Two-Stage Power Supply for High-Power Corded Tool Operation
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Solution Overview
Problem
Existing mains adapters are limited in power output to less than 1200 watts due to space, weight, and cost constraints, and cannot efficiently supply high-power power tools, while battery-operated tools face limitations in working time and availability of replacement batteries.
Innovation Solution
An apparatus comprising a PFC component for converting AC voltage to DC voltage and a DC/DC converter to further convert the DC voltage into a device DC voltage, capable of delivering power exceeding 1700 watts, allowing connection to both energy networks and battery-operated power tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional mains adapters are used to supply power tools with electrical energy, then the power tool can operate without battery limitations, but the power output is limited to less than 1200 watts due to installation space, weight, and cost constraints
Solution Approach 1:
The power supply apparatus is divided into two separate components: a PFC component housed in a first housing and a DC/DC converter housed in a second housing. This segmentation allows each component to be optimized independently, enabling the PFC component to handle high power conversion while keeping individual unit sizes manageable, thus resolving the contradiction between high power output and limited installation space
Solution Approach 2:
The patent transitions from a single integrated mains adapter design to a distributed two-component architecture. By separating the PFC component and DC/DC converter into different spatial locations and housings, the system achieves high power output capability without requiring a single large installation space, effectively utilizing spatial distribution to resolve the power-to-space ratio constraint
2Power
If the PFC component and DC/DC converter are integrated into a single mains adapter, then the power output can exceed 1200 watts, but the adapter becomes too large for practical installation and handling
Solution Approach 1:
By separating the power supply system into a PFC component and a DC/DC converter, each with its own housing, the patent creates two smaller, more manageable units. The PFC component housing and DC/DC converter housing can be installed in separate locations and connected via cable, making installation and maintenance significantly easier while maintaining the combined power output capability of over 1200 watts
Solution Approach 2:
The patent introduces a cable connection as an intermediary element between the PFC component and the DC/DC converter. This intermediary allows the two components to be separated spatially while maintaining electrical connectivity, enabling high power transmission without requiring the components to be physically integrated, thus preserving handling convenience
3Duration of action of moving object
If batteries or rechargeable batteries are used to supply power tools, then the power tool can be portable and free from wiring constraints, but the working time is limited by battery capacity and availability of replacement batteries
Solution Approach 1:
The power supply apparatus is designed to provide DC voltage output that is compatible with both battery-operated and mains-powered power tools. By outputting DC voltage in the same range as battery voltages (through the DC/DC converter), the system can universally power various tool types without requiring separate power supply systems, thus achieving both extended working time and energy supply flexibility
Solution Approach 2:
The patent employs a DC/DC converter that can adjust and regulate the output DC voltage to match the requirements of different power tools. This parameter adjustment capability allows the same apparatus to supply power to tools with different voltage requirements, effectively extending working time while maintaining adaptability to various tool configurations
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 apparatus enables continuous operation of high-power power tools by providing a reliable and high-power alternative energy supply, overcoming limitations of battery life and availability, with improved user convenience and efficiency.
Implementation Method 1
a first component (1) for converting an AC voltage into a DC voltage, as well as a second component (2) which is configured to convert the DC voltage into a device DC voltage
Implementation Method 2
it can be preferred in the context of the invention that the PFC component is used to increase a DC voltage (DC)
Implementation Method 3
a second component (2) which is configured to convert the DC voltage into a device DC voltage
Data Source
AI summary
An apparatus for supplying a power tool with electrical energy is provided. The apparatus can be used, for example, to connect the power tool to an energy network so that it can perform the function of a mains adapter. The apparatus includes a first component for converting an AC voltage into a DC voltage, as well as a second component which is configured to convert the DC voltage generated by the first component into a device DC voltage. In a second aspect, the invention relates to a system which includes a apparatus and a power tool, wherein the power tool can be supplied with electrical energy using the apparatus. A use of the apparatus for supplying a power tool with electrical energy. Advantageously, particularly high power densities can be achieved with the invention and powers of more than 1700 watts can be provided.