Rotary Transformer Lighting for Power Tool End Effector
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Solution Overview
Problem
Power tools often operate in poorly lit environments, making it difficult for users to adequately see the workpiece or work area, as existing solutions do not effectively provide reliable lighting for these conditions.
Innovation Solution
Integration of a lighting system within the power tool, utilizing a rotary transformer and LEDs powered by a primary and secondary coil assembly, which includes a modulation circuit to control the intensity and flashing of the light, ensuring illumination even in low-light conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a light source is integrated into the power tool, then illumination of the workpiece is improved, but device complexity increases
Solution Approach 1:
The patent combines the lighting system with the existing motor assembly by integrating the light source into the motor housing and using the motor's electrical components to power the LED. This merging approach provides workpiece illumination while avoiding the need for separate, standalone lighting systems, thus managing the complexity increase.
Solution Approach 2:
The motor assembly serves multiple functions: it drives the accessory and simultaneously powers the light source through its electrical components. The housing structure also serves dual purposes as both mechanical support and light shielding. This multi-functionality reduces the need for additional dedicated components, addressing the complexity issue.
2Reliability
If a rotary transformer with primary and secondary coils is used to power the light, then reliability of lighting is improved, but device complexity increases
Solution Approach 1:
The primary and secondary coils are integrated into the existing motor assembly structure, combining the motor's electrical system with the lighting power supply. This integration ensures reliable lighting through the transformer mechanism while avoiding the need for separate, standalone coil assemblies, thus managing the complexity increase.
Solution Approach 2:
The rotary transformer acts as an intermediary between the motor's electrical components and the LED light source. It provides a reliable power transfer mechanism through electromagnetic induction, ensuring consistent lighting operation while the integrated design minimizes the added complexity of the coil assembly.
3Illumination intensity
If the light source is positioned on the end effector, then visibility of workpiece is improved, but weight distribution changes
Solution Approach 1:
The light source is strategically positioned on the end effector where it provides the most effective illumination of the workpiece. This localized placement optimizes visibility while the weight of the LED and associated components is minimized through efficient design and integration with the existing end effector structure.
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 provides consistent and controlled lighting for the workpiece, enhancing visibility and usability of power tools in various lighting conditions without additional power sources, improving user experience and operational efficiency.
Implementation Method 1
Current flowing through the primary coil creates a magnetic field that causes current to flow through the secondary winding and power the light source
Implementation Method 2
The light source comprises at least one light emitting diode (LED)
Data Source
Figure 1
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AI summary
A power tool system includes a tool body with a motor having an output member that drives an accessory. The output member defines an output member axis. An end effector is coupled for rotation with the output member relative to the tool body. The end effector is configured to retain the accessory. A light source is disposed on the end effector. A consumable tool, such as a holesaw, is removably attachable to the end effector, and has an illumination opening configured to be substantially aligned with the light source. The holesaw may have a generally cylindrical side wall and a base wall that defines a central opening for receiving an arbor, an aperture spaced radially outward by a first distance for receiving a projection on an arborm and an illumination opening spaced radially a second greater distance.