Hand-Held Tool Rigid Connector Design to Reduce Assembly Complexity
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Solution Overview
Problem
Existing tools, such as cordless vacuums and screwdrivers, have complex designs that require multiple components and wiring, making manufacturing costly and prone to assembly errors.
Innovation Solution
A simplified design for tools that eliminates printed circuit boards and cell monitors, using stamped metal connectors and enameled or uninsulated wires for connections, allowing for a more straightforward assembly and reduced component count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If printed circuit boards and cell monitors are used in tool design, then electrical connections and control functions are achieved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent extracts and removes the printed circuit board and cell monitor components from the tool design. Instead of using these complex electronic components, the invention uses direct wire connections between the battery terminals and motor terminals, eliminating unnecessary complexity while maintaining reliable electrical connections
Solution Approach 2:
The patent segments the electrical connection system into distinct functional parts: battery terminals with attached wires, connectors, and motor terminals. This segmentation allows for simplified assembly where each component performs a specific function without requiring complex integration
2Adaptability or versatility
If multiple components and wiring are used in tool design, then functional requirements are met, but manufacturing cost and assembly difficulty increase
Solution Approach 1:
The patent merges the functions of multiple components into fewer elements. The wire connections directly integrate power transmission and control functions without requiring separate circuit boards, cell monitors, and complex wiring harnesses, thereby simplifying manufacturing while maintaining full functional capability
Solution Approach 2:
The patent implements multi-functional connectors and wire assemblies that perform multiple functions simultaneously - power transmission, control signaling, and mechanical connection - eliminating the need for separate dedicated components for each function
3Reliability
If complex electrical connections are used in tool design, then control and monitoring functions are achieved, but assembly errors and manufacturing costs increase
Solution Approach 1:
The patent implements self-aligning connector designs where the wire connections and terminals are configured to automatically align during assembly, eliminating the need for precise manual positioning and reducing assembly errors while maintaining reliable control functions
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 approach simplifies the manufacturing process, reduces costs, and enhances reliability by minimizing the complexity of electrical connections and assembly steps.
Implementation Method 1
A battery housed in the housing
Implementation Method 2
An electrical connection between the battery and the motor for powering the motor by the battery
Implementation Method 3
a motor housed in the housing and a rotatable spindle driven by the motor
Data Source
AI summary
A hand-held tool that includes a housing. The housing includes a handle. A tool also includes a motor assembly, a battery assembly and a circuit board. The motor assembly includes a motor, the motor including a rotatable motor output shaft, a motor positive terminal and a motor negative terminal. The motor assembly also includes a first rigid conductive electrical connector having a first end fixed to the motor positive terminal and a second end fixed to the circuit board. The battery assembly includes a battery cell with a battery cell positive terminal and a battery cell negative terminal. The battery assembly further includes a second rigid conductive electrical connector having a first end fixed to the battery cell positive terminal and a second end fixed to the circuit board.