Motor control of a gas engine replacement device based on battery pack configuration data

Abstract

A gas engine replacement device includes: a housing; a battery socket coupled to the housing and configured to be removably connected to a battery pack having a memory for storing battery pack configuration data; a motor located within the housing; a power output shaft receiving torque from the motor and projecting from one side of the housing; a power switch network configured to selectively supply power from the battery pack to the motor; and a first electronic processor coupled to the power switch network and configured to control the power switch network to rotate the motor. The first electronic processor is configured to receive the battery pack configuration data in response to the connection of the battery pack to the battery socket and to control the power switch network based on the battery pack configuration data.

Description

[0001] Related applications

[0002] This application claims the benefit of U.S. Provisional Patent Application No. 62 / 946,226, filed on December 10, 2019, the entire contents of which are incorporated herein by reference. Technical Field

[0003] This application relates to a gas engine replacement motor unit, and more particularly to a gas engine replacement motor unit for use with power equipment. Background Technology

[0004] Currently, many outdoor power equipment (e.g., lawn and garden equipment) and construction equipment (e.g., concrete mixers, plate compactors) include gas engines that power the equipment. However, gas engines produce emissions and are generally not suited to the optimal performance of the power equipment. Summary of the Invention

[0005] Gas engine replacement units (also known as power heads) powered by lithium-ion battery packs and using electric brushless motors offer several advantages over gas engines when powering devices. However, battery-powered gas engine replacement units may have limited uptime compared to gasoline-powered engines of similar size. Gasoline has a higher energy density than current lithium-ion battery chemistry or other widely available battery technologies.

[0006] In some embodiments, a gas engine replacement device is provided, comprising: a housing; a battery socket coupled to the housing and configured to be removably connected to a battery pack having a memory for storing battery pack configuration data; a motor located within the housing; a power output shaft receiving torque from the motor and projecting from one side of the housing; a power switch network configured to selectively supply power from the battery pack to the motor; and an electronic processor. The electronic processor is coupled to the power switch network and configured to control the power switch network to rotate the motor. The electronic processor is configured to receive the battery pack configuration data in response to the connection of the battery pack to the battery socket and to control the electric motor based on the battery pack configuration data.

[0007] In some embodiments, a gas engine replacement device is provided, comprising: a housing; a battery socket coupled to the housing and configured to be removably connected to a battery pack including a first electronic processor; a motor located within the housing; a power output shaft receiving torque from the motor and projecting from one side of the housing; a power switch network configured to selectively supply power from the battery pack to the motor; and a second electronic processor. The first electronic processor is configured to transmit battery pack configuration data to the second electronic processor in response to the connection of the battery pack to the battery socket. The second electronic processor is coupled to the power switch network and configured to control the power switch network to rotate the motor based on the battery pack configuration data. The first electronic processor is configured to monitor the condition of the battery pack and, in response to the condition violating a threshold, transmit revised battery pack configuration data to the second electronic processor. The second electronic processor is configured to control the electric motor based on the revised battery pack configuration data.

[0008] In some embodiments, a gas engine replacement device is provided, comprising: a housing; a battery socket coupled to the housing and configured to be removably connected to a battery pack including a first electronic processor; a motor located within the housing; a power output shaft receiving torque from the motor and projecting from one side of the housing; a power switch network configured to selectively supply power from the battery pack to the motor; and a second electronic processor. The second electronic processor is coupled to the power switch network and configured to control the power switch network to rotate the motor. One of the first or second electronic processor is configured to detect the connection of the battery pack, and in response, the first electronic processor is configured to communicate battery pack configuration data to the second electronic processor. The second electronic processor is configured to control the electric motor based on the battery pack configuration data.

[0009] Before detailing any embodiments, it should be understood that these embodiments are not intended to limit their application to the construction details and component arrangements set forth in the following description or shown in the following figures. The embodiments described herein can be practiced or implemented in a variety of different ways. Moreover, it should be understood that the wording and terminology used herein are for descriptive purposes and should not be considered limiting. The use of “comprising,” “including,” “having,” and variations thereof herein is intended to cover the items listed thereafter and their equivalents as well as additional items. The terms “installation,” “connection,” and “coupling” are used broadly and cover direct and indirect installations, connections, and couplings. Further, “connection” and “coupling” are not limited to physical or mechanical connections or couplings but may include electrical connections or couplings, whether direct or indirect. Additionally, as used herein with the list of items, “and / or” indicates that all items, a subset of items, or items may be included (e.g., “A, B, and / or C” means A; B; C; A and B; B and C; A and C; or A, B, and C).

[0010] It should be noted that the embodiments described herein can be implemented using multiple hardware and software-based devices and multiple different structural components. Furthermore, and as described in the following paragraphs, the specific configurations shown in the figures are intended as exemplary embodiments, and other alternative configurations are also possible. Unless otherwise stated, the terms "processor," "central processing unit," and "CPU" are interchangeable. When the terms "processor," "central processing unit," or "CPU" are used to identify a unit performing a specific function, it should be understood that, unless otherwise stated, these functions can be performed by a single processor or multiple processors arranged in any manner, including parallel processors, serial processors, tandem processors, or cloud processing / cloud computing configurations.

[0011] Additionally, it should be understood that embodiments may include hardware, software, and electronic components or modules, which, for the purposes of discussion, may be shown and described as if most components were implemented solely in hardware. However, those skilled in the art will recognize from this detailed description that, in at least one embodiment, the electronic aspects may be implemented in software (e.g., stored on a non-transitory computer-readable medium) executable by one or more processing units (e.g., microprocessors and / or application-specific integrated circuits (“ASICs”)). Thus, it should be noted that embodiments may be implemented using multiple hardware and software-based devices and multiple different structural components.

