Universal Termination System for Power Tool Switches
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Solution Overview
Problem
The diverse electrical configurations of switches in power tools lead to reduced design flexibility, increased complexity in the supply chain, and potential for errors during assembly, due to variations in wire-ups and terminal types, which are not standardized across different switch platforms.
Innovation Solution
A universal termination system is introduced, standardizing the number, type, location, and orientation of terminations for push-button, overhang, and in-line VSR switches, allowing power tools to use standardized switch platforms, with specific configurations such as perpendicular motor lead wire exits for push-button switches, bottom-mounted screw terminals for overhang switches, and push-in type terminals for in-line VSR switches, along with the use of right-angle pin terminals to facilitate easy connection and prevent kinking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different switch platforms from different suppliers are used, then customization options increase, but device complexity and supply chain complexity increase
Solution Approach 1:
The patent establishes a universal termination system where a single switch platform with standardized terminations can serve multiple power tool applications. The standardized termination locations, orientations, and types allow the same switch to be used across different tool types (drills, impact drivers, screwguns), eliminating the need for multiple customized switch platforms and simplifying the supply chain while maintaining adaptability through software or configuration variations
2Adaptability or versatility
If different switch platforms with varying terminations are used, then supplier options increase, but manufacturing precision requirements increase
Solution Approach 1:
The patent defines specific termination parameters including location, orientation, and type that must be maintained across all switches using the universal platform. By establishing fixed parameters (e.g., terminations on specific faces of the switch body at defined angles), the system achieves manufacturing precision while allowing flexibility in other aspects like actuator style or mounting configuration
3Device complexity
If customized wire-ups are used for different switch platforms, then design flexibility decreases, but assembly error potential increases
Solution Approach 1:
The patent pre-defines the termination configuration during switch manufacturing, establishing standardized locations and orientations before the power tool assembly process. This preliminary standardization eliminates the need for complex wire-up variations during assembly, reducing the potential for errors while maintaining design flexibility through the universal platform's ability to accommodate different tool configurations
4Adaptability or versatility
If multiple termination configurations are used across switch platforms, then design flexibility is reduced, but ease of manufacture decreases
Solution Approach 1:
The universal termination system allows a single switch design to be manufactured and used across multiple power tool applications, improving manufacturing efficiency through economies of scale. The standardized terminations maintain design flexibility by allowing the same switch platform to accommodate different tool configurations through variations in wiring harnesses or control electronics rather than requiring customized switches for each application
Data Source
AI summary
A universal termination system is provided for power tools. The universal termination system includes criteria for each of the main switch platforms that define the number, type, location and orientation of the terminations. That is, the number, type, location and orientation of the terminations in each main switch platform are standardized and the power tools that use that type main switch platform use the main switch platform having the standardized terminations. That is, power tools that use push button switches use the push button switch with the standardized terminations, power tools that use overhang switches use the overhang switch with the standardized terminations, and power tools that use in-line VSR switches use the in-line VSR switch with the standardized terminations. In an aspect of the invention, a right-angle pin terminal is received in one or more sets of the standardized terminations. In an aspect of the invention, the switch body has features that cooperate with the right-angle pin terminals to reduce the risk of shorting adjacent terminals. In an aspect of the invention, a switch has standardized connections on a bottom of a switch body that mate with terminals of a plug-in control module. In an aspect of the invention, a switch for a hand-held power tool has cord set terminations that are screw-tab terminals.