Modular Battery Pack Charging With Power Bus Load Balancing
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Solution Overview
Problem
Existing battery charging systems for power tools lack modularity and efficiency in managing different battery characteristics and power supply ratings, leading to potential voltage drops and inefficient charging.
Innovation Solution
A modular battery charging system with a housing featuring multiple ports and a power bus that can receive both power supplies and charging modules, with integrated controllers for authentication and power distribution, ensuring optimal charging based on the rating of the charging module and battery characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a traditional non-modular charging system is used, then the system structure is simple, but it cannot efficiently manage different battery characteristics and power supply ratings
Solution Approach 1:
The charging system is divided into modular components: power supply units with different ratings (e.g., 120V, 240V inputs) and charging modules with different output capabilities. Each module can be independently selected and combined, allowing the system to adapt to various battery characteristics while maintaining a manageable overall structure through standardized interfaces and protocols.
2Productivity
If a traditional charging system is used, then the device complexity is low, but voltage drops occur and charging efficiency is reduced
Solution Approach 1:
The controller continuously monitors charging parameters including voltage, current, and temperature, and adjusts power delivery in real-time based on feedback from the battery pack. This active control prevents voltage drops, optimizes charging speed, and extends battery life, thereby improving charging efficiency through a moderately complex control system.
3Productivity
If multiple battery packs with varying characteristics are charged simultaneously, then the productivity increases, but voltage drops and power distribution issues occur
Solution Approach 1:
The power supply units are designed with universal output capabilities that can serve multiple charging modules simultaneously. The system uses a common power bus with active power management that dynamically allocates power to different battery packs based on their charging requirements, ensuring stable voltage delivery to multiple packs at once while maintaining reliability.
4Productivity
If authentication and rating determination are implemented, then the charging performance is optimized, but the operation complexity increases
Solution Approach 1:
The system automatically performs authentication of charging modules and determination of their ratings through controller communication protocols. The controller identifies each module's capabilities and configures power delivery parameters without user intervention, optimizing charging performance while keeping the user interface simple and easy to operate.
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.