Bidirectional motor for gas engine replacement device

Abstract

A bidirectional motor (36) for a gas engine replacement device (10). One embodiment provides a gas engine replacement device (10) comprising a housing (14), a battery receptacle (54), a motor (36), a power output shaft (38) that receives torque from the motor (36), a power switch network (310) configured to selectively provide power to the motor (36), and an electronic processor (302) coupled to the power switch network (310). The electronic processor (302) is configured to cause the motor (36) to rotate in a first direction and receive an input to switch a direction of rotation of the motor (36). The electronic processor is further configured to control the power switch network (310) to cause the motor (36) to stop and cause the motor (36) to rotate in a second direction after controlling the power switch network (310) to cause the motor (36) to stop.

Description

[0001] Related Applications

[0002] This application claims the benefit of U.S. Provisional Patent Application No. 62 / 932,715, filed November 8, 2019, the entire contents of which are incorporated herein by reference. TECHNICAL FIELD

[0003] The present application relates to gas engine replacement motor units, and more particularly to gas engine replacement motor units for use with power equipment. BACKGROUND

[0004] Small, single-cylinder or multi-cylinder gasoline engines can be installed to power equipment to drive the equipment with a power output shaft. SUMMARY

[0005] One embodiment provides a gas engine replacement device, comprising: a housing; a battery receptacle coupled to the housing and configured to removably receive a battery pack; and a motor located within the housing. The gas engine replacement device further comprises: a power output shaft receiving torque from the motor and protruding from a side of the housing; a power switch network configured to selectively provide power from the battery pack to the motor; and an electronic processor coupled to the power switch network and configured to control the power switch network to rotate the motor. The electronic processor is configured to rotate the motor in a first direction and receive an input to switch a direction of rotation of the motor. The electronic processor is further configured to control the power switch network to stop the motor by performing an operation selected from the group consisting of: inertially stopping the motor, applying a passive brake to stop the motor, applying an active brake to stop the motor, and dynamically pulsing the motor in a phase opposite the first direction, and the electronic processor is further configured to rotate the motor in a second direction after controlling the power switch network to stop the motor.

[0006] Another embodiment provides an outdoor power equipment comprising a gas engine replacement device. The gas engine replacement device comprises a housing, a battery receptacle coupled to the housing and configured to removably receive a battery pack, and a motor located within the housing. The gas engine replacement device further comprises a power output shaft that receives torque from the motor and protrudes from a side of the housing, a power switch network configured to selectively provide power from the battery pack to the motor, and an electronic processor coupled to the power switch network and configured to control the power switch network to rotate the motor. The outdoor power equipment further comprises a first clutch mechanism that couples the power output shaft to a first equipment bit and is configured to enable the first equipment bit when the motor is rotated in a first direction and to disable the first equipment bit when the motor is rotated in a second direction.

[0007] In some configurations, the outdoor power equipment further comprises a second clutch mechanism that couples the power output shaft to a second equipment bit and is configured to enable the second equipment bit when the motor is rotated in the second direction and to disable the second equipment bit when the motor is rotated in the first direction.

[0008] In some configurations, the first equipment bit is a first vibration mechanism configured to drive a first vibration plate, and the second equipment bit is a second vibration mechanism configured to drive a second vibration plate.

[0009] In some configurations, the outdoor power equipment further comprises wheels configured to propel the outdoor power equipment over a ground surface, wherein the first equipment bit is a vibration mechanism configured to drive a vibration plate, and wherein the second equipment bit is a wheel axle that drives the wheels.

[0010] Yet another embodiment provides a compactor system including a frame having a handle, a vibration plate supported by the frame, a vibration mechanism configured to drive the vibration plate, and a gas engine replacement device. The gas engine replacement device includes a housing, a battery receptacle coupled to the housing and configured to removably receive a battery pack, and a motor located within the housing. The gas engine replacement device further includes a power switch network configured to selectively provide power from the battery pack to the motor, and a power output shaft that receives torque from the motor and protrudes from a side of the housing. The power output shaft is connected to the vibration mechanism to drive the vibration mechanism. The gas engine replacement device further includes an electronic processor coupled to the power switch network and configured to control the power switch network to rotate the motor. The electronic processor is configured to rotate the motor in a first direction. When the motor is rotated in the first direction, the vibration mechanism vibrates the vibration plate and propels in a forward direction to move the compactor system. The electronic processor is configured to rotate the motor in a second direction. The vibration mechanism vibrates the vibration plate but does not propel the vibration plate in the forward direction.

[0011] Yet another embodiment provides a compactor system including a frame having a handle, a first vibration plate supported by the frame, and a first vibration mechanism configured to drive the first vibration plate. The compactor system also includes a second vibration plate supported by the frame, a second vibration mechanism configured to drive the second vibration plate, and a gas engine replacement device. The gas engine replacement device includes a housing, a battery receptacle coupled to the housing and configured to removably receive a battery pack, and a motor located within the housing. The gas engine replacement device also includes a power switch network configured to selectively provide power from the battery pack to the motor, an electronic processor coupled to the power switch network and configured to control the power switch network to rotate the motor, and a power output shaft that receives torque from the motor and protrudes from a side of the housing. The power output shaft is connected to the first vibration mechanism to drive the first vibration mechanism through a first clutch mechanism and to the second vibration mechanism to drive the second vibration mechanism through a second clutch mechanism. The first clutch mechanism is operable to engage the power output shaft to the first vibration mechanism when the motor is rotated in a first direction and is operable to disengage the power output shaft from the first vibration mechanism when the motor is rotated in a second direction. The second clutch mechanism is operable to engage the power output shaft to the second vibration mechanism when the motor is rotated in the second direction and is operable to disengage the power output shaft from the second vibration mechanism when the motor is rotated in the first direction.

[0012] Yet another embodiment provides a compactor system including a frame including a handle, a vibration plate supported by the frame, and a vibration mechanism configured to drive the vibration plate. The compactor system also includes wheels supported by the frame to propel the compactor system over a ground surface and a gas engine replacement device. The gas engine replacement device includes a housing, a battery receptacle coupled to the housing and configured to removably receive a battery pack, and a motor within the housing. The gas engine replacement device also includes a power switch network configured to selectively provide power from the battery pack to the motor, an electronic processor coupled to the power switch network and configured to control the power switch network to rotate the motor, and a power output shaft that receives torque from the motor and protrudes from a side of the housing. The power output shaft is connected to the vibration mechanism to drive the vibration mechanism and to the wheels through a clutch mechanism. The clutch mechanism is operable to engage the power output shaft to the wheels to propel the compactor system in a forward direction when the motor is rotated in a first direction and disengage the power output shaft from the wheels when the motor is rotated in a second direction.

[0013] Yet another embodiment provides a compactor system including a frame including a handle, a first vibration mechanism configured to drive a first vibration plate, and a first battery-powered gas engine replacement device. The first battery-powered gas engine replacement device includes a first motor, a first electronic processor coupled to the first motor and configured to control rotation of the first motor, and a first power output shaft that receives torque from the first motor and is connected to the first vibration mechanism to drive the first vibration mechanism. The compactor system also includes a second vibration mechanism configured to drive a second vibration plate and a second battery-powered gas engine replacement device. The second battery-powered gas engine replacement device includes a second motor, a second electronic processor coupled to the second motor and configured to control rotation of the second motor, and a second power output shaft that receives torque from the second motor and is connected to the second vibration mechanism to drive the second vibration mechanism. The compactor system further includes a master electronic processor electrically connected to the first and second electronic processors. The master electronic processor is configured to determine an operating mode of the compactor system, provide a first control signal to the first electronic processor based on the operating mode, and provide a second control signal to the second electronic processor based on the operating mode.

[0014] Before any embodiments are explained in detail, it is to be understood that the embodiments are not limited in their application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. Embodiments described herein are capable of being practiced or being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of "including," "comprising," "having" and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. The terms "mounting," "connected" and "coupled" are used broadly and encompass both direct and indirect mounting, connecting, and coupling. Further, "connected" and "coupled" are not restricted to physical or mechanical connections or couplings, but can include electrical connections or couplings, whether direct or indirect. Additionally, "and / or" where used herein is to be taken as specific disclosure of each of the items listed in the list. For example "A and / or B" is to be taken as specific disclosure of each of the following items: A; B; A and B.

[0015] It should be noted that the embodiments described herein can be implemented utilizing a plurality of hardware and software-based devices and a plurality of different structural components. Further, and as described in subsequent paragraphs, the particular configurations illustrated in the drawings are intended to be exemplary embodiments and other alternative configurations are possible. The terms "processor," "central processing unit," and "CPU" are interchangeable. Where the term "processor," "central processing unit," or "CPU" is used as an identifier for a unit that performs a particular function, it is understood that such function can be performed by a single processor or a plurality of processors arranged in any form, including parallel, serial, columnar, or cloud processing configurations / cloud computing configurations, unless otherwise specified.