[0012] Other features and aspects will become clear by considering the following detailed description and accompanying drawings. Attached Figure Description

[0013] Figure 1 This is a perspective view of a gas engine replacement device according to an embodiment.

[0014] Figure 2 yes Figure 1 A plan view of the gas engine replacement unit.

[0015] Figure 3 yes Figure 1 A schematic diagram of a gas engine replacement device.

[0016] Figure 4 yes Figure 1 A perspective view of the battery pack for a gas engine replacement device.

[0017] Figure 5 yes Figure 4 A cross-sectional view of the battery pack.

[0018] Figure 6 yes Figure 1 A cross-sectional view of the battery socket of the gas engine replacement device.

[0019] Figure 7 yes Figure 1 A cross-sectional view of the motor of the gas engine replacement device.

[0020] Figure 8 yes Figure 1 A schematic diagram of the motor, gear system, and power output shaft of the gas engine replacement device.

[0021] Figure 9 yes Figure 1 A block diagram of a gas engine replacement device.

[0022] Figure 10 yes Figure 1 A flowchart of an example method for battery pack configuration control in a gas engine replacement device.

[0023] Figure 11 Showing included Figure 1 The pump system of the gas engine replacement device.

[0024] Figure 12 Showing included Figure 1 The mixing system of the gas engine replacement device. Detailed Implementation

[0025] like Figure 1 and Figure 2As 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.

[0026] like Figures 1 to 6 As shown, the gas engine replacement device 10 also includes a battery pack 50 removably connected to a battery socket 54 in the housing 14 to transmit current from the battery pack 50 to the motor 36 via control electronics 42. In some embodiments, multiple battery packs 50 are connected to multiple battery sockets 54 in the housing 14. (See also...) Figures 4 to 6 The battery pack 50 includes a battery pack housing 58 having a support portion 62 and a first terminal 66 electrically connected to a plurality of battery cells 68 supported by the battery pack housing 58. The support portion 62 provides a sliding arrangement having a complementary protrusion / recess portion 74 to the battery socket 54 (e.g., Figure 6 The protrusions / recesses 70 (as shown in the diagram) correspond to each other. Figures 4 to 6In the embodiments shown, the protrusion / recess portion 70 of the battery pack 50 is a guide rail, and the protrusion / recess portion 74 of the battery socket 54 is a guide recess. A similar battery pack is described and illustrated 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 80V. In some embodiments, the battery cells 68 have a nominal voltage of up to about 120V. In some embodiments, the battery pack 50 has a weight of up to about 6 lbs. 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 cell 68 is operable to output a continuous operating discharge current, which is between 20A and 60A, between 20A and 50A, between 30A and 50A, between 20A and 40A, or between 40A and 60A. In some embodiments, the capacity of each battery cell in the battery cell 68 is between about 3.0Ah and about 5.0Ah.

[0027] Although the various concepts are described herein as being applied to gas engine replacement devices, in some embodiments these concepts can be applied to other applications where the motor is not the load. For example, the load could be a lighting system powered by battery pack 50.

[0028] Figure 6 A battery socket 54 of a gas engine replacement device 10 according to some embodiments is shown. The battery socket 54 includes a protrusion / recess 74, a second terminal 78, a latching mechanism 82, and a power-off switch 86. The protrusion / recess 74 engages with a protrusion / recess 70 of a battery pack 50 to attach the battery pack 50 to the battery socket 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 the surface of the battery socket 54 and is configured to engage the battery pack 50 to maintain engagement between the battery pack 50 and the battery socket 54. Thus, the battery pack 50 can be connected to and supported by the battery socket 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 socket 54 is arranged on the housing 14 at a position that creates the maximum possible separation distance between the motor 36 and the battery pack 50 to suppress vibrations transmitted from the motor 36 to the battery pack 50. In some embodiments, the elastomeric member is positioned on the battery pack socket 54 to suppress vibrations transmitted from the motor 36 to the battery pack 50 via the housing 14.

[0029] In other embodiments (not shown), the latching mechanism 82 may be located at different positions (e.g., on the side wall, end wall, top end wall, etc. of the battery socket 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 socket 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 disposed in a hole 99 in the battery pack socket 54 and biased toward a latched position by a biasing member 103 (e.g., a spring) to protrude through the surface of the battery socket 54 and into a cavity in the battery pack 50.

[0030] The latching mechanism 82 also includes a power-off switch 86 (e.g., a microswitch) that facilitates electrically connecting / disconnecting the battery pack 50 from the battery socket 54 during actuation of the handle 90 to remove the latching member 94 from the battery pack 50. The power-off switch 86 can be used to electrically disconnect the battery pack 50 from the gas engine replacement device 10 before removing it from the battery socket 54. The power-off 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 an intermediate position. The power-off 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 initiates a power-down operation to safely de-energize the control electronics 42 of the gas engine replacement device 10. A similar latching mechanism and disconnecting switch are described and illustrated in U.S. Patent Publication No. 2019 / 0006980, the entire contents of which are incorporated herein by reference.

