element 115, is disposed in the upper region of the internal space of the gear housing 107.
The motion converting mechanism 113 serves to convert rotation of the driving motor 111 into linear motion and transmit it to the striking element 115. The motion converting mechanism 113 forms a crank mechanism which includes a crank shaft 121 rotationally driven by the driving motor 111, a crank plate 124 that rotates together with the crank shaft 121, an eccentric pin 122 that is disposed in a position displaced from the center of rotation of the crank plate 124, a crank arm 123 that is connected to the crank plate via the eccentric pin 122, and a piston 125 that is caused to reciprocate via the crank arm 123. The piston 125 forms a driving element that drives the striking element 115 and can slide within a cylinder 141 in the axial direction of the hammer bit 119.
The crank mechanism is arranged in front of the driving motor 111 and driven by the driving motor 111 at a lower speed via a reduction gear mechanism 161. The reduction gear mechanism 161 mainly includes a small gear 112a formed on the motor shaft 112, an intermediate gear 163 that engages with the small gear 112a, an intermediate shaft 165 that rotatably supports the intermediate gear 163, and a driven gear 167 that engages with the intermediate gear 163. The driven gear 167 is fixed to the crank shaft 121 such that it rotates together with the crank shaft 121. The crank shaft 121 is arranged such that its axis crosses the axis of the hammer bit and extends parallel to the motor shaft 112 as well as the intermediate shaft 165. The crank mechanism and the reduction gear mechanism 161 form the “driving mechanism” according to this invention. The crank mechanism is housed within a crank chamber 116 which is an enclosed internal space within the gear housing 107. The reduction gear mechanism 161 is housed within a gear chamber 117 which is also an enclosed internal space within the gear housing 107 and located above the crank chamber 116. The crank chamber 116 and the gear chamber 117 are features that correspond to the “housing space” according to this invention.
The striking mechanism 115 includes a striking element in the form of a striker 143 that is slidably disposed within the bore of the cylinder 141, and an intermediate element in the form of an impact bolt 145 that is slidably disposed within the tool holder 137 and transmits the kinetic energy of the striker 143 to the hammer bit 119. An air chamber 141a is defined between the piston 125 and the striker 143 within the cylinder 141. The striker 143 is driven via the action of an air spring of the air chamber 141a of the cylinder 141 which is caused by sliding movement of the piston 125. The striker 143 then collides with (strikes) the intermediate element in the form of the impact bolt 145 that is slidably disposed within the tool holder 137, and transmits the striking force to the hammer bit 119 via the impact bolt 145.
During operation of the hammer 101 (when the hammer bit 119 is driven), impulsive and cyclic vibration is caused in the body 103 in the axial direction of the hammer bit. Main vibration of the body 103 which is to be reduced is a compressing reaction force which is produced when the piston 125 and the striker 143 compress air within the air chamber 141a, and a striking reaction force which is produced with a slight time lag behind the compressing reaction force when the striker 143 strikes the hammer bit 119 via the impact bolt 145.
As shown in
As shown in
The weight 153 is disposed outside the cylinder 141. The front coil spring 155 is disposed between a front spring receiving sleeve 158 and a frond end surface of the weight 153. The front spring receiving sleeve 158 is fitted on the front end of the periphery of the cylinder 141 such that it can slide in the axial direction of the hammer bit. The rear coil spring 157 is disposed between a rear spring receiving sleeve 159 and a rear end surface of the weight 153. The rear spring receiving sleeve 159 is fitted on the rear end of the periphery of the cylinder 141 such that it can slide in the axial direction of the hammer bit. The front and rear coil springs 155, 157 exert respective biasing forces on the weight 153 toward each other in the axial direction of the hammer bit. In other words, the weight 153 can move in the axial direction of the hammer bit under the biasing forces of the front and rear coil springs 155, 157 which act upon it toward each other. As shown in
The front spring receiving sleeve 158, the front coil spring 155, the weight 153, the rear coil spring, the rear coil spring 157 and the rear spring receiving sleeve 159 of the dynamic vibration reducer 151 having the above-described construction are fitted onto the cylinder 141 from its rear end in this order before the cylinder 141 is mounted to the gear housing 107. Subsequently, the stopper ring 142 is fitted on the rear periphery of the cylinder 141, so that the dynamic vibration reducer 151 is prevented from becoming dislodged from the cylinder 141 and is thus integrated. Specifically, the dynamic vibration reducer 151 is mounted on the cylinder 141 in advance in order to form the dynamic vibration reducer assembly A1. In the form of this dynamic vibration reducer assembly A1, the rear end of the cylinder 141 is fitted into a cylindrical portion 107a of the gear housing 107 from the front, so that the dynamic vibration reducer 151 is mounted to the gear housing 107.
