Rotor Shaft Insulator Assembly for Verifiable Tool-Side Isolation
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Solution Overview
Problem
Ensuring electrical safety in handheld electric tools with complex designs and multiple insulators of varying dimensions is challenging, and wear can compromise safety, making compliance with safety standards difficult.
Innovation Solution
A rotor shaft assembly with an electrical insulator connected to the rotor shaft, providing insulation between the electric motor and connected tools or accessories, allowing for easy verification of safety compliance and maintaining insulation even with wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple insulators with variable dimensions are used in the electric motor design, then electrical safety can be maintained, but verification of compliance with safety standards becomes challenging
Solution Approach 1:
The patent combines multiple insulators into a single integrated electrical insulator component that provides all necessary insulation functions. This unified design maintains electrical safety while simplifying verification, as the single insulator can be easily inspected for compliance with safety standards without needing to verify multiple separate components with variable dimensions.
Solution Approach 2:
The electrical insulator is designed to perform multiple insulation functions simultaneously, providing both mechanical support and electrical isolation between different components. This multi-functional design eliminates the need for multiple specialized insulators, thereby maintaining safety while reducing verification complexity.
2Reliability
If traditional insulation methods are used in the rotor shaft assembly, then electrical insulation can be provided, but wear can compromise the insulation over time
Solution Approach 1:
The electrical insulator is constructed from composite materials that combine high electrical insulation properties with exceptional wear resistance. This allows the insulator to maintain both its electrical insulation function and structural integrity over extended operational periods, preventing wear from compromising safety.
Solution Approach 2:
The insulator design incorporates protective features that preemptively compensate for potential wear. The robust construction and material selection ensure that even after prolonged use and exposure to wear, the insulator maintains sufficient insulation properties to meet safety standards throughout its service life.
3Reliability
If complex designs with multiple insulators are used, then electrical safety can be ensured, but the design and manufacturing process becomes more difficult
Solution Approach 1:
The patent integrates multiple insulation functions into a single electrical insulator component that can be manufactured as one piece. This consolidation simplifies the manufacturing process by reducing the number of parts to be produced, assembled, and quality-checked, while still providing comprehensive electrical safety protection.
Solution Approach 2:
The electrical insulator is designed with segmented or modular features that facilitate easier manufacturing and assembly. These design elements allow for simplified production processes while maintaining the overall insulation functionality and safety requirements.
Data Source
AI summary
There is provided a solution for electrical insulation for an output shaft, tool and/or accessory driven by an electric motor, and the presence of the electrical insulation is also easy to verify. A rotor shaft assembly for an electric motor includes at least one section that is configured to extend in an axial direction of the rotor shaft assembly outside of a stator assembly of the electric motor, when the rotor shaft assembly is rotatably mounted inside the stator assembly. An electrical insulator is connected to the at least one section and the electrical insulator is configured to connect to an output shaft for connecting with a tool and/or accessory, or configured to connect directly to a tool and/or accessory to be driven by the electric motor.