Compact Chainsaw Layout Using Nested Motor and PCB Overlap
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Solution Overview
Problem
Conventional chain saws are bulky and cumbersome, causing user fatigue and hindering movement due to their large size, which complicates storage and handling.
Innovation Solution
A compact chain saw design featuring a housing with an accommodation space for an electric motor, transmission system, control system, and power supply assembly, optimized for reduced dimensions and weight, including an external rotor electric motor and innovative air cooling and chip discharge mechanisms, allowing for efficient power output and easy storage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional chain saw components (electric motor, transmission mechanism, oil can, power supply) are mounted in a housing to satisfy power output requirements, then the chain saw can achieve sufficient cutting power, but the housing occupies relatively large space and the whole machine becomes bulky, causing user fatigue during long-term operation
Solution Approach 1:
The patent applies nesting by placing the power supply assembly inside the housing, and positioning the oil can within the accommodation space formed by the housing. The circuit board assembly is arranged to overlap with projections of the electric motor and power supply assembly, creating a nested configuration where components occupy shared spatial volumes, thereby reducing the overall machine volume while maintaining all necessary power-related components
Solution Approach 2:
The circuit board assembly extends in a plane and obliquely intersects with the front-rear direction, creating a two-dimensional arrangement that overlaps with the projections of other three-dimensional components. This dimensional arrangement allows the circuit board to coexist spatially with the electric motor and power supply assembly without increasing the overall machine volume, effectively utilizing spatial overlap in multiple dimensions
2Adaptability or versatility
If the chain saw is designed with large volume to accommodate all components, then sufficient power and functionality are achieved, but the large volume has relatively great influence on the movement of the user and complicates storage
Solution Approach 1:
The patent merges multiple functions into the housing structure: the housing provides mechanical protection, forms an accommodation space for the oil can, and serves as the outer shell for mounting the power supply assembly. The guide plate also serves dual functions by guiding the chain and providing a mounting base for the locking device, thereby reducing the number of separate components and overall volume
Solution Approach 2:
The power supply assembly is nested within the housing, and the oil can is positioned within the accommodation space, creating a compact nested configuration that minimizes the external dimensions of the chain saw while maintaining all necessary functional components for complete operation
3Ease of operation
If the chain saw is hung or stored on the user during operation, then the user can maintain adjusted positions, but a relatively large volume causes relatively great influence on the movement of the user
Solution Approach 1:
The compact nested arrangement of components (power supply inside housing, oil can in accommodation space, overlapping circuit board with motor and power supply projections) minimizes the overall machine volume to 305mm or less in length, making the chain saw small enough to be comfortably carried and stored on the user without significantly impeding movement, while still providing all necessary functions for position adjustment during operation
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 compact design reduces user fatigue, enhances operational ease, and facilitates convenient storage and handling by minimizing the machine's volume and weight while maintaining high cutting efficiency and power output.
Implementation Method 1
an electric motor at least partially disposed in the accommodation space
Implementation Method 2
innovative air cooling and chip discharge mechanisms
Implementation Method 3
innovative air cooling and chip discharge mechanisms
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
A chain saw includes a housing, an electric motor, a transmission system, a control system including a circuit board assembly, and a power supply assembly. The circuit board assembly obliquely intersects with a first straight line; in a direction of a second straight line perpendicular to a direction of the first straight line and extending along an up and down direction, the electric motor has a projection surface perpendicular to the direction of the second straight line, and the circuit board assembly has a projection surface perpendicular to the direction of the second straight line; and the projection surface of the electric motor at least partially overlaps the projection surface of the circuit board assembly. Along the direction of the first straight line, the power supply assembly has a projection surface perpendicular to the direction of the first straight line, and the circuit board assembly has a projection surface perpendicular to the direction of the first straight line. The projection surface of the power supply assembly at least partially overlaps the projection surface of the circuit board assembly.