Magnetic Actuator Switching in Handheld Power Tools
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Solution Overview
Problem
Handheld power tools face issues with reliability and safety in dirty, wet, and dusty environments due to vibration and the risk of sharp tools and powerful power sources, while also requiring compact and lightweight designs with cost-efficient manufacturing.
Innovation Solution
A handheld power tool with an electronic control unit and a housing that includes a movable actuator with a magnet and sensor to determine its position contactlessly, allowing for reliable control of the power source operation, protected from moisture and debris, and enabling a compact, lightweight design with efficient manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a contactless sensor system with magnet and sensor is used to determine actuator position, then reliability is improved by being resistant to moisture, dust, and debris, but device complexity increases due to additional components
Solution Approach 1:
The patent replaces mechanical contact-based switch systems with a contactless magnetic sensing system. A magnet is attached to the actuator and a sensor (such as a Hall effect sensor) is positioned in the housing to detect the magnet's position. This eliminates physical contact between moving and stationary components, making the system resistant to moisture, dust, and debris while determining actuator position without mechanical wear.
Solution Approach 2:
The patent introduces a magnetic field as an intermediary between the actuator and the sensor system. The magnet attached to the actuator generates a magnetic field that the sensor detects to determine actuator position. This magnetic intermediary allows for contactless communication and position detection, improving reliability in harsh environments while adding minimal complexity.
2Ease of operation
If the handheld power tool is made compact and lightweighted, then ease of operation is improved by reducing strain to hands, arms, and back, but device complexity increases due to space constraints for accommodating components
Solution Approach 1:
The patent merges the actuator and electronic control unit into a single integrated assembly that fits within the housing. The actuator is positioned such that it can be actuated by the user while the sensor and magnet are integrated into the housing structure. This consolidation reduces the overall size and weight of the power tool while maintaining all necessary functions.
Solution Approach 2:
The patent employs a nested arrangement where the magnet is attached to the actuator which moves within the housing, and the sensor is positioned within the housing to detect the magnet's position. This nested configuration allows for compact packaging of components, reducing the overall footprint and weight of the power tool while maintaining functionality.
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 solution provides a reliable and safe operation by rendering the power source inoperable quickly and simply, ensuring durability and cost-efficiency, while maintaining a compact and lightweight form factor.
Implementation Method 1
a switch assembly comprising a magnet and a sensor configured to sense the magnitude of a magnetic field
Data Source
AI summary
A handheld power tool (1) is disclosed comprising an electronic control unit (3), a housing (4) accommodating the electronic control unit (3), an actuator (5) movably arranged on the housing (4) between a first position and a second position, and a switch assembly (6) comprising a magnet (M) and a sensor (S) configured to sense the magnitude of a magnetic field. One of the sensor (S) and the magnet (M) is arranged in the housing (4) and the other of the sensor (S) and the magnet (M) is arranged on a portion (5′) of the actuator (5) such that the relative distance between the magnet (M) and the sensor (S) is different when the actuator (5) is in the second position than when the actuator (5) is in the first position.