Handheld Power Tool Cable Carrier Kickback Detection
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Solution Overview
Problem
Existing hand-held power tools lack effective cable management and fail to reliably detect and control sudden speed drops during kickback, leading to potential operator danger and cable damage.
Innovation Solution
A hand-held power tool equipped with a subassembly comprising a tachometer disc, sensor, and electronic control system, along with a frame-like cable carrier that is axially clamped in the housing, ensuring safe operation by preventing kickback and gently routing cables to avoid jamming and damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If cables are routed through a simple hole in the housing without a cable carrier, then the housing structure remains simple, but the cable insulation can chafe through at the edge of the hole causing cable damage
Solution Approach 1:
A cable carrier is introduced as an intermediary component between the housing and cables. The cable carrier provides a smooth bore that guides cables through the housing without direct contact with sharp edges, preventing insulation damage while maintaining structural simplicity through modular design
2Ease of operation
If a cable carrier is provided as a ring-like part fastened axially in the housing, then cable routing friction is reduced and centering is improved, but the cable carrier cannot detect or control sudden speed drops during kickback
Solution Approach 1:
The cable carrier is merged with a tachometer disc to form an integrated assembly. The cable carrier maintains its cable-guiding function while the integrated tachometer disc with sensor provides kickback detection by monitoring speed drops, combining mechanical cable management with safety monitoring functions
Solution Approach 2:
The cable carrier assembly is designed to serve multiple functions: it acts as a cable guide to reduce friction and center cables, while simultaneously serving as a mounting structure for the tachometer disc that enables kickback detection through the sensor system
3Ease of manufacture
If cables are routed loosely in the housing without a cable carrier, then assembly is simple, but cables can become jammed between rotating housing areas and damaged
Solution Approach 1:
The cable carrier acts as an intermediary structure that provides a defined pathway for cables through the rotating handle area. The bore of the cable carrier prevents cables from becoming jammed between rotating housing parts while maintaining assembly simplicity through the modular carrier design that can be easily installed
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
The solution enhances safety by early shutdown during kickback, reduces cable stress, and maintains cable integrity through precise, low-friction routing, minimizing the risk of jamming, wear, and damage, while allowing for versatile integration of electronic components.
Implementation Method 1
over which the cable is guided with low friction
Implementation Method 2
the legs are designed as leaf-spring-like, resilient legs
Implementation Method 3
the legs carry snap hooks at their free ends, which fit into counterparts of the housing in a latching manner
Data Source
AI summary
A hand-held power tool (10) with a housing (11) having a longitudinal axis (13) and at least one cable (41) running in the housing (11) becomes electrically safer and more robust by arranging a frame-like cable support (46) transversely to the longitudinal axis (13) in the housing (11), in particular axially clamped in the housing (12), which holds the cable (41) in a defined position, in particular radially inwards in the middle of the housing (11), wherein the cable support (46) carries a sensor (45).