Modular Power Tool Interface for Fast Function Reconfiguration
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Solution Overview
Problem
Existing power tools require multiple devices for different tasks, leading to increased costs and inefficiencies due to the need to switch between tools, especially when tools are located in difficult-to-reach or inconvenient positions.
Innovation Solution
A convertible tooling system featuring a base unit that can be configured with interchangeable modules, including a servo-free module and a servo amplifier module, allowing for different levels of functionality by physically and electrically connecting these modules to the base unit, enabling operation in various configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple separate power tools are used for different tasks, then each tool can be optimized for its specific function, but the cost increases and the need to switch between tools creates inefficiency
Solution Approach 1:
The base unit is designed with a universal mounting platform that can accommodate multiple different attachment modules, each providing different functionalities (servo-free mode, servo-controlled mode with force feedback, different end effectors). This allows a single base unit to perform multiple tasks that would traditionally require separate tools, directly resolving the contradiction between functional versatility and number of tools.
Solution Approach 2:
The system is divided into a modular architecture where the base unit contains common components (motor, housing, mounting platform) and separate attachment modules contain task-specific components (servo amplifier, processing circuit, different end effectors). This segmentation allows the base unit to remain simple while enabling versatility through module attachment, resolving the contradiction by separating common functionality from specialized functionality.
2Productivity
If tools are located in difficult-to-reach positions, then they can be permanently installed in optimal locations, but switching between tools becomes time-consuming and labor-intensive
Solution Approach 1:
The attachment module interface is designed to allow quick connection and disconnection of modules at the mounting platform. The electrical and physical connections are established through a single docking action, enabling dynamic reconfiguration of tool functionality without requiring tool removal or complex reassembly. This dramatically reduces tool conversion time while maintaining permanent installation benefits.
Solution Approach 2:
The mounting platform integrates both mechanical attachment and electrical connection functions into a single interface. When an attachment module is connected to the base unit, both the physical mounting and electrical contacts are established simultaneously, eliminating the need for separate connection steps and reducing overall tool switching time.
3Device complexity
If a single tool is designed to perform multiple functions, then cost is reduced and tool switching is eliminated, but the tool structure becomes more complex
Solution Approach 1:
The tool is segmented into a standardized base unit and interchangeable attachment modules. The base unit maintains a simple, standardized structure with a universal mounting platform, while functional complexity is distributed across separate modules. This segmentation allows the base unit to remain structurally simple while the system as a whole achieves high versatility through module combinations.
Solution Approach 2:
The mounting platform is designed as a universal interface that can accommodate multiple different attachment module types. This universal design allows the base unit to maintain a simple standardized structure while enabling access to multiple functions through the attachment of different modules, resolving the contradiction between structural simplicity and functional versatility.
4Adaptability or versatility
If different functionality levels are provided in a single tool, then adaptability increases, but the device requires more components and becomes more complex
Solution Approach 1:
Different functionality levels are segmented into separate attachment modules rather than being integrated into the base unit. The servo-free module, servo amplifier module, and processing circuit module are separate interchangeable components. This allows the system to provide multiple functionality levels without increasing the component count of the base unit, as only one module is attached at a time based on the required functionality level.
Solution Approach 2:
Different functionality levels are provided locally through interchangeable modules rather than being distributed throughout the entire tool structure. Each module contains only the components necessary for its specific function (e.g., servo amplifier only in the servo amplifier module), allowing adaptability without requiring every part of the tool to support multiple functions, thus reducing overall component quantity.
Data Source
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AI summary
A convertible power tool that can operate in first and second configurations. The tool includes a base unit configured to receive at one time either a first module or a second module. The different modules provide for different levels of functionality. The first module includes one or more components that provide for a first level of functionality. The second module includes one or more components that provide for an advanced second level of functionality. Each of the base unit and first and second modules may include interfaces that provide for physical engagement as well as power/data engagement. In use, one of the first and second modules is connected to the base unit to provide for the desired functionality incorporated with the tool. The tool may also be reconfigured by removing the attached module and replacing it with the other module thus providing for a different functionality level.