Hybrid Burst Power Circuit for Fastener Driver Shutdown Prevention
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Solution Overview
Problem
Battery-powered fastener drivers face challenges in providing sufficient burst power due to high current requirements, which can lead to voltage drops that cause the device to shut down, especially when using partially charged or high-resistance battery packs.
Innovation Solution
Incorporating a burst circuit with a supercapacitor and electronic processor to control power flow, allowing the supercapacitor to supply high current during burst operations while maintaining voltage for the processor and control circuitry, and using a combination of battery cells with different characteristics to optimize power delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a battery-powered fastener driver uses a standard battery pack to power the motor, then the device structure remains simple, but the battery cannot provide sufficient burst power during high-current operations, causing voltage drops and shutdowns
Solution Approach 1:
The patent combines a battery pack with a supercapacitor burst circuit into a hybrid power system. The battery provides sustained power while the supercapacitor delivers high-current bursts, merging two power sources to overcome the limitations of either alone. This resolves the contradiction by enabling sufficient burst power without compromising operational stability.
Solution Approach 2:
The supercapacitor acts as an intermediary between the battery and the motor. It absorbs power from the battery during low-demand periods and releases it during high-current bursts, mediating the power delivery to prevent voltage drops and protect the battery from excessive current demands.
2Power
If the fastener driver uses high current for burst operations, then the burst power is sufficient, but the voltage drop causes the processor and control circuitry to shut down
Solution Approach 1:
The patent segments the power delivery into two independent circuits: a high-current burst circuit for the motor and a low-voltage control circuit for the processor and control electronics. This segmentation allows the motor to receive high current bursts without affecting the voltage stability of the control circuit, preventing shutdowns and loss of control signals.
Solution Approach 2:
The supercapacitor serves as an intermediary that isolates the high-current motor circuit from the low-voltage control circuit. It handles the current surges independently, preventing voltage drops from propagating to the control electronics and causing interruptions.
3Power
If the battery pack uses cells with different characteristics, then the power delivery is optimized, but the battery pack design becomes more complex
Solution Approach 1:
The patent applies local quality by using battery cells with different characteristics (e.g., different capacities or discharge rates) in specific positions within the battery pack. This allows optimization of power delivery for different operational demands while maintaining a manageable overall design through structured arrangement of the heterogeneous cells.
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
Enables reliable and efficient burst operations by ensuring sufficient current and voltage are maintained during high-demand tasks, extending the operational life of the device and improving its performance with various battery conditions.
Implementation Method 1
a burst circuit with a supercapacitor for providing power to a motor of the fastener driver
Implementation Method 2
battery cells coupled by laser welding conductive straps to terminals of the battery cells
Data Source
AI summary
A system, an electrical combination and a method for powering a load device. The combination may include a burst circuit configured to provide power to the load device to perform a burst operation, the burst circuit including a supercapacitor, a first switch between a power source and the supercapacitor and operable to control whether power is provided from the power source to charge the supercapacitor, and a second switch between the supercapacitor and the load device and operable to control whether power is provided from the supercapacitor to the load device; and an electronic processor configured to control the first switch and the second switch based at least in part on a voltage of the supercapacitor.