Abstract:
A tool that includes an interchangeable drive head and a split gear body for transmitting torque to the drive head. The compact nature of the split gear body allows for an automatic power means, for example, an electric or air motor, to supply torque through the split gear body into the interchangeable drive head. Further, the interchangeable drive head includes a gear that is positioned around a receiving portion for receiving a head of a workpiece, so that the interchangeable drive head itself is part of the gear assembly. The above structure allows for a compact design while still allowing for an automatic power means to transmit the torque to the workpiece.

Description:
FIELD OF THE INVENTION 
     The present application relates generally to powered tools for rotating workpieces. More particularly, the present application relates to powered tools for rotating a workpiece by transmitting torque from a split gear body to a removable drive insert. 
     BACKGROUND OF THE INVENTION 
     Ratchet sets are well-known tools that are used to rotate a workpiece and fasten two objects together. For example, a user can tighten a workpiece by rotating the ratchet, and can return the ratchet to its original position by rotating the ratchet in the opposite direction, which will not rotate the workpiece. Ratchet sets are typically hand-powered, and pneumatically-powered ratchet sets are typically bulky and space consuming. Thus, a need exists for a more compact ratchet set that is powered by pneumatic or other automatic means. 
     Ratchet sets also include a socket that is adapted to engage a workpiece to apply torque to the workpiece. The socket can be, for example, hexagonally shaped to fit around a hexagonally-shaped head of the workpiece. When the user rotates the ratchet, the socket applies torque to the workpiece to fasten or unfasten the workpiece. Conventional sockets are interchangeable with the ratchet by including a friction fit, detent, or locking design so that the socket can engage with corresponding mating portions of the ratchet. However, this structure is difficult to adapt into a more automatic means of powering the tool other than by manual user power, because the socket is only mechanically joined with the ratchet and does not include any functional interface with the ratchet. 
     SUMMARY OF THE INVENTION 
     The present application relates to a power tool with a split gear body that rotates a gear assembly, and that indirectly rotates a removable drive insert component for transmitting torque to a workpiece. In particular, the present application discloses a tool including a base, a motor coupled to the base, a gear train in functional communication with the motor, and an interchangeable drive insert engaged with the gear train, the interchangeable drive insert including a receiving portion adapted to engage a workpiece and apply rotational force thereto, and a plurality of gear teeth adapted to engage and be driven by the gear train. 
     Also disclosed is a tool including a motor, a drive body in functional communication with the motor, the drive body including an upper gear and a lower gear and a first pinion gear disposed therebetween, a second pinion gear engaged with the first pinion gear, an idler gear engaged with the second pinion gear, and a ratchet gear engaged with the idler gear, the ratchet gear adapted to apply rotational force to a workpiece based on torque transmitted by the idler gear. 
     Further disclosed is a tool including an idler gear, and an interchangeable drive insert that includes a ratchet gear having gear teeth on an external radial portion thereof and including a radial opening that extends between first and second endpoints of the ratchet gear and that is shaped and sized to receive a workpiece therein, and an insert cavity adapted to receive the ratchet gear and allow rotational movement thereof and including an opening shaped and sized to cooperate with the radial opening of the ratchet gear and permit entry of a workpiece therein, wherein the insert cavity is positioned adjacent the idler gear such that at least one point of the ratchet gear is engaged with the idler gear during a full radial movement of the ratchet gear. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       For the purpose of facilitating an understanding of the subject matter sought to be protected, there is illustrated in the accompanying drawing embodiments thereof, from an inspection of which, when considered in connection with the following description, the subject matter sought to be protected, its construction and operation, and many of its advantages should be readily understood and appreciated. 
         FIG. 1  is a perspective side view of a tool in accordance with an embodiment of the present application. 
         FIG. 2  is a perspective side, partial cross-sectional view the tool of  FIG. 1 . 
         FIG. 3  is an enlarged, perspective side view of the tool of  FIG. 1 . 
         FIG. 4  is a side perspective view of a removable drive insert component of the present application. 
         FIG. 5A  is a side plan view of an open ended driver embodiment of the present application. 
         FIG. 5B  is an enlarged internal view of the open ended driver embodiment. 
         FIG. 6  is an enlarged side view of the removable drive insert component with arrows depicting the rotation of various components of the insert. 
     
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     While this invention is susceptible of embodiments in many different forms, there is shown in the drawings and will herein be described in detail a preferred embodiment of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to embodiments illustrated. 
