Pole Power Tool Motor-PCB Layout for Compact Cooling and Grip Balance
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Solution Overview
Problem
Existing power tools with high-voltage brushless electric motors face issues with heat dissipation, complexity in structure, and poor grip experience due to the motor and control assembly being arranged in a way that increases tool length and weight, making them inconvenient for miniaturization and user handling.
Innovation Solution
The power tool design integrates the brushless electric motor and control assembly in a compact arrangement where a plane intersects the circuit board assembly and motor axis, allowing for heat dissipation through air paths and electromagnetic interference suppression, with a symmetric grip housing for improved grip and reduced size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the brushless electric motor and control assembly are arranged one before the other along an axis, then the power tool can be assembled, but the length of the power tool becomes relatively long
Solution Approach 1:
The patent transitions from a linear axial arrangement to a three-dimensional spatial arrangement where the control assembly is positioned at the end face of the motor. This dimensional change allows the circuit board assembly to overlap with the motor shaft projection, significantly reducing the overall length of the power tool while maintaining functional separation between components.
2Volume of moving object
If the brushless electric motor and control assembly are disposed in two independent housings spaced relatively far from each other, then the housings can be designed independently, but the overall size and weight of the power tool increase
Solution Approach 1:
The patent merges the motor housing and control assembly housing into a single integrated housing structure. The control assembly is positioned at the end face of the motor within the same housing, eliminating the need for separate housings and reducing the overall volume and weight of the power tool while maintaining manufacturing feasibility.
3Temperature
If heat dissipation components are disposed at both the PCB control unit and the high-voltage brushless electric motor, then heat dissipation performance improves, but the structure becomes complex and weight increases
Solution Approach 1:
The patent combines the heat dissipation functions for the motor and control assembly into a shared heat dissipation chamber. Both components utilize the same air inlet and exhaust passages, allowing heat from both sources to be dissipated through a unified thermal management system, reducing structural complexity and weight compared to separate heat dissipation systems.
4Productivity
If the center of gravity is closer to the grinding head for high sanding efficiency, then sanding efficiency improves, but the user grip experience deteriorates
Solution Approach 1:
The patent repositions the control assembly from a linear axial position to a radial position at the end face of the motor. This spatial rearrangement allows the circuit board assembly to overlap with the motor shaft projection, shifting the center of gravity toward the grip end and improving balance and user comfort without compromising the grinding head's positioning.
Data Source
AI summary
A pole power tool includes a grip, a brushless electric motor, and a control assembly, where the grip is for a user to hold, the brushless electric motor includes a motor shaft movable around a motor axis, and the control assembly is configured to control operation of the brushless electric motor and includes a circuit board assembly and a circuit element. At least a first plane P exists, the first plane P passes through the circuit board assembly of the control assembly and the motor axis of the brushless electric motor, the first plane P intersects the circuit board assembly along a first line segment AB, and a projection of the first line segment AB on the motor axis at least partially falls on the motor shaft.