Further, the barrel part 108 is slipped over the cylinder 141 and the dynamic vibration reducer 151 from the front, and the rear end of the barrel part 108 is fitted on the cylindrical portion 107a of the gear housing 107. Then the barrel part 108 is connected to the gear housing 107 by means of a fastening means such as a screw 114. Thus, the dynamic vibration reducer 151 is arranged within a space having an annular section between the cylinder 141 and the barrel part 108. The barrel part 108 connected to the gear housing 107 has a stepped engagement portion 108a which is engaged with the outer surface of a front end circular portion 158a of the front spring receiving sleeve 158. Specifically, the front spring receiving sleeve 158 is disposed between the outer surface of the cylinder 141 and the inner surface of the barrel part 108 in contact with these outer and inner surfaces. Thus, the cylinder 141 and the barrel part 108 are positioned relative to each other in the radial direction, and more particularly, they are coaxially retained.
In front of the front spring receiving sleeve 158, an air vent 141c for idle driving prevention is formed through the cylinder 141 in the radial direction and an O-ring 146 is provided as a nonreturn valve to close the air vent 141c from radially outside. Under unloaded conditions in which the hammer bit 119 is not pressed against a workpiece, or in which no load is applied to the hammer bit 119, when the striker 143 performs a striking movement, air within the cylinder 141 is pressed forward by the striker 143 and then flows out through the air vent 141c while pushing the O-ring 146 aside. A small hole 158b extends through the front spring receiving sleeve 158 in the axial direction of the hammer bit, so that the air pushed out of the cylinder 141 by the striker 143 is led through the small hole 158b into a rear part of the annular space between the cylinder 141 and the barrel part 108. With this construction, the damper effect of air can be properly set by adjusting the diameter of the small hole 158b.
The weight 155 and the front and rear coil springs 155, 157 serve as vibration reducing elements in the dynamic vibration reducer 151 installed in the body 103 and cooperate to passively reduce vibration of the body 103 during operation of the hammer 101. Thus, the vibration caused in the body 103 of the hammer 101 can be alleviated or reduced.
The vibration mechanism 171 for actively driving the dynamic vibration reducer 151 is now explained. As shown in
The cam shaft 172 of the vibration mechanism 171 has a small-diameter portion 172a underneath the eccentric cam 173, a large-diameter portion 172b on top of the eccentric cam 173, and a crank plate 172c on top of the large-diameter portion 172b. The cam shaft 172 is inserted into upper and lower bearing housing parts 177a, 177b of the bearing housing 177 from above. The small-diameter portion 172a and the large-diameter portion 172b are then rotatably supported by the bearing housing parts 177a, 177b via the bearings 175, 176. Thus, the cam shaft 172 is integrated with the bearing housing 177 via the bearings 175, 176. Further, a needle bearing 178 is fitted over the eccentric cam 173, so that wear of the eccentric cam 173 which may be caused by sliding contact with the power transmitting pin 174 can be prevented. Further, the crank plate 172c of the cam shaft 172 has an engagement portion 172d in the form of a U-shaped recess (or groove or slot) formed in a position displaced from its center. As shown in
The power transmitting pin 174 consists of front and rear pins 174a, 174b disposed in series in the axial direction of the hammer bit. One (rear) pin 174a in contact with the eccentric cam 173 (substantially with an outer ring of the needle bearing 178) is mounted to the bearing housing 177. The other (front) pin 174b is mounted to the cylindrical portion 107a of the gear housing 107. As shown in
As shown in
As shown in
If the power transmitting pin 174 is formed by a single piece, the pin 174 may need to have a diameter of the one pin 174a. As a result, the cylindrical portion 107a and thus the barrel part 108 may increase in diameter. Therefore, according to this embodiment, by forming the power transmitting pin 174 from the two pins 174a, 174b, the barrel part 108 can be made smaller in diameter while maintaining the stability of movement of the power transmitting pin 174.
