Portable Power Supply Charge Control for Shared Circuit Limits

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Solution Overview

Problem

Existing portable power supplies can trip circuit breakers when multiple units are plugged into the same circuit, due to excessive combined charging power.

Innovation Solution

A portable power supply with a controller that adjusts the maximum charge rate based on a received power limit value, determining a supportable charge current and a power-limited current to set a target charge current, thereby preventing circuit breaker tripping.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If multiple portable power supplies charge simultaneously at maximum rate, then charging speed is improved, but circuit breaker trips due to excessive combined power draw

Engineering Contradiction:
Improvecharging speedVSAvoidcircuit stability
Core Design Contradiction:
ProductivityVSReliability

Solution Approach 1:

The patent implements dynamic adjustment of charge rate by continuously monitoring power consumption and modifying charging parameters in real-time. The controller adjusts the charge rate based on detected power limits, transforming a static charging system into a dynamic one that adapts to circuit conditions, thereby preventing breaker trips while maintaining optimal charging speed.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The system changes operating parameters (charge rate, power draw) based on detected circuit conditions. By monitoring power consumption and adjusting the charge rate parameter dynamically, the system optimizes charging speed within safe operational limits, resolving the contradiction between fast charging and circuit stability.

Inventive Principle:
Principle #35Parameter changes

2Reliability

If charge rate is reduced to prevent breaker tripping, then circuit stability is improved, but charging speed decreases

Engineering Contradiction:
Improvecircuit stabilityVSAvoidcharging speed
Core Design Contradiction:
ReliabilityVSProductivity

Solution Approach 1:

The patent employs feedback mechanisms where the controller continuously monitors power draw and circuit conditions, then adjusts the charge rate accordingly. This closed-loop control system provides feedback about circuit stability and modifies charging parameters in response, achieving both circuit protection and optimized charging performance.

Inventive Principle:
Principle #23Feedback

Solution Approach 2:

The system performs self-adjustment by automatically detecting power limits and modifying its own charge rate without external intervention. The controller monitors its own power consumption and autonomously regulates charging parameters to maintain circuit stability while maximizing charging speed within safe limits.

Inventive Principle:
Principle #25Self-service

3Use of energy by moving object

If maximum charge rate is used, then charging efficiency is improved, but risk of circuit overload increases

Engineering Contradiction:
Improvecharging efficiencyVSAvoidcircuit overload risk
Core Design Contradiction:
Use of energy by moving objectVSObject-affected harmful factors

Solution Approach 1:

The system performs preliminary detection of power limits and circuit conditions before initiating maximum charge rate. By advance monitoring and assessment of circuit capacity, the system prepares appropriate charge rate parameters, preventing overload conditions before they occur while maintaining efficient charging operation.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

Continuous feedback monitoring of power draw and circuit conditions allows the system to maintain efficient charging while preventing harmful overload conditions. The controller adjusts charge rate based on real-time feedback, ensuring optimal energy transfer without exceeding circuit capacity.

Inventive Principle:
Principle #23Feedback

Data Source

PatentUS20250132593A1Portable power supply with adjustable maximum charge rate
Publication Date: 2025.04.24 MILWAUKEE ELECTRIC TOOL CORP
  • US20250132593A1 patent drawing
  • US20250132593A1 patent drawing
  • US20250132593A1 patent drawing

AI summary

Portable power supply with a maximum charge rate feature. The portable power supply includes a power source; a power input unit configured to receive power from an external source; a core charger coupled to the power source and the power input unit; and an electronic processor coupled to the core charger. The electronic processor is configured to receive a power limit value and determine a supportable charge current of the internal power source. The core charger is configured to determine a power-limited current based on the power limit value and an output voltage of the core charger, determine a target output current by comparing the power-limited current and the supportable charge current, and charge the power source with the received power at the target output current.