Hand Tool Battery Bridge Rectifier Synchronous Charging
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Solution Overview
Problem
Hand tool batteries with existing charging systems experience high energy losses and heat generation during inductive charging, and there is a risk of battery discharge due to leakage currents, especially during no-load operations.
Innovation Solution
The implementation of a bridge rectifier with synchronous rectifying arrangements, such as MOSFETs, and additional diodes, along with a shut-off device that switches rectifying arrangements to a passive state during no-load operations, reduces energy consumption and heat generation by using body diodes for rectification and controlling rectifying arrangements with low-resistance control signals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a passive bridge rectifier with diodes is used for inductive charging, then the charging function is provided, but high energy losses and heat generation occur
Solution Approach 1:
The patent changes the operating parameters of the rectifying arrangements by switching between synchronous mode (during charging) and passive mode (during no-load operation). This parameter change optimizes energy efficiency by using low-resistance MOSFETs during active charging and minimizing power consumption during idle states, thereby reducing overall energy losses and heat generation.
Solution Approach 2:
The rectifying arrangements are made dynamic by implementing a shut-off device that can switch them between active and passive states. This dynamic adaptation allows the system to optimize performance based on operational conditions, reducing energy losses during no-load operation while maintaining efficient charging during active use.
2Reliability
If rectifying arrangements remain active during no-load operation, then charging readiness is maintained, but energy consumption increases and battery discharge occurs due to leakage currents
Solution Approach 1:
The system implements periodic switching of the rectifying arrangements between active and passive states based on operational needs. During no-load conditions, the shut-off device switches them to passive state to minimize energy consumption, while maintaining the capability to quickly resume charging when needed, thus balancing reliability with energy efficiency.
Solution Approach 2:
The patent extracts the essential charging function from the rectifying arrangements during no-load operation by switching them to passive state with body diodes providing sufficient rectification. This extraction removes the energy-consuming active control while retaining the basic protective and rectifying functionality, preventing battery discharge due to leakage currents.
3Productivity
If synchronous rectification with MOSFETs is implemented, then charging efficiency is improved, but device complexity increases
Solution Approach 1:
The patent merges the synchronous rectification functionality with the existing bridge rectifier structure by integrating MOSFETs into the conventional diode configuration. This combination maintains the proven bridge rectifier topology while enhancing it with synchronous rectification capabilities, achieving improved charging efficiency without completely redesigning the circuit architecture.
Solution Approach 2:
The control device serves as an intermediary that manages the complexity of synchronous rectification by coordinating the switching of MOSFETs based on operational conditions. This intermediary control layer simplifies the overall system management by providing a centralized control mechanism that handles the complexity of synchronous rectification without requiring complex distributed control across multiple components.
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
This configuration minimizes energy losses and heat generation, preventing battery discharge and allowing for efficient and rapid charging by maintaining low battery temperature, even during no-load conditions.
Implementation Method 1
A 'charging coil' is to be understood in particular as a coil which receives inductively transmitted energy during a charging process for charging battery cells of the hand tool battery. The charging coil may receive the energy from an inductive charging device
Implementation Method 2
The bridge rectifier has at least two rectifying arrangements for synchronous rectification. The rectifying arrangement may be configured as a transistor for synchronous rectification
Implementation Method 3
The rectifying arrangement is provided to conduct direct currents greater than 2 amperes, advantageously greater than 5 amperes, particularly advantageously greater than 10 amperes. This configuration minimizes energy losses and heat generation
Data Source
AI summary
A hand tool battery includes a charging coil and a bridge rectifier. The bridge rectifier has at least two rectifying arrangements for synchronous rectification.