Smart Battery Pack Control for Mixed-Type Power Tool Operation
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Solution Overview
Problem
Conventional inverter systems for power tools are limited to a single type of battery pack connected in series, making them unusable if any battery pack is removed or fails, restricting flexibility and functionality.
Innovation Solution
A smart battery control method that checks the state of multiple battery packs, categorizes them, and adjusts discharge modes by connecting them in series or parallel configurations using a microcontroller to prioritize discharge based on energy levels and pack types, allowing for flexible use of different battery types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If single-type battery packs are connected in series as power supply module, then the battery configuration is simple and easy to control, but the system cannot operate if any battery pack is removed or fails, reducing reliability
Solution Approach 1:
The battery pack is segmented into multiple independent battery cells (first battery pack, second battery pack, third battery pack, fourth battery pack) that can be independently controlled and managed. Each battery cell can be individually monitored for voltage, current, and temperature, and can be independently connected or disconnected from the circuit through switching elements, allowing the system to continue operating even if one cell fails or needs removal.
Solution Approach 2:
The battery configuration dynamically adapts based on the operational status of individual battery cells. The control unit monitors each cell's state and automatically adjusts the connection configuration through switching elements, transitioning between series connections (for higher voltage operation) and parallel connections (for current sharing and redundancy), optimizing system reliability under varying conditions.
2Adaptability or versatility
If multiple battery packs of different types are allowed, then flexibility and adaptability increase, but the control system becomes more complex
Solution Approach 1:
The battery control system is designed with universal compatibility to accommodate multiple battery pack types (first type and second type battery packs) with different voltage ratings. The control unit automatically identifies the connected battery types and configures the switching elements accordingly, enabling the same power tool system to operate with various battery configurations without requiring type-specific control circuits.
Solution Approach 2:
The control system dynamically adjusts electrical parameters (voltage, current distribution) based on the detected battery pack types and their states. When different types of battery packs are connected, the control unit modifies the connection topology and discharge characteristics to optimize performance and ensure safe operation, adapting to parameter variations rather than requiring fixed configuration.
3Reliability
If all battery packs must be of the same type connected in series, then the discharge control is straightforward, but the system becomes unusable if any battery pack is removed or fails
Solution Approach 1:
The system incorporates redundant battery cell connections and automatic failure detection mechanisms that prepare for potential battery failures in advance. When a battery cell is removed or fails, the control unit immediately detects the anomaly and reconfigures the circuit through switching elements to maintain operational capability, preventing system shutdown and providing cushioning against usability loss.
Solution Approach 2:
Switching elements act as intermediaries between the battery cells and the load, enabling the control unit to dynamically reconfigure the battery connections. These switching elements facilitate the transition between different operational modes (series connection for normal operation, parallel connection for redundancy, or isolated connections for failure management), allowing the system to maintain usability despite battery cell issues.
Data Source
AI summary
The present invention proposes a method of smart battery control for a power supply module, where the power supply module includes a plurality of battery packs having at least a first type or second type battery pack, the method includes checking whether all battery packs are in a normal state that can be discharged and can be categorized into the first type battery pack, if yes, the power supply module discharges power by a first discharge mode; otherwise, neglecting the abnormal battery packs and forming series-connected battery pack units among the remaining battery packs, the power supply module discharging power by a second discharge mode; calculating electric energy of all battery packs, comparing the electric energy of individual series-connected battery pack unit, and scheduling the discharge priority among the series-connected battery pack units.