Wireless Power Tool Battery Charging With Embedded Coil Feedback
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Solution Overview
Problem
Existing wireless charging systems for power tool battery packs lack efficient communication and adaptive charging characteristics, leading to suboptimal charging performance and potential overheating due to inefficient power transfer and lack of compatibility with varying battery pack types.
Innovation Solution
A wireless charging system that includes a transmitter coil converting DC power to an AC electric field, a communication circuit to detect and adjust charging characteristics based on embedded communication signals, and a controller to optimize charging for multiple battery packs with different current ratings, along with heat transfer devices to manage thermal issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If wireless charging systems use fixed charging characteristics, then system simplicity is maintained, but charging performance is suboptimal and compatibility with varying battery pack types is poor
Solution Approach 1:
The patent implements a feedback mechanism where the battery pack communicates its specifications (current rating, capacity, etc.) to the wireless charger via modulation of the power signal. The controller detects these communication signals and adjusts charging characteristics accordingly, enabling adaptive charging that accommodates different battery pack types while maintaining system simplicity through automated parameter adjustment.
Solution Approach 2:
The charging system transitions from static fixed characteristics to dynamic adaptive characteristics. The controller continuously monitors communication signals from the battery pack and adjusts charging parameters (power level, current, voltage) in real-time based on the detected battery specifications, allowing the system to optimize performance for each specific battery pack type.
2Reliability
If wireless charging systems transmit continuous AC electric field, then power transfer is maintained, but overheating occurs due to inefficient power transfer and lack of adaptive control
Solution Approach 1:
The system uses feedback from the battery pack's communication signals to monitor charging status and adjust power transmission levels. The controller detects the battery's current rating and charging state, then dynamically adjusts the AC electric field strength to prevent excessive heat generation while ensuring safe and efficient charging operation.
Solution Approach 2:
The patent changes the operating parameters of the AC electric field dynamically based on detected battery characteristics. The controller adjusts power level, frequency, and other parameters according to the battery pack's current rating and charging state, optimizing power transfer efficiency and preventing overheating by matching transmission parameters to actual charging needs.
3Adaptability or versatility
If wireless charger supports multiple battery packs with different current ratings, then versatility is improved, but power transfer efficiency decreases without adaptive control
Solution Approach 1:
The wireless charger detects communication signals from each battery pack that encode the battery's current rating and specifications. Based on this feedback information, the controller adjusts the power transmission parameters specifically for each battery pack type, ensuring optimal power transfer efficiency regardless of the battery's current rating or capacity.
Solution Approach 2:
The system applies different charging parameters to different battery packs based on their individual characteristics. Each battery pack receives customized power transmission settings (current, voltage, frequency) matched to its specific requirements, rather than using a uniform charging approach, thereby maintaining high efficiency across diverse battery types.
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 system enables efficient, adaptive wireless charging of multiple battery packs with varying ratings, optimizing power transfer and reducing heat dissipation, ensuring safe and effective charging while managing thermal loads.
Implementation Method 1
a transmitter coil configured to convert the direct current power source to the AC electric field
Implementation Method 2
a receiver coil configured to convert an AC electric field to a power signal
Implementation Method 3
a heat transfer device connected to the transmitter coil, the heat transfer device configured to transfer heat generated by the transmitter coil to an ambient environment
Data Source
AI summary
Systems and methods for wireless charging of a battery pack. One system includes a direct current power source, a battery pack, and a wireless charger. The battery pack includes a receiver coil configured to convert an AC electric field to a power signal and a battery pack communication circuit configured to modulate the power signal. Modulating the power signal embeds communication signals within the AC electric field. The wireless charger includes a transmitter coil configured to convert the direct current power source to the AC electric field, a wireless charger communication circuit configured to detect the communication signals in the AC electric field, and a controller coupled to the transmitter coil and the wireless charger. The controller is configured to adjust charging characteristics of the AC electric field based on the communication signals.