Mid-handle drill housing segmentation for wire routing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The assembly of mid-handle power tools with a 'jam-pot' construction is time-consuming and prone to wire pinching due to complex wiring connections and the need for multiple reorientations, and the tools are difficult to mold with multiple components.
Innovation Solution
A power tool design featuring a housing assembly with symmetrical segments and a field case that allows for easier wire routing and attachment, minimizing the risk of wire pinching, and a method of assembly that includes routing wires through a ventilation path and using wire retention members to secure them, along with a self-contained gear case assembly and integral mid-handle grip.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wires are routed through narrow openings in the housing during assembly, then the tool can be assembled with traditional jam-pot construction, but the assembly process becomes time-consuming and wires are prone to being trapped or pinched
Solution Approach 1:
The housing is divided into first and second generally symmetrical housing segments that can be assembled separately. This segmentation allows wires to be routed through dedicated pathways in each segment before final assembly, eliminating the need to route wires through narrow openings in a fully assembled housing and reducing assembly time.
Solution Approach 2:
Wire retention members are introduced as intermediary components to secure wires during the assembly process. These retention members prevent wires from being trapped or pinched between housing components, solving the wire pinching problem while maintaining efficient assembly procedures.
2Strength
If the jam-pot is molded with the handle attached thereto, then structural integrity is improved, but the tool becomes complex to mold requiring multiple additional components
Solution Approach 1:
The housing is segmented into multiple sections (first housing segment, second housing segment, field case) that can be molded separately with simpler tooling. Each segment maintains necessary structural integrity while avoiding the complexity of molding an integrated jam-pot with handle in a single piece.
Solution Approach 2:
The first and second housing segments are assembled to form the complete housing structure, merging separate molded components into a unified assembly. This approach achieves the structural integrity of an integrated design while utilizing simpler, separate molding processes for each component.
Data Source
AI summary
A power tool can include a gear case, a motor having first and second sets of lead wires, a housing assembly, and a field case. The field case may include a front portion configured for engaging the gear case and a rear portion. The housing assembly may include first and second generally symmetrical housing segments configured for engaging the field case and forming a mid-handle grip. The first set of lead wires may be routed through the front portion of the field case directly to a trigger switch assembly. A method for assembling a mid-handle power tool is also provided and may include routing lead wires through a ventilation path between the field case and trigger assembly.