Battery Powered Impact Wrench
Project Length
15 weeks
Design and Project Intent
The Battery Powered Impact Wrench designed to enhance Ergonomics, Balance Weight, Increase Torque, and Improve Safety for Entry-Level Mechanics.
.png)
demographic target : any level mechanics
Context | ​
Mechanics use impact wrenches to efficiently remove and install bolts and nuts, leveraging the tool's high torque output to handle tough jobs that would be challenging with manual tools. The rapid, concussive force delivered by impact wrenches allows mechanics to complete tasks quickly and with less physical strain. These tools are especially valuable in automotive work, where they streamline processes like tire changes and engine repairs.
​
They desire a battery powered impact wrench that provides them with balanced weight, stronger torque, great ergonomics, safety, and the ability to perform task at any stage.
anatomy of an impact wrench
TRIGGER
GEAR HOUSING
ANVIL
HANDLE
DIRECTIONAL SWITCH
CLIP
TORQUE BUTTON
MOTOR HOUSING
task analysis : a step-by-step study
pain points
Heavy Gear Box Causes Weight
To Be Unbalanced In The Tool
An Open Hand Can Be Dangerous
When Working On Motor Vehicles
Hand Grip Cause Discomfort
When Using Over A Long
Period Of Time
Motor Lacks Torque When Used
On Heavier Or Tighter Bolts
design goals and objectives
BALANCE WEIGHT
Insuring that the tools weight is balanced will decreases the risk of injury.
INCREASE TORQUE
Achieving stronger torque will improve tighter fastenings, overall safety, and overall better performance.
INCREASE SAFETY
Improving safety will reduce the amount of accidents and enhances trust.
brand analysis
brand design language
Vibrant Red Color
Powerful
Industrial Look
Smooth Edges
sketches : ideation level sketching
_edited.jpg)
sketches : second level sketching
_edited_edited.jpg)
full scale foam prototypes : 23 foam models
1.
2.
3.
4.
5.
6.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
7.
8.
.png)
cad model : concepts 1-5
Phase 1
Phase 2
Phase 3
Phase 4
Phase 5
Concept 1
The initial CAD model was designed to house the internal components, but the handle was found to be too tight and uncomfortable for the user's hand, necessitating a revision for improved ergonomics and user comfort.
Concept 2
The second concept addressed the grip issues from the previous design, improving handle comfort. Additionally, this model marked the first attempt at integrating the battery, advancing the development of the internal component fitting.
Concept 3
The third concept aimed to finalize the design, successfully fitting all internal components. However, the barrel casing at the top was oversized, resulting in excessive wiggle room for the motor parts, requiring further refinement.
Concept 4
The fourth concept marks the beginning of the final design. The battery fits seamlessly into the bottom slot, and the Milwaukee lightning bolt has been incorporated to enhance brand identity. The next phase involves adding internal components and fine details.
Concept 5
The final concept fully achieves the design objectives, featuring a front safety guard and enhanced torque through an enlarged motor. All necessary details have been meticulously integrated into the wrench, ensuring it meets performance, safety, and brand requirements.
refinement process: concepts 2 and 3
Concept 2
Concept 3
final full scale model : prime and sanded to a plastic feel
renderings : details
Longer Motor
LED Light
Safety Guard
Dimensions
Brand Logos
Balanced Weight
exploded view
Brushless Motor
Gear Box
LED Light
Trigger
Torque Drive Control
Brushless Motor
Logo
Injection Molded ABS Plastic
Rubber Grip
Battery Connector
Switch
Rotor
final design : Milwaukee's brand language and CMF
.jpg)
Future Adjustments
I would create a alternate
design around the light.
I would try to integrate the
light around the head of the
gear box so it will provide
a more substantial light
direction that matches the
motion of the wrench.