Dynamic Battery Charging for Power Tools
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Solution Overview
Problem
Lithium-ion battery charging is hindered by low temperatures, leading to reduced performance, shortened service life, and safety risks due to lithium metal crystal deposition, while high temperatures can damage the battery and cause accidents, necessitating a method to optimize charging speed and safety.
Innovation Solution
A dynamic battery charging method that adjusts charge current based on temperature and remaining power, employing three charging processes: pulsed charging/discharging at low temperatures, adjusting discharge amounts, and maintaining or reducing charge current according to temperature trends, with active cooling to manage battery temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If battery capacity is increased to meet power tool demands, then battery energy storage is improved, but battery charge time becomes longer
Solution Approach 1:
The charging system dynamically adjusts the charge current based on real-time battery temperature and remaining power levels. The controller switches between different charging modes (first, second, and third charging processes) to optimize charging speed while ensuring battery safety, thereby reducing overall charge time for high-capacity batteries.
Solution Approach 2:
The system changes charging parameters (charge current magnitude, charging mode) based on battery state. By adjusting these parameters dynamically, the system achieves faster charging speeds without compromising battery safety, resolving the contradiction between battery capacity and charge time.
2Productivity
If charge current is increased to speed up charging, then charging speed is improved, but battery temperature rises causing safety risks
Solution Approach 1:
The system continuously monitors battery temperature and remaining power, using this feedback to adjust the charge current in real-time. When temperature approaches unsafe levels or battery is nearly full, the system automatically reduces or stops charging, preventing thermal runaway while maintaining optimal charging speed during safe operating conditions.
Solution Approach 2:
The charging system dynamically adapts the charge current based on real-time temperature conditions. The controller switches between different charging processes (first, second, third) with different current characteristics, enabling fast charging when safe and preventing overheating when temperature rises.
3Ease of operation
If charging is performed at low temperature to meet user demand, then charging availability is improved, but lithium metal crystals deposit causing safety problems
Solution Approach 1:
The system uses pulsed charging and discharging in the first charging process to convert the harmful low-temperature condition into a beneficial effect. The periodic discharge phases help prevent lithium metal crystal deposition by allowing ion redistribution, thus enabling safe charging at low temperatures while maintaining charging availability.
Solution Approach 2:
The system employs periodic pulsed charging and discharging cycles during first charging process. This periodic action prevents continuous ion accumulation that would cause lithium metal crystal deposition, allowing safe charging at low temperatures while maintaining charging availability.
4Reliability
If pulsed charging and discharging are used at low temperature, then safety is improved, but charging efficiency is reduced
Solution Approach 1:
The system dynamically switches between different charging processes based on battery temperature and state of charge. The first charging process (pulsed charging/discharging) is used only when necessary for safety, while the second and third processes provide faster charging when conditions permit, thus balancing safety and efficiency.
Solution Approach 2:
The charging process is segmented into three distinct modes (first, second, third charging processes) with different characteristics. This segmentation allows the system to apply the most appropriate charging method for each battery state, minimizing the use of less efficient pulsed charging while ensuring safety when required.
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 method increases charge speed, improves battery life, reduces waiting time, and enhances safety by dynamically adjusting charge current and discharge amounts based on temperature and power levels, preventing overheating and lithium metal crystal deposition.
Implementation Method 1
detecting a battery temperature and/or a battery remaining power
Implementation Method 2
the battery may be cooled while being charged in the third charging process
Implementation Method 3
A charging and discharging process of a lithium-ion battery is essentially a process in which lithium ions transfer between a positive electrode and a negative electrode
Implementation Method 4
Heat generated by a current in the battery during charging increases the battery temperature
Data Source
AI summary
A battery charging method includes detecting a battery temperature and a battery power, determining whether the battery temperature satisfies a preset temperature condition for switching charging processes, performing a first charging process by alternating pulsed charging and discharging when the battery temperature is less than or equal to a first preset temperature value, performing a second charging process including a charge current dynamically adjusted according to the battery temperature and the battery power when the battery temperature is greater than the first preset temperature value and less than a second preset temperature value, and determining whether the battery power is less than a first preset power value when the battery temperature is equal to or greater than the second preset temperature value and less than a third preset temperature value, and performing a third charging process when the battery power is less than the first preset power value.