Annular LED Light Ring for Power Tool Workpiece Illumination
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Solution Overview
Problem
Handheld power tools often operate in substandard lighting conditions, making it difficult for users to adequately see the workpiece being machined, and existing solutions lack protection from adverse environmental conditions.
Innovation Solution
A power tool design featuring a light ring with annularly arranged light emitting diodes (LEDs) around the end effector, powered by the tool's battery, and protected by a transparent cover and heat staking process, ensuring illumination of the workpiece and resistance to environmental factors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a lighting feature is added to illuminate the workpiece, then visibility of the workpiece is improved, but the lighting feature becomes vulnerable to adverse environmental conditions
Solution Approach 1:
The light emitting assembly is nested within a recess in the power tool housing, with a transparent cover protecting the lighting elements. This nested structure allows the lighting feature to provide illumination while being sheltered from adverse environmental conditions such as dust, moisture, and physical damage.
Solution Approach 2:
A transparent cover is used to protect the lighting elements while allowing light to pass through. This thin film structure provides environmental protection against contaminants and physical damage while maintaining the illumination function, effectively shielding the vulnerable lighting components.
2Illumination intensity
If lighting elements are positioned adjacent to the end effector for optimal illumination, then workpiece visibility is improved, but the lighting elements are exposed to rotating mechanical components
Solution Approach 1:
The light emitting assembly is positioned within a recess in the housing that places it adjacent to the end effector for optimal illumination, while the recess itself and transparent cover create a protective barrier that shields the lighting elements from rotating mechanical components and debris.
Solution Approach 2:
The transparent cover acts as an intermediary barrier between the lighting elements and the rotating end effector. It allows light to pass through for illumination while physically separating and protecting the lighting components from the harmful effects of rotating mechanical parts.
3Loss of information
If the power tool housing is made transparent to allow viewing of internal components, then component visibility is improved, but protection from environmental factors is reduced
Solution Approach 1:
Instead of making the entire housing transparent, only a localized transparent cover is used specifically for the light emitting assembly. This localized transparency provides the necessary visibility and light transmission function while the rest of the housing maintains its protective opaque structure against environmental factors.
Solution Approach 2:
A transparent cover (thin film) is used specifically for the lighting assembly area, providing selective transparency where needed for light transmission and viewing, while the majority of the housing remains opaque to maintain environmental protection. This localized application balances visibility needs with protective requirements.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides effective illumination of the workpiece in various lighting conditions and protects the lighting components from environmental adversity, enhancing user visibility and tool durability.
Implementation Method 1
a light ring having a plurality of light emitting diodes arranged in an annular pattern
Implementation Method 2
The transparent cover is heat staked to the housing
Data Source
AI summary
A power tool includes a housing having a large diameter rear portion and a narrow diameter nosepiece. An end effector is rotatably coupled to the housing. A holder with a substantially annular holder body is received over the nosepiece and non-rotatably coupled to the housing. A substantially annular cover having at least one transparent surface, and an internal annular groove, is received at least partially inside the holder body, and non-rotatably and axially fixed with respect to the holder. A substantially annular printed circuit board is received at least partially inside the annular groove in the cover, and non-rotatably and axially fixed with respect to the cover. A plurality of lighting elements is operatively connected to the printed circuit board and radially disposed about the printed circuit board. The lighting elements are aligned with the at least one transparent surface so as to illuminate a workpiece.