[0031] like Figure 7 As shown, motor 36 includes a motor housing 96 having an outer diameter 97, a stator 98 having a nominal outer diameter 101 of at least 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 herein by reference. In some embodiments, motor 36 is a brushless DC motor. In some embodiments, motor 36 has a power output of at least about 2760 W. In some embodiments, the power output of motor 36 may drop below 2760 W during operation. In some embodiments, the diameter 109 of fan 108 is larger than the diameter 97 of motor housing 96. In some embodiments, motor 36 can be stopped with an electronic clutch (not shown) for rapid overload control. In some embodiments, motor 36 has at least 443,619 mm². 3The volume. In some embodiments, the motor has a weight of approximately 4.6 lb. The housing 14 includes an inlet vent and an outlet vent, such that the motor fan 108 draws air through the inlet vent and along the control electronics 42 to cool the control electronics 42 before the air is exhausted through the outlet vent. Figure 7 In the embodiment shown, motor 36 is an internal rotor motor, but in other embodiments, motor 36 may be an external rotor motor with a nominal outer diameter (i.e., the nominal outer diameter of the rotor) of up to about 80 mm. In some embodiments, the nominal outer diameter of the motor is greater than 80 mm, for example, up to 90 mm, 100 mm, 110 mm, 120 mm, or 125 mm.

[0032] Reference Figure 8 Motor 36 can transmit torque to power output shaft 38 in various configurations. In some embodiments, output shaft 106 is also power output shaft 38, allowing motor 36 to directly drive power output shaft 38 without any intermediate gear system. For example, motor 36 can directly drive a high-pole motor. Figure 8 As shown, in other embodiments, the gas engine replacement device 10 includes a gear train 110 that transmits torque from the motor 36 to the power output shaft 38. In some embodiments, the gear train 110 may include a mechanical clutch (not shown) to interrupt torque transmission from the motor 36 to the power output shaft 38. In some embodiments, the gear train 110 may include a planetary gearbox that transmits torque from the output shaft 106 to the power output shaft 38, and the axis of rotation of the output shaft 106 is coaxial with the axis of rotation of the power output shaft 38. In some embodiments, the gear train 110 includes a spur gear that engages with the output shaft 106 of the rotor such that the axis of rotation of the output shaft 106 is offset from and parallel to the axis of rotation of the power output shaft 38. In some embodiments, the gear train 110 includes a bevel gear such that the axis of rotation of the output shaft 106 is perpendicular to the axis of rotation of the power output shaft 38. In other embodiments utilizing bevel gears, the axis of rotation of the output shaft 106 is not perpendicular to, parallel to, or coaxial with the axis of rotation of the power output shaft 38, and the power output shaft 38 protrudes from the flange 34.

[0033] 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 unloaded debris from the motor 36 and 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 down or stopping). In some embodiments, the gas engine replacement device 10 includes a heat sink 202 in the housing 14 for air cooling of the control electronics 42. Figure 1 and Figure 2 In some embodiments, the gas engine replacement device 10 is liquid-cooled.

[0034] In some embodiments, the output shaft 106 of rotor 102 has forward and reverse capabilities, as further described below. In some embodiments, the forward and reverse capabilities are controllable without shifting gears in the gear train 110, unlike gas engines which cannot achieve forward / reverse capabilities without additional transmission mechanisms and time delays. Therefore, the gas engine replacement device 10 offers increased speed, lighter weight, and lower cost. Because the gas engine replacement device 10 has fewer moving parts and no combustion system compared to a gas engine, it also offers additional speed, weight, and cost advantages.

[0035] The gas engine replacement device 10 can operate for extended periods in any orientation (vertical, horizontal, inverted) relative to the ground surface, making it superior to quadruple-cycle gas engines, which can only operate for shorter periods in one orientation and with a slight tilt. Because the gas engine replacement device 10 does not require gas, oil, or other fluids, it can be inverted or operated, delivered, and stored on any given side without leakage or spillage.

[0036] In operation, the gas engine replacement device 10 can be used to replace a gas engine system. Specifically, the gas engine replacement device 10 can be mounted to a power unit having a second bolt pattern by aligning a first bolt pattern defined by a plurality of orifices in the flange 34 with a second bolt pattern. In some embodiments, the flange 34 may include one or more intermediate mounting members or adapters disposed between the flange 34 itself and the flange of the power unit having the second bolt pattern, such that the adapter(s) connect the flange 34 to the power unit. In these embodiments, the adapter includes both a second bolt pattern and a first bolt pattern, such that the first bolt pattern of the flange 34 is aligned with the first bolt pattern of the adapter, and the second bolt pattern of the adapter is aligned with the second bolt pattern defined in the power unit, thereby allowing the flange 34 of the gas engine replacement device 10 to be connected to the power unit.

[0037] Alternatively, the gas engine replacement device 10 can be connected to the power equipment using a belt system by providing a belt that operatively connects the power output shaft and the equipment's functional parts. Therefore, the power output shaft 38 of the gas engine replacement device 10 can be used to drive the equipment.

[0038] 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.

[0039] 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.

[0040] Table 1

[0041]

[0042] 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.

[0043] Table 2

[0044] Metal Plastic / Rubber chance encounter 70℃ 95℃ Handles and knobs for continuous grip 55℃ 75℃ Handles and knobs (i.e., switches) that are only briefly gripped. 60℃ 85℃

[0045] 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 throttle, trigger, or power button), a transceiver 326, an indicator 330 (e.g., a light-emitting diode), and a vibration sensor 320. 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 9The components of the gas engine replacement device 10 shown include one or more of the following: electronic processor 302, memory 306, power switch network 310, rotor position sensor 314, current sensor 318, user input device 322, transceiver 326, indicator 330, and vibration sensor 320. Figure 3 At least a portion of the control electronics 42 shown is provided, wherein the electronic processor 302 and the memory 306 form Figure 3 At least a portion of the controller 46 shown.

