Handheld Power Tool Sensor Board Layout for Heat and Vibration
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Solution Overview
Problem
Existing hand-held power tools face challenges in achieving a compact design while effectively managing heat and vibrations, which can lead to reduced performance and increased turbulence in airflow, affecting the tool's efficiency and user experience.
Innovation Solution
The arrangement of the sensor board and fan impeller at the end of the electrically commutated drive motor, away from the tool holder, along with a mechanically decoupled mounting element, allows for a compact design that minimizes turbulence in airflow and efficiently directs heat away from the motor, enhancing the tool's performance and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the sensor board and fan impeller are arranged close to the drive motor, then the device complexity is reduced, but the airflow turbulence increases and heat management becomes less effective
Solution Approach 1:
The sensor board and fan impeller are arranged axially at the end of the drive motor facing away from the tool holder, utilizing the longitudinal dimension of the motor assembly. This spatial arrangement allows the components to be positioned in a way that minimizes interference with airflow paths while maintaining mechanical integration, thereby reducing airflow turbulence without significantly increasing device complexity.
Solution Approach 2:
The mounting element serves as an intermediary component that mechanically decouples the sensor board from the drive motor while maintaining positional stability. This mediator allows the sensor board to be positioned optimally for airflow management without being directly coupled to the motor, thus reducing turbulence while keeping the overall structure integrated and manageable.
2Device complexity
If the sensor board is mechanically coupled to the drive motor, then the mounting structure is simplified, but vibration transmission increases reducing reliability
Solution Approach 1:
The mounting element acts as a vibration-isolating intermediary between the drive motor and the sensor board. It provides mechanical support and positioning while decoupling the rigid connection that would transmit vibrations directly to the sensor board, thereby protecting the sensor from vibration-induced errors without requiring a complex mounting structure.
Solution Approach 2:
The mounting element is extracted as a separate, dedicated component with the specific function of mechanical decoupling. By separating the mounting function from the motor housing or other structural elements, the design achieves vibration isolation while maintaining overall structural simplicity through functional specialization.
3Temperature
If the fan impeller is positioned to maximize cooling, then heat management is improved, but the device volume increases
Solution Approach 1:
The fan impeller is merged with the drive motor assembly, with the impeller positioned at the motor end facing away from the tool holder. This integration allows the cooling function to be incorporated into the existing motor structure without adding separate cooling components, thereby achieving effective heat dissipation while minimizing increases in device volume.
Solution Approach 2:
The cooling airflow is directed axially along the length of the motor assembly, utilizing the longitudinal dimension rather than requiring additional radial or lateral space. This dimensional approach allows effective heat management to be achieved within the existing device footprint without significantly increasing overall volume.
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
This configuration enables a more compact and efficient hand-held power tool with reduced vibration transmission and improved airflow, leading to enhanced performance and user experience by effectively managing heat and vibrations.
Implementation Method 1
The hand-held power tool has a fan impeller, wherein the fan impeller and the drive shaft form a non-positive and/or substance-to-substance bond
Implementation Method 2
The drive shaft is supported by means of at least one bearing in the housing
Data Source
AI summary
A hand-held power tool includes a housing, a tool holder for holding an insert tool, an electrically commutated drive motor that is arranged in the housing and has a drive shaft mounted by at least one bearing, a fan impeller, and a sensor board for sensor-controlled commutation of the electrically commutated drive motor, the sensor board being arranged in the housing between the drive motor and the fan impeller. The power tool further includes at least one mounting element designed to arrange the sensor board in the housing in a manner mechanically decoupled from the electrically commutated drive motor. The sensor board and the fan impeller are arranged at an end of the electrically commutated drive motor facing away from the tool holder.