An air bleeding mechanism 181 for regulating pressure of the crank chamber 116 is fitted from below into the lower bearing housing part 177b of the bearing housing 177 through its lower end having an opening 177d. The air bleeding mechanism 181 includes a filter case 184 having an air passage 182 which provides communication between the inside and the outside of the crank chamber 116. The filter case 184 has a filter housing chamber, and a filter 183 is disposed within the filter housing chamber and serves to absorb lubricating oil in order to prevent lubricating oil from leaking out of the crank chamber 116 through the air passage 182. The filter case 184 is removably mounted to the opening 177d of the lower bearing housing part 177b by fitting into it from below and held in the fitted position by friction of a sealing O-ring 185 which is disposed between the mating surfaces in the fitted position. In this embodiment, the filter case 184 for air bleeding is mounted right below the cam shaft 172, and at least an inner opening of the air passage 182 is arranged on the axis of the cam shaft 172. Therefore, entry of lubricating oil from the crank chamber 116 into the air passage 182 can be prevented by centrifugal force which is caused by rotation of the cam shaft 172, so that leakage of lubricating oil can be reduced.
Further, an oil filler port 186 for supplying lubricating oil (grease) into the crank chamber 116 is formed in the bearing housing 177. A filler port cap 187 for closing the oil filler port 186 is removably mounted to the oil filler port 186 by fitting into it from below and held in the fitted position by friction of a sealing O-ring 188 which is disposed between the mating surfaces in the fitted position.
As described above, the vibration mechanism assembly A2 includes not only the vibration mechanism 171 but also the air bleeding mechanism 181 and the filler port cap 187. The vibration mechanism assembly A2 having such a construction is inserted from below into a circular mounting opening 107c which is formed in the bottom of the gear housing 107 on the side opposite to the crank mechanism. Thus, the vibration mechanism assembly A2 is disposed within the crank chamber 116 of the gear housing 107. In this state, the bearing housing 177 is fastened to the gear housing 107 by means of a fastening means such as a screw 189.
Provided that the crank mechanism is already mounted to the gear housing 107 before the vibration mechanism assembly A2 is mounted to the gear housing 107, in order to mount the vibration mechanism assembly A2 to the gear housing 107, the engagement portion 172d formed in the crank plate 172c of the cam shaft 172 needs to be positioned so as to be engaged with the projecting end 122a of the eccentric pin 122 formed on the crank plate 124 in the crank mechanism. In other words, adjustment of the circumferential position of the cam shaft 172 is required in order to mount the vibration mechanism assembly A2 to the gear housing 107.
Therefore, in this embodiment, a square shank (width across bolt) 172e is formed on the lower end of the cam shaft 172, and a square hole 187a is provided in an end of the filler port cap 187 in the direction of insertion and shaped to correspond to the contour of the square shank 172e. The positional adjustment of the cam shaft 172 is naturally performed before the filter case 184 is mounted to the opening 177d of the lower bearing housing part 177b. The filler port cap 187 is dimensioned such that it can be inserted into the opening 177d of the bearing housing part 177b and turned.
Therefore, by making positional adjustment of the cam shaft 172 in the circumferential direction by using the filler port cap 187, the engagement portion 172d of the crank plate 172c can be easily engaged with the projecting end 122a of the eccentric pin 122 of the cam shaft 172. As a result, the cam shaft 172 can rotate together with the crank shaft 121. Further, when the vibration mechanism assembly A2 is mounted to the gear housing 107, the cam shaft 172 is substantially coaxially disposed with the crank shaft 121 of the crank mechanism.
