Electromagnetic Actuator Assembly for Switch-Free Power Tool Mode Changes

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Solution Overview

Problem

Existing power tools require mechanical switches or buttons for mode changes, which can be cumbersome and increase tool size, weight, and complexity.

Innovation Solution

An electromagnetic actuator assembly using a permanent magnet and electromagnet system to move between positions for mode changes, allowing electronic control and eliminating the need for mechanical switches.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If mechanical switches or buttons are used for mode changes, then the power tool can change operating modes, but the tool size, weight, and complexity increase

Engineering Contradiction:

Improvemode change capabilityVSAvoidmechanical switch complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent replaces mechanical switches and buttons with an electromagnetic actuator system. The actuator uses magnetic fields generated by electromagnets to move a collar between different positions, eliminating the need for mechanical switching components. This substitution reduces device complexity while maintaining mode change functionality.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention extracts and eliminates unnecessary mechanical components (switches, buttons, linkages) from the mode change mechanism. By using an electromagnetic field to directly actuate the collar, the design removes intermediate mechanical elements, simplifying the overall structure.

Inventive Principle:

Principle #2Taking out (Extraction)

2Adaptability or versatility

If mechanical switches or buttons are used for mode changes, then the power tool can change operating modes, but the tool size and weight increase

Engineering Contradiction:

Improvemode change capabilityVSAvoidtool weight

Core Design Contradiction:

Adaptability or versatilityVSWeight of moving object

Solution Approach 1:

The electromagnetic actuator system replaces heavy mechanical switches and linkages with lightweight electromagnetic components. The actuator uses magnetic fields rather than mechanical force transmission, significantly reducing the weight of the mode change mechanism while maintaining full functionality.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Adaptability or versatility

If mechanical switches or buttons are used for mode changes, then the power tool can change operating modes, but the operation becomes cumbersome

Engineering Contradiction:

Improvemode change capabilityVSAvoidmode change ease

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

The electromagnetic actuator can be controlled electronically through buttons, switches, or automated sensors, providing easier and more precise control compared to manual mechanical switching. The magnetic actuation provides smooth, reliable collar movement without the friction and wear associated with mechanical linkages.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

Enables mode changes with reduced complexity, size, and weight by using electronic control, conserving energy with momentary bursts of current, and allowing for automated mode transitions based on user input or tool conditions.

Implementation Method 1

An electromagnetic actuator assembly using a permanent magnet and electromagnet system to move between positions for mode changes

Methodology Applied

Scientific EffectElectromagnet: Electromagnet

Implementation Method 2

The actuator includes a permanent magnet and is moveable between a first position for a first mode of operation of the power tool, and a second position a second, different mode of operation of the power tool

Methodology Applied

Scientific EffectMagnetism: Magnetism

Data Source

PatentUS12365076B2Electromagnetic actuator for power tool

Publication Date: 2025.07.22 BLACK & DECKER CORP

AI summary

An actuator assembly for a power tool includes an actuator with a permanent magnet. The actuator is moveable between a first position for a first mode of operation, and a second position for a second mode of operation. A first positioning member is adjacent the first position composed of a ferromagnetic material to attract the permanent magnet. A second positioning member is adjacent the second position and composed of a ferromagnetic material to attract the permanent magnet. An electromagnet may be energized to move the actuator between the first position and the second position. When the electromagnet is not energized and the actuator is in the first position, the actuator is retained in the first position. When the electromagnet is not energized and the actuator is in the second position, the actuator is retained in the second position. When the electromagnet is energized, the actuator moves between the first and second positions.