[0046] Memory 306 includes read-only memory (ROM), random access memory (RAM), other non-transitory computer-readable media, or combinations thereof. Electronic processor 302 is configured to communicate with memory 306 to store and retrieve stored data. Electronic processor 302 is configured to receive instructions and data from memory 306 and execute instructions, etc. In particular, electronic processor 302 executes instructions stored in memory 306 to perform the methods described herein.

[0047] As described above, in some embodiments, the battery pack 50 is removably connected 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 descriptions of the battery pack 50 (e.g., nominal voltage, continuous operating discharge current, dimensions, number of cells, operation, etc.) and the motor 36 (e.g., power output, dimensions, operation, etc.) are provided above regarding... Figures 1 to 8 supply.

[0048] The power switch network 310 enables the electronic processor 302 to control the operation of the motor 36. Typically, when the user input device 322 is pressed (or otherwise actuated), current is supplied from the battery pack 50 to the motor 36 via the power switch network 310. When the user input device 322 is not pressed (or otherwise actuated), current is not supplied from the battery pack 50 to the motor 36. In some embodiments, the amount by which the user input device 322 is pressed is related to or corresponds to a desired rotational speed of the motor 36. In other embodiments, the amount by which the user input device 322 is pressed is related to or corresponds to a desired torque. In other embodiments, a separate input device (e.g., a slider, dial, etc.) is included on the gas engine replacement device 10 and communicates with the electronic processor 302 to provide a desired rotational speed or torque to the motor 36.

[0049] In response to receiving a drive request signal from the user input device 322, the electronic processor 302 activates the power switching network 310 to supply 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 may include a number of field-effect transistors (FETs), bipolar transistors, or other types of electrical switches. For example, the power switching network 310 may include a six-FET bridge (see...). Figure 10 The six-FET bridge receives pulse width modulation (PWM) signals from the electronic processor 302 to drive the motor 36.

[0050] Rotor position sensor 314 and current sensor 318 are coupled to electronic processor 302 and transmit various control signals to electronic processor 302 indicative of different parameters of the gas engine replacement device 10 or motor 36. In some embodiments, rotor position sensor 314 includes one or more Hall sensors. In other embodiments, rotor position sensor 314 includes a quadrature encoder attached to motor 36. Rotor position sensor 314 outputs motor feedback information to electronic processor 302, such as indications (e.g., pulses) as the magnets of the rotor of motor 36 rotate past the surface of the Hall sensor. In other embodiments, rotor position sensor 314 includes, for example, a voltage or current sensor that provides an indication of the back electromotive force (back EMF) generated in the motor coils. Electronic processor 302 can determine rotor position, rotor speed, and rotor acceleration based on the back EMF signal received from rotor position sensor 314 (i.e., the voltage or current sensor). Rotor position sensor 314 can be combined with current sensor 318 to form a combined current and rotor position sensor. In this example, the combined sensor provides the current flowing to the active phase coils of motor 36, and also provides the current in one or more of the inactive phase coils of motor 36. Electronic processor 302 measures the current flowing to the motor based on the current flowing to the active phase coils, and measures the motor speed based on the current in the inactive phase coils.

[0051] Based on motor feedback information from rotor position sensor 314, electronic processor 302 can determine the rotor's position, speed, and acceleration. In response to the motor feedback information and signals from user input device 322, electronic processor 302 transmits control signals to control power switching network 310 to drive motor 36. For example, by selectively enabling and disabling the FETs of power switching network 310, power received from battery pack 50 is selectively applied in a cyclic manner to the stator windings of motor 36 to cause the rotor of motor 36 to rotate. Electronic processor 302 uses the motor feedback information to ensure proper timing of the control signals to power switching network 310 and, in some cases, provides closed-loop feedback to control the speed of motor 36 at a desired level. For example, in order to drive motor 36, using motor positioning information from rotor position sensor 314, electronic processor 302 determines the position of rotor magnet relative to stator windings, and (a) excites the next stator winding pair (or multiple stator winding pairs) in a predetermined pattern to provide magnetic force to rotor magnet in the desired rotation direction, and (b) de-excites a previously excited stator winding pair (or multiple stator winding pairs) to prevent the application of magnetic force on rotor magnet opposite to the rotor rotation direction.

[0052] The current sensor 318 monitors or detects the current level of the motor 36 during operation of the gas engine replacement unit 10 and provides a control signal to the electronic processor 302 indicating 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.

[0053] Transceiver 326 allows electronic processor 302 to communicate with external device 338 (e.g., a smartphone, tablet, or laptop computer) via wired or wireless communication network 334. In some embodiments, transceiver 326 may include separate transmitting and receiving components. In some embodiments, transceiver 326 may include a wireless adapter attached to gas engine replacement device 10. In some embodiments, transceiver 326 is a wireless transceiver that encodes information received from electronic processor 302 into carrier wireless signals and transmits the encoded wireless signals to external device 338 via communication network 334. Transceiver 326 also decodes information from wireless signals received from external device 338 via communication network 334 and provides the decoded information to electronic processor 302. In some embodiments, transceiver 326 communicates with one or more external sensors 340 via communication network 334. For example, external sensors 340 may be associated with a device on which gas engine replacement device 10 is installed. In some embodiments, external sensors 340 are speed sensors, position sensors, etc. In some embodiments, battery pack 50 includes a transceiver. In some embodiments, the battery pack transceiver communicates wirelessly with transceiver 326 in the power tool 10 or with external device 338. In some embodiments, external device 338 transmits data, such as battery pack configuration data, to the power tool 10. For example, the transceiver in the battery pack 50 may transmit battery pack configuration data to external device 338, and external device 338 may transmit battery pack configuration data to transceiver 326 in the power tool 10.