     The present application discloses an apparatus, method and system for transmitting power to a workpiece.  FIG. 1  depicts a tool  100  including a main body  105  and a drive head  110  that is interchangeable with the main body  105 . The main body  105  can include a motor  115  with an attached button  115 A that is adapted to actuate the motor  115  to transmit mechanical energy through the tool  100 . Lever arms  120  are provided on the drive head  110  to releasably engage the drive head  110  with the main body  105 . The drive head  110  also defines a receiving portion  125  adapted to engage a workpiece, for example, a bolt with a hexagonal head, and to transmit torque from the tool  100  to the workpiece. In an embodiment, the drive head  110  is configured as a box-ended wrench. 
       FIG. 2  illustrates the tool  100  of  FIG. 1  with the external casing removed to reveal an embodiment of the internal components of the tool  100  and illustrate the structural configuration thereof. As shown, the tool  100  transmits power from the motor  115  through the offset crank  130  to the gear train  135 . The gear train  135  transmits torque from the motor  115  through various gears and to the drive head  110  in order to rotate a workpiece (not shown). For example, the motor  115  can transmit power to a drive body  140  via offset crank  130 . The drive body  140  can then transmit torque to a pinion gear  145 , which thereby transmits torque to one or more idler gears  150 , and ultimately to ratchet gear  155  of the drive head  110 , which is adapted to apply torque directly to the workpiece. 
     The motor  115  can be any form of motor, for example electric, pneumatic, hydraulic or manually-powered, that is adapted to transmit torque indirectly or directly to the ratchet gear  155  to rotate a workpiece. As discussed, a user can actuate the motor  115  by pushing on a button  115   a , and can deactivate the motor  115  by pushing on the button  115   a  a second time. Alternate forms of turning the motor on and off can be provided without departing from the scope and spirit of the present application. Also, the motor  115  can have different modes of power output (e.g., low, medium, and high) where button  115   a  can actuate the motor  115  between these different power outputs through successive actuations of the button  115   a.    
     The drive body  140  can include an upper gear  140   a , a lower gear  140   b , and a pinion gear  140   c  disposed in between the upper gear  140   a  and the lower gear  140   b . A pawl gear  160  can be spring loaded against the drive body  140  in order to limit rotational movement of the drive body  140  in at least one rotational direction. 
     As shown, the pawl gear  160  is meshingly engageable with a plurality of teeth of the upper gear  140   a  and the lower gear  140   b , but is not coupled to the pinion gear  140   c . This split gear body affords a more compact design and further maintains a symmetric loading on the pawl gear  160  when coupled to the upper gear  140   a  and lower gear  140   b . The pawl gear  160  can also engage each of the upper gear  140   a , lower gear  140   b  and pinion gear  140   c  to more securely hold the gears during rotational movement of the ratchet. 
     In an embodiment, the upper gear  140   a  and lower gear  140   b  can be thinner and wider relative to the pinion gear  140   c . However, the drive body  140  can be structured differently. For example, the pinion gear  140   c  can be wider than the upper gear  140   a  and the lower gear  140   b , and the pawl gear  160  can be split in two portions in order to provide a symmetric load on the drive body  140 . 
     The pinion gear  145  engages the pinion gear  140   c  of the drive body  140  to transmit torque from the drive body  140  to the idler gears  150 . The pinion gear  145  can be positioned at approximately mid-plane in the tool  100  so as to have sufficient clearance from the top and bottom of the case enclosing the tool components. As shown, the pinion gear  145  includes similar features as the pinion gear  140   c . However, the pinion gear  145  can be of a different shape, size, material, structure, or appearance from that of the pinion gear  140   c  without departing from the spirit and scope of the present application. 
     The idler gears  150  are adapted to transmit torque from the pinion gear  145  to the ratchet gear  155 . As shown, the idler gears  150  are provided on two sides of the ratchet gear  155 , and include two idler gears  150  on each side: one idler gear  150  that meshingly engages the pinion gear  145 , and a second idler gear  150  that meshingly engages the ratchet gear  155 . In an embodiment, one idler gear  150  is provided and the tool  100  still functions as intended. For example, one idler gear  150  can be disposed intermediate the pinion gear  145  and the ratchet gear  155  to transmit torque from the drive body  140  to the ratchet gear  155 . Further, idler gears  150  need not be disposed on multiple sides of the ratchet gear  155 , and only one set of idler gears  150  can be disposed in engagement with the ratchet gear  155 . In another embodiment, no idler gears  150  are necessary, and pinion gear  145  meshingly engages directly with the ratchet gear  155  to provide torque to the ratchet gear  155 . 
