Power Tool Battery Pack Disconnection Protection Circuit

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Solution Overview

Problem

Power tools that use electromagnetic switches and battery packs as power supplies can inadvertently turn on when the battery pack is dislodged and quickly reinserted, leading to safety hazards and operational issues.

Innovation Solution

Incorporating a power-off protection module with an electromagnetic switch, a motor driving circuit, and energy storage components that disconnect the electrical connection between the coil and energy storage component when the battery pack is removed, preventing immediate reactivation of the power tool.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the battery pack is quickly reinserted after being dislodged, then the power tool can be quickly restored to operation, but the power tool may turn on immediately without user intent causing safety hazards

Engineering Contradiction:
Improvequick restoration to operationVSAvoidunintended activation causing safety hazards
Core Design Contradiction:
ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent applies preliminary action by detecting the battery insertion event beforehand and setting a time delay period before allowing power tool activation. The control circuitry monitors whether the battery remains inserted throughout the delay period, and only enables operation if the battery is still present after the delay expires. This preliminary detection and delay mechanism prevents unintended activation while allowing quick restoration when the battery is intentionally reinserted.

Inventive Principle:
Principle #10Preliminary action

2Ease of operation

If the electromagnetic switch is used for switching function, then the power tool can be controlled to operate, but the power tool may inadvertently turn on when the battery pack is dislodged and reinserted

Engineering Contradiction:
Improvecontrol operationVSAvoidunintended activation
Core Design Contradiction:
Ease of operationVSReliability

Solution Approach 1:

The patent implements feedback by using control circuitry that continuously monitors battery pack insertion status and provides feedback signals to the electromagnetic switch. When the battery is detected as inserted, the control circuitry generates a feedback signal that enables the electromagnetic switch to respond to trigger inputs. When the battery is removed or not properly inserted, the feedback signal disables the electromagnetic switch, preventing unintended activation while maintaining operational control when the battery is present.

Inventive Principle:
Principle #23Feedback

3Device complexity

If the battery pack connection is not monitored, then the circuit design is simpler, but the power tool cannot distinguish between intentional power-off and accidental disconnection

Engineering Contradiction:
Improvecircuit designVSAvoidpower-off detection accuracy
Core Design Contradiction:
Device complexityVSReliability

Solution Approach 1:

The patent introduces an intermediary power-off detection module that acts as a mediator between the battery pack connection status and the electromagnetic switch control. This module includes detection circuitry that monitors the connection state and generates appropriate control signals. The intermediary module adds minimal complexity while significantly improving reliability by accurately distinguishing between intentional power-off (user removes battery) and accidental disconnection (battery loosens during operation), enabling appropriate responses in each scenario.

Inventive Principle:
Principle #24Intermediary (Mediator)

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

Prevents the power tool from turning on immediately after a power-off event due to battery pack dislodgement and reinsertion, enhancing safety and reliability while maintaining a high current capacity and low cost.

Implementation Method 1

an electromagnetic switch that includes a coil, a first switch, and a second switch, wherein the first switch is electrically connected to the coil and configured to turn on and off an electrical connection between the coil and the battery pack

Methodology Applied
Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

an energy storage component connected in parallel with the motor driving circuitry

Methodology Applied
Scientific EffectElectrical energy storage: Capacitance

Data Source

PatentUS11296581B2Power tool
Publication Date: 2022.04.05 NANJING CHERVON IND
  • US11296581B2 patent drawing
  • US11296581B2 patent drawing
  • US11296581B2 patent drawing

AI summary

A power tool that is powered by a battery pack includes a function member, a motor, a motor driving circuitry, an energy storage component, an electromagnetic switch, and a power-off protection module. The electromagnetic switch includes a coil, a first switch electrically connected to the coil and configured to turn on and off an electrical connection between the coil and the battery pack, and a second switch electrically connected to the motor driving circuitry and configured to turn on and off an electrical connection between the battery pack and the motor driving circuitry. The power-off protection module is electrically connected to the coil and to the energy storage component and is configured to cut off an electrical connection between the coil and the energy storage in response to the power tool and the battery pack being electrically disconnected.