Shared Terminal Block for Wireless-Connected Power Tools
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Solution Overview
Problem
Power tools lack integrated wireless communication capabilities that allow for seamless data transfer and configuration, limiting their functionality and user interaction.
Innovation Solution
Incorporating an insertable wireless communication device within a power tool's battery pack compartment, which shares terminal connections with the battery pack, enabling wireless communication and data exchange with external devices for tool status, configuration, and operation control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate terminal block is provided for the wireless communication device, then the device can be electrically connected, but the structural complexity and manufacturing difficulty increase
Solution Approach 1:
The patent merges the terminal block structure by having the wireless communication device share the same terminal block with the battery pack. The terminal block includes first terminals for the battery pack and second terminals for the wireless communication device, integrated into a single structure rather than using separate terminal blocks for each device.
Solution Approach 2:
The terminal block is designed with multi-functionality to serve both the battery pack and the wireless communication device. The same terminal block structure provides electrical connections for power supply to the motor and for wireless communication operations, reducing the number of separate connection components needed.
2Adaptability or versatility
If wireless communication components are integrated into the power tool, then communication functionality is achieved, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The wireless communication device is designed as a separate, removable module that can be independently manufactured and then integrated into the power tool. This segmentation allows the communication components to be produced separately using optimized processes, then assembled into the final product, reducing overall manufacturing complexity.
Solution Approach 2:
The wireless communication device is nested within the power tool housing, with the communication module fitting into a designated compartment. The device terminals connect to the terminal block through this nested arrangement, allowing compact integration without requiring separate mounting structures.
3Device complexity
If the wireless communication device shares terminal connections with the battery pack, then the number of terminals is reduced, but the electrical connection requirements become more complex
Solution Approach 1:
The terminal block is designed with different terminal regions optimized for different functions: first terminals configured for battery pack connections with appropriate current-carrying capacity, and second terminals for wireless communication device connections. Each terminal region has localized structural characteristics suited to its specific electrical connection requirements.
Data Source
AI summary
An example power tool includes a battery pack receiving portion including a battery pack compartment including a battery pack support structure configured to receive and support a battery pack including battery terminals. The power tool further includes a terminal block located in the battery pack receiving portion and including tool terminals. At least two terminals of the tool terminals are configured to electrically and physically couple to the battery terminals. The power tool further includes an insertable device compartment located in the battery pack receiving portion and configured to receive an insertable wireless communication device including a first electronic processor, a transceiver, and device terminals. At least one device terminal is configured to electrically and physically couple to at least one shared terminal of the at least two terminals of the tool terminals. The insertable wireless communication device is configured to wirelessly communicate with an external device.