Modular Electrical Housing with Interchangeable Power Inserts
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Solution Overview
Problem
The proliferation of different electrical power connection standards across countries necessitates manufacturers to redesign the housing of power tools and gardening equipment, leading to increased tooling costs and manufacturing complexity.
Innovation Solution
A modular housing design with interchangeable inserts allows for various power connector types to be accommodated using a single housing design, enabling adaptation to different international standards while preventing dust and moisture ingress through secure, non-linear fixing arrangements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manufacturers redesign the housing for each power connection standard, then compliance with various international electrical standards is achieved, but tooling costs and manufacturing complexity increase
Solution Approach 1:
The power connection component is segmented from the housing, allowing it to be independently replaced. The housing remains a single standardized design while different power connection types (sockets, plugs, fixed cables) can be installed by swapping the modular power connection component, eliminating the need to redesign the entire housing for each standard.
Solution Approach 2:
The housing is designed with universal compatibility to accommodate multiple power connection standards through a single standardized interface. The housing structure includes a standardized cavity and mounting features that work with all power connection types, making the housing itself multi-functional across different international electrical standards.
2Adaptability or versatility
If manufacturers redesign the housing for each power connection standard, then compliance with various international electrical standards is achieved, but tooling costs increase
Solution Approach 1:
By segmenting the power connection component from the housing, manufacturers can produce the housing in a single standardized design using one set of expensive molding tools. The modular power connection components can be manufactured separately with different tooling for each standard, but the high-cost housing tooling is reused across all product variants, significantly reducing overall tooling costs.
Solution Approach 2:
The standardized housing design serves multiple functions across different markets and standards, allowing manufacturers to invest in high-quality housing tooling once and reuse it for all power connection variants. This universal housing design eliminates the need for multiple expensive housing tooling sets, directly reducing tooling costs while maintaining compliance with various international standards.
Data Source
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AI summary
The present invention provides an electrical device (1), the device comprising: a housing (6); electrical circuitry in the housing, wherein the walls of the housing define a cavity (11) having a first end (12) that is open to the exterior of the device and a second end (13) that is inside the housing, the housing having a first fixing arrangement (14) at the first end (12) of the cavity and a second fixing arrangement (15) at the second end (13) of the cavity, wherein the first and second fixing arrangements are each capable of fixing a power connection insert (20,30,40) in position; and, a power connection insert (20,30,40) fixed by either the first or second fixing arrangement (14,15), wherein the power connection insert and that fixing arrangement are constructed and arranged to mechanically interlock with each other, wherein the power connection insert provides a power cable (43) or power connector, said power cable or power connector being electrically connected to said electrical circuitry such that external electrical power can be supplied to the device via the power cable or power connector.