Ferrite Core Nesting in Electric Power Tool Grip
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Solution Overview
Problem
The diameter of the grip in electric power tools increases when a ferrite core is housed inside, affecting handling and operation, especially in tools like random orbital sanders where the motor is housed within the grip.
Innovation Solution
The ferrite core is positioned inside the grip with its axis parallel to the motor axis, allowing it to be housed within the grip without increasing its diameter, and is supported by a rib structure that minimizes obstruction, with electric wires connected through the ferrite core to reduce noise, and a tubular cover for dustproof and waterproof insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a ferrite core is housed inside the grip to reduce electrical noises, then noise reduction is improved, but the diameter of the grip increases affecting handling
Solution Approach 1:
The ferrite core is repositioned from a location that would increase grip diameter to a location inside the motor housing along the motor axis. This dimensional repositioning allows the ferrite core to maintain its noise reduction function while being contained within the existing grip diameter envelope, thus resolving the contradiction between noise reduction and ease of operation.
Solution Approach 2:
The ferrite core is nested within the motor housing structure, specifically positioned inside the stator along the motor axis. This nesting approach allows the ferrite core to be housed within the grip without increasing the overall grip diameter, as it utilizes the internal space of the motor assembly rather than occupying additional external space.
2Object-affected harmful factors
If the ferrite core is positioned to reduce noise, then noise reduction is improved, but the grip diameter becomes larger
Solution Approach 1:
The ferrite core is repositioned from a location that would increase grip diameter to a location inside the motor housing along the motor axis. This dimensional repositioning allows the ferrite core to maintain its noise reduction function while being contained within the existing grip diameter envelope, thus resolving the contradiction between noise reduction and ease of operation.
Solution Approach 2:
The ferrite core is positioned specifically in the second housing part of the grip where electrical components are housed, rather than uniformly distributed or placed in the first housing part. This localized positioning optimizes noise reduction for the electrical components while minimizing impact on grip dimensions.
3Object-affected harmful factors
If the ferrite core is housed in the grip, then noise reduction is improved, but the structure becomes more complex
Solution Approach 1:
The ferrite core housing is merged with the existing motor housing structure. The motor housing is divided into a first housing part and a second housing part, with the ferrite core positioned in the second housing part. This merging approach integrates the ferrite core containment into the existing structure rather than adding a separate housing component, thus reducing overall structural complexity.
Solution Approach 2:
The motor housing serves multiple functions: it houses the motor components (stator and rotor), provides structural support, and contains the ferrite core for noise reduction. By making the housing multi-functional, the patent avoids adding separate dedicated housing structures for each function, thereby reducing device complexity.
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 configuration maintains a minimal grip diameter, enhances noise reduction, and ensures secure housing of the ferrite core, improving the handling and operation of electric power tools without enlarging the grip.
Implementation Method 1
a ferrite core is located inside an outer peripheral surface of the stator in a radial direction... an electric wire for the motor is passed through a ferrite core... the noise can be effectively and/or greatly reduced
Data Source
AI summary
In an electric power tool, a stator of a motor is housed in a grip and the stator is located coaxial to the grip. An electric wire for the motor is passed through a ferrite core. Further, the ferrite core is located inside an outer peripheral surface of the stator in a radial direction.