[0016] Additionally, it is to be understood that the embodiments can include hardware, software, and electronic components or modules that can be adapted in a variety of ways to implement the various aspects disclosed herein. Furthermore, it is to be understood that the embodiments can be implemented by hardware, software, and / or firmware, including one or more signal processors or microprocessors, and any associated circuitry. As such, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting. As used herein, the term "and / or" encompasses all combinations of one or more of the associated listed items. As used herein, the term "includes" means includes but not limited to, or is equivalent to "comprising." As used herein, the term "estimates" means estimates, but not necessarily exactly, or is equivalent to "estimates approximately." As used herein, the term "coupled" means directly coupled, or is equivalent to various forms of "coupled" such as "connected," "attached," "adjoined," "bound," "fastened," "joined," "engaged," "interconnected," "routed," "suspended," "transmitted," "transferred," "exchanged," "routed," "directly connected," "indirectly connected," "fluidly connected," "electrically connected," "electrically coupled," "electronically connected," "electronically coupled," "magnetic coupled," "hydraulically connected," "hydraulically coupled," "pneumatic connected," "pneumatically coupled," "chemical coupled," "mechanically connected," "mechanically coupled," "physically connected," "physically coupled," and the like, depending upon the dictates of the specifications. As used herein, the term "includes" means includes but not limited to, or is equivalent to "comprising." As used herein, the term "estimates" means estimates, but not necessarily exactly, or is equivalent to "estimates approximately." As used herein, the term "coupled" means directly coupled, or is equivalent to various forms of "coupled" such as "connected," "attached," "adjoined," "bound," "fastened," "joined," "engaged," "interconnected," "routed," "suspended," "transmitted," "transferred," "exchanged," "routed," "directly connected," "indirectly connected," "fluidly connected," "electrically connected," "electrically coupled," "electronically connected," "electronically coupled," "magnetic coupled," "hydraulically connected," "hydraulically coupled," "pneumatic connected," "pneumatically coupled," "chemical coupled," "mechanically connected," "mechanically coupled," "physically connected," "physically coupled," and the like, depending upon the dictates of the specifications.

[0017] Other features and aspects will become apparent by consideration of the following detailed description and accompanying drawings. BRIEF DESCRIPTION OF DRAWINGS

[0018] Figure 1 This is a perspective view of a gas engine replacement device according to an embodiment.

[0019] Figure 2 yes Figure 1 A plan view of the gas engine replacement unit.

[0020] Figure 3 yes Figure 1 A schematic diagram of a gas engine replacement device.

[0021] Figure 4 yes Figure 1 A perspective view of the battery pack for a gas engine replacement device.

[0022] Figure 5 yes Figure 4 A cross-sectional view of the battery pack.

[0023] Figure 6 yes Figure 1 A cross-sectional view of the battery socket of the gas engine replacement device.

[0024] Figure 7 yes Figure 1 A cross-sectional view of the motor of the gas engine replacement device.

[0025] Figure 8 yes Figure 1 A schematic diagram of the motor, gear system, and power output shaft of the gas engine replacement device.

[0026] Figure 9 yes Figure 1 A block diagram of a gas engine replacement device.

[0027] Figure 10 It is used for driving Figure 1 A schematic diagram of the power switch network for the motor of a gas engine replacement device.

[0028] Figure 11A This demonstrates the operation of the motor during forward rotation. Figure 10 A diagram illustrating the operation of a power switch network.

[0029] Figure 11B This demonstrates the operation during motor reverse operation. Figure 10 A diagram illustrating the operation of a power switch network.

[0030] Figure 12 It is used for Figure 1 A flowchart of a method for bidirectional operation of a gas engine replacement device.

[0031] Figure 13 It includes Figure 1 A perspective view of the compactor of the gas engine replacement device.

[0032] Figure 14 yes Figure 13 A plan view of the compactor.

[0033] Figure 15 It includes Figure 1 A three-dimensional diagram of the pump system of the gas engine replacement device.

[0034] Figure 16 It includes Figure 1 A schematic diagram of the outdoor power equipment for a gas engine replacement device.

[0035] Figure 17 It includes Figure 1 A schematic diagram of the outdoor power equipment for a gas engine replacement device.

[0036] Figure 18 It includes two Figure 1 A schematic diagram of the compactor of the gas engine replacement device.

[0037] Figure 19 It is used for operation Figure 18 The flowchart shows the method of using a compactor. Detailed Implementation

[0038] like Figure 1 and Figure 2 As shown, a gas engine replacement device 10 for use with a power unit includes a housing 14 having a first side 18, a second side 22 adjacent to the first side 18, a third side 26 opposite to the second side 22, a fourth side 28 opposite to the first side 18, a fifth side 30 extending between the second side 22 and the third side 26, and a sixth side 32 opposite to the fifth side 30. The gas engine replacement device 10 also includes a flange 34 coupled to the housing 14 on the first side 18, an electric motor 36 located within the housing 14, and a power output shaft 38 projecting from the second side 22 and receiving torque from the motor 36. As explained in further detail below, in some embodiments, the power output shaft 38 projects from the first side 18 and from the flange 34. Figure 3 As shown, the gas engine replacement device 10 also includes control electronics 42, which is located within the housing 14 and includes wiring and a controller 46 electrically connected to the motor 36. A similar gas engine replacement device 10 is described and illustrated in U.S. Patent Application No. 16 / 551,197, filed August 26, 2019, the entire contents of which are incorporated herein by reference.

[0039] like Figures 1 to 6As shown in FIG. 1, the gas engine replacement device 10 also includes a battery pack 50 that is removably received in a battery receptacle 54 in the housing 14 to deliver electrical current from the battery pack 50 to the motor 36 via the control electronics 42. Referring to Figures 4 to 6 , the battery pack 50 includes a battery pack housing 58 having a support portion 62 and a first terminal 66 that is electrically connected to a plurality of battery cells 68 supported by the pack housing 58. The support portion 62 provides a sliding arrangement having raised / depressed portions 70 that mate with complementary raised / depressed portions 74 of the battery receptacle 54, as shown in Figure 6 . In the embodiment shown in Figures 4 to 6 , the raised / depressed portions 70 of the battery pack 50 are rails and the raised / depressed portions 74 of the battery receptacle 54 are guide depressions. A similar battery pack is described and shown in U.S. Patent Publication No. 2019 / 0006980, filed July 2, 2018, the entire contents of which are incorporated herein by reference. In some embodiments, the battery cells 68 have a nominal voltage of up to about 80 V. In some embodiments, the battery cells 68 have a nominal voltage of up to about 120 V. In some embodiments, the battery pack 50 has a weight of up to about 6 lb. In some embodiments, each of the battery cells 68 has a diameter of up to 21 mm and a length of up to about 71 mm. In some embodiments, the battery pack 50 includes up to twenty battery cells 68. In some embodiments, the battery cells 68 are connected in series. In some embodiments, the battery cells 68 are operable to output a sustained run discharge current of between about 40 A and about 60 A. In some embodiments, each of the battery cells 68 has a capacity of between about 3.0 Ah and about 5.0 Ah.

[0040] Figure 6A battery receptacle 54 of the gas engine replacement device 10 is shown in accordance with some embodiments. The battery receptacle 54 includes a protrusion / recess 74, a second terminal 78, a latching mechanism 82, and a power-off switch 86. The protrusion / recess 74 cooperates with the protrusion / recess 70 of the battery pack 50 to attach the battery pack 50 to the battery receptacle 54 of the gas engine replacement device 10. When the battery pack 50 is attached to the gas engine replacement device 10, the second terminal 78 and the first terminal 66 are electrically connected to each other. The latching mechanism 82 protrudes from a surface of the battery receptacle 54 and is configured to engage the battery pack 50 to maintain engagement between the battery pack 50 and the battery receptacle 54. Thus, the battery pack 50 can be connected to and supported by the battery receptacle 54 such that the battery pack 50 can be supported by the housing 14 of the gas engine replacement device 10. In some embodiments, the battery pack receptacle 54 is arranged at a location on the housing 14 such that a maximum possible separation distance is created between the motor 36 and the battery pack 50 in order to dampen vibrations transmitted from the motor 36 to the battery pack 50. In some embodiments, an elastomeric member is positioned on the battery pack receptacle 54 in order to dampen vibrations transmitted from the motor 36 to the battery pack 50 via the housing 14.

