Tool Load Sensor Reducing Switch Stroke and Size
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Solution Overview
Problem
Conventional electric tools with load sensors require a large stroke for the switch manipulation part to activate the control circuit, leading to increased tool size and complexity, and difficulty in ensuring waterproofness and dustproofness.
Innovation Solution
A tool incorporating a load sensor with a pressure-sensitive conductive elastic member dispersed in a non-conductive elastic material, allowing the control unit to be activated with a reduced stroke of the switch manipulation part, eliminating the need for a mechanical variable resistor and simplifying the switch structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a mechanical switch with contact points is used to activate the control circuit, then the control circuit can be activated, but the stroke of the switch manipulation part becomes large and the structure becomes complex
Solution Approach 1:
The patent replaces the mechanical switch with contact points with a load sensor that detects load through elastic deformation. The trigger manipulation part directly presses the load sensor, eliminating mechanical contact points and their associated complexity while reliably activating the control circuit through load detection.
Solution Approach 2:
The patent changes the operational parameter from mechanical contact (on/off) to physical quantity detection (load magnitude). The load sensor converts the mechanical load applied by the trigger into an electrical signal, allowing the control circuit to be activated based on load magnitude rather than simple contact closure.
2Reliability
If a mechanical switch with contact points is used, then the control circuit can be activated, but the stroke of the switch manipulation part increases leading to increased tool size
Solution Approach 1:
The load sensor replaces the mechanical switch structure, allowing the trigger to have a much shorter stroke. Instead of requiring contact points to close over a large distance, the trigger simply needs to press the load sensor enough to generate a detectable load signal, significantly reducing the manipulation stroke and tool size.
3Reliability
If a mechanical switch structure is used, then the control circuit can be activated, but waterproofness and dustproofness become difficult to ensure
Solution Approach 1:
By replacing the mechanical switch with contact points with a load sensor, the patent eliminates the need for openable/closable switch structures. The load sensor can be fully enclosed within the trigger assembly, creating a sealed structure that prevents water and dust ingress while maintaining reliable control circuit activation through load detection.
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
The solution enables the activation of the control unit and control of electric components using one set of switches, reducing the tool's size and improving waterproofness and dustproofness by minimizing the stroke required for the switch manipulation part.
Implementation Method 1
The load sensor includes a pressure-sensitive conductive elastic member in which conductive particles are dispersed in a non-conductive elastic material
Data Source
AI summary
A tool includes a switch and a handle. The switch is configured to cause an electric component to operate. The handle is held by a hand to manipulate the switch. The switch includes a switch manipulation part to be manipulated, and a load sensor. The load sensor is configured to receive a pressing force through the switch manipulation part. The load sensor includes a pressure-sensitive conductive elastic member in which conductive particles are dispersed in a non-conductive elastic material.