[0054] The communication network 334 provides wired or wireless connectivity between the gas engine replacement device 10, the external device 338, and the external sensor 340. The communication network 334 may include short-range networks, such as Bluetooth networks, Wi-Fi networks, etc., or long-range networks, such as the Internet, cellular networks, etc.

[0055] like Figure 9As 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.

[0056] 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 positive and negative / ground lines; etc. Additionally, the power lines may have 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.

[0057] In some embodiments, the battery pack 50 includes an electronic processor 336, a memory 339, and one or more battery sensors 341. The memory 339 includes read-only memory (ROM), random access memory (RAM), other non-transitory computer-readable media, or combinations thereof. The electronic processor 336 is configured to communicate with the memory 339 to store and retrieve stored data. The electronic processor 336 is configured to receive instructions and data from the memory 339 and execute instructions, etc. Specifically, the electronic processor 336 executes instructions stored in the memory 339 to perform the battery control functions described herein. The battery sensors 341 provide information associated with the battery pack 50, such as temperature, charging stage, discharge rate, etc. The sensors 341 may provide information to the electronic processor 336, which may, for example, store sensor data in the memory 339, analyze the information and take responsive action, or both. In some embodiments, the memory 339 stores battery configuration data, such as maximum discharge current, aging parameters (e.g., manufacturer's date or number of charge / discharge cycles), etc. In some embodiments, battery configuration data can be determined non-digitally, for example by reading or determining the values ​​of capacitance, resistance, inductance, magnetic field strength, etc., associated with the battery pack 50, which can be determined by the gas engine replacement device 10.

[0058] The electronic processor 336 in the battery pack 50 communicates with the electronic processor 302 in the gas engine replacement device 10 to exchange configuration data and status data associated with the battery pack 50. In some embodiments, the configuration data includes the maximum discharge current associated with the battery pack. In some embodiments, the electronic processor 336 also communicates status data associated with the battery pack 50 to the electronic processor 302, such as age, state of charge, discharge rate, etc. The electronic processor 336 in the battery pack 50 can communicate with the electronic processor 302 in the gas engine replacement device via a wired or wireless interface.

[0059] The battery pack 50 has a specific cell arrangement that affects its power supply capability. Different cell types can provide different current levels at recommended operating temperatures. For example, a “30T” cell might be able to continuously discharge at 30A in the battery pack 50 through a specific airflow design that reaches thermal equilibrium at a temperature below the maximum permissible temperature of the battery pack 50. A “40T” cell might only be able to discharge at 25A in a similar design. If the gas engine replacement device 10 is optimized for 30A discharge, it might cause an overheating condition in a battery pack 50 with “40T” cells under similar operating conditions, without discharging all available energy within the cells. If an overheating condition is reached, the electronic processor 336 in the battery pack 50 will issue a fault condition signal and interrupt power until the battery pack 50 cools to an acceptable temperature before the remaining charge in the battery pack 50 can be retrieved. Alternatively, if the gas engine replacement device 10 is optimized for 25A discharge, it will operate at a lower and potentially less desirable operating load point, which could result in the gas engine replacement device 10 performing its function at a slower rate or with lower efficiency.

[0060] Figure 10 It is used for Figure 1 A flowchart of an example method 400 for controlling the battery pack configuration in a gas engine replacement device 10. At block 405, the connection or insertion of the battery pack 50 is detected. In some embodiments, an electronic processor 336 in the battery pack 50 detects the connection of the battery pack 50, while in other embodiments, an electronic processor 302 in the gas engine replacement device 10 detects the connection of the battery pack 50. In some embodiments, the connection of the battery pack 50 is detected by the electronic processor 336 or the electronic processor 302 by: (a) using wired communication from the other of the electronic processor 336 and the electronic processor 302, or (b) a hardware detection circuit that detects or measures (e.g., at terminals 66 or 78) a change in resistance or voltage above a certain threshold and provides a signal to the electronic processor 336 or the electronic processor 302.

[0061] At block 410, battery pack configuration data is communicated to the gas engine replacement device 10. In some embodiments, the electronic processor 336 in the battery pack 50 broadcasts the battery pack configuration data in response to a connection detection at block 405. In some embodiments, the electronic processor 302 in the gas engine replacement device 10 polls the battery pack 50 to retrieve the battery pack configuration data in response to an insertion detection at block 405. In some embodiments, the electronic processor 302 in the gas engine replacement device 10 reads the battery pack configuration data directly from the memory 339 in the battery pack 50. In embodiments where the electronic processor 302 in the gas engine replacement device 10 reads the battery pack configuration data directly from the memory 339 in the battery pack 50, the electronic processor 336 in the battery pack 50 may be omitted. In some embodiments, one or more battery pack configuration data parameters may be measured or inferred. For example, techniques including pulsed current and measuring voltage drop or resistance in the battery pack 50 in response to the pulses may be used to measure the battery pack configuration parameters.

[0062] Upon receipt, the gas engine replacement device 10 stores the battery pack configuration data in memory 306. In some embodiments, the battery pack configuration data includes parameters such as cell size, maximum cell temperature, maximum discharge current, and minimum operating speed. The battery pack configuration data may be written to the memory 339 of the battery pack 50 during manufacturing or rewritten by an authorized service center during periodic service or calibration intervals. In some embodiments, the maximum discharge current represents the maximum current that the battery pack 50 can provide until fully discharged without thermal overload.

