Battery Pack Power Segmentation for Stable Tool Signal Control
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Solution Overview
Problem
Suction force cleaning systems face issues with debris scattering on hard surfaces due to high-speed brush operation, leading to inefficient cleaning and potential battery pack power management challenges, including high current surges that can disrupt digital signal interpretation.
Innovation Solution
A battery pack design with a low current power supply and a controller to manage power distribution, allowing continuous low current power to the cleaning system, enabling the microcontroller to differentiate logic signals even during high current usage, and a power tool configuration with separate high and low current terminals to optimize motor operation and user interface functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the battery pack provides power only when the three-position switch is in an ON state, then power consumption is reduced, but additional functionality is lost when the switch is in an OFF state
Solution Approach 1:
The patent segments the power supply into two separate circuits: a high-current power circuit that operates only when the switch is ON, and a low-current power circuit that operates continuously even when the switch is OFF. This segmentation allows the microcontroller to remain powered and functional in standby mode without consuming significant battery power, thereby providing additional functionality (such as status monitoring, wireless communication, or quick restart capability) while maintaining energy efficiency.
2Power
If high current is supplied from the battery pack to the cleaning system, then motor power is sufficient, but the microcontroller has difficulty deciphering digital signals
Solution Approach 1:
The patent separates the high-current power delivery path from the low-current signal communication path. The high-current circuit powers the motor through the switch, while the low-current circuit continuously powers the microcontroller and its digital communication interfaces. This segmentation ensures that motor operation does not interfere with signal integrity, as the microcontroller maintains a stable low-current power supply independent of the high-current motor circuit.
Solution Approach 2:
The patent introduces a low-current power circuit as an intermediary that bridges the battery pack and the microcontroller. This intermediary circuit acts as a buffer, providing a stable, filtered power supply to the microcontroller that is isolated from the high-current motor circuit. The low-current circuit includes voltage regulation and noise filtering components that prevent high-current transients from corrupting digital signals, thereby maintaining reliable communication even during motor operation.
Data Source
AI summary
A battery pack, power tool, and power tool combination. The battery pack includes one or more battery cells, a first terminal electrically connected to the one or more battery cells, a high current power supply terminal, a power switch electrically connected between the one or more battery cells and the high current power supply terminal, and a low current power supply terminal electrically connected to the one or more battery cells. The first terminal and low current power supply terminal are operable to provide a substantially continuous low current to the power tool during a normal operating state of the battery pack. The battery pack also includes a controller operable to control the power switch to provide high current power through the high current power supply terminal in response to a call for power from the power tool.