Power Tool Control Unit for Universal Battery Compatibility
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Solution Overview
Problem
Conventional power tools require specialized battery packs matching their specific voltage and capacity, limiting the use of battery packs across different power tools and increasing manufacturing and storage costs for consumers.
Innovation Solution
A power tool design featuring a secondary battery with a detecting unit and control unit that adjusts voltage and current based on load, allowing the use of various battery packs by ensuring power dissipation remains within allowable limits, and incorporating a current interrupting unit for chopping control to manage temperature and prevent damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If specialized battery packs are used for each power tool type, then the power tool can operate reliably within its designed voltage and power limits, but the battery pack cannot be used with other power tools and consumers must store and manage multiple battery packs
Solution Approach 1:
The power tool is designed with a control unit that can detect battery voltage and adjust operating parameters to accommodate different battery pack types (14.4V, 18V, 36V). This allows a single power tool to universally accept multiple battery pack voltages while maintaining reliable operation through adaptive control of the drive unit.
2Power
If a battery pack with higher voltage than designed is used, then the power output can be increased and work efficiency improved, but the power dissipation may exceed allowable limits and damage components
Solution Approach 1:
The control unit dynamically adjusts the drive unit operating parameters based on the detected battery voltage. When a higher voltage battery is detected, the control unit modifies current limits and power dissipation thresholds to match the battery's capabilities, enabling increased power output while preventing component damage through real-time adaptive control.
Solution Approach 2:
The system changes operating parameters (current limits, power dissipation thresholds, drive unit control settings) based on the detected battery voltage level. This allows the power tool to safely utilize higher voltage batteries for increased power output while maintaining component safety through parameter adjustment.
3Ease of operation
If the power tool structure is simplified to accept any battery pack, then user convenience is enhanced and manufacturing costs are reduced, but the risk of excessive load and component damage increases
Solution Approach 1:
The control unit continuously detects the battery voltage and provides feedback to adjust the drive unit operating parameters. This feedback mechanism allows the system to accept any battery pack type for user convenience while automatically preventing excessive load and component damage by adapting control parameters to the actual battery capabilities.
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
Enables the universal use of battery packs with different voltages, optimizing power output and reducing the risk of component damage, while simplifying the power tool structure and enhancing user convenience by allowing the use of any battery pack without excessive load on the tool.
Implementation Method 1
a control unit (control FET, for example) configured to control an effective voltage and an effective current applied to the drive unit depending on a load imposed thereon to fall within an allowable power dissipation value
Implementation Method 2
a detecting unit configured to detect a current value and a voltage value supplied from the secondary battery to the drive unit
Implementation Method 3
a motor that produces an output suited to the application of the power tool
Data Source
AI summary
A power tool includes: a secondary battery; a drive unit; a detecting unit; and a control unit. The secondary battery has positive and negative terminals across which a battery voltage is developed. The drive unit is connected to the secondary battery. The detecting unit is configured to detect a current value and a voltage value supplied from the secondary battery to the drive unit. The control unit is configured to control an effective voltage and an effective current applied to the drive unit depending on a load imposed thereon to fall within an allowable power dissipation value.