Power Tool Handle Assembly With Internal Cavity for Easier Wiring
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Solution Overview
Problem
The assembly of trigger switches in power tools, such as routers, is time-consuming and difficult due to limited space within the handle, making it challenging to attach electrical wires and resulting in a harder overall assembly process.
Innovation Solution
A power tool design featuring a handle with an internal cavity and a handle slot configured to receive electrical connections, allowing for easier assembly and attachment of power cables and electronic components, with optional features like a handle slot insert and cap portion for secure engagement and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the trigger switch is assembled inside the handle with limited space, then the electrical connection is more compact, but the assembly process becomes time-consuming and difficult
Solution Approach 1:
The handle is divided into multiple components: handle body, cap portion, and handle slot insert. This segmentation allows the electrical connection to be assembled in a modular fashion, where wires can be attached to the trigger switch before insertion, and the handle slot insert provides a dedicated pathway for wire routing, significantly easing the assembly process while maintaining compact integration.
Solution Approach 2:
The handle slot insert acts as an intermediary component that facilitates the connection between the electrical wires and the trigger switch. It provides a structured pathway and mounting surface within the handle, enabling easier wire attachment and routing without requiring complex manual assembly in the confined handle space.
2Force
If electrical wires are attached to the trigger switch before mounting in the handle, then the electrical connection is prepared in advance, but the overall assembly becomes harder due to limited space
Solution Approach 1:
The handle assembly is segmented into the handle body, cap portion, and handle slot insert. This segmentation creates a modular assembly process where the trigger switch with pre-attached wires can be inserted as a complete unit into the handle body through the handle slot, reducing the overall assembly complexity despite the preliminary wire attachment.
Solution Approach 2:
The handle slot insert provides an additional dimensional pathway for wire routing through the handle structure. By creating a dedicated slot that extends through the handle, the design adds a spatial dimension for wire management, allowing pre-attached wires to pass through easily without complicating the overall assembly.
3Reliability
If the handle slot is designed to receive electrical connections after handle mounting, then the electrical connection is more secure, but the assembly process is more complex
Solution Approach 1:
The handle slot insert is pre-formed with integrated wire routing pathways and engagement features. This preliminary preparation of the slot structure allows electrical connections to be securely received and routed once the trigger switch assembly is inserted, ensuring connection stability without requiring complex post-assembly wiring operations.
Data Source
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AI summary
A power tool comprises 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.