Electric Power Tool Controller Positioning for Compact Cooling
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Solution Overview
Problem
Conventional electric power tools for machining, such as edging or grooving wood, face a challenge in maintaining airflow for cooling while attempting to lower the height of the tool main body, as the airflow is often blocked by the controller when it is positioned above the drive motor, leading to reduced cooling efficiency.
Innovation Solution
The electric power tool design positions the controller to overlap at least a portion of the drive motor or stator in a direction orthogonal to the spindle's axis, allowing for a more compact head design while maintaining airflow efficiency by ensuring that the airflow is not obstructed, and also offsets the controller from the spindle axis to allow air to pass through, thereby improving cooling efficiency without increasing the tool's volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If the controller is positioned above the drive motor to lower the head height, then the height of the head of the tool main body is reduced, but the airflow is blocked and cooling efficiency deteriorates
Solution Approach 1:
The controller is repositioned from a vertical arrangement (above the drive motor) to a lateral arrangement (side by side with the drive motor), utilizing the horizontal dimension to achieve compact vertical height while preserving airflow pathways. This dimensional transition allows both the controller and drive motor to coexist without blocking the airflow needed for cooling.
Solution Approach 2:
The housing structure is designed with differentiated local regions: a first housing portion accommodating the drive motor and a second housing portion accommodating the controller, with specific openings positioned to maintain airflow to the drive motor while providing mounting space for the controller. This local structural differentiation enables simultaneous achievement of compact size and effective cooling.
2Ease of manufacture
If the controller is arranged on the head side of the tool main body, then the structure is simplified and maintenance is easier, but the head height increases reducing compactness
Solution Approach 1:
The controller is positioned laterally adjacent to the drive motor rather than vertically above it, utilizing horizontal space to achieve compact vertical dimensions. This lateral arrangement maintains the benefit of having the controller accessible on the head side for maintenance while preventing increase in overall head height.
Solution Approach 2:
The controller and drive motor are housed in closely integrated housing portions, with the controller mounted on the housing that also contains the drive motor. This merged structure allows both components to be maintained together as a unit while maintaining compact overall dimensions.
3Volume of stationary object
If the controller overlaps the drive motor in the orthogonal direction, then the head volume is reduced, but the airflow path may be obstructed
Solution Approach 1:
The housing structure incorporates specifically positioned openings in the first housing portion that align with the drive motor's airflow requirements. These localized opening regions ensure that even though the controller and drive motor overlap in space, the airflow path to the drive motor remains unobstructed, maintaining cooling efficiency while achieving compact volume.
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 design achieves a more compact and efficient cooling system within the tool main body, allowing for lower height and improved usability without compromising airflow, thus enhancing the tool's performance and stability during machining operations.
Implementation Method 1
the tool main body includes an air blower fan for cooling the internal components such as the drive motor and the controller etc. This air blower fan is attached to the spindle so as to rotate together with the spindle. The airflow generated by this air blower fan helps take outside air from the above-mentioned workpiece facing side into the tool main body, and emit the air to the outside after passing it through the tool main body.
Data Source
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AI summary
In an electric power tool (10), a controller (46), a capacitor (47), a terminal stand (48), a speed change controller (49), and a switch (50) are arranged at positions offset from the axis of a spindle (41) so as not to overlap the spindle (41) as seen in a direction corresponding to the direction in which the spindle (41) axially extends. The controller (46), the capacitor (47), the terminal stand (48), the speed change controller (49), and the switch (50) are located so as to overlap a part of a drive motor (40) as seen in a direction orthogonal to the direction in which the spindle (41) axially extends. The controller (46), the capacitor (47), the terminal stand (48), the speed change controller (49), and the switch (50) are located so as to overlap at least a part of a field as seen in a direction corresponding to the direction in which the spindle (41) axially extends.