Hybrid Supercapacitor Power Switching for Low-Voltage Power Tools

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing power tools often face inefficiencies in power management, particularly when primary power sources like battery cells experience low voltage, leading to inconsistent performance and limited functionality, especially when integrated with wireless communication devices.

Innovation Solution

Implementing a hybrid supercapacitor system that switches power sources based on voltage thresholds, using a controller to connect or disconnect the hybrid supercapacitor to ensure stable power delivery, and incorporating a recharge circuit to maintain power levels.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Duration of action of moving object

If a primary power source (battery cells) is used to power the device, then the device can operate for extended periods, but the voltage becomes inconsistent and performance degrades when voltage drops below threshold

Engineering Contradiction:

Improveoperational durationVSAvoidvoltage stability

Core Design Contradiction:

Duration of action of moving objectVSReliability

Solution Approach 1:

The patent combines a primary power source (battery cells) with a secondary power source (supercapacitor) into a hybrid power system. The controller monitors voltage levels and automatically switches between power sources, merging their advantages to provide both extended operational duration and stable voltage output.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The controller acts as an intermediary between the primary power source, secondary power source, and the device. It continuously monitors voltage levels and manages power flow, switching to the secondary power source when voltage drops below a threshold to maintain stable operation.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If a hybrid supercapacitor system is added to manage power switching, then voltage stability is improved, but device complexity increases

Engineering Contradiction:

Improvevoltage stabilityVSAvoidpower management system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The hybrid power system is designed to be self-regulating. The controller automatically monitors voltage levels and switches between power sources based on pre-set thresholds, eliminating the need for manual intervention and reducing the operational complexity for the user.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system uses voltage threshold parameters to trigger automatic switching between power sources. By monitoring and responding to voltage parameter changes, the system maintains stability without requiring complex control algorithms or user intervention.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If the primary power source is disconnected when voltage is low, then device performance is maintained, but power supply continuity is interrupted

Engineering Contradiction:

Improveperformance consistencyVSAvoidcontinuous operation time

Core Design Contradiction:

ReliabilityVSDuration of action of moving object

Solution Approach 1:

The hybrid power system ensures continuous useful action by automatically switching to the secondary power source when the primary power source voltage drops below a threshold. This seamless transition maintains continuous operation without interruption or performance degradation.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The secondary power source acts as a pre-prepared backup that is activated before the primary power source is completely depleted. This beforehand cushioning ensures that the device continues operating without interruption when voltage drops occur.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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 hybrid supercapacitor system provides consistent power to power tools and wireless communication devices, enhancing operational reliability and extending battery life by managing power distribution efficiently.

Implementation Method 1

a hybrid supercapacitor configured to provide power to the controller when the voltage of the battery cells is below a threshold voltage

Methodology Applied

Scientific EffectCapacitance: Capacitance

Data Source

PatentUS20250364824A1Hybrid supercapacitors in power tool devices

Publication Date: 2025.11.27 MILWAUKEE ELECTRIC TOOL CORP

AI summary

Systems and methods for implementing a hybrid supercapacitor within power tool devices. One device includes a primary power source, a hybrid supercapacitor, and a controller. The controller is selectively coupled to the primary power source and the hybrid supercapacitor. The controller is configured to receive power from the primary power source and to determine a voltage of the primary power source. The controller is configured to determine whether the voltage of the primary power source is less than or equal to a voltage threshold and connect, in response to the voltage of the primary power source being less than or equal to the voltage threshold, the hybrid supercapacitor to the controller.