Further, the vibration mechanism assembly A2 is covered with a covering member 191 which is mounted to the gear housing 107 in order to close the opening 107c in the bottom of the gear housing 107. The covering member 191 presses and holds the filter case 184 and the filler port cap 187 of the vibration mechanism assembly A2 from below. The covering member 191 further extends to a lower region of the motor housing 107 disposed at the rear of the gear housing 107. Thus, the covering member 191 also covers the lower region and presses and holds the lower bearing housing part 105a of the motor housing 107 from below. The covering member 191 is fastened to the gear housing 107 by screws which are not shown.
In the electric hammer 101 having the above-described construction, when the crank mechanism is driven by driving the driving motor 111, the cam shaft 172 of the vibration mechanism 171 rotates together with the crank shaft 121 of the crank mechanism. The rotation of the cam shaft 172 is converted into linear motion via the eccentric cam 173 and the power transmitting pin 174 and then inputted to the dynamic vibration reducer 151. Thus, the weight 153 is forcibly driven in the axial direction of the hammer bit via the rear spring receiving sleeve 159 and the rear coil spring, so that the dynamic vibration reducer 151 is caused to perform a vibration reducing function. Specifically, the dynamic vibration reducer 151 serves not only as a passive vibration reducing mechanism as described above, but as an active vibration reducing mechanism by forced vibration in which the weight 153 is actively driven. Therefore, vibration caused in the body 103 during hammering operation can be further effectively reduced
According to this invention, component parts of the dynamic vibration reducer 151, i.e. the weight 153, the front and rear coil springs 155, 157 and front and rear spring receiving sleeves 158, 159, are mounted on the cylinder 141 in advance in order to form the dynamic vibration reducer assembly A1. In the form of this dynamic vibration reducer assembly A1, the dynamic vibration reducer 151 is mounted to the gear housing 107. Thus, the dynamic vibration reducer 151 can be handled as one part integrated with the cylinder 141, so that mounting operation to the gear housing 107 is facilitated and ease of assembly is increased. Further, removal from the gear housing 107 is also facilitated so that ease of repair is increased.
In this embodiment, also as for the vibration mechanism 171 for actively driving the dynamic vibration reducer 151, its component parts, i.e. the cam shaft 172, the eccentric cam 173, the bearings 175, 176 and the pin 174a, are mounted to the bearing housing 177 in advance in order to form the vibration mechanism assembly A2. In the form of this vibration mechanism assembly A2, the vibration mechanism 171 is mounted to the gear housing 107. Thus, the vibration mechanism 171 can be handled as one part, so that the mounting operation to the gear housing 107 is facilitated and ease of assembly is increased. Further, removal from the gear housing 107 is also facilitated so that ease of repair is increased.
Further, in this embodiment, component parts of the dynamic vibration reducer 151 are mounted onto the cylinder 141 in advance in order to form the dynamic vibration reducer assembly A1, but they may be mounted not to the cylinder 141 but to the barrel part 108. Further, in this embodiment, the electric hammer is described as being of the type in which the driving motor 111 is arranged such that the axis of the motor shaft 112 crosses the axis of the hammer bit. However, the present invention can also be applied to electric hammers of the type in which the driving motor 111 is arranged such that the axis of the motor shaft 112 does not cross the axis of the hammer bit. Further, in this embodiment, the electric hammer is described as a representative example of the impact tool, but the present invention can also be applied to a hammer drill in which the hammer bit 119 can perform a striking movement and a rotation.
As shown in
Further, a wave washer 126 is disposed between the bearing housing part 105a and an axial rear end face of the bearing 139b within the bearing housing part 105a and exerts a spring force on the bearing 139b in the axial direction of the bearing 139b. If it is constructed such that the wave washer 126 is disposed simply by inserting into the bearing housing space of the bearing housing part 105a, when the motor housing 105 is oriented upward (with the bearing housing part 105a side up), for example, in order to mount the driving motor 111 into the motor housing 105, the wave washer 126 may fall out of the bearing housing part 105a, which causes inconvenience in handling.
