Power Tool Switch Panel Tilt and Controller Overlap
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Solution Overview
Problem
Power tools and rotary tools with battery packs as power supplies face challenges in visibility and ease of operation due to the tilted position of the switch panel and the arrangement of the tool-side terminal and controller, which also limits the compactness of the device in the up-down direction.
Innovation Solution
The design includes a battery pack with an upper portion tilted upward, a controller with a matching tilt attitude, and a tool-side terminal with a plate shape that intersects with the controller's plane, allowing the battery pack and controller to overlap in the sliding direction, enabling a more compact design and improved visibility and operation of the switch panel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the switch panel is provided on the upper surface of the battery-mount part in a tilted manner (lower in the front), then the battery-mount part structure is simplified, but the visibility and ease of operation of the switch panel deteriorates
Solution Approach 1:
The switch panel is moved from the upper surface of the battery-mount part to the grip part, changing its spatial location to a different dimension. This allows the switch panel to be positioned in a location that is easily visible and operable while maintaining the simplified battery-mount part structure.
2Device complexity
If the tool-side terminal and controller are arranged side-by-side in the up-down direction inside the battery-holding housing, then the electrical connection is simplified, but the thickness of the battery-holding housing increases
Solution Approach 1:
The controller is repositioned from a side-by-side arrangement with the tool-side terminal to an overlapping arrangement in the sliding direction. This dimensional change allows both components to coexist within the same projection area, reducing the battery-holding housing thickness in the up-down direction while maintaining simplified electrical connection.
3Ease of manufacture
If the battery pack and controller are arranged side-by-side, then the battery pack mounting is simplified, but the overall product height increases
Solution Approach 1:
The controller is repositioned to overlap with the battery pack in the sliding direction, changing from a side-by-side arrangement to a layered arrangement. This allows the components to share the same longitudinal space, reducing the overall product height while maintaining easy battery pack mounting through the sliding mechanism.
Data Source
AI summary
A power tool (1), such as an impact wrench (1), includes: a brushless motor (8); a motor housing (7), which houses the brushless motor (8); an anvil (4), which is rotationally driven by the brushless motor (8) and disposed forward of the brushless motor (8); a handle (3), which is disposed downward of the motor housing (7); a battery-mount part (5), which is disposed downward of the handle (3); a battery pack (6), which is mounted on the battery-mount part (5) by being slid relative to the battery-holding housing (5); and a controller (70) for controlling the brushless motor (8). A switch panel (73) having at least one manipulatable button (73c) and at least one display part is provided downward of the handle (3) and is tilted such that the switch panel (73) is higher in the front.