Radio motor drive system for handheld knives

Abstract

A power pack for a power tool controls and dissipates energy from motor operation. The power pack includes an electric motor that provides power to the power tool, and a non-transitory computer-readable storage medium having computer-executable instructions configured to monitor and control operation of the electric motor and the power tool.

Description

[0001] Cross-reference to related applications

[0002] This patent application claims priority to U.S. Patent Application Serial No. 63 / 116,957, filed November 23, 2020, the entire contents of which are incorporated herein by reference. Technical Field

[0003] This invention generally relates to powered cutting tools, such as those commonly used in meat processing in slaughterhouses. More specifically, this invention relates to braking and control components for powered rotary knives. Background Technology

[0004] Existing powered rotary cutters are commonly used in the meat processing industry for processing animal carcasses. The process typically involves removing meat and fat from bones and cutting the bones. Powered rotary cutters enable workers to perform this process efficiently.

[0005] However, existing powered rotary cutters can be dangerous in terms of operation and control. For example, existing drive and control methods are rudimentary and can lead to unsafe operating conditions. In addition, due to design flaws, existing powered rotary cutters are often exposed to unnecessary wear and tear, which may make them unsafe or prone to premature failure.

[0006] The discussion of this background art is intended to provide information relevant to the present invention and is not necessarily prior art. Summary of the Invention

[0007] The following brief overview is provided to indicate the nature of the subject matter disclosed herein. While certain aspects of the invention are described below, this overview is not intended to limit the scope of the invention.

[0008] A first aspect of the invention relates to a power pack for a power tool. The power pack includes an electric motor configured for drive engagement with the power tool. The power pack also includes a motor controller having a relay circuit for electrical communication with the electric motor. The relay circuit includes a switch selectively electrically connected to a power source, thereby providing power to the electric motor by electrically connecting it to the power source. The power pack also includes a non-transitory computer-readable storage medium having computer-executable instructions for monitoring the operation of the power pack. When executed by at least one processor, the computer-executable instructions cause at least one processor to: monitor input data relating to the operation of the power pack; determine, at least in part, based on the input data, that the operation of the power pack deviates from an ideal state; and, based on the determination of the deviation, cause the switch to electrically disconnect the electric motor from the power source.

[0009] A second aspect of the invention relates to a system for selectively powering a power tool. The system includes the power tool, an electric motor configured to engage with the drive of the power tool, a braking resistor, and a relay circuit electrically in communication with the electric motor. The relay circuit includes a switch selectively electrically connected to the braking resistor. The electrical connection from the electric motor to the braking resistor allows electrical energy from the electric motor to be dissipated at least partially as heat by the braking resistor.

[0010] A third aspect of the invention relates to a power pack / power source / power assembly for a power tool. The power pack includes an electric motor configured to engage with the power tool drive. The power pack also includes a motor controller having a relay circuit electrically communicating with the electric motor. The relay circuit includes a switch selectively electrically connected to a power source. The electric motor is powered by the electrical connection between the motor and the power source. The motor controller also includes a non-transitory computer-readable storage medium having computer-executable instructions for monitoring stored operations of the power pack. When executed by at least one processor, the computer-executable instructions cause at least one processor to: monitor input data relating to the operation of the power pack; determine, at least in part, based on the input data, that the operation of the power pack deviates from an ideal state; and, based on the determination of the deviation, cause the switch to electrically disconnect the motor from the power source.

[0011] A fourth aspect of the invention relates to a system for selectively powering a power tool. The system includes a power pack having a motor controller and a motor configured to engage with the power tool drive. The motor controller is in electrical communication with the motor and includes at least one processor and a non-transitory computer-readable storage medium having computer-executable instructions for monitoring the operation / running of the motor. When executed by the at least one processor, the computer-executable instructions cause the at least one processor to: monitor input data relating to the operation of the motor; determine, at least in part, based on the input data, that the operation of the motor deviates from an ideal state; and, based on the determination of the deviation, electrically disconnect the motor from the power supply.