In view of this problem, in this embodiment, a washer retaining ring 127 is provided for retaining the wave washer 126 so as to prevent the wave washer 126 from falling out of the bearing housing space. The washer retaining ring 127 is a cylindrical member having a flange 127a on its upper end and an engagement claw 127b on its lower end. The engagement claw 127b is engaged with the edge of an opening formed in the bottom of the bearing housing part 105a, so that the washer retaining ring 127 is mounted to the bearing housing part 105a and can move in the axial direction with respect to the bearing housing part 105a. The amount of this relative movement is designed to be larger than at least the amount of elastic deformation of the wave washer 126. The washer retaining ring 127 retains the wave washer 126 by holding it between the upper end flange 177a and the bottom of the bearing housing part 105a. Thus, the wave washer 126 is retained in the bearing housing part 105a and thus prevented from falling out. Therefore, ease of assembly in mounting the driving motor 111 into the motor housing 105 can be improved.
A generally circular motor installation space having an open bottom is formed at the rear of the crank chamber 116 within the gear housing 107. As shown in
The covering member 191 has a generally rectangular dish-like shape and is removably fastened to the gear housing 107 by a plurality of screws which are not shown. In this fastened state, as shown in
As shown in
As shown in
As shown in
In the embodiment having the above-described construction, the covering member 191 has not only a function of covering various internal mechanisms housed within the gear housing 107, but a function of retaining some of the component parts of the internal mechanisms, i.e. the bearing housing part 105a, the air bleeding mechanism 181 and the filler port cap 187. As described above, in the construction in which the driving motor 111 is provided with the brush holder unit 138, the connecting region 105b between the body region 105c and the bearing housing part 105a of the motor housing 105 is designed to have a smaller outside diameter in order to install the brush holder unit 138 thereon and designed to have the notch 105d in order to allow the brush holder 138b to face the commutator 136. For such reasons, the connecting region 105b may be reduced in strength.
Therefore, according to this invention, the construction in which the covering member 191 retains the bearing housing part 105a by pressing it in the axial and radial directions can compensate for insufficient strength of the connecting region 105b. As a result, runout of the motor shaft 112 can be prevented. Further, the construction in which the bearing housing part 105a is elastically retained via the O-ring 195 has a dust prevention effect on the bearing 139b and an effect of preventing abnormal noise (chatter) from being caused by contact between the covering member 191 and the bearing housing part 105a due to vibration. Further, in this embodiment, the bearing housing part 105a is retained by pressing from radially outside, but it may be constructed such that it is retained by pressing from radially inside.
Further, with the construction in which the air bleeding mechanism 181 and the filler port cap 187 are pressed and retained by the covering member 191, additional means for preventing the air bleeding mechanism 181 and the filler port cap 187 from falling out due to vibration or other causes are not required. Further, by detaching the covering member 191 from the gear housing 107, for example, for replacement of the carbon brushes, replacement of the air bleeding filter 173 and supply of lubricating oil can also be made at the same time, so that ease of use can be enhanced.
Further, as shown in
Specifically, in the electric hammer 101, air used for cooling the motor is led into a space 106a between the gear housing 107 and a body cover 106 which covers the outside of the gear housing 107, through an upper opening of the motor housing 105 by the cooling fan 132. Then the air flows forward through a space 106b between the barrel part 108 and the body cover 106 which covers the outside of the barrel part 108, and then, the air is discharged to the outside of the tool via outlets 106c (shown by a broken line in
A controller 140 and its peripheral structure in this embodiment is now explained with reference to
The controller 140 in this embodiment is disposed at the rear of the body 103 between the body 103 and the handgrip 109 to be held by the user. The handgrip 109 forms the “handle” according to this invention. As shown in
In this embodiment, the electrical components mounted in advance in the controller housing 140c of the controller 140c specifically includes an AC cord 150 for AC power supply, an AC terminal 144, a power switch 131, a control unit 147, male terminals 140a, 140b of the controller 140 for controlling the driving motor 111, a rotation speed control dial 148 and a motor speed sensor 149. The electrical component assembly in this embodiment is based on a controller that houses the control unit 147 for the driving motor 111 and formed as an assembly by additionally mounting other electrical components together with the controller. Therefore, in this embodiment, this controller-based electrical component assembly is referred to as the controller 140 in this embodiment.
