Brushless Motor Power Supply Segmentation for Hand-Held Sanding Machines
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Solution Overview
Problem
Existing hand-held machine tools, such as sanding machines, face challenges with power and weight distribution due to the conventional drive motor placement and speed reduction mechanisms, leading to inefficiencies and increased weight.
Innovation Solution
A brushless motor with a remotely located power supply system connected via a line arrangement, combined with a gear unit on the machining head for speed reduction, allowing for a smaller, more compact drive motor and improved torque distribution, while also incorporating features like hypercycloid motion and eccentric gear units for enhanced functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a conventional drive motor with integrated power supply is used, then the structure is simple, but the weight increases and power output is reduced
Solution Approach 1:
The drive system is segmented into separate components: the brushless drive motor is mounted on the machining head while the power supply system is remotely located on the handle element. This segmentation allows the motor to be optimized for power output without the weight penalty of an integrated power supply, while the power supply can be positioned where it does not adversely affect the center of gravity or handling characteristics.
2Power
If a high-speed drive motor is used, then power output is improved, but torque at the tool holder is insufficient
Solution Approach 1:
A speed-reducing gear unit is introduced as an intermediary mechanism between the high-speed drive motor and the tool holder. This gear unit reduces the rotational speed from the motor while simultaneously increasing the torque delivered to the tool holder, effectively decoupling the motor's operating speed from the tool holder's required speed and torque characteristics.
3Device complexity
If the power supply system is integrated with the drive motor, then device complexity is reduced, but dust exposure and wear increase
Solution Approach 1:
The power supply system is extracted from the machining head and relocated to the handle element. This extraction removes the power supply from the dust-prone environment at the machining head, thereby reducing dust exposure and potential wear on electrical components. The line arrangement provides reliable electrical connection while allowing the power supply to operate in a cleaner environment.
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
This configuration optimizes power output at reduced weight, enhances torque, and reduces wear, providing a more efficient and compact drive system with improved mobility and reduced dust exposure.
Implementation Method 1
the drive motor is a brushless motor
Implementation Method 2
a gear unit is arranged directly on the machining head, via which the tool holder is driven. The gear unit is a gear unit that reduces the speed of the drive motor, in particular a toothed gear unit
Data Source
AI summary
A hand-held machine tool, in particular a sanding machine, including a rod-type handle element for the user to grip and a processing head which is moveably mounted on the handle element by means of a joint assembly. The processing head has an electric drive motor for driving a tool holder provided for holding a processing tool and a speed-reducing gearbox between the drive motor and the tool holder, the gearbox being designed to achieve a reduction in speed of an output of the drive motor relative to a speed of the tool holder. The drive motor is a brushless motor and a power supply system for the drive motor is arranged at a distance from the drive motor on the handle element, the power supply system being connected to the drive motor by means of a cable arrangement.