[0041] In other embodiments (not shown), the latching mechanism 82 can be provided at different locations (e.g., on a side wall, an end wall, an upper end wall, etc. of the battery receptacle 54) such that the latching mechanism 82 engages a corresponding structure on the battery pack 50 to maintain engagement between the battery pack 50 and the battery receptacle 54. The latching mechanism 82 includes a pivotable actuator or handle 90 that operatively engages a latching member 94. The latching member 94 is slidably provided in a bore 98 of the receptacle 54 and is biased by a biasing member 102 (e.g., a spring) toward a latching position to protrude through a surface of the battery receptacle 54 and into a cavity of the battery pack 50.

[0042] The latching mechanism 82 also includes a de-energization switch 86 (e.g., a micro switch) that facilitates electrically connecting / disconnecting the battery pack 50 with the battery receptacle 54 during actuation of the handle 90 to withdraw the latching member 94 from the battery pack 50. The de-energization switch 86 can be used to electrically disconnect the battery pack 50 from the gas engine replacement device 10 prior to removal of the battery pack 50 from the battery receptacle 54. The de-energization switch 86 is actuated when the latching member 94 moves from the latched position (i.e., when the latching member 94 is fully within the cavity of the battery pack 50) to the intermediate position. The de-energization switch 86 is electrically connected to the controller 46 and can generate an interrupt to indicate that the battery pack 50 is being disconnected from the gas engine replacement device 10. When the controller 46 receives the interrupt, the controller 46 begins a brownout operation to safely power down the control electronics 42 of the gas engine replacement device 10. A similar latching mechanism and disconnect switch is described and illustrated in U.S. Patent Publication No. 2019 / 0006980, which is incorporated by reference herein in its entirety.

[0043] As shown in Figure 7 The motor 36 includes a motor housing 96 having an outer diameter 97, a stator 98 having a nominal outer diameter 102 of up to about 80 mm, a rotor 102 having an output shaft 106 and supported for rotation within the stator 98, and a fan 108. A similar motor is described and illustrated in U.S. Patent Publication No. 2019 / 0006980, which is incorporated by reference herein. In some embodiments, the motor 36 is a brushless DC motor. In some embodiments, the motor 36 has a power output of at least about 2760 W. In some embodiments, the power output of the motor 36 can drop below 2760 W during operation. In some embodiments, the diameter 109 of the fan 108 is greater than the diameter 97 of the motor housing 96. In some embodiments, the motor 36 can be stopped with an electronic clutch (not shown) for fast overload control. In some embodiments, the motor 36 has a volume of up to about 443,619 mm 3 The housing 14 includes an inlet vent and an outlet vent such that the motor fan 108 pulls air through the inlet vent and along the control electronics 42 to cool the control electronics 42 before the air is expelled through the outlet vent. In the embodiment illustrated in Figure 7 In some embodiments, the motor 36 is an inner rotor motor, but in other embodiments, the motor 36 can be an outer rotor motor having a nominal outer diameter (i.e., the nominal outer diameter of the rotor) of up to about 80 mm.

[0044] Referring to Figure 8, the motor 36 can transmit torque to the power take-off shaft 38 in a variety of configurations. In some embodiments, the output shaft 106 is also the power take-off shaft 38, such that the motor 36 directly drives the power take-off shaft 38 without any intervening gear train. For example, the motor 36 can be a direct drive high pole count motor. As shown in FIG. 1 4, Figure 8 In other embodiments, the gas engine replacement device 10 includes a gear train 1 10 that transmits torque from the motor 36 to the power take-off shaft 38. In some embodiments, the gear train 1 10 can include a mechanical clutch (not shown) to interrupt the transmission of torque from the motor 36 to the power take-off shaft 38. In some embodiments, the gear train 1 10 can include a planetary transmission that transmits torque from the output shaft 106 to the power take-off shaft 38, and the rotational axis of the output shaft 106 is coaxial with the rotational axis of the power take-off shaft 38. In some embodiments, the gear train 1 10 includes a spur gear that engages with the output shaft 106 of the rotor, such that the rotational axis of the output shaft 106 is offset from and parallel to the rotational axis of the power take-off shaft 38. In some embodiments, the gear train 1 10 includes a bevel gear, such that the rotational axis of the output shaft 106 is perpendicular to the rotational axis of the power take-off shaft 38. In other embodiments that utilize a bevel gear, the rotational axis of the output shaft 106 is not perpendicular, parallel, or coaxial with the rotational axis of the power take-off shaft 38, and the power take-off shaft 38 protrudes from the flange 34.

[0045] In some embodiments, the gas engine replacement device 10 includes an on / off indicator (not shown). In some embodiments, the gas engine replacement device 10 includes a filter (not shown) to block airborne debris from the motor 36 and the control electronics 42. In some embodiments, the filter includes a dirty filter sensor (not shown) and a self-cleaning mechanism (not shown). In some embodiments, the motor 36 will simulate a gas engine response when encountering resistance, such as slowing or stalling. In some embodiments, the gas engine replacement device 10 includes a heat sink 202 in the housing 14 for air cooling the control electronics 42 Figure 1 and Figure 2 In some embodiments, the gas engine replacement device 10 is liquid cooled.

[0046] In some embodiments, the output shaft 106 of the rotor 102 has forward and reverse capability, as described further below. In some embodiments, the forward and reverse capability is controllable without shifting the gear train 110, as compared to gas engines that cannot achieve forward / reverse capability without additional gearing and time delay. Thus, the gas engine replacement 10 provides increased speed, lighter weight, and lower cost. Because the gas engine replacement 10 has fewer moving parts and no combustion system as compared to a gas engine, the gas engine replacement also provides additional speed, weight, and cost advantages.

[0047] The gas engine replacement 10 is capable of operating for long periods of time in any orientation (vertical, horizontal, inverted) relative to the ground surface, which makes it superior to four-cycle gas engines that can only operate in one orientation and for a short period of time with slight tilting. Because the gas engine replacement 10 does not require gas, oil, or other fluids, the gas engine replacement can be inverted or run on any given side, shipped, and stored without leaking or spilling.

[0048] In operation, the gas engine replacement 10 can be used to replace a gas engine system. Specifically, by aligning a first bolt pattern defined by a plurality of apertures in the flange 34 with a second bolt pattern, the gas engine replacement 10 can be installed onto a power equipment having the second bolt pattern. In some embodiments, the flange 34 can include one or more intermediate mounting members or adapters arranged between the flange 34 itself and a flange of the power equipment having the second bolt pattern, such that the adapter(s) couple the flange 34 to the power equipment. In these embodiments, the adapters include both the second bolt pattern and the first bolt pattern, such that the first bolt pattern of the flange 34 is aligned with the first bolt pattern of the adapters, and the second bolt pattern of the adapters is aligned with the second bolt pattern defined in the power equipment, thereby allowing the flange 34 of the gas engine replacement 10 to be coupled to the power equipment.

[0049] Alternatively, the gas engine replacement 10 can be connected to a power equipment using a belt system by providing a belt that is operably connected to the power output shaft and the equipment functionality. Thus, the power output shaft 38 of the gas engine replacement 10 can be used to drive the equipment.

[0050] During operation, the housing 14 of the gas engine replacement unit 10 can be much cooler than the housing of the internal combustion unit because there is no combustion in the gas engine replacement unit 10. Specifically, when the gas engine unit is operating, the housing of the gas engine unit is 220 degrees Celsius or higher. In contrast, when the gas engine replacement unit 10 is operating, all outer surfaces of the housing 14 are below 95 degrees Celsius. Tables 1 and 2 below list in more detail the temperature limits of different components on the housing 14 of the gas engine replacement unit 10.

[0051] Table 1 below lists the Underwriters Laboratories (UL) temperature limits for different components typically used in power tools, whether they are made of metal, plastic, rubber, wood, ceramic, or glass. For example, in at least some embodiments, the gas engine replacement unit 10 will never exceed the rated temperature for plastics.

[0052] Table 1

[0053] Metal Plastic / rubber / wood Ceramic / glassy Accidental contact 85℃ 85℃ 85℃ Continuously held knobs and switches 55℃ 75℃ 65℃ Momentarily held knobs and switches (i.e. switches) 60℃ 80℃ 70℃

[0054] Table 2 below lists the UL temperature limits of the different components of the battery pack housing 58 of the battery pack 50, regarding whether these components are made of metal, plastic, or rubber. For example, in at least some embodiments, the gas engine replacement device 10 will never exceed the rated temperature for plastic.