[0063] At block 412, the electronic processor 302 of the gas engine replacement device 10 operates the motor 36 based on battery pack configuration data received from the battery pack 50. For example, the electronic processor 302 can use a motor control algorithm that takes into account the maximum discharge current to control the motor 36 to ensure that the current drawn from the battery pack 50 does not exceed a specified maximum discharge current. In some embodiments, a current sensor 318 measures current parameters, such as motor current, and is used by the electronic processor 302 to estimate the discharge current. In some embodiments, the current sensor 318 directly monitors the current drawn from the battery pack 50 as a current parameter. In some embodiments, a battery sensor 341 measures the battery current as a current parameter. In some embodiments, the motor current is measured indirectly by measuring the motor back electromotive force signal (e.g., from the output of the rotor position sensor 314) or by measuring the voltage drop across the motor 36.

[0064] In some embodiments, the electronic processor 302 can initialize a motor control algorithm by operating the motor with 100% PWM (i.e., controlling the switching of the power switch network 310 using a control signal with a 100% PWM duty cycle) while monitoring the current drawn from the battery pack 50, which is compared to the maximum discharge current specified in the battery pack configuration data. If the current from the battery pack 50 reaches the maximum discharge current, the electronic processor 302 can reduce the PWM parameters, thereby reducing the current consumption compared to 100% PWM operation. The electronic processor 302 can continue to reduce the PWM parameters until a minimum device operation setting or 0% PWM is reached. In this way, the electronic processor 302 can generate an operating curve that correlates the PWM parameters with the current drawn by the gas engine replacement device 10 in the current ambient environment. In some embodiments, the electronic processor 302 stores an upper limit of the PWM parameters determined based on the maximum discharge current in memory 306. The electronic processor 302 can control the operation of the gas engine replacement device 10 based on the upper limit of the PWM parameters without continuously monitoring the current drawn from the battery pack 50. In some embodiments, the electronic processor 302 may continuously monitor the current drawn from the battery pack 50, compare the measured current with the maximum discharge current, and reduce PWM parameters, such as the duty cycle of the signal driving the power switch network 310, in response to the current exceeding the maximum discharge current.

[0065] In some embodiments, the control algorithm used by the electronic processor 302 in the gas engine replacement device 10 may employ predetermined operating parameters, such as upper limits for PWM parameters, which are defined based on battery pack configuration data (e.g., cell size, maximum cell temperature, maximum discharge current, state of discharge, etc.). For example, a lookup table mapping various battery pack configuration data to associated PWM limits may be used.

[0066] In some embodiments, method 400 ends at block 412 and does not perform the remaining steps. In other embodiments, the method proceeds to block 415.

[0067] At box 415, an electronic processor 336 in the battery pack 50 monitors the battery pack condition. In some embodiments, the battery pack condition includes a temperature parameter. In some embodiments, the battery pack condition includes the rate of capacity change of the battery pack or the power usage of the gas engine replacement device 10. The maximum discharge current associated with the battery pack 50 is typically set based on certain assumptions about the thermal condition of the battery pack 50 during operation (e.g., airflow design for cooling the battery pack 50). Under certain conditions, cooling may be affected, or the ambient temperature may rise, causing the actual operating conditions to differ from the assumptions. As a result, the temperature of the battery pack 50 may approach a failure threshold even if the gas engine replacement device 10 does not exceed the maximum discharge current. In some embodiments, the maximum discharge current may be set based on an assumed discharge rate of the battery pack 50. For example, the discharge rate may be defined by assuming that the battery pack 50 can deliver power at the maximum discharge current over a known time period. The actual rate of battery charge discharge may vary due to conditions such as temperature or other factors. In some embodiments, the electronic processor 336 in the battery pack 50 monitors the battery pack discharge rate as the battery pack condition.

[0068] At box 420, the electronic processor 336 in the battery pack 50 determines whether the condition of the battery pack 50 violates a threshold. For example, the temperature of the battery pack 50, as measured by the battery sensor 341, may exceed the threshold, or the rate of battery pack depletion may exceed the threshold. In some embodiments, the threshold is set below a level that would cause a power outage.

[0069] If a threshold is violated at box 420, the electronic processor 336 in the battery pack 50 revises the battery pack configuration data. For example, the maximum discharge current of the battery pack 50 may be reduced. In embodiments where the electronic processor 336 in the battery pack 50 is omitted, the electronic processor 302 in the gas engine replacement device 10 may receive data from the battery sensor 341, determine at box 420 whether the condition of the battery pack 50 violates the threshold, and revise the battery pack configuration data.

[0070] At box 425, revised battery pack configuration data is communicated to the gas engine replacement device 10. In some embodiments, the electronic processor 336 in the battery pack 50 pushes the revised battery pack configuration data to the electronic processor 302 in the gas engine replacement device 10. In some embodiments, the electronic processor 302 in the gas engine replacement device 10 polls the battery pack 50 at regular intervals or between operating cycles to identify any changes to the battery pack configuration data. In embodiments where the electronic processor 336 in the battery pack 50 is omitted, the electronic processor 302 revises the battery pack configuration data.

