Power Tool Light Holder and Wiring Configuration
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Solution Overview
Problem
Power tools with integrated lights and wiring become bulky and difficult to assemble due to the spatial constraints and complexity of integrating lighting components with other tool components.
Innovation Solution
A power tool design featuring a motor, lighting power source, and housing assembly with a light holder that supports the light and energy line, allowing the energy line to extend unsupportedly and connect to the lighting power source, while the light and power source are positioned in a spaced relationship along an axis, facilitating easier assembly and a more compact form factor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If lights and wiring are integrated into the power tool, then illumination function is provided, but the size and bulkiness of the power tool increases
Solution Approach 1:
The light holder is received within a recess of the field case, nesting the lighting assembly inside the existing motor housing structure. This allows the light and wiring to be integrated without increasing the overall external dimensions of the power tool, resolving the contradiction between providing illumination and maintaining compact size.
2Illumination intensity
If lights and wiring are integrated into the power tool, then illumination function is provided, but the difficulty of assembly increases
Solution Approach 1:
The lighting assembly is segmented into separate components: the light holder, the light, and the energy line. The light holder is assembled into the field case recess first, then the light is installed in the light holder, allowing for modular assembly that simplifies the overall manufacturing process while maintaining integration.
Solution Approach 2:
The energy line acts as an intermediary element that connects the light to the lighting power source through the opening in the field case. This intermediary wiring structure simplifies assembly by providing a clear path for electrical connection without requiring complex integrated wiring harnesses.
3Ease of manufacture
If the light and lighting power source are disposed in spaced relationship, then easier assembly is achieved, but the wiring complexity increases
Solution Approach 1:
The energy line is extracted through the opening in the field case, separating the wiring path from the main housing structure. This allows the light and power source to be spaced apart for easier assembly while the extracted wiring minimizes complexity by following a simple, defined path through the opening rather than requiring complex routing within the housing.
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 enables improved illumination for tasks while reducing the bulkiness and complexity of power tool assembly, ensuring proper electrical coupling and easier manufacturing by allowing looser tolerancing and a more compact design.
Implementation Method 1
an energy line that transmits energy to the light to thereby provide illumination
Implementation Method 2
a motor with a field member that creates a magnetic field
Data Source
AI summary
A power tool includes a motor, a lighting power source, and a housing assembly defining an axis that supports the motor and the lighting power source. The power tool also includes a lighting assembly with a light and an energy line that transmits energy to the light to thereby provide illumination. The light and the lighting power source are disposed in spaced relationship from each other relative to the axis. Furthermore, the power tool includes a light holder supported by the housing assembly. The light holder supports the light and a portion of the energy line such that an end of the energy line unsupportedly extends beyond the light holder and electrically couples to the lighting power source.