[0055] Table 2

[0056] Metal Plastic / rubber Accidental contact 70℃ 95℃ Continuously held knobs and switches 55℃ 75℃ Momentarily held knobs and switches (i.e. switches) 60℃ 85℃

[0057] Figure 9 A simplified block diagram of a gas engine replacement device 10 according to an example embodiment is shown. Figure 9 As shown, the gas engine replacement device 10 includes an electronic processor 302, a memory 306, a battery pack 50, a power switch network 310, a motor 36, a rotor position sensor 314, a current sensor 318, a user input device 322 (e.g., a trigger or power button), a transceiver 326, and an indicator 330 (e.g., a light-emitting diode). In some embodiments, the gas engine replacement device 10 includes a... Figure 9 The components shown are fewer or additional. For example, the gas engine replacement device 10 may include a battery pack fuel gauge, work lights, additional sensors, a cut-off switch, a power-off switch 86, etc. In some embodiments, Figure 9 The gas engine replacement device 10 shown includes one or more of the following components: electronic processor 302, memory 306, power switch network 310, rotor position sensor 314, current sensor 318, user input device 322 (e.g., trigger or power button), transceiver 326, and indicator 330 (e.g., light-emitting diode).Figure 3 At least a portion of the control electronics 42 shown in FIG. 1, where the electronic processor 302 and the memory 306 form Figure 3 At least a portion of the controller 46 shown in FIG. 1.

[0058] The memory 306 includes read-only memory (ROM), random-access memory (RAM), other non-transitory computer-readable media, or a combination thereof. The electronic processor 302 is configured to communicate with the memory 306 to store data and retrieve stored data. The electronic processor 302 is configured to receive instructions and data from the memory 306 and execute the instructions, among other things. In particular, the electronic processor 302 executes instructions stored in the memory 306 to perform the methods described herein.

[0059] As described above, in some embodiments, the battery pack 50 is removably attached to the housing of the gas engine replacement device 10, such that different battery packs 50 can be attached to and removed from the gas engine replacement device 10 to provide different amounts of power to the gas engine replacement device 10. Further description of the battery pack 50 (e.g., nominal voltage, continuous operating discharge current, size, number of battery cells, operation, etc.) and further description of the motor 36 (e.g., power output, size, operation, etc.) are described above with respect to Figures 1 to 8 Provided.

[0060] The power switching network 310 enables the electronic processor 302 to control the operation of the motor 36. Generally, when the user input device 322 is depressed (or otherwise actuated), current is supplied from the battery pack 50 to the motor 36 via the power switching network 310. When the user input device 322 is not depressed (or otherwise actuated), current is not supplied from the battery pack 50 to the motor 36. In some embodiments, the amount that the user input device 322 is depressed correlates to or corresponds to a desired rotational speed of the motor 36. In other embodiments, the amount that the user input device 322 is depressed correlates to or corresponds to a desired torque. In other embodiments, a separate input device (e.g., a slider, a dial, etc.) is included on the gas engine replacement device 10 that communicates with the electronic processor 302 to provide a desired rotational speed or torque to the motor 36.

[0061] In response to the electronic processor 302 receiving a drive request signal from the user input device 322, the electronic processor 302 activates the power switching network 310 to provide power to the motor 36. Through the power switching network 310, the electronic processor 302 controls the amount of current available to the motor 36, thereby controlling the speed and torque output of the motor 36. The power switching network 310 can include a number of field effect transistors (FETs), bipolar transistors, or other types of electrical switches. For example, the power switching network 310 can include a six-FET bridge (seeFigure 10 ), which receives pulse width modulated (PWM) signals from the electronic processor 302 to drive the motor 36.

[0062] The rotor position sensor 314 and the current sensor 318 are coupled to the electronic processor 302 and communicate various control signals to the electronic processor 302 indicative of different parameters of the gas engine replacement device 10 or the motor 36. In some embodiments, the rotor position sensor 314 includes one Hall sensor or multiple Hall sensors. In other embodiments, the rotor position sensor 314 includes a quadrature encoder attached to the motor 36. The rotor position sensor 314 outputs motor feedback information to the electronic processor 302 such as an indication (e.g., a pulse) when a magnet of a rotor of the motor 36 rotates past a surface of a Hall sensor. In other embodiments, the rotor position sensor 314 includes a voltage or current sensor, for example, that provides an indication of back electromotive force (back emf) generated in a motor coil. The electronic processor 302 can determine rotor position, rotor speed, and rotor acceleration based on the back emf signals received from the rotor position sensor 314 (i.e., voltage or current sensor). The rotor position sensor 314 can be combined with the current sensor 318 to form a combined current and rotor position sensor. In this example, the combined sensor provides current to the active phase coil(s) of the motor 36 and also provides current in one or more of the inactive phase coil(s) of the motor 36. The electronic processor 302 measures current to the motor based on the current to the active phase coils and measures motor speed based on the current in the inactive phase coils.

[0063] Based on motor feedback information from the rotor position sensor 314, the electronic processor 302 can determine the position, velocity, and acceleration of the rotor. In response to the motor feedback information and signals from the user input device 322, the electronic processor 302 transmits control signals to control the power switch network 310 to drive the motor 36. For example, by selectively enabling and disabling the FETs of the power switch network 310, power received from the battery pack 50 is selectively applied to the stator windings of the motor 36 in a cyclical fashion to cause the rotor of the motor 36 to rotate. The electronic processor 302 uses the motor feedback information to ensure proper timing of the control signals to the power switch network 310, and in some cases, provides closed loop feedback to control the velocity of the motor 36 at a desired level. For example, to drive the motor 36, using motor positioning information from the rotor position sensor 314, the electronic processor 302 determines the position of the rotor magnet relative to the stator windings and (a) energizes the next stator winding pair (or stator winding pairs) in a predetermined pattern to provide a magnetic force to the rotor magnet in a desired direction of rotation, and (b) de-energizes the previously energized stator winding pair (or stator winding pairs) to prevent the application of a magnetic force on the rotor magnet in the opposite direction of rotation of the rotor.

[0064] The current sensor 318 monitors or detects the current level of the motor 36 during operation of the gas engine replacement device 10 and provides control signals to the electronic processor 302 indicative of the detected current level. The electronic processor 302 can use the detected current level to control the power switch network 310, as explained in more detail below.

[0065] The transceiver 326 allows the electronic processor 302 to communicate with an external device (e.g., a smartphone, tablet, or laptop) through a wired or wireless communication network 334. In some embodiments, the transceiver 326 can include separate transmitting and receiving components. In some embodiments, the transceiver 326 can include a wireless adapter attached to the gas engine replacement device 10. In some embodiments, the transceiver 326 is a wireless transceiver that encodes information received from the electronic processor 302 into a carrier wireless signal and transmits the encoded wireless signal through the communication network 334 to the external device 338. The transceiver 326 also decodes information from wireless signals received through the communication network 334 from the external device 338 and provides the decoded information to the electronic processor 302.

[0066] The communication network 334 provides a wired or wireless connection between the gas engine replacement device 10 and the external device 338. The communication network 334 can include a short-range network, such as a BLUETOOTH (Bluetooth®) network, a Wi-Fi network, or the like, or a long-range network, such as the Internet, a cellular network, or the like.

[0067] like Figure 9 As shown, indicator 330 is also connected to electronic processor 302 and receives control signals from electronic processor 302 to turn the gas engine replacement device 10 on and off based on different states or otherwise transmit information. Indicator 330 includes, for example, one or more light-emitting diodes (“LEDs”) or a display screen. Indicator 330 can be configured to display the status of gas engine replacement device 10 or information associated with gas engine replacement device. For example, indicator 330 is configured to indicate measured electrical characteristics of gas engine replacement device 10, status of gas engine replacement device 10, mode of gas engine replacement device 10, etc. Indicator 330 may also include elements that transmit information to a user via auditory or tactile output. In some embodiments, indicator 330 includes an eco indicator that indicates the electrical force used by the load during operation.

[0068] Figure 9 The connections between the components of the gas engine replacement device 10 are simplified in the diagram. In reality, the wiring of the gas engine replacement device 10 is more complex because the components are interconnected via several lines for power and control signals. For example, each FET of the power switch network 310 is connected to the electronic processor 302 via a control line; each FET of the power switch network 310 is connected to a terminal of the motor 36; the power lines from the battery pack 50 to the power switch network 310 include a positive line and a negative / ground line; and so on. Additionally, the power lines may have a large gauge / diameter to handle increased current. Furthermore, although not shown, additional control signal lines and power lines are used to interconnect additional components of the gas engine replacement device 10.

[0069] Figure 10 An example of a power switch network 310 for driving a motor 36 of a gas engine replacement device 10 is shown. The power switch network 310 includes three high-side FETs H1, H2, and H3 and three low-side FETs L1, L2, and L3, each having a first or on state and a second or off state. The power switch network 310 is used to selectively apply power from a battery pack 50 to the motor 36. An example of how the high-side and low-side switches are controlled to operate the motor 36 in forward and reverse directions is described below.

