Three-Dimensional Coding for Battery Pack Assignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing battery pack systems for hand-held power tools lack a secure and tamper-proof mechanism to prevent incorrect assignment of battery packs, as they rely on mechanical coding systems that only ensure dimensional matching, not spatial arrangement, leading to potential damage or improper usage.
Innovation Solution
A three-dimensional coding system is implemented, where coding means are arranged relative to three axes (insertion direction, two transverse axes) to ensure exact dimensional and spatial matching, preventing incorrect battery pack assignment by requiring corresponding counter-coding on both the battery pack and the power tool.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a mechanical coding system with only dimensional matching is used, then the battery pack can be easily manufactured and connected, but it cannot reliably prevent incorrect assignment of battery packs to electrical devices
Solution Approach 1:
The patent transitions from two-dimensional coding (only dimensional matching in planar view) to three-dimensional coding by adding depth information through coding means extending in the insertion direction. This includes coding means on the battery pack side and corresponding counter-coding means on the electrical device side, where at least one coding means extends in the insertion direction to create depth-based coding. This third dimension (depth/height) significantly increases the number of possible coding combinations, making it much harder to create incorrect assignments while maintaining mechanical simplicity.
2Reliability
If a three-dimensional coding system is implemented, then the reliability of preventing incorrect battery pack assignment is significantly improved, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The coding system is segmented into separate coding means on the battery pack and corresponding counter-coding means on the electrical device. The coding means can be divided into multiple independent elements (such as protrusions, recesses, or coded features) that can be manufactured separately and then assembled. This segmentation allows for easier manufacturing compared to creating a single complex integrated coding structure, as each coding element can be produced using standard manufacturing processes and then combined during assembly.
Solution Approach 2:
The coding means serve multiple functions: they provide mechanical coding for identification, guide the insertion direction, and can also serve as structural support elements or integration points for other battery pack components. By making the coding means multi-functional, the patent reduces the need for separate dedicated coding components, thereby simplifying manufacturing while maintaining the three-dimensional coding capability.
3Ease of operation
If only two-dimensional coding is used, then the coding system is simple to implement, but it allows for easier tampering and incorrect battery pack assignment
Solution Approach 1:
By adding the third dimension (depth/height) to the coding system through coding means that extend in the insertion direction, the patent creates a more complex coding space that is much harder to tamper with. The three-dimensional arrangement of coding means requires precise alignment in three directions rather than just two, making it significantly more difficult for users to incorrectly assign battery packs or attempt tampering. This enhanced complexity directly reduces the risk of harmful factors while maintaining ease of proper operation.
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The invention describes a battery pack for an electrical appliance, in particular for a handheld machine tool, having means (21, 22, 23, 24, 25, 26, 27, 28, 29) for mechanical coding for interaction with corresponding coding means on an electrical appliance, wherein the coding means (21, 22, 23, 24, 25, 26, 27, 28, 29) are arranged in relation to one another with respect to a first axis (1) in the insertion direction, a second axis (2) transverse to the insertion direction and a third axis (3) transverse to the insertion direction and transverse to the second axis (2) in such a way that they form a three-dimensional coding system (20).