Handheld Tool System Carrier for Battery Integration
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Solution Overview
Problem
Existing hand-held tools with electric drive motors and battery packs face challenges in assembly complexity and battery pack arrangement, where the battery often protrudes, hindering handling and requiring impractical attachment methods.
Innovation Solution
A hand-held tool design featuring a system carrier with integrated electrical components and a U-shaped battery compartment that allows for simplified assembly, complete battery pack enclosure, and enhanced cooling, along with safety features like power interruption switches and a prefabricated wiring harness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the battery pack is attached to the lower end of the handle with electrical contacts extending into the handle, then electrical connection is achieved, but handling is hindered by the attached battery
Solution Approach 1:
The battery pack is separated from the handle assembly, allowing the handle to be used independently without the battery attached. The battery pack can be removed and replaced as a separate unit, improving handling ease while maintaining electrical connection capability when needed.
Solution Approach 2:
The battery pack is repositioned from a fixed attachment at the lower end of the handle to a removable compartment location within the handle body. This dimensional reorganization allows the battery to be accessed and replaced without compromising handle maneuverability.
2Adaptability or versatility
If electrical components are assembled individually in the housing, then assembly flexibility is maintained, but assembly complexity increases
Solution Approach 1:
Multiple electrical components (battery pack, electrical contacts, control elements) are pre-assembled into an integrated unit before installation in the housing. This merging reduces the number of separate assembly steps and simplifies the overall assembly process while maintaining flexibility in component selection.
Solution Approach 2:
The electrical components are pre-assembled and tested as a complete unit before final installation in the housing. This preliminary assembly allows for quality control and functional testing to be performed early, reducing the complexity of final assembly operations.
3Volume of moving object
If the battery pack is completely enclosed within the housing, then a compact design is achieved, but assembly precision requirements increase
Solution Approach 1:
A dedicated battery compartment with defined mounting features serves as an intermediary structure within the housing. This compartment provides precise positioning and secure mounting for the battery pack, ensuring accurate alignment and complete enclosure without requiring extremely tight tolerances on the main housing assembly.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The tool i.e. motor saw (1), has a support for a rechargeable battery package (11) provided at a housing. An accommodation space is provided in the housing, and a system carrier is arranged in the space. Electric components e.g. electric switching devices (12), electronic controllers (13) and switches (16), and electric lines are attached at the carrier. A rechargeable battery shaft is formed in the carrier, and contact elements are arranged at the carrier for contacting the package. The electric components are connected one below the other with the contact elements by the lines.