Rotatable Electrical Connector for Torque-Decoupled Power Tools
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Solution Overview
Problem
Existing power tools with electrical connectors, such as concrete vibrators, face issues with hose restrictions and potential damage due to torque transfer, limiting user mobility and causing electrical connection problems.
Innovation Solution
A rotatable electrical connector system that decouples torque between the tool device and the main housing, allowing flexible tool connections to rotate freely while maintaining electrical connection, featuring a first and second connector element that can align in multiple orientations and a locking mechanism to secure the connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a protective hose is used to connect the vibrator device to the electric supply line, then electrical connection is protected, but the hose restricts user movement and can become twisted causing connection damage
Solution Approach 1:
The electrical connection system is segmented into modular components: a rotatable electrical connector at the main housing, a flexible cable, and a plug at the tool device. This segmentation allows each component to perform its specific function optimally - the rotatable connector handles torque decoupling, the flexible cable provides movement freedom, and the plug ensures secure connection at the tool end.
Solution Approach 2:
The rotatable electrical connector introduces dynamic capability to the otherwise static electrical connection system. It can rotate freely to accommodate movements and twisting of the flexible cable, preventing torque transfer to the main housing while maintaining continuous electrical connection. This dynamic feature directly resolves the contradiction by allowing user mobility without compromising connection reliability.
2Reliability
If a fixed electrical connector is used between the main housing and the flexible tool connection, then electrical connection is stable, but torque applied to the tool device damages the electrical connection
Solution Approach 1:
The rotatable electrical connector acts as an intermediary element between the main housing and the flexible tool connection. It mediates the torque forces by providing a rotation interface that decouples the tool device from the main housing, preventing torque from reaching and damaging the electrical connection while maintaining stable power transmission.
Solution Approach 2:
The rotatable electrical connector transforms the static electrical connection into a dynamic system that can absorb and accommodate torque through rotation. This dynamic capability allows the connector to maintain electrical stability while protecting against torque damage by allowing the tool device to rotate independently of the main housing.
3Ease of operation
If the electrical connector is made rotatable to allow free movement, then user maneuverability is improved, but the complexity of the connector increases
Solution Approach 1:
The rotatable electrical connector merges multiple functions into a single integrated component: electrical connection, torque decoupling through rotation, and flexible cable management. By combining these functions in one element rather than using separate components, the design achieves improved user maneuverability while minimizing the increase in overall system complexity.
Data Source
AI summary
A power tool includes a main housing including an electrical power source and a tool device having at least one electrical component. A flexible tool connection is connected between the main housing and the tool device. The flexible tool connection includes at least one electrical wire configured to electrically connect the electrical power source and the at least one electrical component. A rotatable electrical connector is between the main housing and the flexible tool connection. The rotatable electrical connector is configured to decouple torque applied to the tool device or the flexible tool connection from the main housing.