[0012] A fifth aspect of the invention relates to a system for controlling the operation of a power tool. The system includes a handheld device having a power tool, a radio frequency identification (RFID) tag, and a first wireless transceiver. The system also includes a power pack having an electric motor that is driven and engaged with the power tool. The power pack further includes the wireless transceiver, an RFID reader, and a non-transitory computer-readable storage medium having computer-executable instructions for pairing the handheld device with the power pack. When executed by at least one processor, the computer-executable instructions cause the at least one processor to perform the following steps: querying the RFID tag using the RFID reader; receiving an RFID signal from the RFID tag including unique identification information of the handheld device; and wirelessly pairing the handheld device with the power pack based at least in part on the received unique identification information.

[0013] A sixth aspect of the invention relates to a power pack for wireless pairing with a handheld device having a radio frequency identification (RFID) tag. The power pack includes an electric motor configured to drive engagement with the handheld device. The power pack also includes a motor controller having at least one processor, a wireless transceiver, an RFID reader, and a non-transitory computer-readable storage medium having computer-executable instructions for pairing the handheld device with the power pack. When executed by at least one processor, the computer-executable instructions cause at least one processor to: query an RFID tag via the RFID reader; receive an RFID signal from the RFID tag including unique identification information of the handheld device; store the unique identification information of the handheld device at the power pack; and complete the wireless pairing of the handheld device with the power pack, at least in part based on the receipt of the unique identification information.

[0014] The advantages of these and other embodiments will become more apparent to those skilled in the art from the following description of exemplary embodiments, which have been illustrated and described by way of illustration. As will be appreciated, the embodiments of the invention described herein can be had other and different embodiments, and their details can be modified in various respects. Therefore, the drawings and description are to be considered illustrative in nature and not restrictive. Attached Figure Description

[0015] The accompanying drawings described below depict various aspects of the systems and methods disclosed herein. It should be understood that each drawing depicts an embodiment of a specific aspect of the disclosed systems and methods, and each drawing is intended to correspond to its possible embodiments. Furthermore, where possible, the following description refers to the reference numerals included in the following drawings, wherein features depicted in the plurality of drawings are indicated by consistent reference numerals.

[0016] Figure 1 The components of a power pack, suspension, and flexible shaft according to an embodiment of the present invention are shown in schematic diagrams and block diagrams.

[0017] Figure 2 The components of a handheld device according to an embodiment of the present invention are shown in schematic block diagram form. Figure 1 The second end of the flexible shaft, the handheld component and Figure 1 The power pack engages and is driven by it;

[0018] Figure 3 The schematic block diagram shows the respective... Figure 1 and Figure 2 The signals and current on the wired and wireless connections between the power pack and the handheld components;

[0019] Figure 4 It is shown in the form of a block diagram. Figure 1 and Figure 3 Components of the motor controller;

[0020] Figure 5 The embodiments of the present invention are illustrated in schematic diagrams and block diagrams, respectively for use in... Figure 1 and Figure 2 The circuit layout of the power pack and handheld components;

[0021] Figure 6 This is a flowchart illustrating at least a portion of the steps for controlling a handheld device according to an embodiment of the present invention; and

[0022] Figure 7 This is a flowchart illustrating at least a portion of the steps for monitoring one or more inputs reflecting system operation according to an embodiment of the present invention.

[0023] The accompanying drawings depict exemplary embodiments for illustrative purposes only. Those skilled in the art will readily recognize from the following discussion that alternative embodiments of the systems and methods described herein may be employed without departing from the principles of the invention as described herein. Detailed Implementation

[0024] First go to Figure 1The diagram illustrates the components of an exemplary power pack 10, including a motor 12, a power supply 14, a motor controller 16, and a housing 18. The motor 12 may include a direct current (DC) motor powered by, for example, a 24-volt (24V) power supply 14. The motor 12 may also include a connection to a grounding circuit. In one embodiment, the power supply 14 receives line power (e.g., 120 or 240 volts alternating current (AC)) and converts the line power into 24-volt (24V) power to supply the motor 12. The line power may also be used to power one or more of the electronic components of the power pack 10 and / or the handheld device 38, discussed in more detail below. As will be understood by those skilled in the art as described above, various AC and DC motors (including brushless motors) operating with various power supplies fall within the scope of this invention.

