Integrated PCB Switch Assembly for Electric Tool Speed Reversing
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Solution Overview
Problem
The high cost of electric tools is attributed to the separate production of speed regulation switches and commutators, which are typically manufactured by specialized companies, leading to increased purchasing costs.
Innovation Solution
An electronic device with a main body, electric connecting parts, a variable resistor, speed regulating contacts, and reversing handles, where the resistance value of the variable resistor changes along its length, allowing for speed regulation and reversal functions integrated within a single unit, connected using a melt adhesive curing mode to simplify assembly and prevent pollution from external impurities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a speed regulation switch and commutator are used separately to achieve speed regulation and commutation functions, then the electric tool can meet different working conditions requirements, but the parts purchasing cost increases leading to high overall cost
Solution Approach 1:
The patent combines the speed regulation switch and commutator into a single integrated component. The commutator serves dual functions: it performs commutation for the motor while also acting as the speed regulation switch. This merging eliminates the need for separate components, reducing parts purchasing cost while maintaining both speed regulation and commutation functions.
Solution Approach 2:
The commutator is designed to perform multiple functions simultaneously. It serves as both the commutation device for motor operation and the speed regulation switch for controlling motor speed. This multi-functionality allows the electric tool to meet different working conditions requirements without requiring additional specialized components, thereby reducing overall cost.
2Adaptability or versatility
If separate speed regulation switch and commutator components are used, then specific functions are achieved, but the device complexity increases
Solution Approach 1:
The patent merges the speed regulation switch and commutator into a single integrated component structure. The commutator incorporates the speed regulation functionality within its design, eliminating the need for separate components. This reduces device complexity by consolidating multiple functions into one component while maintaining the ability to perform both speed regulation and commutation.
3Ease of manufacture
If traditional connection methods are used for assembling electric components, then assembly is possible, but production cost increases and stability decreases
Solution Approach 1:
The patent replaces traditional mechanical connection methods (such as screws, welds, or adhesive bonding) with a melt injection connection method. Melt material is injected to directly bond the commutator to the motor shell, creating a strong, stable connection that is resistant to vibration and environmental factors. This substitution improves connection stability while simplifying the assembly process and reducing production costs.
4Ease of manufacture
If components are assembled using traditional methods, then assembly is achievable, but external impurities can cause short circuits and poor contacts
Solution Approach 1:
The patent integrates the speed regulation switch and commutator into a single sealed assembly that is then mounted to the motor shell via melt injection. This creates a sealed environment that protects the internal components from external impurities such as dust, moisture, and other contaminants. The integrated design with sealed connections prevents impurity ingress that could cause short circuits or poor contacts.
Solution Approach 2:
The melt injection connection method creates a sealed, integrated structure that eliminates gaps and openings present in traditional mechanical assemblies. This sealed construction prevents external impurities from entering the component assembly, thereby protecting against short circuits and poor contacts while maintaining manufacturing efficiency.
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
This solution reduces production costs, enhances stability, and prevents short circuits and poor contacts by integrating speed regulation and reversal functions within a single unit, ensuring normal operation while minimizing external contamination.
Implementation Method 1
the first electric connecting part and the reversing electric connecting part are respectively connected with the main body in a melt adhesive curing mode
Data Source
AI summary
The invention provides an electronic device, a PCB and an electric tool; the electronic device comprises a main body, a first electric connecting part, a variable resistor, a speed regulating contact, a reversing electric connecting part, a reversing contact, a speed regulating handle and a reversing handle, the first electric connecting part is connected with the main body in a melt adhesive curing mode, and one end of the first electric connecting part is exposed out of the main body; the speed regulating handle and the main body form a first space, the speed regulating contact and the variable resistor are arranged in the first space, and under the drive of the speed regulating handle, the speed regulating contact and the variable resistor relatively slide; under the driving of the reversing handle, the reversing contact and the reversing electric connecting part relatively slide for reversing.