Modular Handheld Tool Coupling for Tool-Less Head Swaps
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Solution Overview
Problem
Existing modular handheld electric tool systems lack improvements in versatility, cost-effectiveness, and storage efficiency, as they require multiple components and tools for assembly and maintenance, leading to increased costs and complexity.
Innovation Solution
A modular handheld electric tool system comprising a handle, motor module, and tool heads with tool-less mechanical couplings, allowing for easy assembly and disassembly without tools, reducing the need for multiple motors and costly components, and enabling the use of interchangeable tool heads for various functions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If modular tool systems are designed with multiple separate components for different functions, then versatility is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent implements a universal motor module with standardized mechanical and electrical coupling interfaces that can be used across multiple tool types (drills, drivers, impact drivers, hammer drivers). This single motor module design serves multiple functions by simply changing the tool head attachment, eliminating the need for separate motors for each tool type and reducing overall system complexity while maintaining versatility
Solution Approach 2:
The tool system is divided into distinct modular segments: a universal motor module, interchangeable tool heads, and a handle assembly. These segments can be independently manufactured, tested, and replaced. The motor module separates the power source function from the tool-specific functions contained in the tool heads, allowing for simplified design of each component while maintaining system versatility
2Ease of operation
If modular tool systems use tool-less mechanical couplings for easy assembly, then ease of operation is improved, but manufacturing precision requirements increase
Solution Approach 1:
The mechanical coupling system is designed to be self-aligning and self-latching. The tool head and motor module features complementary geometric profiles that automatically guide alignment during attachment. Once engaged, the coupling mechanism self-locks without requiring tools or external assistance, providing tool-less assembly while maintaining secure mechanical and electrical connections through precision-matched interface features
3Adaptability or versatility
If multiple separate power tools are manufactured for different functions, then versatility is improved, but manufacturing cost increases
Solution Approach 1:
The patent designs a universal motor module that can serve multiple tool functions through interchangeable tool heads. This single motor module design replaces what would traditionally require separate motors for drills, drivers, impact drivers, and hammer drivers. The standardized electrical coupling allows the same motor module to power different tool types, significantly reducing manufacturing costs through economies of scale while maintaining full functional versatility
Solution Approach 2:
The patent merges the common functional elements (motor, electrical connections, mechanical drive interface) into a single universal motor module that serves multiple tool types. By combining these shared components into one standardized unit and separating only the function-specific elements into interchangeable tool heads, the system achieves cost-effective manufacturing through component consolidation while preserving the ability to perform multiple different functions
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 system achieves cost savings by minimizing the replication of expensive parts, simplifies repair and maintenance, and provides enhanced versatility and storage capabilities through a modular design that allows for easy configuration and reconfiguration without tools.
Implementation Method 1
a motor module including a motor casing that holds an electric motor
Data Source
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AI summary
A modular handheld electric tool system comprises a handle, a motor module and a tool head. The handle includes a handle housing with an elongate portion configured to provide a grip, a handle electrical coupling on the handle housing, a circuit including a tool switch in the handle housing, the tool switch connected between a power supply and the handle electrical coupling. The motor module including a motor casing that holds an electric motor, a motor electrical coupling on the motor casing that is complementary to the handle electrical coupling and electrically connected to the electric motor, and a rotary output mounted to the motor casing and driven by the electric motor. At least one tool head is releasably attachable both to the motor module via a tool-less tool-head-to-motor mechanical coupling, and to the handle via a tool-less tool-head-to-handle mechanical coupling, the tool head including an accessory and tool body wherein, to supply torque to the accessory from the electric motor, a rotary input mounted to the tool body engages the rotary output of the motor module.