Replaceable Torch Trigger Module With PCB Sensor Upgrades
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Solution Overview
Problem
Conventional handheld arc plasma torches have triggers that are difficult to replace or service, and sensors are often sealed within the torch, making it challenging to upgrade or modify the device to accommodate new functionalities or repair worn components without replacing the entire torch.
Innovation Solution
A removable trigger module with a housing, pivotably coupled trigger, and a printed circuit board (PCB) that can be electrically coupled to accessories such as light sources, temperature sensors, and motion sensors, allowing for easy replacement and upgrade of functionalities by swapping out different trigger modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the trigger is integrated into the handle assembly, then the structural integrity and reliability are improved, but the ease of repair and replacement deteriorates
Solution Approach 1:
The trigger assembly is segmented from the handle assembly into a separate, removable module. The trigger module includes the trigger, housing, and PCB assembly that can be detached from the handle, allowing the trigger to be replaced independently without replacing the entire handle assembly, thus improving ease of repair while maintaining structural integrity through proper coupling mechanisms
Solution Approach 2:
The trigger module is extracted as a separate serviceable unit from the integrated handle assembly. By taking out the trigger module as an independent component with its own housing and mounting features, the design enables easy removal and replacement of the trigger mechanism while the handle assembly remains intact
2Reliability
If sensors are sealed within the torch, then the protection from environmental factors is improved, but the ease of operation for modification and upgrade deteriorates
Solution Approach 1:
The PCB assembly with sensors is segmented into a separate serviceable module within the trigger module. The PCB is mounted on the trigger module housing with accessible connectors, allowing sensors to be replaced or modified by simply removing the trigger module, thus enabling easy upgrades while maintaining environmental protection through the sealed housing
Solution Approach 2:
The electronic components including sensors are extracted into a separate PCB assembly that is mounted on the removable trigger module. This extraction allows the electronic components to be accessed and modified by removing the trigger module from the handle, providing ease of modification while the components remain protected when installed
3Ease of repair
If the trigger module is removable, then the ease of repair and upgrade is improved, but the device complexity increases
Solution Approach 1:
The trigger module is designed as a universal, standardized module that can be used across different torch models. The housing includes standardized mounting features such as engagement elements, mounting holes, and bracket portions that provide a universal coupling system, reducing overall device complexity through standardization while maintaining ease of repair and upgrade
Data Source
AI summary
A torch having a replaceable trigger module is disclosed. The trigger module includes a housing defining a cavity; a trigger operatively coupled to the housing; and a printed circuit board (PCB) configured to be electrically coupled to one or more accessories. The PCB and the one or more accessories are disposed at least partially in the cavity and are coupled to the housing so that coupling the housing to a torch handle mechanically couples the PCB and trigger to the torch handle.