Power Tool Battery Temperature Feedback for Dynamic Power Limiting

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Solution Overview

Problem

Power tools often exceed the thermal limits of battery packs, compromising their health and performance, leading to incomplete discharge and reduced capability.

Innovation Solution

A power tool system with a communication interface that allows continuous monitoring of battery pack temperature, adjusting power consumption based on temperature thresholds to maintain optimal operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If power tools push the limits of continuous power, then power output is improved, but thermal limits of battery packs are encountered more frequently

Engineering Contradiction:

Improvepower outputVSAvoidbattery pack temperature

Core Design Contradiction:

PowerVSTemperature

Solution Approach 1:

The system continuously monitors battery pack temperature and uses this feedback to dynamically adjust motor power consumption. The controller receives temperature data from the battery pack and modulates motor power accordingly, creating a closed-loop control system that prevents overheating while maximizing power utilization.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The motor power consumption is made dynamic rather than static. The system adjusts motor power levels in real-time based on battery temperature conditions, transitioning between different power states to optimize both power output and thermal management throughout battery discharge cycles.

Inventive Principle:

Principle #15Dynamics

2Productivity

If power tools operate at full power, then productivity is improved, but battery pack health is compromised due to thermal limits

Engineering Contradiction:

Improvecontinuous operation capabilityVSAvoidbattery pack health

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The system takes preliminary action by monitoring battery temperature early in the discharge cycle and proactively adjusting motor power before thermal damage occurs. This preventive approach allows the battery to discharge closer to its full capacity while maintaining health, extending both runtime and battery lifespan.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system changes operational parameters dynamically by adjusting motor power consumption based on real-time battery temperature measurements. This parameter modulation enables the system to operate at higher power levels when the battery is cool and reduce power when temperature rises, optimizing both productivity and battery health.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If the power tool limits power supply to the motor based on temperature, then battery pack health is improved, but power output is reduced

Engineering Contradiction:

Improvebattery pack healthVSAvoidmotor power output

Core Design Contradiction:

ReliabilityVSPower

Solution Approach 1:

The system implements periodic temperature monitoring and power adjustment cycles. Rather than continuously limiting power, the system checks battery temperature at intervals and adjusts motor power in periodic cycles, allowing full power output during safe temperature periods while providing thermal management when needed.

Inventive Principle:

Principle #19Periodic action

Data Source

PatentUS12620828B2Battery temperature based tool power reduction

Publication Date: 2026.05.05 TECHTRONIC CORDLESS GP

AI summary

A power tool may include a power tool housing. A power tool may include a drive unit located within the power tool housing. A power tool may include a power tool controller located within the power tool housing, the power tool controller configured to: receive a signal from battery pack, the signal indicative of a temperature of the battery pack, and do not limit a drive unit power if the temperature is less than a temperature threshold.