[0070] High-side and low-side switches can be controlled using (pulse width modulation) commutation, centerline commutation, or other commutation schemes. Figure 11A A simple PWM commutation method is demonstrated for controlling the rotation of motor 36 in the positive direction. For example... Figure 11AAs shown, each high-side FET H1, H2, and H3 is periodically turned on throughout the commutation phase. When one of the FETs H1, H2, and H3 stops conducting, the next high-side FET begins conducting. Similarly, each low-side FET L1, L2, and L3 is periodically turned on throughout the commutation phase. When one of the FETs L1, L2, and L3 stops conducting, the next low-side FET begins conducting. However, one or both of the high-side or low-side FETs can be activated (e.g., with a PWM signal having a 75%, 50%, 25%, or another duty cycle) for only certain periods of the commutation phase based on a desired speed of the motor 36 or a load on the motor 36. In the example shown, to drive the motor 36 in the forward direction, the high-side and low-side FETs are activated in a predetermined pair and a predetermined order. In Figure 11A In the example shown, H1 and L2 are activated first, then H2 and L3 are activated, and then H3 and L1 are activated. In forward operation, this order continues during operation of the motor 36. Figure 11B A simple PWM commutation for controlling the motor 36 to rotate in the reverse direction is shown. In the example shown, H1 and L3 are activated first, then H3 and L2 are activated, and then H2 and L1 are activated. In reverse operation, this order continues during operation of the motor 36. In some embodiments, one or more variations to this order can be performed based on a desired motor operation. For example, one or both of the high-side and low-side FETs can be switched at a certain frequency during their activation phase to control the speed of the motor. Additionally, the activation phases of the high-side and low-side FETs can transition to create overlap with other activations to enable different controls (e.g., field-oriented control). Figure 11B In the example shown, H1 and L2 are activated first, then H2 and L3 are activated, and then H3 and L1 are activated. In forward operation, this order continues during operation of the motor 36.

[0071] Figure 12 is a flowchart of an example method 400 for bidirectional operation of the motor 36. The method 400 includes causing the motor 36 to rotate in a first direction (at block 405). Depending on the desired functionality of the power device, the motor 36 can rotate in the forward or reverse direction. For example, the electronic processor 302 provides a PWM control signal as shown to cause the motor to rotate in the forward direction (e.g., the first direction). The electronic processor 302 can adjust the duty cycle of the PWM signal to adjust the speed of operation. Figure 11A In the example shown, H1 and L2 are activated first, then H2 and L3 are activated, and then H3 and L1 are activated. In forward operation, this order continues during operation of the motor 36.

[0072] The method 400 also includes receiving an input to switch the direction of rotation of the motor 36 (at block 410). The user can provide this input through the user input device 322. For example, the user input device 322 can be a forward / reverse switch that is actuated by the user, or a mode selection switch that allows the user to select an operating mode. The user input device 322 provides a control signal to the electronic processor 302 to switch the direction of rotation of the motor 36 based on actuation of the user input device 322. In some embodiments, the input can be received from one or more sensors of the power plant that the gas engine replacement device 10 is replaced from or coupled with. In some embodiments, the input can be received from, for example, a smartphone over the communication network 334.

[0073] The method 400 further includes controlling the power switching network 310 to stop the motor 36 (at block 415). The electronic processor 302 can use several techniques to stop the motor 36. In one example, the electronic processor 302 controls all the high-side and low-side FETs to turn off to allow the motor 36 to stop by inertia. Since no current is supplied to the motor when the FETs are turned off, the motor 36 stops due to friction or load acting on the motor 36. In other examples, passive or active braking can be used to stop the motor 36. During passive braking, the electronic processor 302 can provide control signals to the high-side and low-side FETs to connect the motor to a braking load (e.g., a braking coil or a braking resistor coupled between one or more stator coils and ground) in order to quickly dissipate the energy in the motor 36 and brake the motor 36. During active braking, the electronic processor 302 can control the high-side FETs to turn off and the low-side FETs to turn on to short the motor coils to ground and dissipate the remaining energy in the coils to ground. In other examples, the electronic processor 302 can provide control signals to the high-side and low-side FETs to perform regenerative braking and provide the energy in the motor 36 back to the battery pack 50 through the power switching network 310. In yet another example, dynamic pulses can be used to brake the motor 36. The electronic processor 302 can provide control signals to the high-side and low-side FETs to provide an electric braking force on the rotor of the motor 36. The electronic processor 302 can monitor the rotor position sensor 314 to activate a phase (i.e., a corresponding pair of high-side and low-side FETs) as the rotor just passes through the phase. For example, the rotor position sensor 314 indicates that the rotor just turned through a phase corresponding to FETs H1 and L2. In response, the electronic processor 302 can activate FETs H1 and L2 to drive current through the stator coils to generate a magnetic field that provides a braking force to the rotor in a direction opposite to the direction of rotation of the rotor to stop the rotation. The electronic processor 302 can continue to activate the phases in a similar manner as the rotor passes through each phase. Figure 11AThe FET pairs are activated sequentially, but with timing based on rotor position information from rotor position sensor 314, so that the resulting magnetic field generated by the coupled stator coils continues to provide braking force to stop the rotation.

[0074] Method 400 also includes rotating motor 36 in a second direction (in block 420) after the motor has stopped by the control power switch network 310. For example, electronic processor 302 provides, for example, Figure 11B The PWM control signal shown is used to cause the motor to rotate in the opposite direction (e.g., a second direction). The electronic processor 302 can adjust the duty cycle of the PWM signal to adjust the operating speed. Method 400 is repeated whenever a change in rotation direction is needed.

[0075] Figure 13 A compactor 576 is shown, comprising a frame 580 supporting a gas engine replacement device 10, a vibrating plate 584, and a vibration mechanism 588 located between the gas engine replacement device 10 and the vibrating plate 584, such that the gas engine replacement device 10 can drive the vibration mechanism 588 to drive the vibrating plate 584. The frame 580 includes a handle 592 and also supports a water tank 596 having a valve 600 through which water or other liquids can be applied to the surface to be compacted or the vibrating plate 584. In some embodiments, the compactor 576 includes a sprayer 604 for spraying and marking lines or boundaries during and around the compaction operation.

[0076] During operation, the operator can grasp handle 592 and activate the gas engine replacement device 10 to drive the vibratory plate 584 to compact soil or asphalt, including most non-sticky granular mixtures. During operation, the operator can control valve 600 to allow water from water tank 596 to be applied to the compacted surface, such that in some applications, the water allows the compacted particles to form a paste and bind together, resulting in a denser or more compact finished surface. Additionally, the water from water tank 596 prevents asphalt or other materials from adhering to the vibratory plate 584 during operation.

[0077] The compactor 576 can be used in parking lot and highway or bridge construction. Specifically, the compactor 576 can be used in building areas close to structures, curbs, and foundations. The compactor 576 can also be used for subbase and paving compaction landscaping. The compactor 576, including the gas engine replacement device 10, has advantages over conventional internal combustion engine compactors, some of which will be discussed below. For example, the motor 36 of the gas engine replacement device 10 can operate in either forward or reverse direction, allowing the operator to switch the directional bias of the vibration mechanism 588. Thus, the vibration mechanism 588 is configured to move or "walk" itself in either forward or reverse direction, depending on how the operator switches the directional bias of the vibration mechanism 588.

[0078] Figure 14 Another example of a compactor 700 is shown that includes a frame 704 supporting the gas engine replacement device 10, a vibrating plate 708, and a vibrating mechanism 712 (e.g., an exciter) between the gas engine replacement device 10 and the vibrating plate 708 such that the gas engine replacement device 10 can drive the vibrating mechanism 712 to drive the vibrating plate 708. The frame 704 includes a handle 716 for a user to hold and move the compactor 700. The gas engine replacement device 10 is connected to the vibrating mechanism 712 using a belt 720. The belt 720 couples the power output shaft 38 to the vibrating mechanism 712 such that when the power output shaft 38 rotates, the belt 720 rotates with the power output shaft 38, thereby causing the vibrating mechanism 712 to be excited. The vibrating mechanism 712 in turn vibrates the vibrating plate 708.

