Auxiliary Energy Circuit With Ultra-Capacitor for Power Tool Peak Loads
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Solution Overview
Problem
Battery-powered power tools often require significant power that exceeds the capacity of the battery pack, leading to rapid drainage and potential shutdown, especially when executing demanding tasks.
Innovation Solution
An auxiliary energy circuit, incorporating an ultra-capacitor, is integrated within the power tool housing or battery pack, which supplements power by selectively connecting in series with the battery pack to provide additional energy based on operational characteristics such as motor current, speed, or trigger pull, thereby reducing the power burden on the battery pack.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If power tools use battery packs as the sole power source, then portability and convenience are improved, but power capacity and operational duration deteriorate during high-power tasks
Solution Approach 1:
The patent combines a battery pack and an ultra-capacitor into a hybrid power system. The ultra-capacitor is electrically connected in parallel with the battery pack, creating a dual-power-source configuration that merges the high energy density of batteries with the high power density of ultra-capacitors, thereby resolving the contradiction between portability and power capacity.
Solution Approach 2:
The power system is designed to serve multiple functions: the battery pack provides sustained energy for general operation, while the ultra-capacitor delivers bursts of high power during demanding tasks and can also recover energy during regenerative braking. This multi-functional design allows the system to adapt to varying power requirements without sacrificing portability.
2Use of energy by moving object
If battery packs are sized to provide sufficient power for high-power tasks, then power capacity is improved, but weight and volume increase
Solution Approach 1:
By merging a smaller battery pack with a lightweight ultra-capacitor, the system achieves high power capacity without requiring a single large battery. The ultra-capacitor's ability to deliver high instantaneous power allows the battery to be downsized, reducing overall weight while maintaining the capability to handle high-power tasks.
Solution Approach 2:
Instead of relying on the battery to provide excessive power for all tasks, the system uses partial action from the battery for sustained energy needs and supplements with the ultra-capacitor only when high power bursts are required. This selective power delivery optimizes the weight-to-power ratio.
3Device complexity
If the power tool relies solely on battery power, then device simplicity is maintained, but operational reliability deteriorates during high-power demands
Solution Approach 1:
The patent integrates an ultra-capacitor module with the existing battery pack architecture, creating a unified power system with shared control circuitry and coordination logic. This merging approach enhances reliability during high-power demands while minimizing the increase in overall system complexity through standardized integration protocols.
Solution Approach 2:
The control system continuously monitors the state of charge and power output of both the battery pack and ultra-capacitor, dynamically adjusting their contribution based on real-time power requirements. This feedback mechanism ensures reliable operation during high-power tasks while maintaining simple, automated control without requiring complex user intervention.
4Use of energy by moving object
If an auxiliary ultra-capacitor is added to supplement power, then power capacity and operational duration are improved, but device complexity increases
Solution Approach 1:
The ultra-capacitor is merged into the existing battery pack assembly as an integrated module, sharing common structural support, electrical connections, and control systems. This integration approach adds power capacity while minimizing the increase in device complexity by reusing existing architectural elements rather than adding completely separate subsystems.
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 auxiliary energy circuit enables the power tool to sustain operation during high-power tasks by providing supplementary power, extending battery life and preventing shutdowns.
Implementation Method 1
the auxiliary power source includes an ultra-capacitor
Implementation Method 2
the auxiliary power source is configured to receive charging energy from regenerative braking during operation of the power tool
Data Source
AI summary
A power tool comprising a power tool housing, an auxiliary power source, a user input for user control of power tool operation, and a controller. The controller is configured to receive a control signal from the user input, control the power tool in response to the control signal, receive, from a sensor, a signal indicative of an operational characteristic of the power tool, and selectively provide energy from the auxiliary power source to a load of the power tool based on the operational characteristic of the power tool.