Asymmetric Power Tool Connector for Wrong-Voltage Insertion Prevention
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Solution Overview
Problem
Pole saw and pole hedge trimmer products face damage due to incorrect voltage insertion, as they share a common platform with different voltage configurations, leading to increased design, production, and storage costs.
Innovation Solution
A power tool system with a unique connector design that ensures tools of different voltages cannot be energized when incorrectly connected, using a non-rotationally symmetrical triangle configuration of terminals and limiting members to prevent incorrect insertion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If different voltage configurations share the same platform (operating rod, electrical connector), then design cost, production cost and storage cost are reduced, but incorrect voltage insertion causes damage to the machine
Solution Approach 1:
The connector adopts an asymmetric terminal arrangement where terminals A, B, C are positioned at specific locations on the first connector portion, and corresponding terminals A', B', C' are positioned on the second connector portion. This asymmetric configuration ensures that only the correct voltage-matched connector can be properly inserted, preventing incorrect voltage connections while maintaining a unified platform design.
Solution Approach 2:
The connector acts as an intermediary component between the power source and the working assembly. It includes a first connector portion connected to the power source and a second connector portion connected to the working assembly, with terminal arrangements that mediate the electrical connection and prevent mismatched voltage connections.
2Device complexity
If a unified connector design is used for all voltage configurations, then device complexity is reduced, but incorrect insertion leads to harmful electrical connections
Solution Approach 1:
The connector employs asymmetric terminal positioning where terminals A, B, C are arranged in specific locations on the first connector portion, and corresponding terminals A', B', C' are positioned on the second connector portion. This asymmetric design creates a unique mechanical and electrical interface that only accepts the correct voltage-matched connector, preventing incorrect insertions while maintaining a single unified connector design across all voltage configurations.
Solution Approach 2:
The connector design incorporates preliminary mechanical constraints through the asymmetric terminal arrangement and positioning structures. Before electrical connection can occur, the mechanical geometry must align correctly, which preliminarily prevents incorrect voltage connections from being inserted in the first place.
Data Source
AI summary
A power tool system includes a first power tool and a second power tool. The first power tool includes a first connecting rod having a first working assembly, a second connecting rod having a first battery assembly, a first connector having a first connector portion with terminals A, B and C and a second connector portion with terminals A′, B′ and C′. The second power tool includes a third connecting rod with a second working assembly, a fourth connecting rod with a second battery assembly and a second connector with a same structure as the first connector; voltages of the first and second battery assemblies are different; terminals A, B are connected with first working assembly, and terminals A′, B′ are connected with first battery assembly; and terminals B, C are connected with second working assembly, and terminals B′, C′ are connected with second battery assembly.