Wireless Two-Handle Switch Design for High-Torque Tools

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Solution Overview

Problem

Existing electric tools with high torque output in industrial settings face challenges in providing a safe and reliable method for operators to manage torque with two hands, as traditional solutions require complex wiring arrangements for secondary handles, which are impractical for movable or removable handles.

Innovation Solution

An electric tool design featuring two handles, where one handle is equipped with a second switch coupled to a wireless transmitter, allowing wireless communication with a receiver in the tool housing to enable operation only when both switches are actuated, eliminating the need for exposed wires or movable contacts.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a wired connection is used between the second handle and the trigger switch, then the tool can operate with two-hand control, but the wiring becomes complex and impractical for movable or removable handles

Engineering Contradiction:

Improvetwo-hand control reliabilityVSAvoidwiring complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces the mechanical wired connection system with a wireless communication system. The second handle includes a wireless transmitter that communicates with the tool body via wireless signals, eliminating the need for physical wires, movable contacts, or exposed wiring. This substitution resolves the contradiction by maintaining reliable two-hand control while removing the complexity of wiring arrangements.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Adaptability or versatility

If movable or removable second handles are used, then the tool offers flexibility, but traditional wired connections become impractical

Engineering Contradiction:

Improvehandle flexibilityVSAvoidwiring implementation difficulty

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The wireless communication system replaces the mechanical wiring system, allowing movable and removable handles to function without complex wiring. The wireless transmitter in the second handle communicates with the tool body through wireless signals, making the system adaptable to various handle configurations while eliminating the manufacturing difficulty of implementing wiring in movable or removable components.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of operation

If exposed wires or movable electric contacts are used for the second handle, then the tool can provide two-hand operation, but the arrangement becomes complicated and less reliable

Engineering Contradiction:

Improvetwo-hand operation capabilityVSAvoidconnection reliability

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent replaces exposed wires and movable electric contacts with a wireless communication system. The wireless transmitter in the second handle sends signals to the tool body without requiring physical electrical connections, thereby maintaining two-hand operation capability while significantly improving connection reliability by eliminating vulnerable wired components.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS11919141B2Tool with wireless switch

Publication Date: 2024.03.05 INGERSOLL RAND IND US INC

AI summary

An electric tool is provided with a second switch that is actuated in order for the tool to be used. The second switch is on a second handle that is grasped by the operator with a different hand than the hand that actuates the main trigger switch. Communication between the second switch and the tool occurs with a wireless signal indicating that the second switch has been actuated.