[0025] The motor controller 16 may include a radio frequency identification (RFID) reader 20 and / or communicate electronically with it. The RFID reader 20 may be housed within the same power package housing 18 as the motor 12, power supply 14, and / or motor controller 16. The RFID reader 20 may also be positioned externally to and / or attached to the housing 18. The RFID reader 20 may be compatible with one or more low-frequency, high-frequency, and / or ultra-high-frequency tags and may operate according to passive and / or active classification protocols and components without departing from the spirit of the invention.

[0026] The power pack 10 may also include a bracket 22 for engaging and supporting a portion of the handheld component 38 when not in operation (see discussion below). For example, the shape of the bracket 22 may be complementary to the profile of one or more portions of the handheld component 38, and may be designed to grip and support such complementary profiles (e.g., by providing a space narrower than the rotating blade holder 55 of the handheld component 38 but larger than the handle 52, into which the handle 52 can be inserted). Similarly, the power pack 10 may include a suspension bracket 24 attached to the housing 18 and configured to engage with and be supported by a suitable support structure (e.g., a hook embedded in a nearby wall or a tower or support frame for carrying the power pack 10).

[0027] It will be understood by those skilled in the art that the bracket 22 and / or the suspension bracket 24 may be omitted or alternatively constructed without departing from the scope of the invention.

[0028] The power pack 10 may also include a flexible shaft quick-connect 26. An output shaft or other output component for transmitting power generated by the motor 12 may be configured to be connected at the quick-connect 26. In one or more embodiments, the output of the motor 12 is transmitted to the handheld device 38 via a cable or flexible shaft 28 releasably connected to the quick-connect 26.

[0029] The power pack may also include an ON button 30, an OFF button 32, and a wireless pairing button 34. The ON and OFF buttons 22 and 32 may include push-button switches, etc., which respectively connect or disconnect one or more circuits supplying power from line power to the power pack components described herein (e.g., motor 12, power supply 14, motor controller 16, and RFID reader 20). Those skilled in the art will understand that a single button and / or switch may be used instead of separate ON and OFF buttons without departing from the spirit of the invention.

[0030] In addition, the wireless pairing button 34 may also include a switch that, when actuated, provides a signal to the controller 16 to initiate the wireless pairing operation described in more detail below.

[0031] It is foreseeable that, without departing from the spirit of the invention, one or more of the ON button 30, OFF button 32 and wireless pairing button 34 may optionally be represented as a digital interface for receiving user input, such as a touch screen display.

[0032] Item 38 is now being transferred to Figure 2 The handheld component 38 can receive mechanical power transmitted from the power pack 10 via the flexible shaft 28. The handheld component may also include a wireless transceiver 40 configured to transmit a wireless signal triggered by a magnetic switch 42, substantially as described above. The handheld component 38 may also include a battery 44 for powering the electronic components of the handheld component 38. The battery 44 may be rechargeable and may include a port for receiving a Universal Serial Bus (USB) connector 58 or a plug for charging, and / or for electronic communication with the Universal Serial Bus (USB) connector 58 or a plug for charging (see [link to relevant documentation]). Figure 5 In one or more embodiments, if the battery voltage drops below a threshold for supplying power to the handheld device, the wireless transceiver 40 can be configured to receive power from a wired or wireless power source other than the battery 44. For example, the wireless transceiver can switch power from the battery 44 to the USB connector 58 when power is connected to the USB connector 58.

[0033] The handheld device 38 may also include an RFID tag 46 for use in wireless pairing and related procedures discussed in more detail below. More generally, the handheld device 38 also includes a trigger 48 (including a magnet for actuating the switch 42 whenever the trigger 48 is pressed to a threshold degree) and a power tool 51, which includes a high-speed cutter comprising a handle 52, a rotary cutter 54, and a rotary cutter holder 55 (see the discussion above). The power tool 51 may include or contain components of a power tool according to embodiments of the invention, substantially corresponding to those components of the rotary cutter described in U.S. Patent No. 10,889,018 entitled "ROTARY KNIFE BLADEWITH DOUBLE BEVELED INSIDE SURFACE," issued January 12, 2021, the entire contents of which are incorporated herein by reference. However, it will be understood by those skilled in the art that various handheld device constructions fall within the scope of this invention.

