Hand-Held Battery Pack and Motor Layout for 3000 W Power
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Solution Overview
Problem
Existing battery-powered devices face challenges in increasing power output while maintaining a compact, hand-held form factor, managing high current and heat generation, and adhering to shipping regulations, particularly with lithium-based cells.
Innovation Solution
The solution involves a battery pack with up to 20 cells connected in series, a brushless DC motor, and control electronics to manage high power and current, along with a switch mechanism to adjust voltage and power capacity, and a modular motor controller to optimize power transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the number of battery cells is increased to increase deliverable power, then power output is improved, but size and weight of the battery power source increase
Solution Approach 1:
The battery power source is divided into multiple individual battery cells (up to 20 cells) that can be connected in series and/or parallel configurations. This segmentation allows the system to achieve high power output (3000W or more) by combining multiple smaller units, each contributing to the total power while maintaining manageable individual sizes and weights.
2Power
If the cell form factor is increased to reduce impedance and increase available power, then power output is improved, but size and weight of the battery power source increase
Solution Approach 1:
The patent utilizes cells with optimized form factors and impedance characteristics. By carefully selecting and configuring cells with specific electrical parameters (impedance, capacity, voltage), the system achieves low overall impedance and high available power without requiring excessively large individual cell sizes, thus maintaining a compact battery pack volume.
3Power
If high voltage is used to increase power output, then power output is improved, but arcing occurs when the battery pack is disconnected
Solution Approach 1:
The patent incorporates diodes as intermediary components in the battery pack circuitry. These diodes are strategically placed to control current flow during disconnection events, preventing arcing by providing a controlled path for current dissipation and isolating high voltage sections from potential arcing points.
4Power
If increased voltage and power are used, then power output is improved, but control components and switches are damaged upon start-up
Solution Approach 1:
The patent implements preliminary protective measures including current limiting circuitry and controlled start-up sequences. Before full power is delivered, the system gradually increases current flow and activates protection circuits that prevent sudden high current surges from damaging control components and switches, ensuring reliable operation during start-up.
5Power
If motor size is increased to maximize power output, then power output is improved, but the device size exceeds hand-held limitations
Solution Approach 1:
The patent employs a high-efficiency brushless DC motor with optimized magnetic circuit design and winding configurations. By improving the motor's power density through advanced electromagnetic design rather than simply increasing physical size, the system achieves 3000W or more output while maintaining a compact form factor suitable for hand-held devices.
6Power
If high current is discharged to achieve sustained power output, then power output is improved, but heat generation increases requiring additional cooling structures
Solution Approach 1:
The patent replaces traditional mechanical cooling systems with thermally conductive material pathways integrated into the battery pack structure. Heat generated during high current discharge is conducted through thermally conductive materials to heat dissipation surfaces, eliminating the need for complex mechanical cooling structures while maintaining effective thermal management.
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 achieves high power output (up to 3000 W) with reduced impedance and heat management, fitting within hand-held device constraints and complying with shipping regulations.
Implementation Method 1
a battery pack with up to 20 cells connected in series
Implementation Method 2
a brushless DC motor
Implementation Method 3
the increased power for sustained durations requires relatively-high current which generates heat
Implementation Method 4
reduced impedance and heat management
Data Source
AI summary
An electrical combination, a tool system, an electric motor, a battery pack, and operating and manufacturing methods. The tool may include a tool housing, a motor supported by the tool housing, the motor having a nominal outer diameter of up to about 80 millimeters (mm), the motor being operable to output at least about 2760 watts (W), and a tool terminal electrically connected to the motor; a battery pack including a pack housing defining a volume of the battery pack, the volume being up to about 5.2×106 cubic millimeters (mm3), battery cells supported by the pack housing, the battery cells being electrically connected and having a nominal voltage of up to about 80 volts (V), and a pack terminal electrically connectable to the tool terminal to transfer current between the battery pack and the tool; and a controller operable to control the transfer of current.