Auxiliary Energy Circuit Using Ultra-Capacitor for Peak Tool Power
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Solution Overview
Problem
Battery-powered power tools often require significant power that exceeds the capacity of their battery packs, leading to rapid battery drain and potential shutdowns, especially when performing tasks that demand high current or prolonged operation.
Innovation Solution
An auxiliary energy circuit is integrated within the power tool, utilizing an ultra-capacitor as the auxiliary power source, which is selectively connected in series with the battery pack to provide supplementary power to the motor based on operational characteristics such as motor speed, current, or trigger pull percentage, allowing the tool to continue operating without overburdening the battery pack.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If battery-powered power tools use only battery pack power, then the tool maintains simplicity and portability, but the battery drains rapidly during high-power tasks
Solution Approach 1:
The patent combines two power sources (battery pack and ultra-capacitor) into a hybrid power system. The ultra-capacitor is electrically connected in parallel with the battery pack to form a composite power source that can deliver high peak currents while the battery provides sustained energy, thereby resolving the contradiction between power output and operation duration.
Solution Approach 2:
The system dynamically switches between battery-only mode and hybrid mode based on power demands. During high-power tasks, the ultra-capacitor is activated to supplement battery power; during normal operation, only the battery is used. This dynamic adaptation allows the tool to maintain high power output when needed while preserving battery life during lower-demand periods.
2Power
If the auxiliary power source is always connected, then power availability is maximized, but the device complexity increases
Solution Approach 1:
The control circuit dynamically manages the connection between the ultra-capacitor and the load based on real-time power demands. The system monitors battery voltage and current draw, and only connects the ultra-capacitor when high-power conditions are detected, thereby maintaining power availability when needed while avoiding unnecessary complexity during normal operation.
Solution Approach 2:
The control circuit automatically detects when high-power mode is required and activates the ultra-capacitor without user intervention. The system self-regulates the switching between power sources based on operational conditions, reducing the need for complex manual control mechanisms while maintaining optimal power availability.
3Duration of action of moving object
If the ultra-capacitor is used during high-power tasks, then battery drain is reduced, but the device requires additional components
Solution Approach 1:
The ultra-capacitor is integrated into the existing battery pack structure, combining two energy storage devices into a unified power module. This merging approach extends battery operation duration through the ultra-capacitor's high-power supplement while minimizing the increase in overall device complexity by sharing structural and control resources.
Solution Approach 2:
A control circuit acts as an intermediary between the battery pack, ultra-capacitor, and motor. This intermediary intelligently manages power distribution, activating the ultra-capacitor only when high-power demands are detected, thereby extending battery operation duration while keeping the additional componentry actively engaged only when necessary, thus justifying the added complexity.
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 auxiliary energy circuit enables the power tool to perform tasks requiring higher power without draining the battery pack quickly, by providing additional energy only when needed, thus extending tool operation and reducing battery burden.
Implementation Method 1
The auxiliary power source includes an ultra-capacitor
Data Source
AI summary
A power tool comprising a power tool housing, an auxiliary power source, a user input for user control of power tool operation, and a controller. The controller is configured to receive a control signal from the user input, control the power tool in response to the control signal, receive, from a sensor, a signal indicative of an operational characteristic of the power tool, and selectively provide energy from the auxiliary power source to a load of the power tool based on the operational characteristic of the power tool.