Operating Switch Integration on Control Circuit Board
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Solution Overview
Problem
Battery-powered hand-held tools face challenges with electrical wiring errors due to loosening or oxidation, and require precise adjustment of the switch-on point for the operating switch, which is often complicated by mechanical actuation and tolerance issues.
Innovation Solution
The operating switch is integrated directly onto the circuit board of the control unit, with a support device that statically supports it independently, reducing wiring needs and allowing precise adjustment through conductor tracks on the circuit board, eliminating mechanical connections and tolerance-related errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the operating switch is arranged near the actuator, then the switch-on point can be coordinated with the actuating stroke, but wiring errors due to loosening or oxidation occur
Solution Approach 1:
The operating switch is integrated directly onto the circuit board of the control unit, merging the switching function with the electronic control system. This eliminates separate wiring connections and cable lugs, thereby preventing loosening and oxidation issues while maintaining precise switch-on point coordination through direct electrical contact on the circuit board.
Solution Approach 2:
The circuit board serves as an intermediary between the operating switch and the control unit, providing a stable, integrated platform that eliminates the need for external wiring. The conductor tracks on the circuit board act as reliable electrical pathways, replacing traditional cable connections that are prone to loosening and oxidation.
2Reliability
If the operating switch is arranged at a greater distance from the actuator, then wiring can be reduced, but lever arrangements or mechanical connections are necessary
Solution Approach 1:
The operating switch is merged with the circuit board assembly, allowing it to be positioned optimally for electrical connection while eliminating the need for separate mechanical actuation mechanisms. The switch is directly actuated by the operating element through the circuit board structure, avoiding complex lever arrangements.
Solution Approach 2:
The mechanical actuation mechanism is extracted from separate components and integrated into the circuit board structure itself. The circuit board provides both the electrical connection and the mechanical support for the operating switch, eliminating the need for external lever arrangements or mechanical linkages.
3Reliability
If the operating switch is mounted on the circuit board, then wiring can be minimized, but the position on the circuit board is subject to tolerances
Solution Approach 1:
The circuit board is designed with pre-defined conductor tracks and mounting positions for the operating switch. The switch is soldered onto predetermined locations on the circuit board, ensuring consistent positioning that compensates for manufacturing tolerances. The support device is also pre-positioned to provide stable mechanical support independent of circuit board variations.
Solution Approach 2:
The circuit board structure itself provides the positioning and support for the operating switch through its rigid construction and pre-fabricated conductor tracks. The support device, integrated with the circuit board, automatically compensates for minor position variations, ensuring reliable electrical and mechanical connection without requiring additional adjustment mechanisms.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to an electromechanical functional unit for a battery-powered, handheld power tool, comprising an operating switch (10) for starting the power tool. The operating switch (10) is actuated by an actuator (8, 9) of the power tool (1), and the operating switch (10) is connected to a control unit (30) for operating the power tool (1). The control unit (30) comprises a circuit board (29) with electronic components (34) and has a first circuit board side (31) and a second circuit board side (32) facing away from the first circuit board side (31). To avoid wiring and reduce tolerances, the operating switch (10) is arranged on the second circuit board side (32). The operating switch (10) is statically supported independently of the circuit board (29) by a support device (46).The support device (46) has no mechanical connection to the circuit board (29) and leads from the second circuit board side (32) to the first circuit board side (31).