The AC cord 150 is a power cord for introducing AC power into the controller 140 and is a feature that corresponds to the “power cord” according to this invention. The AC cord 150 itself is mounted and retained on the controller housing 140c. Specifically, as shown in
The power switch 131 can be switched between the on position in which power inputted via the AC cord 150 is supplied to a motor circuit of the driving motor 111 and the off position in which the power supply is cut off. The power switch 131 is a feature that corresponds to the “power switch” according to this invention. The control unit 147 performs controls relating to power supply to the driving motor 111. Specifically, it has a function of controlling electric current to be passed through the motor circuit of the driving motor 111 based on the settings of the rotation speed control dial 148 on which the rotation speed (number of revolutions) of the driving motor 111 can be set. In the control unit 147, an output part that outputs control signals relating to motor speed control to the driving motor 111 may also have a function as an output part that outputs control signals relating other than motor speed control, or the output parts may be separately independently provided. The control unit 147 is a feature that corresponds to the “control unit” according to this invention.
As shown in
The pair terminals 140a and the terminal 140b are configured as plug-in type terminals or male terminals (projections) which are inserted into a female terminal 138c (recess) formed in the brush holder 138b for terminal connection. For the terminal connection of the male terminals 140a, 140b, the male terminals 140a, 140b are plugged into the female terminal 138c formed in the rear of the body 103 in a direction transverse to the motor shaft 112 of the driving motor 111. The male terminals 140a, 140b on the controller 140 side and the female terminal 138c on the body 103 side are features that correspond to the “connecting terminal” and the “connected terminal”, respectively, according to this invention. Further, the terminal 140b for detecting carbon life may be omitted as necessary. Moreover, a female terminal may be provided on the controller 140 side and a male terminal may be provided on the brush holder 138b side.
With the controller 140 having the above-described construction, various electrical components installed in the controller housing 140c can be handled as one part in the form of the electrical component assembly. Further, the electrical components can be easily mounted to the body 103 side in one operation by plug-in terminal connection between the connecting terminal and the connected terminal. Therefore, ease of mounting the electrical components of the controller 140 can be improved.
In this embodiment, after the controller 140 is mounted to the body 103, the handgrip 109 is further mounted to the body 103 from the controller 140 side. The construction and operation of mounting the handgrip 109 is specifically described with reference to
As shown in
An operating member 133 is provided on the handgrip 109 and can be slid in the direction of an arrow 10 or the direction of an arrow 20 in
In such a construction, the operation member 133 has a function of matching the set position of the switch lever 131a with the set position of the operation member 133 by cooperation of the pair guides 133c and the slit 133d. This is now specifically considered as to the case in which the handgrip 109 is to be mounted to the body 103 from the controller side as shown in
In this embodiment, the electrical components mounted in advance in the controller housing 140c of the controller 140c are described as to include the AC cord 150, the AC terminal 144, the power switch 131, the control unit 147, the male terminals 140a, 140b, the rotation speed control dial 148 and the motor speed sensor 149. In this invention, however, it is necessary to mount at least an AC terminal, a power switch, a control unit and a connecting terminal to the housing and form an assembly. When other electrical components are additionally incorporated into the assembly, the kind and number of the electrical components can be appropriately selected as necessary.
Further, in this embodiment, the electric hammer is described as being of the type in which the driving motor 111 is arranged such that the axis of the motor shaft 112 extends transversely to the axis of the hammer bit. However, the present invention can also be applied to electric hammers of the type in which the driving motor 111 is arranged such that the axis of the motor shaft 112 does not extend transversely to the axis of the hammer bit. Further, in this embodiment, the electric hammer is described as a representative example of the impact tool, but the present invention can also be applied to a hammer drill in which the hammer bit 119 can perform a striking movement and a rotation.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2008-55214 | Mar 2008 | JP | national |
| 2008-64977 | Mar 2008 | JP | national |
| 2008-74649 | Mar 2008 | JP | national |
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