Coiled Motor Power Cord Layout to Prevent Sharp Bends
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Solution Overview
Problem
Portable electrical assemblies, such as magdrills, face issues with electric motor power cord failure due to excessive strain from being grabbed as a handle or subjected to sharp bends during movement, leading to premature wear and failure.
Innovation Solution
The electric motor power cord is housed within a cavity of the assembly, coiled in a circular or helical manner, allowing it to expand and contract without creating sharp bends as the motor moves between operating positions, keeping the cord inaccessible to users and reducing strain.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the electric motor power cord is positioned externally and accessible to the user, then ease of operation is improved, but reliability deteriorates due to excessive strain from incorrect handling
Solution Approach 1:
The power cord is extracted from the external environment and placed inside the housing cavity, removing it from the user's direct access area. This prevents users from grabbing the cord as a handle while maintaining the cord's functional connection between the motor and power module.
Solution Approach 2:
The power cord is nested within the housing cavity, concealed inside the portable electrical assembly. The cord is positioned within the internal space of the housing, making it inaccessible to users from the outside while remaining functional for power transmission.
2Reliability
If the electric motor power cord is positioned within the housing, then reliability is improved, but device complexity increases due to sharp bends required for motor movement
Solution Approach 1:
The power cord is configured in a circular or helical coil shape within the housing cavity. This curved, coiled configuration allows the cord to accommodate the linear movement of the motor without creating sharp bends, as the coil can expand and contract smoothly during motor operation.
Solution Approach 2:
The coiled power cord is designed to dynamically expand and contract as the motor moves between operating positions. The cord's configuration changes from a tightly coiled state to a more extended state and back, accommodating motor movement without permanent deformation or sharp bending.
3Reliability
If the power cord is coiled within the housing, then reliability is improved by eliminating sharp bends, but ease of operation deteriorates due to inaccessibility
Solution Approach 1:
The power cord is extracted from the user's reach by placing it inside the housing cavity, preventing users from grabbing or manipulating the cord. This eliminates the harmful action of users using the cord as a handle while maintaining all necessary electrical functions.
Solution Approach 2:
The housing structure serves as an intermediary barrier between the user and the power cord. The cord remains accessible to the electrical system for power transmission while being physically isolated from user interaction through the housing enclosure.
Data Source
AI summary
A portable electrical assembly includes an electric motor, a power module, and an electric motor power cord. The electric motor power cord is placed within a cavity of a housing of the portable electrical assembly and is operatively connected to the electric motor at first end and to the power module at a second end. The electric motor power cord is configured to move in response to the movement of the electric motor without the creation of sharp bends along its length as the electric motor moves between all of its possible operating positions including an extended position and a resting position and a plurality of intermediate position between the extended and resting position.