Compact Electric Switch With Integrated Plunger Contacts
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Solution Overview
Problem
Existing electric switches for manually operated power tools are complex due to the high number of contact systems required for rotational speed control and torque regulation, leading to a cumbersome structure.
Innovation Solution
A compact electric switch design featuring a plunger-connected actuation element that moves sliding contacts on a circuit board to control motor speed and torque, with potentiometer tracks integrated on the same surface, allowing for adjustable rotational speed and direction of rotation, and omitting soldered and clamping connections for simplified assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple separate contact systems are used for rotational speed control and torque regulation, then the control functions are achieved, but the structural complexity increases significantly
Solution Approach 1:
The patent combines multiple contact systems (rotational speed control contacts and torque regulation contacts) into a single integrated contact system on one circuit board. The contact paths for both functions are arranged on the same surface, allowing a single slider to control both rotational speed and torque through coordinated contact with different contact paths, thereby reducing structural complexity while maintaining full control functionality.
Solution Approach 2:
The single slider is designed to perform multiple functions simultaneously: it controls both rotational speed (through interaction with potentiometer tracks) and torque (through interaction with contact paths for contactless switching). This multi-functional design eliminates the need for separate control mechanisms, reducing the overall device complexity while achieving comprehensive motor control.
2Adaptability or versatility
If multiple separate contact systems with soldered and clamping connections are used, then the control functions are achieved, but the assembly complexity and manufacturing cost increase
Solution Approach 1:
The patent integrates all contact paths, potentiometer tracks, and connection points onto a single circuit board, eliminating the need for multiple separate components requiring soldered and clamping connections. This unified design simplifies assembly by reducing the number of connection steps and manufacturing operations required.
3Length of stationary object
If a compact layout with contact paths and potentiometer tracks on the same surface is used, then the switch profile is reduced, but the routing complexity increases
Solution Approach 1:
The patent utilizes the two-dimensional surface of a single circuit board to arrange both contact paths and potentiometer tracks in different spatial zones. The slider moves along a defined path that sequentially engages different contact regions, effectively using spatial arrangement and movement trajectory to manage the complexity of multiple control functions within a compact footprint.
Data Source
AI summary
An electric switch for electrical devices that includes a circuit board immovably arranged in a switch housing, the circuit board includes on one of its surfaces the contact paths of a contact system as well as contact surfaces in the form of potentiometer tracks. The contact paths interact with sliding contacts of the contact system and the potentiometer tracks interact with additional sliding contacts in order to set the revolutions per minute or the torque of the electric motor, movement of the plunger causes the sliding contacts of the contact system to come into contact with the associated contact paths, and, in this position of the plunger, which is the on position of the switch, the sliding contacts used for changing the direction of rotation are in the same way already in contact with the associated potentiometer tracks on the circuit board.