Handheld Power Tool Barrel Layout for Compact Motor-Gear Integration
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Solution Overview
Problem
Existing handheld power tools face challenges in miniaturization, leading to increased size and complexity, which hinders further reduction in overall dimensions and enhances manufacturing and machining processes.
Innovation Solution
The handheld power tool design incorporates a housing with a barrel and head housing, a drive mechanism with an electric motor and drive shaft, a transmission mechanism with a gear assembly, and an output mechanism with an output shaft, where the gear assembly is mounted in a tight-fit manner within the barrel, and the electric motor is partially housed in the barrel with a barrier dividing the accommodation cavities for the motor and gear assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the handheld power tool is miniaturized to improve user experience and operation convenience, then the overall size is reduced, but the structure complexity increases and manufacturing becomes more difficult
Solution Approach 1:
The patent merges multiple functions into the barrel structure: it serves as both the motor housing and the gear assembly housing. The barrier is integrally formed with the barrel, eliminating the need for separate housing components. This consolidation reduces the number of parts and simplifies the overall structure while maintaining compact dimensions.
Solution Approach 2:
The barrel is designed as a multi-functional component that simultaneously accommodates the electric motor, houses the gear assembly, and provides structural support. The barrier within the barrel serves dual purposes: separating the motor and gear assembly cavities while also acting as a mounting surface for bearings.
2Volume of moving object
If the barrel houses both the electric motor and gear assembly to reduce size, then the overall dimensions are reduced, but the machining and manufacturing difficulty increases
Solution Approach 1:
The barrel is divided into two distinct accommodation cavities by the barrier: a first cavity for the electric motor and a second cavity for the gear assembly. This segmentation allows each component to be independently positioned and assembled, simplifying the manufacturing process while maintaining a compact integrated structure.
Solution Approach 2:
The barrier is integrally formed with the barrel during the manufacturing process, creating pre-formed mounting surfaces and cavities. Bearing mounts are incorporated into the barrier structure, allowing bearings to be directly installed without additional machining operations. This preliminary integration of features reduces subsequent assembly complexity.
Data Source
AI summary
A handheld power tool including a housing including a barrel and a head housing; a drive mechanism including an electric motor and a drive shaft, where the electric motor outputs power through the drive shaft; a transmission mechanism including a gear assembly; and an output mechanism including an output shaft for outputting power to the outside and at least partially disposed in the head housing; where the transmission mechanism drivingly connects the drive mechanism to the output mechanism. The barrel is formed with a first accommodation cavity and a second accommodation cavity, the electric motor is at least partially mounted in the first accommodation cavity, and the gear assembly is at least partially mounted in the second accommodation cavity.