Energy Storage Plug-in Arm for Compact Handheld Power Tools
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Solution Overview
Problem
Handheld power tools with integrated energy storage devices face challenges in achieving a compact design while maintaining adequate support and stability, as the energy storage housing often increases the overall height of the tool, compromising ergonomics and usability.
Innovation Solution
The energy storage device is integrated into the tool's design by incorporating storage elements and electrical circuits within the plug-in arm, which also serves as a stabilizing feature, allowing for a more compact form factor and improved hold on the machine housing, with additional support provided by a second plug-in arm and latching mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the energy storage housing is mounted on the bottom of the machine housing, then the energy store is securely held, but the overall height of the tool increases
Solution Approach 1:
The plug-in arm extends laterally from the energy storage housing base rather than mounting the energy store directly on the bottom surface. This lateral extension into the protective section area allows the energy store to be held securely without increasing the overall height of the tool, effectively moving the solution from a vertical dimension to a horizontal/lateral dimension.
Solution Approach 2:
The plug-in arm is inserted into the protective section of the machine housing, nesting the energy storage device within the existing housing structure. This nesting approach allows the energy store to be accommodated without adding external height, as the plug-in arm utilizes the internal space of the protective section.
2Volume of stationary object
If storage elements are placed in the plug-in arm, then the energy storage housing base can be made more compact, but the plug-in arm must be designed to accommodate both storage elements and electrical circuits
Solution Approach 1:
The plug-in arm combines multiple functions into a single structural element: it serves as a support for storage elements (battery cells), provides mounting for electrical circuits (monitoring circuit and charge controller), and acts as a mechanical connector between the energy storage housing and the machine housing. This merging of functions reduces the overall volume of the energy storage housing base while consolidating complexity into the plug-in arm component.
3Reliability
If a second plug-in arm is arranged in the handle section, then the energy store can be a two-armed energy store, but the handle section has less space for control components
Solution Approach 1:
The energy storage device is segmented into two separate plug-in arms: a first plug-in arm extending into the protective section and a second (shorter) plug-in arm extending into the handle section. This segmentation allows the energy store to be securely held in two locations while keeping the second plug-in arm compact enough to leave sufficient space in the handle section for control components.
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The tool (10) has a drive motor (13) arranged in a machine housing (12), which comprises a supporting section (20) that lies opposite to a hand grip section (19). An energy storage housing (51) comprises a connection arm (54) for insertion into a connecting arm holder (28), which is provided at the supporting section of the machine housing. The connection arm protrudes in front of an energy storage housing-base (53). A storage element (52) i.e. lithium-ion cell, and/or an electrical circuit (83) i.e. monitoring circuit, is arranged in the connection arm of the storage housing.