Stranded Wire Retaining Channel for Electrical Tools
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Solution Overview
Problem
Existing electrical tools face issues with stranded conductors being damaged during assembly due to lack of fixation, leading to increased costs and reduced durability, especially when vibration-reducing mechanisms are involved.
Innovation Solution
A conductor channel with a flexible and rigid section is used to securely position and align stranded conductors, protecting them from damage and accommodating vibrations, while being easily adaptable to different tools and reducing logistical costs through a single-piece design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If stranded conductors are held with separate retaining elements or freely arranged in the housing, then the conductors can be positioned in the housing, but the conductors can be pinched or damaged during final assembly of housing parts
Solution Approach 1:
The patent combines multiple retaining elements into a single integrated conductor channel structure. The conductor channel is formed as one piece with a receptacle that holds the stranded conductor and flexible sections that accommodate movement, eliminating the need for multiple separate retaining elements while providing comprehensive protection against pinching and damage during assembly.
Solution Approach 2:
The conductor channel is pre-formed as a single-piece structure with integrated retaining features, receptacles, and flexible sections before installation. This preliminary preparation ensures that the conductor is protected from damage during assembly without requiring complex assembly steps or multiple separate components to be installed during final housing assembly.
2Reliability
If a large number of retaining elements is provided in the housing for securing the stranded conductors, then the conductors are protected from damage, but the mounting of the conductors becomes very expensive
Solution Approach 1:
The patent merges multiple separate retaining elements into a single integrated conductor channel component. This consolidation reduces the number of parts that need to be manufactured, inventoried, and assembled, thereby significantly reducing mounting costs while maintaining comprehensive conductor protection through the integrated design.
Solution Approach 2:
The single-piece conductor channel performs multiple functions simultaneously: it holds the stranded conductor, provides protection against pinching and damage, accommodates conductor movement through flexible sections, and maintains proper alignment. This multi-functionality eliminates the need for multiple specialized retaining elements, reducing overall manufacturing and mounting costs.
3Adaptability or versatility
If the stranded conductors are provided with sufficient length to accommodate swingings or oscillation of the vibration-reducing system, then the conductors can move freely, but the conductors can be pinched or damaged during final assembly
Solution Approach 1:
The conductor channel incorporates flexible sections that allow the channel itself to move and deform dynamically, accommodating the swingings and oscillations of the vibration-reducing system. This dynamic flexibility protects the stranded conductor from pinching and damage during assembly and operation, while maintaining proper conductor length and movement capability.
Solution Approach 2:
The conductor channel acts as an intermediary structure between the fixed housing and the moving vibration-reducing system. The flexible sections of the channel absorb and accommodate the relative movement, protecting the stranded conductor from the harmful effects of oscillation while allowing necessary movement freedom.
Data Source
AI summary
An electrical tool includes a housing, a conductor channel, and a stranded conductor. The housing includes a motor, electronics, and drive gear. The conductor channel has a flexible section and a rigid section. The stranded conductor is in a receptacle of the conductor channel. One end of the stranded conductor is connected to a conductor of a network cable of the electrical tool. Another end of the stranded conductor is conductively connected with a component of the electrical tool.