Power Tool Battery Lock Actuator Mechanism
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Solution Overview
Problem
Existing battery-powered power tools lack a mechanism to prevent accidental activation when a battery is removed or inserted, potentially leading to unsafe operation and unintended start-ups.
Innovation Solution
A mechanical and electrical actuator mechanism that includes a switch trigger and a lock actuator, which inhibits electrical communication between the battery and motor when the battery is uncoupled, ensuring the power tool remains in an off state until a battery is properly coupled, using a biasing member to maintain the switch in an off position until the battery is inserted.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a battery-powered power tool allows the switch trigger to operate freely, then the tool can be activated quickly and easily, but accidental activation may occur when the battery is removed or inserted
Solution Approach 1:
A lock actuator is introduced as an intermediary component between the battery and the switch trigger circuit. This lock actuator mechanically blocks the switch trigger from completing the electrical circuit when the battery is absent, thereby preventing accidental activation while preserving easy operation when the battery is properly installed
Solution Approach 2:
The lock actuator applies a preliminary blocking action to the switch trigger mechanism before the user can accidentally activate the tool during battery removal or insertion. This pre-emptive mechanical block prevents the harmful effect of unintended start-up
2Object-affected harmful factors
If a lock actuator is added to prevent accidental activation, then safety is improved, but the device complexity increases
Solution Approach 1:
The lock actuator is merged with the existing battery receptacle structure and switch trigger mechanism. The lock actuator utilizes the same spatial envelope and mechanical movements as the battery installation/removal process, combining the safety function with the existing operational structure rather than adding a completely separate mechanism
Solution Approach 2:
The lock actuator serves multiple functions: it blocks the switch trigger during battery removal to prevent accidental activation, and simultaneously enables normal switch operation when the battery is properly installed. This single component addresses both safety and operational requirements
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
Prevents accidental power-on states when batteries are changed, enhancing safety by ensuring the power tool only activates when a charged battery is securely coupled, thereby preventing unintended start-ups and ensuring safe operation.
Implementation Method 1
The lock actuator is biased into the unlocked position while the battery is positioned in the receptacle
Data Source
AI summary
A power tool includes an electric motor, an output member selectively driven by the electric motor and a battery receptacle configured to receive a battery. The power tool also includes a switch trigger moveable between a first position and a second position. The switch trigger inhibits electrical communication between the battery and the electric motor while the switch trigger is in the first position. The switch trigger operates a switch to provide electrical communication between the electric motor and the battery while the switch trigger is in the second position. A lock actuator prevents movement of the switch trigger to the second position while the lock actuator is in a locked position, and the lock actuator permits movement of the switch trigger to the second position while in an unlocked position. The lock actuator is biased into the unlocked position while the battery is positioned in the receptacle.