Integrated Switch Control PCB for Compact DC Motor Tools
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Solution Overview
Problem
Conventional power tools face challenges in reducing component size and assembly complexity due to separate and spaced electrical switching contacts, signaling, and control modules, which occupy more space and require additional wiring, leading to increased assembly time and potential operational issues.
Innovation Solution
Integration of the control module with the signaling module on a single PCB and a separate power module PCB, with direct electrical connections and a two-sided heat dispersion configuration to enhance thermal management, allowing for a compact design and reduced assembly complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate and spaced electrical switching contacts, signaling module, and control module are used, then functional reliability is improved, but device volume and assembly complexity increase
Solution Approach 1:
The patent combines the electrical switching contacts, signaling module, and control module onto a single PCB, merging previously separate functional components into one integrated unit. This reduces the overall device volume while maintaining the functional reliability of each component through proper PCB layout and electrical connections.
2Reliability
If separate and spaced electrical switching contacts, signaling module, and control module are used, then functional reliability is improved, but assembly time increases
Solution Approach 1:
By integrating multiple components onto a single PCB, the patent reduces the number of assembly steps. The PCB serves as a pre-assembled unit containing all electrical connections, eliminating the need for separate wiring and mounting operations for each component, thus significantly reducing assembly time while maintaining reliability.
3Reliability
If separate and spaced electrical switching contacts, signaling module, and control module are used, then functional reliability is improved, but device complexity increases
Solution Approach 1:
The patent merges multiple functional modules into a single PCB assembly, which simplifies the overall device complexity. The PCB provides a standardized platform with pre-established electrical connections, reducing the complexity of wiring and assembly procedures while maintaining the functional integrity and reliability of each module.
4Ease of manufacture
If conventional wiring connections are used between separate modules, then ease of manufacturing is improved, but thermal dissipation is insufficient
Solution Approach 1:
By integrating the power module with the control module on the same PCB, the patent enables more effective thermal management. The close proximity of components allows for optimized heat sinks and thermal pathways to be implemented directly on the PCB, improving thermal dissipation while maintaining ease of manufacture through standardized PCB fabrication processes.
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 reduces the need for external wiring, simplifies assembly, enhances thermal dissipation, and enables a more compact and reliable power tool design with improved torque output from the brushless DC motor.
Implementation Method 1
a heat transfer element arranged in thermal communication with a bottom region of the power module to allow heat dissipation from out of the power module
Data Source
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AI summary
An electrical switch unit to control operation of a DC motor of an electrical device, comprising: a housing (205) housing a pair of electrical switching contacts (101), and, an actuator (207) operably connected with at least one of the pair of electrical switching contacts; a signaling module (102) associated with the electrical switch unit comprising signaling circuitry for sensing the movement of the actuator and outputting a signaling module signal indicative of the sensed movement or position of the actuator; a power module (203) comprising at least one power switching device for controllably supplying power from the DC power source to the DC motor; a control module (201) comprising control circuitry for receiving the signaling module signal, and responsive to the received signaling module signal, outputting a control module signal to control the at least one power switching transistor device of the power module wherein the at least one power switching device controllably supplies power from the DC power source to the DC motor to allow operation of the DC motor at a speed corresponding to the sensed movement or position of the actuator; and wherein, the signaling module is integrally connected to a first end of the control module that is located within the electrical switch unit housing to allow relatively direct electrical communication between the pair of electrical switching contacts and the control module, and, whereby the control module is configured to extend outwardly of the electrical switch housing so as to terminate at a distal second end.