Power Tool Control Assembly With Integrated PCB and Metal Base
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Solution Overview
Problem
Existing power tool electronic control assemblies face issues with connection stability due to vibration and aging, leading to reliability concerns, increased maintenance costs, and complexity in manufacturing, with limited integration and compactness.
Innovation Solution
The electronic control assembly features a metal substrate power circuit board stacked with a control circuit board within a mounting base, using a connecting unit with conductive members and a blocking unit to ensure reliable electrical connections and heat dissipation, integrated into a compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wires are used to connect power supply to electrical elements, then the connection is flexible and easy to install, but the connection stability is poor and reliability is low due to vibration and aging
Solution Approach 1:
The patent integrates the power circuit board and control circuit board into a unified PCB assembly structure, eliminating the need for separate wire connections between power supply and electrical elements. The circuit boards are directly mounted on the housing with integrated connection terminals, merging the power distribution and control functions into a single reliable structure that resolves the contradiction between connection flexibility and stability.
2Ease of manufacture
If wires are used for electrical connections, then the assembly is easy to manufacture, but the wiring method is complicated and manufacturing difficulty increases
Solution Approach 1:
The patent extracts the wires and separate connection terminals from the assembly, replacing them with an integrated PCB structure where electrical connections are made through printed circuit traces and mounted components. This extraction simplifies the manufacturing process by eliminating complex wiring steps while maintaining electrical connectivity through the circuit board design.
3Adaptability or versatility
If basic control and driving functions are implemented separately, then the functions are clear and maintainable, but the integration degree is low and space occupation is large
Solution Approach 1:
The patent combines the power circuit board and control circuit board into a single integrated PCB assembly mounted on the housing. The power circuit board handles power distribution while the control circuit board manages control signals, and both are integrated into the same structural space with shared mounting locations and connection points, achieving high functional integration without increasing overall device volume.
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
This configuration enhances the reliability and integration of the power tool, reduces size, and simplifies manufacturing, while providing effective heat dissipation and adaptability for use in various handheld power tools.
Implementation Method 1
a power circuit board which is made of a metal substrate; a mounting base, wherein the power circuit board is in contact with the mounting base which is a metal base
Implementation Method 2
the mounting base further includes heat dissipation fins disposed on a side of the baseplate facing away from the electronic control unit
Data Source
Figure 1~2
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AI summary
Provided are a power tool and an electronic control assembly thereof. The power tool includes a main body and a battery pack. The main body includes a housing and a motor, a switch assembly, and an electronic control assembly which are mounted in the housing, where the electronic control assembly is electrically connected to the switch assembly and the motor, separately. The battery pack is detachably coupled to the main body and has a connection state in which electricity is conducted between the battery pack and the electronic control assembly and a separate state in which the battery pack is disconnected from the electronic control assembly. The electronic control assembly includes an electronic control unit, a mounting base, and a connecting unit. The electronic control unit includes a power circuit board. The power circuit board is in contact with the mounting base which is a metal base and provided with an opening. The connecting unit conductively connects the battery pack to the electronic control unit, is inserted to the mounting base via the opening, and mates with the mounting base to form a mounting space in which the electronic control unit is mounted.