External PCB Electrical Switch for Power Tools
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Solution Overview
Problem
Existing electrical switches for power tools have complex designs due to integrated printed circuit boards, limiting flexibility and increasing production costs, and are not easily adaptable to different power tool installations.
Innovation Solution
The electrical switch design features a printed circuit board located outside the housing, with parts of the signaling device and contact system divided between the housing and the circuit board, allowing for flexible configuration and cost-effective adaptation to various power tools, including non-contact signaling for harsh conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the printed circuit board is integrated inside the housing, then the switch structure is compact and complete, but the design complexity increases and adaptability to different power tools decreases
Solution Approach 1:
The switch is divided into two independent parts: the housing containing mechanical components (actuator, contact system) and the printed circuit board containing electronic components (signaling device). This segmentation allows each part to be designed and manufactured separately, then assembled together, reducing housing design complexity while maintaining adaptability.
Solution Approach 2:
The printed circuit board is extracted from the housing and positioned externally. This extraction removes the electronic components from the housing structure, simplifying the housing design and allowing the switch to be adapted to different power tool installations without redesigning the entire housing assembly.
2Ease of manufacture
If the printed circuit board is integrated inside the housing, then the switch is complete, but production costs increase
Solution Approach 1:
By segmenting the switch into housing and printed circuit board components, each can be manufactured using optimized processes and assembled through standardized connections, reducing overall production costs despite the structural division.
3Adaptability or versatility
If the signaling device and contact system are integrated in the housing, then the switch is self-contained, but flexibility for adaptation decreases
Solution Approach 1:
The signaling device is separated from the housing and placed on the externally positioned printed circuit board. This segmentation allows the electronic signaling components to be configured and adapted independently from the mechanical housing, reducing configuration effort for different power tool applications.
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
This design results in a compact, cost-effective, and adaptable electrical switch that can be easily adjusted for different power tools, maintaining mechanical robustness and flexibility while allowing for a sealed housing.
Implementation Method 1
The sensor element is a magnetic sensor, in particular a Hall sensor
Implementation Method 2
The sensor element is a magnetic sensor, in particular a Hall sensor, a reed sensor
Implementation Method 3
The sensor element is an inductive sensor and the transmitter element is an electrical conductor
Implementation Method 4
The sensor element is a capacitive sensor and the transmitter element is an electrical conductor and/or a dielectric
Implementation Method 5
The sensor element is at least one light source and at least one photo sensor
Implementation Method 6
The sensor element is at least one light source and at least one photo sensor
Data Source
AI summary
The invention relates to an electrical switch (1), in particular in the form of a signal transmitter for an electric tool comprising an electric motor, such as for an electric drill, a hammer drill, an electric screwdriver or the like, having a housing (2). An operating element (3) which can be adjusted between a starting position and an end position is arranged on the housing (2). A signal device for generating a signal which is associated with the adjustment path of the operating element (3) and/or a contact system for switching the contact system in a position of the operating element (3) are/is operatively connected to the operating element (3). A printed circuit board (5) which is arranged outside the housing (2) is provided, wherein at least parts of the signal device and/or of the contact system are located on the printed circuit board (5).