Bidirectional DC-DC Adapter for Battery Pack and USB Power Matching
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Solution Overview
Problem
Existing power conversion solutions for cordless power tools lack efficient and versatile adapters that can effectively convert power between battery packs, chargers, and electric devices, particularly in outdoor scenarios where power supply networks are not available.
Innovation Solution
A bidirectional DC-DC conversion adapter with a housing, battery pack port, device port, protocol matching module, and power switching elements, capable of adjusting energy transmission direction and magnitude, and energy storage elements to ensure reliable power conversion and charging across various voltage ranges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a bidirectional DC-DC conversion module with power switching elements is used to enable flexible power transmission between battery pack and device, then the adaptability and power conversion capability are improved, but the device complexity increases
Solution Approach 1:
The adapter incorporates a bidirectional DC-DC conversion module that can operate in multiple modes: charging the battery pack from a charger, powering electric devices from the battery pack, and bidirectional power flow. This multi-functional design allows a single device to replace multiple separate power conversion solutions, improving adaptability while managing complexity through integration
Solution Approach 2:
The power switching elements (MOS tubes Q1-Q4) are dynamically controlled by the control unit to adjust the transmission direction and magnitude of electrical energy. The switching elements can be turned on or off based on the operational mode, enabling flexible power conversion between different voltage levels and directions without requiring multiple static circuit configurations
2Reliability
If energy storage elements are added to ensure reliable power conversion and stable voltage output, then the reliability is improved, but the volume of the adapter increases
Solution Approach 1:
The adapter incorporates energy storage elements (capacitors C1-C6 and inductors L1-L2) that are carefully selected with specific capacitance and inductance values to provide voltage stabilization and power conversion reliability. These components are optimized to achieve the required stability with minimal volume, balancing reliability improvement against size constraints
3Productivity
If the adapter is designed with high power output capability (45-600W) for versatile power supply, then the productivity is improved, but the power-to-volume ratio becomes a critical constraint
Solution Approach 1:
The adapter is designed to operate across a wide power range (45-600W) by dynamically adjusting the duty cycle of the PWM controller and the switching frequency of the MOS tubes. This allows the adapter to deliver high power when needed while maintaining a compact form factor, effectively managing the power-to-volume ratio through parameter optimization rather than physical size scaling
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 adapter provides efficient power conversion and charging capabilities, achieving a high power-to-volume ratio, reduced noise, and improved stability, enabling effective use of cordless power tools in outdoor scenarios with a compact and efficient design.
Implementation Method 1
a bidirectional DC-DC conversion module capable of converting electrical energy outputted by the battery pack into direct current power supply electrical energy or converting electrical energy from the charging apparatus into direct current charging electrical energy
Implementation Method 2
a power switching element disposed on the power transmission loop between the battery pack port and the device port and capable of adjusting the transmission direction and/or magnitude of electrical energy in the power transmission loop
Implementation Method 3
a first energy storage element disposed on the first transmission path and capable of storing electrical energy during electrical energy transmission and discharging the electrical energy when the electrical energy transmission is interrupted
Data Source
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AI summary
Provided is an adapter. The adapter includes: a housing; a battery pack port including at least a positive terminal and a negative terminal for accessing a battery pack; a device port including multiple USB-type ports capable of accessing an electric device or a charging apparatus; a protocol matching module configured to perform a protocol handshake with the electric device or the charging apparatus accessed by the device port; and a bidirectional DC-DC conversion module capable of converting electrical energy outputted by the battery pack into direct current power supply electrical energy or converting electrical energy from the charging apparatus into direct current charging electrical energy. The bidirectional DC-DC conversion module includes: a power switching element disposed on the power transmission loop between the battery pack port and the device port and capable of adjusting the transmission direction and/or magnitude of electrical energy in the power transmission loop; and a power control unit electrically connected to at least the power switching element and capable of controlling the conducting state of the power switching element.