[0071] In some embodiments, upon receiving revised battery pack configuration data, the electronic processor 302 stores the revised battery pack configuration data (e.g., updated or overwritten previous battery pack configuration data) in memory 306, thereby revising its control algorithm. For example, the revised maximum discharge current may be stored in memory 306. In some embodiments, the PWM initialization procedure described above may be repeated to generate new PWM limits, or a lookup table may be accessed based on the revised battery pack configuration data. At a later point in time, such as after the temperature of battery pack 50 has decreased to a lower level, the electronic processor 336 in battery pack 50 may again revise the battery pack configuration data to increase the maximum discharge current. In this way, the maximum discharge current associated with battery pack 50 can be dynamically controlled based on the actual operating environment of the gas engine replacement device 10.

[0072] The method then returns to block 412, where the electronic processor 302 operates the motor according to the revised battery pack configuration data at block 425 (i.e., according to the revised battery pack configuration data).

[0073] The aforementioned mechanical system driven by the gas engine replacement device 10 includes many advantages over conventional equipment driven by internal combustion engines, some of which will be discussed below.

[0074] In some embodiments, the gas engine replacement device 10 can be coupled with a new device, and the memory 306 can be reprogrammed to optimize the gas engine replacement device 10 for operation with the new device. In some embodiments, the electronic processor 302 automatically identifies the type of new device to which the gas engine replacement device 10 has been coupled and controls 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 coupled with via radio frequency identification (RFID) communication with the new device.

[0075] In some embodiments, the memory 306 can be reprogrammed via BLUETOOTH or Wi-Fi communication protocols. In some embodiments, the electronic processor 302 has control modes for different purposes 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 so that the gas engine replacement device 10 can apply unidirectional control to the device, or an operator can apply unidirectional control to the gas engine replacement device 10 using a smartphone application.

[0076] In some embodiments, an operator or original equipment manufacturer (OEM) is allowed to control the speed of the gas engine replacement unit 10 in a limited manner via an interface such as a Controller Area Network (CAN) through an electronic processor 302. In some embodiments, the electronic processor 302 is capable of utilizing a wider range of speed selections using a single gear set in the gear train 110 compared to a gasoline engine. For example, control electronics 42 is configured to drive motor 36 at less than 2,000 RPM (below any speed a gasoline engine can reach), thus allowing the associated equipment a longer total operating time when the battery pack 50 is fully discharged, compared to a gasoline engine. Furthermore, control electronics 42 is configured to drive the motor at more than 3,600 RPM (above any speed a gasoline engine can reach) and has the ability to deliver greater torque. The wider speed range of motor 36 provides greater efficiency and capability compared to a gasoline engine. In some embodiments, in addition to speed, the operator can also control the current drawn by motor 36.

[0077] 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 may monitor and record the operating time of the gas engine replacement device 10, for example, in a leased situation. 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 a lamp or accessory. In some embodiments, the electronic processor 302 may detect anomalies or malfunctions of the gas engine replacement device 10 via voltage, current, motion, speed, and / or thermocouples. In some embodiments, the electronic processor 302 may detect unintended use or cessation of the gas engine replacement device 10. If the equipment driven by the gas engine replacement device 10 does not operate with the expected characteristics or is not used correctly or safely, the electronic processor 302 may detect the anomaly and deactivate the gas engine replacement device 10. For example, the gas engine replacement device 10 may include one or more accelerometers to sense whether the gas engine replacement device 10 and the equipment are in the expected orientation. Furthermore, if the electronic processor 302 determines that the gas engine replacement device 10 is not in the intended orientation (i.e., the device has tipped over), the electronic processor 302 can deactivate the gas engine replacement device 10.

[0078] In some embodiments, the gas engine replacement device 10 includes accessible sensor ports (not shown) for electrical connection to user-selected sensors (such as accelerometers, gyroscopes, GPS units, or real-time clocks) used with the power equipment, allowing the operator to customize variables sensed and detected by the electronic processor 302. In some embodiments, the electronic processor 302 may indicate the status of the battery pack 50 to the operator via visual, auditory, or tactile notifications, such as when the battery is low. In some embodiments, the electronic processor 302 may operate an auxiliary motor, separate from the motor 36, to drive auxiliary devices, such as a winch. The auxiliary motor may be internal or external to the gas engine replacement device 10.

[0079] In some embodiments, the gas engine replacement device 10 may 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 may be modular, wired, or wireless, and may be attachable to or manually held. In some embodiments, the gas engine replacement device 10 may be controlled by a remote control that includes status indicators for certain characteristics of the gas engine replacement device 10, such as the charge and temperature of the battery pack 50. In some embodiments, the gas engine replacement device 10 may provide status indications using a remotely programmable device.

[0080] Figure 11 and Figure 12 An example of a power unit driven by a gas engine replacement device 10 that implements the above method 400 is shown. Figure 11 A pump system 1100 is shown, comprising a frame 1102 supporting a gas engine replacement device 10, and a pump 1104, wherein the gas engine replacement device 10 is operable to drive the pump 1104. The pump 1104 shown is a centrifugal pump having an impeller positioned within a housing 1106 of the pump 1104, the impeller being rotatable about an axis to move material from an inlet 1108 of the pump 1104 to an outlet 1110 of the pump 1104. Figure 12 A mixing system 1200 is shown, which includes a frame 1205 supporting a gas engine replacement device 10 and a mixing drum 1210, wherein the gas engine replacement device 10 is operable to rotate the mixing drum 1210.