     In an embodiment, the ratchet gear  155  is a gear provided on the drive head  110  and is adapted to transmit torque from the idler gears  150  to a workpiece. As shown, the ratchet gear  155  has an internal opening that defines the receiving portion  125  for receiving a head of a workpiece. The receiving portion  125  engages and rotates the workpiece with torque transmitted from the motor  115  to the ratchet gear  155 . In an embodiment, the ratchet gear  155  is not integral with a structure that defines the receiving portion  125 , and can be separate therefrom. 
       FIG. 4  illustrates an embodiment of the drive head  110  in accordance with the present application. The drive head  110  defines a receiving portion  125  for engaging with a head of a workpiece to rotate the workpiece. The drive head  110  is adapted to be releasably retained on the main body  105  of the tool  100  by the lever arms  120 , and is further supported within the main body  105  by a support  170 . 
     The lever arms  120  can be any structure that allows the drive head  110  to releasably engage the main body  105  of the tool  100 . For example, the lever arms  120  can be resiliently biased against receiving portions of the main body  105  by way of a biasing structure, such as springs. Alternately, the lever arms  120  can be magnetically coupled to corresponding magnetic structures on the main body  105  of the tool  100  in order to releasably hold the drive head  110  thereon. The support  170  can be any structure that is adapted to support the drive head  110  within the main body  105  of the tool  100 . In an embodiment, and as shown, the support  170  is a small column that extends between the two sets of idler gears  150  and is adapted to support the drive head  110  within the inside of the tool  100 . 
     The drive head  110  provides a convenient and releasable structure wherein a user can actuate the lever arms  120  to remove the drive head  110  from the main body  105  of the tool  100 . Further, the drive head  110  may include gear teeth disposed on the ratchet gear  155  that engage directly with the idler gears  150  on the main body  105 . Thus, a more compact design can be obtained that allows for the motor  115  to transmit power to a releasable drive head  110  and eventually to a workpiece disposed within the receiving portion  125  of the drive head  110 . 
       FIG. 5A  depicts an embodiment of an open-ended engagement driver  500  of the present application. The open-ended driver  500  can be an interchangeable drive insert, similar to the drive head  110  disclosed above. The open-ended driver  500  differs from the drive head  110  in that the open ended driver  500  allows easier access to hard to reach or “tight quartered” fasteners where a traditional box-end wrench configuration could not reach the fastener. 
     As shown in  FIG. 5A , the open-ended driver  500  includes an open ratchet gear  505  disposed within an insert cavity  510  and including an opening  515  defined therein. The open-ended driver  500  can be releasably coupled to the tool  100  by lever arms  520 , similar to the lever arms  120  discussed above. Also, a support  525  can be provided that extends from the insert cavity  510  to further guide the ratchet gear  505  within the insert cavity  510 . 
     The open-ended ratchet gear  505  is similar to the ratchet gear  155  discussed above, except that the open-ended ratchet gear  505  is arcuately shaped. The opening  515  of the ratchet gear  155  allows a workpiece to be radially inserted into the ratchet gear  505 , and further allows the ratchet gear  155  to transmit torque to the workpiece without the necessity to axially engage the workpiece with the tool  100 . 
     The insert cavity  510  includes a radial boundary that is adapted to allow the open-ended ratchet gear  505  to rotate and meshingly engage one or more of the idler gears  550 . The open ratchet gear  505  is disposed within the insert cavity  510  such that at least one point of the ratchet gear  505  is engaged with the idler gear(s)  150  during full radial movement of the ratchet gear  505 . The geometry of the insert cavity  510  thus allows uninterrupted power transmission to the ratchet gear  505 . 
       FIG. 6  shows the gear design of the present application with the direction of the gears shown by rotational arrows. As shown, the pinion gear  140   c  rotates counterclockwise, and by engaging the pinion gear  145 , allows the pinion gear  145  to rotate clockwise. The clockwise rotation of the pinion gear  145  is transmitted to the two sets of idler gears  150 , which transmit torque to the ratchet gear  155 , to rotate the ratchet gear  155  in a counterclockwise direction. Thus, the user can rotate the ratchet gear  155  in a counterclockwise manner by actuating the tool  100  in a manner that rotates the pinion gear  140   c  in a counterclockwise manner. Alternately, the user can reverse the direction of rotation with a switch or a button (not shown), which would thereby rotate the pinion gear  140   c  in a clockwise manner, thereby transmitting torque to the ratchet gear  155  in a clockwise direction. 
     The manner set forth in the foregoing description and accompanying drawings and examples, is offered by way of illustration only and not as a limitation. More particular embodiments have been shown and described, and it will be apparent to those skilled in the art that changes and modifications may be made without departing from the broader aspects of Applicant&#39;s contribution. The actual scope of the protection sought is intended to be defined in the following claims when viewed in their proper prospective based on the prior art.