Modular Battery Pack Charging for Mixed Power Tool Loads
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Solution Overview
Problem
Existing portable power supplies lack flexibility in charging multiple battery packs with varying power ratings simultaneously, requiring multiple charging ports and limited customization for different battery pack characteristics.
Innovation Solution
A portable power supply system with modular charging blocks that can be added to a base module, featuring a controller to determine battery pack characteristics and provide appropriate charging currents, including integrated fans for cooling, allowing for simultaneous charging of multiple battery packs with different power ratings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple charging ports are added to charge different battery packs simultaneously, then charging versatility is improved, but device complexity increases
Solution Approach 1:
The charging system is divided into modular charging blocks, each designed to charge specific battery pack types. Users can select and attach only the charging blocks needed for their specific charging needs, rather than having all charging capabilities built into the base unit. This segmentation reduces the complexity of the base device while maintaining versatility through modular additions.
Solution Approach 2:
The base charging unit is designed with universal compatibility to work with multiple types of battery packs through the modular charging blocks. The controller can identify and adapt to different battery pack characteristics (capacity, voltage, charging current requirements) automatically, providing a universal charging solution that doesn't require separate dedicated chargers for each battery type.
2Adaptability or versatility
If modular charging blocks are added to accommodate different battery pack characteristics, then charging adaptability is improved, but manufacturing complexity increases
Solution Approach 1:
The charging system is divided into modular charging blocks, each designed to charge specific battery pack types. Users can select and attach only the charging blocks needed for their specific charging needs, rather than having all charging capabilities built into the base unit. This segmentation reduces the complexity of the base device while maintaining versatility through modular additions.
Solution Approach 2:
The controller automatically detects battery pack parameters (capacity, voltage, charging current requirements) and adjusts charging parameters dynamically. This allows a single modular charging block to adapt to different battery characteristics through software control rather than requiring hardware variations for each battery type, simplifying manufacturing.
3Productivity
If the controller automatically determines battery characteristics and adjusts charging current, then charging efficiency is improved, but control complexity increases
Solution Approach 1:
The controller automatically identifies battery pack characteristics and configures optimal charging parameters without user intervention. The system self-adjusts charging current based on detected battery capacity and type, eliminating the need for manual settings or complex user interfaces while maintaining high charging efficiency through automated optimization.
Solution Approach 2:
The controller continuously monitors charging progress and battery parameters, using feedback to dynamically adjust charging current. This closed-loop control optimizes charging efficiency by preventing overcharging and adapting to battery state changes, while the automation keeps control complexity manageable through algorithmic decision-making rather than manual intervention.
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 flexible and efficient charging of various battery packs with different power ratings simultaneously, enhancing convenience and adaptability in charging multiple devices at once.
Implementation Method 1
The controller is further configured to enable a fan configured to cool the first charging port, wherein the fan is integrated into the first modular charger block
Data Source
AI summary
A portable power supply for charging power tool battery packs. The portable power supply includes a battery core including a plurality of battery cells and a converter, a first modular charger block received in a first charging slot and connected to a first charging port, a second modular charger block received in a second charging slot and connected to a second charging port and a third charging port, and a controller including an electronic processor. The controller is configured to determine that a first battery pack is received by the first charging port, determine that a device is received by the second charging port, determine a first characteristic of the first battery pack, and provide a first current to the first battery pack based on the first characteristic and a second current to the second battery pack based on the device being received by the second charging port.