Modular Electrical Switch for Power Tools
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Solution Overview
Problem
Existing electrical switches for power tools are costly and complex due to the need for multiple device-specific designs and numerous individual parts, making them expensive and difficult to assemble.
Innovation Solution
A modular electrical switch design featuring a device-independent switch unit and a device-specific mounting frame, allowing for flexible adaptation to various power tool handles while reducing the number of individual parts by integrating functions into multifunctional components, such as a multifunction part with a contact spring for power supply.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the housing and actuating element are adapted to each respective installation space in the power tool, then the switch can be installed in different power tools, but a large number of device-specific switches have to be provided which makes the switch more expensive and requires increased storage
Solution Approach 1:
The switch is divided into two independent segments: a device-independent switch unit (with contact system and actuating element) and a device-specific mounting frame. The switch unit can be produced in large quantities as a standard component, while only the mounting frame needs to be adapted to different power tool handles. This segmentation reduces the number of variants from many device-specific switches to just a few mounting frame variations.
Solution Approach 2:
The switch unit is designed as a universal base module that can be used in multiple different power tool applications. By making the switch unit device-independent and adaptable, it serves multiple functions across different power tools, eliminating the need for separate device-specific switch designs for each power tool type.
2Reliability
If the contact system consists of a large number of individual parts, then the switch can be assembled with precise functions, but the switch becomes more expensive and complicated to assemble
Solution Approach 1:
The contact system components are merged into integrated assemblies. The contact system with its fixed and movable contacts is combined with the actuating element to form a unified switch unit. This merging reduces the number of separate parts that need to be handled and assembled, while maintaining the precise functional requirements of the contact system.
3Device complexity
If a modular design with device-independent switch unit and device-specific mounting frame is used, then the number of parts is reduced and assembly is simplified, but the switch unit must be precisely designed to function independently
Solution Approach 1:
The switch unit is pre-designed and pre-assembled as a complete functional module before being installed in the power tool. All precise contact system components and actuating elements are configured in advance during switch unit manufacturing, ensuring high precision is achieved in the controlled production environment rather than during final assembly in the power tool.
Data Source
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AI summary
The invention relates to an electrical switch (1) for an electrical device, especially for electric tools, such as drills, grinders, saws, planes, angle grinders, or similar. Said electrical switch (1) comprises an actuating element (13) and a contact system, upon which the actuating element acts in a switching manner. The contact system and the actuating element (13) are configured as an autonomously operable switch unit (14) similar to a module. Said switch unit (14) can be disposed inside a mounting frame (15) which is used for fastening purposes in the electrical device. To this avail, the mounting frame (15) is provided with a receptacle for the switch unit (14), the size of said receptacle approximately matching the size of the switch unit (14).