[0079] Typically, gas engine plate compactors include only one mode of operation. In particular, the gas engine can cause the motor to rotate in only one direction, which limits the functionality of the plate compactor. In contrast, the compactor 700 includes the gas engine replacement device 10 that includes the motor 36 that can rotate in both the forward and reverse directions. Accordingly, the compactor 700 is adapted to perform different functions based on the direction of rotation of the motor. When the electronic processor 302 causes the motor 36 to rotate in the first direction (e.g., as in block 405), the vibrating mechanism 712 can drive the vibrating plate 708 to provide both compaction and movement in the forward direction of the compactor 700. The vibrating mechanism 712 is, for example, an asymmetric rotating mass. As the mass rotates about the axle, the mass exerts an unbalanced force on the axle, which is then transferred to the vibrating plate 708. The vibrating mechanism 712 can be located at the front of the vibrating plate 708, e.g., forward of the center of mass of the vibrating plate 708, to allow the vibrating plate 708 to move forward. During rotation, the mass of the vibrating mechanism first transfers rotational force to the vibrating plate 708 in an upward movement, lifting the front of the vibrating plate 708. The mass then transfers force in a forward movement, driving the vibrating plate 708 forward. That is, when the mass rotates in the first direction, the vibrating plate 708 is lifted during the upward movement of the mass and the vibrating plate 708 moves forward during the forward movement of the mass. The phase or vibration of the vibrating mechanism 712 can be controlled to provide the dual function of compaction and movement as described above. The phase can be controlled to cause the compactor 700 to advance forward at a slow walk pace. Accordingly, a user can operate the compactor 700 to easily traverse a work area while also providing compaction. Such operation reduces the physical strain on the user.

[0080] When the electronic processor 302 causes the motor 36 to rotate in the second direction (e.g., as in block 420), the vibration mechanism 712 can drive the vibration plate 708 to provide only compaction of the compactor 700 without providing movement of the compactor 700 in the reverse direction. When the mass of the vibration mechanism 712 rotates in the second direction, the mass lifts the front of the vibration plate 708 during the upward movement of the mass as described above. Additionally, the mass can also transfer the rearward movement of the mass to the vibration plate 708. However, because the rear of the vibration plate 708 is not lifted, the friction between the ground and the vibration plate 708 prevents the rearward movement of the compactor 700. The phase or vibration of the vibration mechanism 712 can be controlled to provide only the compaction function as described above. Thus, the user can operate the compactor 700 in areas where additional compaction is needed, for example, in tight spaces. This allows the user to loiter the compactor 700 where additional compaction is needed, which would otherwise need to be stopped from advancing when operating in the forward direction. A typical gas engine plate compactor requires a complex mechanical clutch and linkage to drive the vibration mechanism 712 in the reverse direction. For example, a gas engine plate compactor can use two vibration mechanisms to achieve reverse operation as described above. In contrast, the compactor 700 provides reverse operation with only a single vibration mechanism 712 and does not require a complex mechanical clutch.

[0081] Figure 15 A pump system 520 is shown that includes a frame 524 that supports the gas engine replacement device 10, and a pump 528 that is operable by the gas engine replacement device 10. The pump 528 shown is a centrifugal pump having an impeller positioned within a housing 532 of the pump 528 that is rotatable about an axis to move material from an inlet 536 of the pump 528 to an outlet 540 of the pump 528. In particular, the pump 528 is a "trash pump" that includes sufficient clearance (e.g., 8 millimeters) between the impeller and the housing 532 of the pump 528 to provide a mixture of liquid (e.g., water) and debris (e.g., solid material like mud, small stones, dirt, sand, sludge, etc.) to pass through the pump 528 from the inlet 536 to the outlet 540 without the debris becoming trapped within the pump 528 and degrading the performance of the pump system 520.

[0082] Typically, gas engine pumps include only one mode of operation. In particular, the gas engine can cause the motor to rotate in only one direction, which limits the functionality of the pump. In contrast, the pump system 520 includes the gas engine replacement device 10, which includes a motor 36 that can rotate in both a forward and a reverse direction. Accordingly, the pump system 520 is adapted to perform different functions based on the direction of rotation of the motor. When the electronic processor 302 causes the motor 36 to rotate in a first direction (e.g., as in block 405), the pump 528 can drive the impeller in a forward direction to move material from the inlet 536 of the pump 528 to the outlet 540 of the pump 528. When the electronic processor 302 causes the motor 36 to rotate in a second direction (e.g., as in block 420), the pump 528 can drive the impeller to clear a clog or to clear the pump 528 if debris is stuck within the pump 528 (without using a transmission including a forward gear and a reverse gear). In some embodiments, the motor 36 can be controlled by the electronic processor 302 to rotate in the second direction at a slower speed than in the first direction to clear a clog in the pump 528. For example, the electronic processor 302 can provide a PWM signal to the FETs of the power switch network 310 at a higher duty cycle when driving in the first direction than when driving in the second direction in order to cause the motor 36 to rotate at a higher speed in the first direction than in the second direction.

[0083] Figure 16 An example of an outdoor power equipment 750 including the gas engine replacement device 10, a first equipment function 754, and a second equipment function 758 is shown. The first equipment function 754 is coupled to the power output shaft 38 of the gas engine replacement device 10 using a first clutch mechanism 762. In the example shown, the first clutch mechanism 762 includes a first one-way clutch 766 mounted to the power output shaft 38. A first belt 770 couples the first one-way clutch 766 to the first equipment function 754. The first one-way clutch 766 is, for example, a ratchet bearing or the like that transmits rotational motion to the first belt 770 when the power output shaft 38 is rotating in a first direction but does not transmit rotational motion to the first belt 770 when the power output shaft 38 is rotating in a second, opposite direction. Accordingly, the first clutch mechanism 762 enables the first equipment function 754 when the motor 36 is rotating in the first direction and disables the first equipment function 754 when the motor 36 is rotating in the second direction. The first one-way clutch 766 and the first belt 770 are one example implementation of the first clutch mechanism 762. In some implementations, different mechanical components can be used to implement the first clutch mechanism 762 that enables the first equipment function 754 only when the rotor is rotating in the first direction.

[0084] The second device function 758 is coupled to the power take-off shaft 38 of the gas engine replacement 10 using a second clutching mechanism 778. In the illustrated example, the second clutching mechanism 778 includes a second one-way clutch 782 mounted to the power take-off shaft 38. A second belt 786 couples the second one-way clutch 782 to the second device function 758. The second one-way clutch 782 is, for example, a ratchet bearing that transmits rotational motion to the second belt 786 when the power take-off shaft 38 is rotating in a second direction but does not transmit rotational motion to the second belt 786 when the power take-off shaft 38 is rotating in a first direction. Thus, the second clutching mechanism 778 enables the second device function 758 when the motor 36 is rotating in the second direction and disables the second device function 758 when the motor 36 is rotating in the first direction. The second one-way clutch 782 and the second belt 786 are one example implementation of the second clutching mechanism 778. In some implementations, different mechanical components can be used to implement the second clutching mechanism 778 that enables the second device function 758 only when the rotor is rotating in the second direction.

[0085] The outdoor power equipment 750 is, for example, a dual-impeller plate compactor. In this example, the first device function 754 is a first vibration mechanism configured to drive a first vibration plate, and the second device function 758 is a second vibration mechanism configured to drive a second vibration plate. When the motor 36 is rotating in the first direction, power is transmitted to the first vibration mechanism via the first clutching mechanism 762. The first vibration mechanism thereby drives the first vibration plate and causes the plate compactor to advance, for example, in a forward direction. When the motor 36 is rotating in the second direction, power is transmitted to the second vibration mechanism via the second clutching mechanism 778. The second vibration mechanism thereby drives the second vibration plate and causes the plate compactor to advance, for example, in a reverse direction.

[0086] Figure 17 Another example outdoor power equipment 750 (e.g., a wheeled plate compactor) is illustrated. In the illustrated example, the outdoor power equipment 750 includes wheels 790 that cause the outdoor power equipment 750 to advance over the ground. In this example, the first device function 754 is a vibration mechanism configured to drive a vibration plate, and the second device function 758 is a wheel shaft 794 that is coupled to the wheels 790. When the motor 36 is rotating in the first direction, power is transmitted to the vibration mechanism via the first clutching mechanism 762. The vibration mechanism thereby drives the vibration plate. When the motor 36 is rotating in the second direction, power is transmitted to the wheels 790 via the second clutching mechanism 778. The wheels 790 can be used to drive the outdoor power equipment 750.

[0087] Figure 18An exemplary dual-actuator compactor 800 is shown that includes a frame 804 that supports two gas engine replacement devices 10 labeled first gas engine replacement device 10A and second gas engine replacement device 10B. The frame further supports a first vibrating plate 808 and a first vibration mechanism 812 (e.g., a first actuator) located between the first gas engine replacement device 10A and the first vibrating plate 808 such that the first gas engine replacement device 10A can drive the first vibration mechanism 812 to drive the first vibrating plate 808. The first gas engine replacement device 10A is connected to the first vibration mechanism 812 using a first belt 816. The first belt 816 couples the first power output shaft 38A of the first gas engine replacement device 10A to the first vibration mechanism 812 such that when the first power output shaft 38A rotates, the first belt 816 rotates with the first power output shaft 38A, thereby causing the first vibration mechanism 812 to be actuated. The first vibration mechanism 812 in turn vibrates the first vibrating plate 808.

