Cordless Tool Step-Up Converter for Brownout Prevention
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Solution Overview
Problem
Power tools experience unexpected shutdowns and internal component damage due to voltage drops during high current loads, which current solutions like using high voltage batteries or reducing current load are impractical and costly.
Innovation Solution
Implementing a step-up converter in power tools to maintain voltage above a threshold, preventing brownout conditions by boosting voltage when necessary, thus allowing tools to operate at higher loads without shutdown.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If current load is decreased to prevent voltage drop, then voltage stability is improved, but tool power and performance deteriorate
Solution Approach 1:
The patent changes the voltage parameter by using a step-up converter to boost the battery voltage to a higher level (e.g., from 18V to 36V) before delivering it to the motor and electronic components. This allows the system to maintain stable voltage delivery while enabling higher power operation, as the boosted voltage can support higher current loads without dropping below the minimum operating threshold.
2Reliability
If high voltage battery is used to prevent voltage drop, then voltage stability is improved, but device complexity and cost increase
Solution Approach 1:
Rather than changing the battery voltage parameter directly (which would require higher voltage batteries), the patent uses a step-up converter to dynamically transform the voltage parameter. This approach maintains compatibility with standard voltage batteries while achieving stable voltage delivery, avoiding the complexity of redesigning the entire power system for higher voltages.
Solution Approach 2:
The step-up converter acts as an intermediary device between the battery and the motor/electronic components. It mediates the voltage mismatch by boosting the battery voltage to the required level, preventing brownout conditions without requiring changes to the battery or the load components.
3Device complexity
If standard voltage battery is used, then device complexity is reduced, but voltage stability under high load deteriorates
Solution Approach 1:
The step-up converter serves as an intermediary that protects the standard voltage battery system from voltage drop issues. It monitors the output voltage and activates voltage boosting when the voltage approaches the brownout threshold, thereby maintaining voltage stability under high load while keeping the battery system simple and cost-effective.
4Reliability
If step-up/step-down converter is used to manage voltage, then voltage stability is improved, but device size and cost increase
Solution Approach 1:
The patent extracts only the necessary voltage boosting function from a full step-up/step-down converter. By using a dedicated step-up converter that only increases voltage rather than providing both step-up and step-down capabilities, the design reduces component size, complexity, and cost while still effectively preventing brownout conditions in power tools that operate primarily at boosted voltage levels.
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 step-up converter effectively prevents unintentional shutdowns and component damage by maintaining voltage above the minimum operating level, enhancing tool performance and reducing size and cost compared to step-up/step-down converters.
Implementation Method 1
a step-up converter, that are housed or disposed in a housing of the tool. The step-up converter is adapted to prevent the voltage to be passed to a component or integrated circuit (IC) from dropping below a threshold voltage value
Data Source
AI summary
A motorized hand tool, such as a cordless ratchet wrench, that has a motor, one or more electronic components and/or integrated circuits, and a step-up converter that are housed or disposed in a housing of the tool. The step-up converter is adapted to prevent a voltage of a battery of the tool from dropping below a threshold voltage of a component or integrated circuit when current draw from the battery increases, thus preventing a “brownout” condition.