Claims

1. A gas engine replacement device, comprising: case; A battery socket is attached to the housing and configured to be removably connected to a battery pack having a memory for storing battery pack configuration data; The motor is located inside the housing; A power take-off shaft that receives torque from the motor and protrudes from one side of the housing; A power switching network configured to selectively supply power from the battery pack to the motor; as well as A first electronic processor, connected to the power switch network and configured to control the power switch network to cause the motor to rotate, is configured to: In response to the connection between the battery pack and the battery socket, the battery pack configuration data is received; and The power switch network is controlled based on the battery pack configuration data; and The battery pack includes a second electronic processor, which is configured to: Monitor the condition of the battery pack; and In response to the condition violating the threshold, revised battery pack configuration data is transmitted to the first electronic processor, and The first electronic processor is configured as follows: The revised battery pack configuration data is used to control the power switch network to make the motor rotate.

2. The gas engine replacement device as described in claim 1, wherein, The first electronic processor is configured to read the battery pack configuration data from the memory.

3. The gas engine replacement device as described in claim 1, wherein, The battery pack configuration data includes the maximum discharge current, and The first electronic processor is configured to control the pulse width modulation parameters of the power switching network based on the maximum discharge current.

4. The gas engine replacement device as described in claim 3, wherein, The first electronic processor is configured to generate the upper limit of the pulse width modulation parameter based on the maximum discharge current; and The power switching network is controlled based on the upper limit of the pulse width modulation parameter.

5. The gas engine replacement device as described in claim 3, comprising: A current sensor, configured to measure current parameters, wherein... This current parameter includes at least one of the battery current or the motor current, and The first electronic processor is configured to control the pulse width modulation parameters of the power switching network based on the current parameter and the maximum discharge current control.

6. The gas engine replacement device as described in claim 1, wherein, The second electronic processor is configured as follows: Read the battery pack configuration data from the memory; and The battery pack configuration data is transmitted to the first electronic processor.

7. A gas engine replacement device, comprising: case; A battery socket, which is attached to the housing and configured to be removably connected to a battery pack including a first electronic processor; The motor is located inside the housing; A power take-off shaft that receives torque from the motor and protrudes from one side of the housing; A power switching network configured to selectively supply power from the battery pack to the motor; as well as A second electronic processor, connected to the power switching network and configured to control the power switching network to rotate the motor, is also connected to the second electronic processor. In this configuration, either the first electronic processor or the second electronic processor is configured to detect the connection between the battery pack and the battery socket, and in response, the first electronic processor is configured to transmit battery pack configuration data to the second electronic processor. The second electronic processor is configured to control the motor based on the battery pack configuration data; and The first electronic processor is configured as follows: Monitor the condition of the battery pack; and In response to the condition violating the threshold, revised battery pack configuration data is transmitted to the second electronic processor; and The second electronic processor is configured as follows: The revised battery pack configuration data is used to control the power switch network to make the motor rotate.

8. The gas engine replacement device as described in claim 7, wherein, The battery pack includes a memory configured to store battery pack configuration data, and The second electronic processor is configured to read the battery pack configuration data from the memory.

9. The gas engine replacement device as described in claim 7, wherein, The battery pack configuration data includes the maximum discharge current, and The second electronic processor is configured to control the pulse width modulation parameters of the power switching network based on the maximum discharge current.

10. The gas engine replacement device as claimed in claim 9, wherein, The second electronic processor is configured as follows: The upper limit of the pulse width modulation parameter is generated based on the maximum discharge current; and The power switching network is controlled based on the upper limit of the pulse width modulation parameter.

11. The gas engine replacement device as claimed in claim 10, further comprising: A current sensor configured to measure a current parameter, wherein the current parameter includes at least one of battery current or motor current, and The second electronic processor is configured to control the pulse width modulation parameters of the power switching network based on the current parameter and the maximum discharge current control.

12. A method for operating a gas engine replacement device, the gas engine replacement device comprising: case; A battery socket is attached to the housing and configured to be removably connected to a battery pack having a memory for storing battery pack configuration data; The motor is located inside the housing; A power take-off shaft that receives torque from the motor and protrudes from one side of the housing; A power switching network configured to selectively supply power from the battery pack to the motor; and a first electronic processor, the first electronic processor being connected to the power switching network and configured to control the power switching network to cause the motor to rotate, the method comprising: The first electronic processor receives battery pack configuration data in response to the connection between the battery pack and the battery socket. The first electronic processor controls the power switching network based on the battery pack configuration data; and The battery pack includes a second electronic processor, and the method further includes: The status of the battery pack is monitored through this second electronic processor; The second electronic processor, in response to a condition violating a threshold, transmits revised battery pack configuration data to the first electronic processor, and The first electronic processor controls the power switching network to rotate the motor based on the revised battery pack configuration data.

13. The method of claim 12, further comprising: The first electronic processor reads the battery pack configuration data from the memory.

14. The method of claim 12, wherein, The battery pack configuration data includes the maximum discharge current, and the method further includes: The pulse width modulation parameters of the power switching network are controlled by the first electronic processor based on the maximum discharge current control.

15. The method of claim 14, further comprising: The upper limit of the pulse width modulation parameter is generated based on the maximum discharge current by the first electronic processor; as well as The first electronic processor controls the power switching network based on the upper limit of the pulse width modulation parameter.

16. The method of claim 14, wherein, The gas engine replacement device further includes a current sensor configured to measure a current parameter, which includes at least one of battery current or motor current, and the method further includes: The pulse width modulation parameters of the power switching network are controlled by the first electronic processor based on the current parameters and the maximum discharge current.

17. The method of claim 12, wherein, The method further includes: The second electronic processor reads the battery pack configuration data from the memory; and The second electronic processor transmits the battery pack configuration data to the first electronic processor.

Images