Power Tool Stator Positioning Unit for Circuit Board Alignment
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Solution Overview
Problem
The existing power tools with electronically commutated drive motors require time-consuming and costly screw connections or special receptacles for positioning circuit boards, complicating the manufacturing process.
Innovation Solution
A power tool design featuring a stator core with an insulating body and a positioning unit that allows for easy and quick alignment of a circuit board using integrally molded plastic positioning elements, such as pins, which securely mount the circuit board on the stator components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If screw connections or special receptacles are used for positioning the circuit board, then the circuit board can be securely positioned in the drive motor, but the manufacturing process becomes time-consuming and cost-intensive
Solution Approach 1:
The positioning unit is integrated directly into the insulating body of the stator components, combining the positioning function with the existing structural element. This eliminates the need for separate receptacles or mounting brackets, thereby securing the circuit board while simplifying the manufacturing process and reducing assembly steps
Solution Approach 2:
The insulating body itself provides the positioning function through integrated positioning elements, making the system self-sufficient. The positioning unit leverages the existing insulating body structure to perform the positioning task without requiring additional dedicated components, thus improving productivity while maintaining reliability
2Reliability
If screw connections or special receptacles are used for positioning the circuit board, then the circuit board can be securely positioned in the drive motor, but the manufacturing process becomes complex and expensive
Solution Approach 1:
The positioning unit is merged with the insulating body, reducing the total number of components. This integration eliminates the need for separate receptacles or mounting structures, thereby securing the circuit board while reducing device complexity and manufacturing cost
Solution Approach 2:
The insulating body serves multiple functions: electrical insulation, structural support, and circuit board positioning. By making the insulating body multi-functional, the patent eliminates the need for dedicated positioning receptacles, simplifying the overall device structure and reducing manufacturing complexity
3Productivity
If integrally molded positioning elements are used on the insulating body, then the circuit board can be quickly and easily positioned, but additional manufacturing steps are required for the insulating body
Solution Approach 1:
The positioning elements are pre-integrated into the insulating body during its molding process. This preliminary action ensures that the positioning structure is already prepared before assembly, enabling quick and easy positioning of the circuit board without requiring additional manufacturing steps during final assembly
Data Source
AI summary
In a power tool having an electronically commutated drive motor to which stator components are assigned, which stator components have a stator core equipped with an insulating body, a positioning unit is provided on the insulating body. The positioning unit is designed to enable a positioning of a circuit board, which is assigned to the drive motor, in a predefined alignment on the insulating body.