Modular Battery Charger Storage with PFC Flyback Power Sharing
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Solution Overview
Problem
Existing power tool battery chargers lack efficient and modular solutions for charging multiple battery packs and additional devices, with limited flexibility in design and functionality.
Innovation Solution
A modular storage unit with a charger compartment that includes an active clamp flyback topology DC-DC converter, active power factor correction (PFC) converter, and a DC bus system, enabling efficient conversion of AC power to high-voltage DC for charging power tool battery packs and supporting USB charging for other devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional charger designs are used, then the charger can charge battery packs, but the charger lacks flexibility and cannot efficiently charge multiple battery packs and additional devices simultaneously
Solution Approach 1:
The charger is divided into multiple independent charging bays (first charging bay, second charging bay, third charging bay) that can operate independently. Each bay can charge different types of devices (battery packs, USB devices) simultaneously, providing modular flexibility without requiring a completely complex redesign of the entire system.
Solution Approach 2:
The charger is designed with universal charging capability across multiple bays. The first charging bay accepts battery packs with various connector types (first connector, second connector), the second charging bay supports USB devices, and the third charging bay supports additional battery packs. This multi-functional design allows a single charger to handle diverse charging needs without requiring separate devices.
2Adaptability or versatility
If multiple charging bays are added to increase versatility, then the charger can charge more devices, but the power conversion efficiency may decrease
Solution Approach 1:
Multiple charging bays are merged into a single integrated charger unit that shares common power conversion components. The power factor correction converter and DC-DC converters are consolidated in one system, allowing efficient power distribution to multiple bays simultaneously. This merging approach maintains high power conversion efficiency while supporting multiple charging operations.
Solution Approach 2:
The power conversion system dynamically adjusts operating parameters based on the charging demands of different bays. The controller monitors the state of each battery pack and USB device, then optimizes the power conversion parameters (voltage, current, switching frequency) to maintain high efficiency across varying load conditions and device types.
3Device complexity
If a single power conversion system is used, then the charger design is simplified, but the charger cannot efficiently handle different power requirements of multiple device types
Solution Approach 1:
A central controller acts as an intermediary between the power conversion system and multiple charging bays. The controller receives power from the power factor correction converter and intelligently distributes it to different bays based on device requirements. It monitors battery pack voltage, current, and charging state, then adjusts power delivery parameters in real-time to ensure reliable and efficient charging of diverse device types.
Solution Approach 2:
The power conversion system is designed to be dynamic and adaptive. The DC-DC converters can adjust their output voltage and current based on the specific requirements of each charging bay. The system transitions smoothly between different operating modes (charging different battery pack types, USB device charging) to maintain optimal power delivery efficiency and reliability across varying conditions.
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 modular storage unit provides efficient charging for multiple power tool battery packs and other devices, offering flexibility in design and functionality, with improved power conversion efficiency and compatibility.
Implementation Method 1
a DC-DC converter connected between the converter and the battery pack interface. The DC-DC converter includes an active clamp (AC) flyback topology and is configured to convert the high-voltage DC output to a charging DC power
Implementation Method 2
an active power factor correction (PFC) converter receiving AC power from the power cord and configured to convert the AC power to a high-voltage DC output
Data Source
AI summary
Embodiments described herein provide a modular storage for power tool devices including a charging compartment for power tool battery packs. The modular storage includes a housing, a storage compartment in the housing, and a charger compartment in the housing including a battery pack interface configured to receive a power tool battery pack. The modular storage also includes an AC input receiving universal AC power and an active power factor correction (PFC) converter receiving AC power from the AC input and configured to convert the AC power to a high-voltage DC output. The modular storage further includes a DC-DC converter electrically connected between the active PFC converter and the battery pack interface, the DC-DC converter including an active clamp flyback converter.