Foamed Cable for Hand Tool Wiring
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Solution Overview
Problem
Existing hand tools with vibration-reducing mechanisms in the connection area between the handle and main housings often suffer from damaged cabling due to loose strands rubbing against each other or the housing, especially when drilling dust is present, leading to tool failure.
Innovation Solution
Embedding the strands in a foamed protective sheath to prevent friction and damage, allowing for parallel arrangement and stretchable design to accommodate movement and provide protection for both wires and electronic components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If strands are arranged loosely in the connection area, then assembly is simpler, but strands rub against each other and housing causing damage
Solution Approach 1:
Multiple loose strands are merged into a single integrated cable assembly with a common protective sheath. This combines previously separate components into one unit that is easier to handle and assemble while preventing internal friction between strands through the enclosing sheath structure.
Solution Approach 2:
A protective sheath is introduced as an intermediary element between the strands and the external environment. This sheath mediates the interaction by providing a friction-reducing interface that prevents strands from rubbing against each other and against the housing during relative movements.
2Reliability
If strands are fixed together in a protective sheath, then friction damage is prevented, but flexibility to accommodate movement is reduced
Solution Approach 1:
The protective sheath is designed as a flexible structure that can deform and stretch to accommodate the relative movements between handle housing and main housing. This flexible shell maintains strand protection while adapting to dynamic operational conditions without causing damage.
Solution Approach 2:
The cable assembly incorporates dynamic characteristics through its flexible sheath design that allows for movement and deformation during operation. The structure transitions from a static fixed arrangement to a dynamic system that can adapt its configuration based on operational demands while maintaining protective functions.
3Adaptability or versatility
If multiple strands are handled separately, then routing is more flexible, but assembly complexity increases
Solution Approach 1:
Multiple strands that would otherwise require separate routing and assembly operations are merged into a single pre-assembled cable unit. This merging reduces the number of assembly steps and complexity while the flexible sheath design maintains the ability to accommodate various routing requirements.
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
The foamed protective sheath effectively prevents strand damage from friction and jamming, simplifies assembly, and provides flexibility to accommodate relative movements, reducing the risk of electrical connection failure during operation.
Implementation Method 1
the strands are embedded in a foamed protective sheath in such a way that they are largely fixed to one another. This prevents the two strands from rubbing against each other and causing damage
Implementation Method 2
Such a protective jacket made of foamed material can effectively prevent damage to the strands caused by friction, and the protective jacket can also be made sufficiently stiff to prevent the cabling from jamming
Data Source
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AI summary
The device has a main housing (10), in which an electric motor (12) is placed. A handle housing (6) is movably held against the main housing in a spatial direction. A motor switch (16) is provided in the handle housing and is electrically connected with the drive motor using a wiring (14). The wiring has a foam filled protective cladding and strands that are fixed in the cladding. The strands are arranged at a distance from each other. The protective cladding is formed from a thermosetting polyurethane-foam.