Power Tool Housing Layout for Easier Gearcase and Wiring Assembly
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Solution Overview
Problem
The assembly of power tools with a housing divided into front and rear portions is complicated, particularly in assembling the rotation mechanism, switch, and wiring, which reduces workability.
Innovation Solution
The power tool design includes a cylindrical case holder integrally formed with either the left or right grip portion, allowing the motor and rotation mechanism to be assembled in the front-rear direction along the rotation axis, with the grip portion divided in the left-right direction for easy assembly of switches and wiring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the housing is divided into front and rear portions, then the rotation mechanism can be assembled in a stacked manner along the rotation axis, but the assembly of the switch or wiring in the handle portion becomes complicated
Solution Approach 1:
The housing is divided into a first housing (front portion) and a second housing (rear portion) along the rotation axis. The first housing accommodates the rotation mechanism while the second housing contains the switch and wiring. This segmentation allows independent assembly of each housing, simplifying the overall assembly process despite the complex internal arrangements.
2Productivity
If the housing is divided into front and rear portions, then the rotation mechanism components can be stacked along the rotation axis, but the workability of assembling switches and wiring is reduced
Solution Approach 1:
By dividing the housing into two separate portions, the patent enables parallel assembly processes. The first housing can be assembled with the rotation mechanism while the second housing is prepared separately with switch and wiring components, improving overall productivity without compromising ease of operation.
Solution Approach 2:
The patent transitions from a single-housing design to a two-housing configuration, adding a spatial dimension to the assembly process. This allows switch and wiring assembly to occur in a separate housing space, improving workability while maintaining high productivity through efficient spatial utilization.
Data Source
AI summary
A power tool includes: a motor; a rotation mechanism disposed forward of the motor and including an output portion that is rotated about a rotation axis by the motor; a rotation mechanism case that houses at least a part of the rotation mechanism; a case holder having a cylindrical shape and covering a circumference of the rotation mechanism case such that the output portion protrudes forward; and a grip portion to be gripped by an operator. The grip portion includes a left grip portion and a right grip portion that are divided in a left-right direction. The case holder is integrally formed with either the left grip portion or the right grip portion.