Brushless Rechargeable Shear With Rotatable Head for Cordless Power
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Solution Overview
Problem
Existing rechargeable shears lack improved ergonomics and higher power output, particularly in cordless designs used for cutting materials like air-conditioning ducts and cement boards.
Innovation Solution
A rechargeable shear equipped with a brushless motor, featuring a stator and rotor that is rotatable relative to the stator, integrated with a motor housing, grip housing, and battery-holding housing, along with a shear part driven by the rotor, and an optional light for illumination, allowing for adjustable cutting angles and enhanced power delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a rechargeable battery pack is used to power the shear, then portability and ease of operation are improved, but power output and productivity deteriorate
Solution Approach 1:
The patent replaces the traditional brushed motor with a brushless motor that uses electronic commutation instead of mechanical brushes. This substitution enables higher power output while maintaining cordless operation, as the brushless motor can deliver more torque and power without the limitations of mechanical contact components.
Solution Approach 2:
The patent changes the motor type from brushed to brushless, which fundamentally alters the power delivery characteristics. The brushless motor enables higher rotational speed and torque output, directly addressing the power output limitation of battery-powered shears while maintaining the portability advantage.
2Device complexity
If a brushed motor is used in the shear, then device complexity is reduced, but power output and productivity deteriorate
Solution Approach 1:
The patent replaces the brushed motor with a brushless motor, eliminating mechanical brushes and commutators. Although the motor structure becomes more complex electronically, this substitution enables significantly higher power output and efficiency, resolving the trade-off between simplicity and power capability.
Solution Approach 2:
The patent removes the brushes and mechanical commutation system from the motor design. By extracting these components, the motor achieves higher efficiency and power output, compensating for the increased electronic control complexity through performance gains.
3Device complexity
If the shear head is fixed in position, then device complexity is reduced, but adaptability deteriorates
Solution Approach 1:
The patent implements a rotatable shear head that can be adjusted to multiple angular positions and locked in place. This dynamic design allows the shear head to adapt to different cutting angles and orientations, enhancing versatility while maintaining operational simplicity through a lockable mechanism.
Solution Approach 2:
The rotatable shear head design enables the tool to perform cutting operations at various angles and orientations, making it adaptable to different workpiece configurations and cutting requirements. This multi-position capability provides universal applicability across diverse cutting tasks.
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 brushless motor design provides improved ergonomics and higher power output, enabling efficient cutting with adjustable angles and illumination, enhancing work efficiency and safety, especially in dark environments.
Implementation Method 1
a brushless motor having a stator and a rotor, which is rotatable relative to the stator
Data Source
AI summary
A rechargeable shear (1) includes: a motor (5) having a rotor (21) that is rotatable relative to a stator (20); a motor housing (4), which houses the motor (5); a grip housing (8) connected to the motor housing (4); a battery-holding housing (9) connected to the grip housing (8); and a shear part (3) disposed forward of the rotor 21 and operably driven by the rotor (21). The motor (5) may be brushless. The shear part (3) may be rotatable relative to the motor housing (4) using a manipulatable ring (85) and a detent system (89, 92-94). A light (48) for illuminating the shear part (3) and a workpiece being cut thereby may be provided on the grip housing (8) or the battery-holding housing (9).