[0088] The dual-actuator compactor 800 also includes a second gas engine replacement device 10B, a second vibrating plate 820, and a second vibration mechanism 824 (e.g., a second actuator) located between the second gas engine replacement device 10B and the second vibrating plate 820 such that the second gas engine replacement device 10B can drive the second vibration mechanism 824 to drive the second vibrating plate 820. The second gas engine replacement device 10B is connected to the second vibration mechanism 824 using a second belt 828. The second belt 828 couples the second power output shaft 38B to the second vibration mechanism 824 such that when the second power output shaft 38B rotates, the second belt 828 rotates with the second power output shaft 38B, thereby causing the second vibration mechanism 824 to be actuated. The second vibration mechanism 824 in turn vibrates the second vibrating plate 820.

[0089] The dual-actuator compactor 800 further includes a main controller 832 coupled to the first gas engine replacement device 10A to provide control signals to the first electronic processor 302A of the first gas engine replacement device 10A and coupled to the second gas engine replacement device 10B to provide control signals to the second electronic processor 302B of the second gas engine replacement device 10B. The main controller 832 can be implemented similarly to the electronic processor 302 and provides control signals to the first electronic processor 302A and the second electronic processor 302B based on a selected operating mode or a desired operation of the dual-actuator compactor 800.

[0090] Figure 19is a flowchart of an example method 850 for operating the dual-actuator compactor 800. The method 850 includes determining, using the host controller 832, an operating mode of the compactor 800 (at block 855). The host controller 832 can receive a user input through a user input device (e.g., a mode selector slider, dial, or button) of the compactor 800 or through a communication network from the external device 338 that is set based on input received through a graphical user interface on the external device 338. The user input indicates an operating mode of the compactor 800. The operating modes of the compactor 800 include, for example, forward push compaction, reverse push compaction, neutral compaction. Each mode can correspond to specific controls of the first gas engine replacement device 10A and the second gas engine replacement device 10B. A mapping between operating modes and controls of the first gas engine replacement device 10A and the second gas engine replacement device 10B can be stored in a memory of the host controller 832.

[0091] The method 850 also includes providing, using the host controller 832, a first control signal to the first electronic processor 302A based on the operating mode (at block 860) and providing, using the host controller 832, a second control signal to the second electronic processor 302B based on the operating mode (at block 865). As discussed above, the host controller 832 can determine specific controls for the first gas engine replacement device 10A and the second gas engine replacement device 10B based on the operating mode and provide corresponding control signals to the first gas engine replacement device 10A and the second gas engine replacement device 10B. For example, when the user selects forward push compaction, the host controller 832 can provide first and second control signals to control the speed, direction, and phase offset of the first gas engine replacement device 10A and the second gas engine replacement device 10B. By controlling the speed, direction, and / or phase offset of the first gas engine replacement device 10A and the second gas engine replacement device 10B, the vibratory plates 808, 820 can be controlled to provide compaction and push in a forward direction. In one example, forward push compaction can be achieved by controlling the motors 36 of the first gas engine replacement device 10A and the second gas engine replacement device 10B to rotate in a first direction.

[0092] In another example, when the user selects to advance the compactor backward, the master controller 832 can provide first and second control signals to control the speed, direction, and phase offset of the first and second gas engine replacement devices 10A, 10B. By controlling the speed, direction, and / or phase offset of the first and second gas engine replacement devices 10A, 10B, the vibratory plates 808, 820 can be controlled to provide compaction and advance in a backward direction. In one example, backward advancing compaction can be achieved by controlling the motors 36 of the first and second gas engine replacement devices 10A, 10B to rotate in a second direction.

[0093] In yet another example, when the user selects to center compaction, the master controller 832 can provide first and second control signals to control the speed, direction, and / or phase offset of the first and second gas engine replacement devices 10A, 10B. By controlling the speed, direction, and / or phase offset of the first and second gas engine replacement devices 10A, 10B, the vibratory plates 808, 820 can be controlled to provide compaction while remaining stationary. In one example, center compaction can be achieved by controlling the motors 36 of the first and second gas engine replacement devices 10A, 10B to rotate in opposite directions. That is, the motor 36 of the first gas engine replacement device 10A is controlled to rotate in a forward direction, and the motor 36 of the second gas engine replacement device 10B is controlled to rotate in a reverse direction, or vice versa.

[0094] The method 850 is repeated for each mode selection or mode change of the compactor 800. Those of ordinary skill in the art understand that the master controller 832 can be used to operate the dual-actuator compactor 800 in several other modes not explicitly described herein. Additionally, in some embodiments, the functions of the master controller 832 are incorporated into one of the electronic processors of the first or second gas engine replacement devices 10A, 10B, and the master controller 832 is not included in the dual-actuator compactor 800.

[0095] The several outdoor power equipment devices described above that are driven by gas engine replacement devices 10 include a number of advantages over conventional devices that are driven by internal combustion engines, some of which are discussed below.

[0096] In some embodiments, the gas engine replacement device 10 can be paired with a new device, and the memory 306 can be reprogrammed to optimize the gas engine replacement device 10 to operate with the new device. In some embodiments, the electronic processor 302 automatically identifies the type of new device that the gas engine replacement device 10 has been paired with, and governs the operation of the gas engine replacement device 10 accordingly. In some embodiments, the electronic processor 302 can automatically detect which device the gas engine replacement device 10 has been paired with via radio frequency identification (RFID) communication with the new device.

[0097] In some embodiments, the memory 306 is reprogrammable via BLUETOOTH or Wi-Fi communication protocols. In some embodiments, the electronic processor 302 has control modes for different uses of the same device. The control modes can be preset or user programmable, and can be remotely programmed via BLUETOOTH or Wi-Fi. In some embodiments, the electronic processor 302 utilizes master / slave device-to-device communication and coordination, such that the gas engine replacement device 10 can exert unidirectional control over the device, or an operator can exert unidirectional control over the gas engine replacement device 10 using a smartphone app.

[0098] In some embodiments, the operator or original equipment manufacturer (OEM) is allowed to limit control of the speed of the gas engine replacement device 10 by the electronic processor 302 via an interface such as a controller area network (CAN) bus. In some embodiments, the electronic processor 302 is able to utilize a single gear set in the gear train 110 for a wider range of speed selection compared to a gasoline engine. For example, the control electronics 42 are configured to drive the motor 36 at less than 2,000 RPM, which is lower than any speed that a gasoline engine is capable of reaching, allowing the associated device to have a longer total run time when the battery pack 50 is fully discharged compared to a gasoline engine. In addition, the control electronics 42 are configured to drive the motor at more than 3,600 RPM, which is higher than any speed that a gasoline engine is capable of reaching, and have the ability to deliver greater torque. The wider range of speeds of the motor 36 provides higher efficiency and capability compared to a gasoline engine. In some embodiments, in addition to speed, the operator can also control the current drawn by the motor 36.

[0099] In some embodiments, the electronic processor 302 is configured to record and report data. For example, the electronic processor 302 is configured to provide wired or wireless diagnostics for monitoring and reading the status of the gas engine replacement device 10. For example, the electronic processor 302 can monitor and record the run time of the gas engine replacement device 10, for example, in the case of a lease. In some embodiments, the motor 36 and the electronic processor 302 use regenerative braking to charge the battery pack 50. In some embodiments, the gas engine replacement device 10 includes a DC output (not shown) for lights or accessories. In some embodiments, the electronic processor 302 can detect abnormalities or malfunctions of the gas engine replacement device 10 via voltage, current, motion, speed, and / or thermocouples. In some embodiments, the electronic processor 302 can detect unintended use or stoppage of the gas engine replacement device 10. If the equipment being driven by the gas engine replacement device 10 is not operating with expected characteristics or is not being used properly or safely, the electronic processor 302 can detect the abnormality and deactivate the gas engine replacement device 10. For example, the gas engine replacement device 10 can include one or more accelerometers to sense whether the gas engine replacement device 10 and equipment are in an expected orientation. Also, if the electronic processor 302 determines that the gas engine replacement device 10 is not in an expected orientation (i.e., the equipment has been tipped over), the electronic processor 302 can deactivate the gas engine replacement device 10.

