Supercapacitor Burst Circuit for Battery Fastener Drivers
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Solution Overview
Problem
Existing fastener drivers face power, size, and cost constraints when providing burst operations for driving fasteners into a work piece.
Innovation Solution
A battery-powered fastener driver incorporating a burst circuit with a supercapacitor to supply power to the motor, along with a battery pack comprising cells with varying characteristics for optimized performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a battery-powered fastener driver uses a conventional battery alone to power the motor for burst operations, then the device structure remains simple, but the battery experiences voltage drop under high current demand, limiting burst power delivery
Solution Approach 1:
The patent combines a battery and a supercapacitor into a hybrid power source where the supercapacitor handles high current burst demands while the battery provides sustained power, merging the advantages of both energy storage devices to deliver stable voltage during burst operations
Solution Approach 2:
The supercapacitor acts as an intermediary between the battery and the motor, absorbing high current demands during burst operations and preventing voltage drops that would otherwise affect the battery and motor performance
2Productivity
If the fastener driver uses high power to drive fasteners quickly, then productivity increases, but the size and weight of the power source must increase
Solution Approach 1:
By merging a lightweight supercapacitor with a compact battery, the system achieves high power output for fast fastening operations without requiring a single large heavy battery, as the supercapacitor provides the burst power in a lightweight form factor
Solution Approach 2:
The system changes the energy delivery parameters by using the supercapacitor's ability to rapidly discharge high current for short durations, enabling high productivity burst operations without increasing the overall power source weight
3Ease of operation
If the fastener driver is designed for portability with a compact battery, then ease of operation improves, but the battery cannot sustain high current bursts without voltage drop
Solution Approach 1:
The compact battery is merged with a small supercapacitor module that adds burst power capability without significantly increasing size, maintaining portability while enabling high current delivery for fastener driving operations
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 solution enables efficient burst operations by providing high current without voltage drop, extending the operational life of the fastener driver and improving its performance.
Implementation Method 1
A battery-powered fastener driver may include a burst circuit with a supercapacitor for providing power to a motor of the fastener driver
Implementation Method 2
a battery pack may include battery cells with different characteristics
Implementation Method 3
a battery pack may include battery cells coupled by laser welding conductive straps to terminals of the battery cells
Data Source
AI summary
A system, an electrical combination and a method for powering a load device. The combination may include a burst circuit configured to provide power to the load device to perform a burst operation, the burst circuit including a supercapacitor, a first switch between a power source and the supercapacitor and operable to control whether power is provided from the power source to charge the supercapacitor, and a second switch between the supercapacitor and the load device and operable to control whether power is provided from the supercapacitor to the load device; and an electronic processor configured to control the first switch and the second switch based at least in part on a voltage of the supercapacitor.