[0034] Typically, it should be noted that RFID components 20 and 46 can communicate with each other using radio waves, thereby allowing the digital data encoded in RFID tag 46 to be captured by RFID reader 20. RFID reader 20 can capture the digital data encoded in RFID tag 46 when triggered by an electromagnetic query pulse from a nearby RFID reader 20. In one or more embodiments, after completing the pairing process described in more detail below, wireless transceiver 40 can receive additional data from wireless transceiver 48 (e.g., related to configuration, encryption key data, etc., for further communication).

[0035] Now go to Figure 3-5 The diagram illustrates various logic components of the power pack 10 and handheld device 38. Initially, it should be noted that the controller 16 may include a processing element 70, a memory element 72, and a communication element 74. The communication element 74 typically allows communication with other systems or devices such as the handheld device 38, for example, via wireless communication and / or data transmission through one or more direct or indirect radio links between devices. The communication element 74 may include signal or data transmission and reception circuitry, such as antennas, amplifiers, filters, mixers, oscillators, digital signal processors (DSPs), etc. The communication element 74 can utilize technologies compliant with cellular networks such as 2G, 3G, or 4G, WiFi, WiMAX, Bluetooth, etc. TM Wireless communication is established using RF signals and / or data from communication standards or combinations thereof. Furthermore, communication element 74 can utilize 2.4 GHz ANT, ANT+, Bluetooth, etc. TM Communication standards for bands such as Low Energy (BLE) and Industrial Science and Medical (ISM).

[0036] In one or more specific embodiments, the wireless transceiver 48 and / or the RFID reader 20 may include or be integrated with a communication element 74. Furthermore, in one or more embodiments, the wireless transceivers 40, 48 and / or the communication element 74 may individually or collectively include software applications for describing, performing, and enabling wireless communication, such as those labeled Bluetooth according to the initial filing of this application. TM The Bluetooth standard proposed by the Bluetooth Special Interest Group (SIG) transmits the signals. Those skilled in the art will understand that pairing and wireless communication can be implemented according to other wireless communication standards and technologies without departing from the spirit of the invention. In one or more embodiments, the wireless transceivers 40, 48 and the communication element 74 can use signals corresponding to one or more such wireless standards to process, route, connect, establish, disconnect, or search for wireless signals between one or more devices, including performing operations described in more detail below.

[0037] The memory element 72 of the controller 16 may include non-volatile and / or non-transitory electronic hardware data storage components, such as read-only memory (ROM), programmable ROM, erasable programmable ROM, random access memory (RAM) (such as static RAM (SRAM) or dynamic RAM (DRAM)), cache memory, hard disk, floppy disk, optical disk, flash memory, thumb drive, universal serial bus (USB) drive, etc., or combinations thereof. The memory element 72 may include or may constitute a "computer-readable medium". The memory element 72 may store instructions, code segments, software, firmware, programs, applications, apps, modules, agents, services, daemons, etc., executed by the processing element 70, including programs configured to perform wireless pairing with the motor control transceiver 48, dynamic braking using the braking resistor 50, watchdog 52 operation, and other steps outlined herein. The memory element 72 may also store items described throughout this disclosure, such as operating parameters and readings outlined herein. In the illustrated embodiment, the memory element 72 includes an electrically erasable programmable read-only memory (EEPROM) 53.