[0100] In some embodiments, the gas engine replacement device 10 includes an accessible sensor port (not shown) to electrically connect with a user-selected sensor (such as an accelerometer, gyroscope, GPS unit, or real-time clock) for use with the powered equipment, allowing the operator to customize the variables sensed and detected by the electronic processor 302. In some embodiments, the electronic processor 302 can indicate to the operator the status of the battery pack 50 via visual, audible, or tactile notifications, such as when the battery is low. In some embodiments, the electronic processor 302 can operate an auxiliary motor separate from the motor 36 to drive an auxiliary device, such as a winch. The auxiliary motor can be internal or external to the gas engine replacement device 10.

[0101] In some embodiments, the gas engine replacement device 10 can include digital controls on a customizable user interface, such as a touch display, or a combination of knobs and buttons. In contrast, analog gasoline engines do not include such digital controls. In some embodiments, the user interface of the gas engine replacement device 10 can be modular, wired or wireless, and can be attachable to the gas engine replacement device 10 or handheld. In some embodiments, the gas engine replacement device 10 can be controlled with a remote control that includes status indicators for certain characteristics of the gas engine replacement device 10, such as charge of the battery pack 50, and temperature. In some embodiments, the gas engine replacement device 10 can provide status indications with a remote programmable device.

Claims

1. A gas engine replacement device, comprising: a housing; a battery receptacle coupled to the housing and configured to removably receive a battery pack; a motor located within the housing; a power output shaft receiving torque from the motor and protruding from a side of the housing; a power switch network configured to selectively provide power from the battery pack to the motor; and an electronic processor coupled to the power switch network and configured to control the power switch network to rotate the motor, the electronic processor configured to: rotate the motor in a first direction, receive an input to switch a direction of rotation of the motor, and in response to receiving the input to switch the direction of rotation of the motor: (i) control the power switch network to stop the motor by performing an operation selected from the group consisting of: inertially stopping the motor, applying a passive brake to stop the motor, applying an active brake to stop the motor, and dynamically pulsing the motor in a phase opposite the first direction, and (ii) after controlling the power switch network to stop the motor in (i), rotate the motor in a second direction.

2. The gas engine replacement device of claim 1, further comprising: elastomeric members positioned on the battery receptacle, wherein the elastomeric members are configured to reduce vibrations transmitted from the motor to the battery pack.

3. The gas engine replacement device of claim 1, further comprising: a gear train coupled between an output shaft of the motor and the power output shaft, wherein a direction of rotation of the power output shaft is switched from the first direction to the second direction without a shift of the gear train. an operating temperature of the gas engine replacement device is less than 95 degrees Celsius.

4. The gas engine replacement device of claim 1, wherein, 5. The gas engine replacement device of claim 1, further comprising: a transceiver coupled to the electronic processor for communicating with an external device, wherein the input to switch the direction of rotation of the motor is received from the external device.

6. A compactor system comprising a gas engine replacement device, the compactor system comprising: a frame including a handle; a vibration plate supported by the frame; a vibration mechanism configured to drive the vibration plate; the gas engine replacement device, comprising: a housing, a battery receptacle coupled to the housing and configured to removably receive a battery pack, a motor located within the housing, a power switch network configured to selectively provide power from the battery pack to the motor, a power output shaft receiving torque from the motor and protruding from a side of the housing, the power output shaft connected to the vibration mechanism to drive the vibration mechanism; and an electronic processor coupled to the power switch network and configured to control the power switch network to rotate the motor, the electronic processor configured to: ​ rotating the motor in a first direction, wherein, when the motor is rotated in the first direction, the vibration mechanism vibrates the vibration plate and propels in a forward direction to move the compactor system, and rotating the motor in a second direction, wherein, when the motor is rotated in the second direction, the vibration mechanism vibrates the vibration plate but does not propel the vibration plate in the forward direction.

7. The compactor system of claim 6, further comprising: a clutch mechanism coupling the power output shaft to the vibration mechanism and configured to enable the vibration mechanism when the motor is rotated in the first direction and to disable the vibration mechanism when the motor is rotated in the second direction.

8. The compactor system of claim 6, further comprising a belt coupling the power output shaft to the vibration mechanism.

9. The compactor system of claim 6, further comprising: a gear train coupled between an output shaft of the motor and the power output shaft, wherein a direction of rotation of the power output shaft is switched from the first direction to the second direction without a shift of the gear train.

10. The compactor system of claim 6, further comprising: a transceiver coupled to the electronic processor for communicating with an external device, wherein the input for switching the direction of rotation of the motor is received from the external device.

11. A compactor system comprising a gas engine replacement device, the compactor system comprising: a frame comprising a handle; a vibration plate supported by the frame; a vibration mechanism configured to drive the vibration plate; and the gas engine replacement device comprising: a housing, a battery receptacle coupled to the housing and configured to removably receive a battery pack, a motor within the housing, a power switch network configured to selectively provide power from the battery pack to the motor, a power output shaft receiving torque from the motor and protruding from a side of the housing, the power output shaft connected to the vibration mechanism to drive the vibration mechanism; and an electronic processor coupled to the power switch network and configured to control the power switch network to rotate the motor, the electronic processor configured to: rotate the motor in a first direction, receive an input for switching a direction of rotation of the motor, and rotate the motor in a second direction.

12. The compactor system of claim 11, wherein, when the motor is rotated in the first direction, the vibration mechanism vibrates the vibration plate and propels in a forward direction to move the compactor system.

13. The compactor system of claim 12, wherein, when the motor is rotated in the second direction, the vibration mechanism vibrates the vibration plate but does not propel the vibration plate in the forward direction.

14. The compactor system of claim 11, further comprising: a clutch mechanism coupling the power output shaft to the vibration mechanism and configured to enable the vibration mechanism when the motor is rotated in the first direction and to disable the vibration mechanism when the motor is rotated in the second direction.

15. The compactor system of claim 11, further comprising: The system comprises wheels supported by the frame to propel the compactor system on the ground, wherein the power take-off shaft is connected to the wheels via a clutch mechanism, wherein the clutch mechanism is operable to engage the power take-off shaft with the wheels to propel the compactor system in a forward direction when the motor rotates in the first direction, and wherein the clutch mechanism is operable to disengage the power take-off shaft from the wheels when the motor rotates in the second direction.

16. The compactor system of claim 11, wherein, The vibration mechanism is a first vibration mechanism, and the vibrating plate is a first vibrating plate. The compactor system further includes: The second vibrating plate is supported by the frame; A second vibration mechanism is configured to drive the second vibration plate, wherein the power output shaft is connected to the first vibration mechanism via a first clutch mechanism to drive the first vibration mechanism, and is connected to the second vibration mechanism via a second clutch mechanism to drive the second vibration mechanism.

17. The compactor system of claim 16, wherein, When the motor rotates in the first direction, the first clutch mechanism operably engages the power output shaft with the first vibration mechanism, and when the motor rotates in the second direction, the first clutch mechanism operably disengages the power output shaft from the first vibration mechanism.

18. The compactor system of claim 17, wherein, When the motor rotates in the second direction, the second clutch mechanism operably engages the power output shaft with the second vibration mechanism, and when the motor rotates in the first direction, the second clutch mechanism operably disengages the power output shaft from the second vibration mechanism.

19. The compactor system of claim 17, further comprising a belt that connects the power output shaft to the first vibration mechanism.

20. The compactor system of claim 17, further comprising: A transceiver, connected to the electronic processor, is used to communicate with an external device, wherein the input for switching the rotation direction of the motor is received from the external device.

21. A pump system including a gas engine replacement device, the pump system comprising: frame; Pump; as well as The gas engine replacement device includes: case, A battery socket, which is attached to the housing and configured to removably receive a battery pack. The motor, which is located inside the housing, A power switching network configured to selectively supply power from the battery pack to the motor. A power output shaft that receives torque from the motor and protrudes from one side of the housing; the power output shaft is connected to the pump to drive the pump. as well as An electronic processor, connected to and configured to control the power switching network to rotate the motor, is configured as follows: Make the motor rotate in the first direction. Receives input for switching the rotation direction of the motor, and This causes the motor to rotate in the second direction.

22. An outdoor power unit, including a gas engine replacement device, the outdoor power unit comprising: Equipment Functional Department; as well as The gas engine replacement device includes: case, A battery socket, which is attached to the housing and configured to removably receive a battery pack. The motor, which is located inside the housing, A power switching network configured to selectively supply power from the battery pack to the motor. A power output shaft that receives torque from the motor and protrudes from one side of the housing; the power output shaft is connected to the device functional unit to drive the device functional unit. as well as An electronic processor, connected to and configured to control the power switching network to rotate the motor, is configured as follows: Make the motor rotate in the first direction. Receives input for switching the rotation direction of the motor, and This causes the motor to rotate in the second direction.

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