Inductive Power Transfer for Dust Extractor Reliability

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Solution Overview

Problem

Existing power tool accessory systems, such as dust extractors for hammer drills, often malfunction due to dust accumulation in mechanical interfaces or electrical connector damage, leading to reliability issues.

Innovation Solution

A power tool and accessory system utilizing induction coils for wireless power transfer, eliminating the need for physical mechanical or electrical connections, where a first induction coil in the power tool induces a voltage in a second coil in the accessory, powering its motor through inductive coupling.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a mechanical coupling is used to power the dust extractor from the drill motor, then power is transferred reliably, but dust accumulation in the mechanical interface causes malfunction

Engineering Contradiction:

Improvepower transfer reliabilityVSAvoiddust accumulation in mechanical interface

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the mechanical coupling system with an inductive coupling system using electromagnetic fields. The drill includes a primary induction coil that wirelessly transfers power to a secondary coil in the dust extractor, eliminating mechanical contact points where dust could accumulate and cause failures.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces an electromagnetic field as an intermediary medium to transfer power between the drill and dust extractor. This intermediary allows energy transfer without direct physical contact, preventing dust from interfering with the power transfer mechanism.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If an electrical connection is used to power the dust collector motor, then power is supplied to the accessory, but damaged connectors render the dust collector inoperable

Engineering Contradiction:

Improveaccessory operation reliabilityVSAvoidelectrical connector damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the direct electrical connection system with an inductive coupling system. The primary coil in the drill generates an alternating magnetic field that induces current in the secondary coil of the dust extractor, eliminating exposed electrical connectors that could be damaged or bent.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent uses an alternating magnetic field as an intermediary to transfer electrical energy without direct contact between electrical components. This eliminates the vulnerability of physical electrical connectors to damage while maintaining power supply functionality.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Power

If physical connections are used between power tool and accessory, then power and control are transferred effectively, but the connections are vulnerable to dust and damage

Engineering Contradiction:

Improvepower transfer effectivenessVSAvoidconnection reliability

Core Design Contradiction:

PowerVSReliability

Solution Approach 1:

The patent substitutes mechanical and electrical connection systems with an electromagnetic induction system. Power is transferred through inductive coupling between coils, maintaining effective power transfer while eliminating the reliability issues associated with physical connections in dusty environments.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 solution significantly reduces the likelihood of malfunction by eliminating the risk of dust accumulation and electrical connector damage, ensuring reliable operation of the accessory.

Implementation Method 1

a first induction coil in the power tool induces a voltage in a second coil in the accessory, powering its motor through inductive coupling

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentEP3599060B1Power tool and accessory system

Publication Date: 2021.12.15 BLACK & DECKER CORP

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AI summary

A power tool and accessory system 2 is described and comprises a power tool such as hammer drill 4 and an accessory such as dust extractor 6. In order to provide electrical power to the drive motor of the dust extractor 6, a first induction coil is disposed in the hammer drill 4 and is electrically connected to the power supply of the hammer drill. A second induction coil is disposed in the dust extractor 6 at a location in which when the hammer drill 4 and dust extractor 6 are connected. Current through the first induction coil induces a voltage in the second induction coil through inductive coupling. As a consequence, the drive motor of the dust collector 6 is powered by inductive power transfer from the electrical power source of the hammer drill 4.