[0038] The processing element 70 of controller 16 may include electronic hardware components such as a processor. Processing element 70 may include multiple digital processing units. Processing element 70 may include multiple microprocessors (single-core and multi-core), microcontrollers, digital signal processors (DSPs), field-programmable gate arrays (FPGAs), analog and / or digital application-specific integrated circuits (ASICs), and combinations thereof. Processing element 70 can typically execute, process, or run instructions, code segments, software, firmware, programs, applications, apps, modules, agents, processes, services, daemons, etc., including programs configured to perform the wireless pairing, dynamic braking, and watchdog operations outlined herein. Processing element 70 may also include hardware components such as finite state machines, sequential and combinational logic, and other electronic circuitry necessary to perform the operations required to perform the operations of this invention. The processing element can communicate with other electronic components via serial or parallel links including address buses, data buses, control lines, etc. Through hardware, software, firmware, or combinations thereof, processing element 70 can be configured or programmed to perform the operations described elsewhere herein.

[0039] Figure 3 Other components of the exemplary controller 16 shown include a braking resistor 50, a relay 54, and a driver / half-bridge 56. The driver / half-bridge 56 receives converted 24-volt (24V) power and responds to inputs from the controller 16 to change the feed to the motor 12 according to a control algorithm (and manages its polarity). For example, the controller 16 may be configured to change the output from the motor 12 at least in part based on user input. In one or more embodiments, this output may change in response to the strength of a signal generated, for example, by a magnetic switch 42 (i.e., user input), which in turn may depend on the proximity of the trigger 48 (i.e., the degree to which the user presses the trigger 48). Furthermore, in one or more embodiments, the controller 16 may be configured to match the motor back electromotive force (EMF) to the controller output ramp to avoid initial dynamic braking and minimize stress on the controller 16. The controller 16 and / or the driver / half-bridge 56 may implement pulse width modulation (PWM) for powering the motor 12. It should be noted that various motor control strategies can be implemented without departing from the spirit of the invention.

[0040] Relay 54 includes a switch that responds to inputs from watchdog 52 components or logic of controller 16. The watchdog 52, discussed in more detail below, at least partially determines whether relay 54 remains open or closed (thus cutting off or allowing the flow of power from driver / half-bridge 56 to motor 12, respectively).

[0041] The braking resistor 50 includes a power resistor for dynamic braking of the motor 12. The braking resistor 50 can be configured such that the motor 12 decelerates at a variable rate depending on the resistance of the braking resistor 50. More specifically, when the motor 12 is to decelerate or stop, the kinetic energy of the motor can be converted into electrical energy, which can be dissipated as heat using the (preferably variable resistance) braking resistor 50.

[0042] Furthermore, it should be noted that, without departing from the spirit of the invention, the control functions performed by the controller 16 can be implemented via a variety of electronic components.

[0043] In addition, refer to Figure 1 The RFID reader 20 is shown positioned near or integrated with the bracket 22, such that the operating range of the RFID reader 20 covers the bracket 22 and / or the portion of the bracket 22 configured to receive the handheld device 38. In this way, bringing the RFID tag 46 close to or into contact with the bracket 22 also brings the RFID tag 46 close to the RFID reader 20, thereby enabling the pairing operation described in more detail below.

[0044] It will be understood by those skilled in the art that the RFID tag 46 can be positioned within the rotating blade holder 56 without departing from the spirit of the invention. Furthermore, the rotating blade holder 56 can be configured to provide partial or complete protection against the ingress of water and / or environmental contaminants, and to isolate the ingress of water and / or environmental contaminants.

[0045] In addition, it should be noted that the preferred embodiment includes several status indicator lights (e.g., wireless status LED 60, wireless status LED 61, motor status LED 62, battery status LED 64, etc.) embedded in the housings of the power pack housing 18 and the handheld device 38, respectively.

[0046] The system may include additional, fewer, or alternative devices or components, including those discussed elsewhere herein and / or in the accompanying figures.

[0047] Exemplary method for wireless control of power hand tools

[0048] Figure 6 A block flowchart is depicted associated with an exemplary computer-implemented method for pairing, using, and wirelessly controlling a handheld powered tool. Some steps may be performed simultaneously rather than sequentially, and in some cases, in a different order. Additionally, some steps may be optional. For ease of reference, the computer-implemented method is described below by utilizing… Figure 1-5The exemplary apparatus and components described in the embodiments illustrated herein are used for execution. For example, the steps of a computer-implemented method can be performed at least in part by utilizing a processor, transceiver, hardware, software, firmware, or a combination thereof by the power pack and handheld device shown therein and described above. In one or more embodiments, the steps set forth below for a single handheld device and power pack are substantially repeated by combining the pairing, use, and wireless control of multiple other electric handheld tools in the same generally nearby area or at the same location. Those skilled in the art will also understand that, without departing from the spirit of the invention, responsibility for all or part of such operation may be allocated differently among these devices or other computing devices.

