Portable Power Supply AC Passthrough and Battery Flow Control

Resolve Bottlenecks,
Find Innovative Solutions
Generate Solutions

Solution Overview

Problem

Existing portable power supplies lack efficient mechanisms to manage power flow between AC and DC sources, leading to suboptimal performance in charging and discharging modes, especially when the state of charge of the battery core is not fully utilized.

Innovation Solution

A portable power supply system with a controller that selectively switches between AC passthrough, AC bypass, DC discharge, and idle modes based on the presence and request of AC power, state of charge of the battery core, and power consumption, using switches and voltage converters to manage power flow between AC and DC interfaces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If the portable power supply uses a simple power management system without selective switching between AC and battery sources, then the device complexity is reduced, but the power utilization efficiency deteriorates and energy wastage increases

Engineering Contradiction:
Improvepower utilization efficiencyVSAvoidpower management system complexity
Core Design Contradiction:
Use of energy by moving objectVSDevice complexity

Solution Approach 1:

The power management system dynamically switches between different power sources (AC input and battery core) based on real-time conditions such as AC power availability and battery state of charge. The controller adjusts the switching state of power flow paths to optimize power utilization efficiency, transitioning between passthrough mode, bypass mode, and battery discharge mode as needed.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The controller monitors the state of charge of the battery core and the presence of AC power input, using this feedback information to make intelligent decisions about power flow management. This feedback mechanism enables the system to select the most efficient power source at any given moment, improving overall power utilization without requiring overly complex manual intervention.

Inventive Principle:
Principle #23Feedback

2Productivity

If the portable power supply implements selective switching between AC passthrough, AC bypass, DC discharge, and idle modes, then the power flow management efficiency is improved, but the device complexity increases

Engineering Contradiction:
Improvepower flow management efficiencyVSAvoidswitching control system complexity
Core Design Contradiction:
ProductivityVSDevice complexity

Solution Approach 1:

The controller serves multiple functions: it monitors AC power input, tracks battery state of charge, determines optimal power flow paths, and controls switching between different operational modes (passthrough, bypass, battery discharge, idle). This multi-functional approach consolidates complex power management tasks into a single control unit, improving power flow management efficiency while managing system complexity through functional integration.

Inventive Principle:
Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system proactively manages power flow by anticipating power needs and pre-positioning power sources. For example, when AC power is available, the system prepares to charge the battery core in advance; when battery charge levels are monitored to be sufficient, the system pre-switches to bypass mode to conserve battery energy, thereby improving overall power management efficiency.

Inventive Principle:
Principle #10Preliminary action

3Loss of energy

If the portable power supply optimizes charging and discharging operations, then the energy wastage is reduced, but the control system complexity increases

Engineering Contradiction:
Improveenergy wastageVSAvoidcharging control system complexity
Core Design Contradiction:
Loss of energyVSDevice complexity

Solution Approach 1:

The power management system operates autonomously to optimize charging and discharging operations. The controller automatically monitors battery state of charge levels and AC power availability, making decisions about when to charge the battery core from AC input and when to discharge to AC output without external intervention. This self-service capability reduces energy wastage by preventing unnecessary charging/discharging cycles while keeping the control system relatively simple through automated decision-making algorithms.

Inventive Principle:
Principle #25Self-service

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 system optimizes power utilization by ensuring efficient charging and discharging, reducing energy wastage, and providing reliable power output to devices regardless of the AC power input availability, thereby enhancing the overall efficiency and functionality of the portable power supply.

Implementation Method 1

a voltage converter electrically connected between the first switch and the battery core

Methodology Applied
Scientific EffectElectrical energy conversion:

Implementation Method 2

an electromagnetic interference ('EMI') filter electrically connected between the AC power input and the first switch

Methodology Applied
Scientific EffectElectromagnetic interference filtering:

Data Source

PatentUS20240097468A1Portable power supply with bidirectional charging and passthrough
Publication Date: 2024.03.21 MILWAUKEE ELECTRIC TOOL CORP
  • US20240097468A1 patent drawing
  • US20240097468A1 patent drawing
  • US20240097468A1 patent drawing

AI summary

A portable power supply including an alternating current (“AC”) power input interface, an AC power output interface, a battery core, a charger electrically connected to the AC power input interface, an inverter configured to output AC power to the AC power output interface, and a controller configured to, when the charger is active and AC power is requested at the AC power output interface, control the charger to provide direct current (“DC”) power to the inverter. When the charger is active, the battery core selectively outputs or receives power based on a power consumption of the inverter.