Integrated Pole Power Tool Layout for Cooling and Grip Balance
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Solution Overview
Problem
Existing power tools, particularly pole power tools with high-voltage brushless electric motors, face issues with heat dissipation, compact size, and user grip due to the placement of the motor and control assembly, leading to structural complexity and weight.
Innovation Solution
The power tool design integrates the brushless electric motor and control assembly in a compact arrangement, with a shared mounting cavity and overlapping projections to facilitate heat dissipation and improve grip experience, utilizing a cooling fan and electromagnetic interference suppression, and a human-machine interaction structure for speed control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the high-voltage brushless electric motor and PCB control unit are disposed separately in different locations (motor in grinding head, PCB in handle), then the sanding efficiency is improved, but the center of gravity shifts closer to the grinding head causing poor grip experience and heat dissipation difficulties
Solution Approach 1:
The patent merges the brushless electric motor and PCB control unit into a single integrated housing, allowing them to be disposed close to each other. This integration enables the center of gravity to be positioned at the geometric center of the tool, improving grip experience while maintaining the motor's high-voltage capabilities for efficient sanding. The merged structure also facilitates shared heat dissipation pathways.
2Temperature
If heat dissipation components are disposed at both the PCB control unit and high-voltage brushless electric motor, then heat dissipation performance is improved, but the structure becomes complex and weight increases
Solution Approach 1:
The patent combines the heat dissipation systems of the motor and PCB into a shared structure. The housing includes integrated heat dissipation channels and air inlets/outlets that serve both components simultaneously. This merged heat dissipation approach maintains effective temperature control for both the high-voltage motor and PCB while avoiding the structural complexity and weight increase that would result from separate heat dissipation systems.
3Device complexity
If the brushless electric motor and control assembly are arranged one before the other along an axis, then the control is simplified, 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 configuration within the housing. The motor and PCB are positioned adjacent to each other in different spatial zones rather than end-to-end along the axis. This dimensional reorganization reduces the overall length of the power tool while maintaining simplified control connections through the integrated housing structure.
4Volume of moving object
If the brushless electric motor and control assembly are disposed in two independent housings spaced far apart, then the housing sizes are reduced, but the overall tool length increases and grip experience deteriorates
Solution Approach 1:
The patent merges previously separate housings into a single integrated housing that accommodates both the brushless electric motor and PCB control unit. This unified housing structure reduces the overall tool length by eliminating gaps between separate housings and allows the center of gravity to be positioned optimally for improved grip experience, while the internal compact arrangement maintains reasonable housing external dimensions.
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 design achieves efficient heat dissipation, compact structure, and enhanced user grip by optimizing the placement of the motor and control assembly, ensuring better performance and usability.
Implementation Method 1
a cooling fan and electromagnetic interference suppression
Implementation Method 2
a high-voltage brushless electric motor
Data Source
Figure 1
Figure 2
Figure 3~4
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.