Power Tool Handle Cavity Assembly for Trigger Switch Wiring
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Solution Overview
Problem
The assembly of trigger switches in routers is time-consuming and difficult due to limited space within the handle, making it challenging to attach electrical wires and assemble the power tool effectively.
Innovation Solution
A power tool design featuring a handle with an internal cavity and a handle slot that allows for easier assembly and attachment of power cables and electronic components, including a trigger switch, by providing a dedicated path for electrical connections within the handle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the trigger switch is assembled inside the handle with limited space, then the electrical connection can be made within the handle structure, but the assembly process becomes time-consuming and difficult
Solution Approach 1:
The handle is divided into multiple components: a handle body, a trigger switch assembly, and a separate cap portion. The cap portion can be detached to provide access to the internal cavity where the trigger switch is mounted, allowing assembly and maintenance without disassembling the entire handle structure.
Solution Approach 2:
The electrical connection assembly is extracted as a separate component that can be independently accessed. The cap portion is removed to expose the internal cavity, allowing the trigger switch and electrical connections to be assembled separately before being installed in the handle body.
2Reliability
If electrical wires are attached after the trigger switch is inserted within the handle, then the trigger switch is securely positioned, but there is limited room to attach the electrical wires
Solution Approach 1:
The trigger switch is pre-assembled with its electrical connections in the external cavity before being installed in the handle. The cap portion is removed, the trigger switch is mounted in the internal cavity, and the electrical wires are attached while there is sufficient working space, avoiding the constraint of limited room after final assembly.
3Volume of moving object
If the handle structure is made compact to reduce overall size, then the power tool is more portable, but the assembly of electrical components becomes harder
Solution Approach 1:
The handle is segmented into a compact handle body and a removable cap portion. This segmentation allows the internal cavity to be accessed by simply removing the cap, providing sufficient workspace for assembling electrical components without increasing the overall handle volume.
Solution Approach 2:
The trigger switch assembly is nested within the handle body's internal cavity, and the cap portion is nested over this assembly to complete the handle structure. This nested arrangement maintains a compact overall size while allowing sequential access to internal components for assembly.
Data Source
AI summary
A power tool including a housing, at least one handle mountable to the housing, a motor mounted in the housing and electrically connected to a power source, and at least one component with at least one electrical connection electrically connected to the power source. The handle includes an internal cavity, and the component is mountable within the cavity. The handle also features a handle slot configured to receive the electrical connection when the component is mounted within the handle. This design allows for easier assembly and attachment of power cables and electronic components within the handle of the power tool.