Handheld Tool Motor Carrier Integration
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Solution Overview
Problem
Electrical faults in handheld work apparatuses due to corrosion of cable lugs in electrical wiring connections between the operating switch, battery pack, and control unit lead to reliability issues.
Innovation Solution
Integrating all necessary electrical elements, including the operating switch, control unit, and electrical contacts, onto a common carrier such as a circuit board with conductor paths, minimizing the need for external wiring and separable connections, and using separable plug-in contacts only for the battery pack.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrical wiring with cable lugs is used to connect the operating switch, battery pack, and control unit, then the electrical connection can be established, but the cable lugs corrode over time leading to electrical faults and reduced reliability
Solution Approach 1:
The patent merges the operating switch, control unit, and electrical contacts onto a single common carrier (circuit board). This integration eliminates the need for separate cable lugs and wiring connections between these components, as they are electrically connected through conductor paths on the same substrate. The only remaining cable lug connections are between the battery pack and the carrier, significantly reducing the number of corrosion-prone joints.
Solution Approach 2:
The patent replaces the mechanical cable lug connection system with an integrated circuit board architecture. Instead of using separate cable lugs and wiring harnesses to connect the operating switch and control unit to the battery pack, all electrical connections are realized as conductor paths on the circuit board, eliminating the mechanical connection interfaces that are susceptible to corrosion.
2Adaptability or versatility
If multiple separate electrical components are connected via cable lugs and wiring, then each component can be independently positioned, but the increased wiring creates more fault sources and reduces overall system reliability
Solution Approach 1:
The patent combines multiple electrical components (operating switch, control unit, electrical contacts) onto a single common carrier. This merging approach reduces the total number of electrical connections required, as components that would previously need separate cable lug connections are now electrically interconnected through conductor paths on the same circuit board, minimizing fault sources.
3Ease of manufacture
If cable lugs are used for electrical connections, then the wiring can be easily assembled, but the cable lugs are prone to corrosion and electrical faults over the operating period
Solution Approach 1:
The patent substitutes the cable lug and wiring assembly system with an integrated circuit board architecture. The conductor paths on the circuit board provide permanent, corrosion-resistant electrical connections that eliminate the need for repeated assembly and disassembly of cable lugs, thereby preventing corrosion while maintaining manufacturing efficiency.
Data Source
AI summary
A handheld work apparatus has an electric motor for driving a tool. A function module is to be connected to a battery pack via electrical contacts, there being provided an electrical operating switch, for putting the electric motor into operation, which is coupled to an actuating element of the handheld work apparatus. The electric motor is put into operation upon a command of the operating switch, via a control unit. To constitute the function module, provision is made to dispose the electrical contacts, the control unit and the operating switch on a common carrier. The carrier has a first side that faces toward the battery pack, and at least one second side that faces away from the battery pack. The electrical contacts are provided on the first side of the carrier, while the operating switch is held on the second side of the carrier.