Contactless Trigger Switch Module With Hall Sensor Position Sensing
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Solution Overview
Problem
Conventional variable-speed trigger switches in power tools experience mechanical wear and failure due to contact between the wiper and potentiometer, especially in harsh environments like jack hammers or impact drills, leading to reduced module life and potential risks.
Innovation Solution
A contactless position detection system using a Hall sensor and displacement mechanism to displace a magnet member relative to the Hall sensor, allowing for non-contact detection of the plunger member's position through a rack and pinion or slip and groove system, with optional use of multiple magnet members for enhanced detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a wiper contacts with a potentiometer to detect position, then position detection is achieved, but mechanical wear occurs reducing module life
Solution Approach 1:
The patent replaces the mechanical contact-based position detection system (wiper and potentiometer) with a contactless magnetic field-based detection system using a Hall sensor. The Hall sensor detects the position of the plunger member by sensing the magnetic field of a magnet member without any physical contact, thereby eliminating mechanical wear while maintaining position detection accuracy.
2Reliability
If contactless detection is used to eliminate wear, then module life is increased, but device complexity increases
Solution Approach 1:
The patent introduces a magnet member as an intermediary between the plunger member and the Hall sensor. The magnet member is attached to the plunger member and moves with it, creating a magnetic field that the Hall sensor can detect. This intermediary enables contactless position detection while keeping the overall structure relatively simple and compact.
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 system increases the operational life of the electronic switch module by reducing mechanical wear and maintaining accurate position detection in harsh conditions, ensuring reliable operation.
Implementation Method 1
a Hall sensor disposed within the housing and operable to output a signal associated with a first location of the plunger member along the first axis based on a second location of the magnet member along the second axis
Data Source
AI summary
An aspect of the present disclosure is drawn to an electronic switch module including: a housing having a chute; a plunger member moveably mounted within the chute so as to be able to move along a first axis with a first velocity; a magnet member disposed within the housing; a Hall sensor disposed within the housing; and a displacement mechanism disposed within the housing and operable to displace the magnet member along a second axis with a second velocity by a distance away from the Hall sensor, wherein the first velocity is greater than the second velocity, and wherein the Hall sensor is operable to output a signal associated with a first location of the plunger member along the first axis based on a second location of the magnet member along the second axis.