Modular Battery Pack Charging With Authenticated Power Distribution
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Solution Overview
Problem
Existing battery charging systems lack flexibility and efficiency in accommodating different types of rechargeable power tool battery packs, particularly in managing power distribution and authentication of charging modules and power supplies.
Innovation Solution
A modular charging system with a housing featuring multiple ports and a power bus that can accommodate various charging modules and power supplies, equipped with controllers for power management and authentication, and communication capabilities for status monitoring and external device interaction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed charging system is used, then the structure is simple, but it lacks flexibility in accommodating different types of battery packs
Solution Approach 1:
The charging system is divided into modular components: a power supply unit, multiple charging modules (each capable of charging different battery types), and a control unit. This segmentation allows the system to accommodate various battery packs by simply changing or reconfiguring the charging modules without redesigning the entire system, thus improving adaptability while managing complexity through modular architecture.
Solution Approach 2:
The charging modules are designed with universal interfaces and control logic that can handle multiple battery pack types (different voltages, capacities, and chemistries). The control unit communicates with various battery packs using standardized protocols, enabling a single charging module to serve multiple functions and different battery types, thereby enhancing versatility without proportionally increasing system complexity.
2Reliability
If power is supplied without authentication, then charging speed is fast, but safety and reliability are compromised
Solution Approach 1:
The control unit performs authentication of the battery pack and charging module compatibility before initiating power supply. This preliminary action includes verifying battery type, voltage rating, and communication protocol compatibility. By completing authentication beforehand, the system ensures safe and reliable power distribution while minimizing charging delays, as the verification process is streamlined and automated.
Solution Approach 2:
The control unit continuously monitors charging parameters (current, voltage, temperature) and communicates with the battery pack to detect its state and requirements. This feedback mechanism allows the system to adjust power delivery in real-time, ensuring safety and reliability while optimizing charging speed. The ongoing communication also provides user feedback on charging status and compatibility, enhancing overall system reliability.
3Productivity
If multiple battery packs are charged simultaneously, then productivity is improved, but power management complexity increases
Solution Approach 1:
The system uses multiple independent charging modules, each capable of charging one or more battery packs simultaneously. Each module has its own power management and control circuitry, which segments the overall power management task into smaller, manageable units. This modular approach enables parallel charging of multiple battery packs while keeping the complexity of each individual module manageable through standardized designs.
Solution Approach 2:
Multiple charging modules are integrated into a single system with a centralized control unit that coordinates power distribution across all modules. The control unit merges the individual module operations into a unified power management strategy, optimizing total system throughput while simplifying user interaction through a single interface. This combining approach allows simultaneous charging of multiple battery packs while managing overall power consumption and heat dissipation efficiently.
Data Source
AI summary
A system for charging a rechargeable power tool battery pack. The system includes a housing having a first port, a second port, and a power bus. The first port is configured to receive at least one selected from a power supply and a charging module. The second port is configured to receive the other of the at least one selected from the power supply and the charging module. Wherein the power supply is configured to supply a charging voltage, and wherein the charging module includes a battery receptacle configured to receive the rechargeable power tool battery pack, the rechargeable power tool battery pack having a first battery characteristic. The power bus is within the housing. The power bus is configured to provide an electrical connection between the first port and the second port and distribute the charging voltage.