[0049] One or more computer-readable media may also be provided. These computer-readable media may include one or more executable programs, such as controller programs, stored thereon, wherein the programs instruct one or more processing elements to perform all or some of the steps outlined herein. The programs stored on the computer-readable media may instruct the processing elements to perform additional, fewer, or alternative actions, including those discussed elsewhere herein.

[0050] Referring to step 100, the user can place the handheld device, including the powered rotary blade, on the holder of the power pack. The motor controller can sense the proximity of the handheld device's wireless transceiver or RFID tag (e.g., via an RFID reader and / or a motor-controlled wireless transceiver, or by otherwise detecting that the handheld device is placed on the holder of the power pack), and this proximity can trigger or serve as a prerequisite for the wireless pairing process. As discussed in more detail below, the pairing button on the motor controller can also or alternatively be pressed to trigger or serve as a prerequisite for pairing the handheld device with the power pack. It will be understood by those skilled in the art that various wireless signals containing handheld device identification data can be used to pair a new handheld device with the power pack. When a new handheld device is placed inside the holder on the power pack, the wireless pairing signal can be received by the motor-controlled wireless transceiver.

[0051] Referring to step 102, the pairing button on the motor controller can be pressed. In the illustrated embodiment, the motor controller detects or determines whether the pairing button has been pressed. In this embodiment, such determination may include determining whether the pairing button or switch is currently active, or whether it has been activated within a predetermined time period.

[0052] Referring to step 104, if the determination result related to whether the pairing button was pressed in step 102 is "no", the pairing process may not continue and / or may be terminated.

[0053] Referring to step 106, alternatively, if the determination at step 102 is "yes", the motor controller may determine whether to read one or more RFID tags. In one or more embodiments, the motor controller activates an RFID reader to receive signals from the RFID tags related to the determination made at step 106.

[0054] Referring to step 108, if no RFID tag signal is read / detected at step 106, or if the pairing process is terminated due to unmet conditions, the motor controller or its ability to initiate power supply to the motor can be disabled. Furthermore, referring to step 110, in this case, the motor controller can also confirm that it has not wirelessly paired with an unknown handheld device (i.e., the RFID tag signal does not match the RFID signal of a previously paired handheld device and / or the complete wireless pairing process has not been completed), as a condition for resetting the motor controller for future pairing processes. After confirming at step 110 that the motor controller has not wirelessly paired with an unknown handheld device, the motor controller can loop back to step 102 to again determine if the pairing button has been pressed.

[0055] Referring to step 112, if the RFID tag signal is read / detected in step 106, the motor controller can continue pairing with the corresponding handheld device. In one or more embodiments, the pairing process may include writing unique information related to the handheld device into memory (e.g., into the motor controller's EEPROM). For example, the RFID reader may comply with the Near Field Communication (NFC) protocol, and the handheld device RFID tag signal may include credentials or unique identification information for the handheld device and / or a wireless transceiver embedded in the handheld device. In this way, the RFID signal can uniquely identify the handheld device to the motor controller, and such unique identification information can be stored at the motor controller and / or used to complete the wireless pairing between the handheld device and the motor controller.

[0056] In one or more embodiments, all or some of the information in the RFID tag signal can be used for security applications, such as for establishing encryption keys to protect wireless communication between the handheld device and the motor controller.

[0057] In one or more embodiments, the pairing process may further include the establishment of an associated encryption protocol and key for secure wireless communication between the handheld device and the motor controller. It should also be noted that the pairing of the handheld device with the power pack is preferably persistent. In one or more embodiments, the pairing is retained in the controller's memory elements regardless of whether the power pack or the handheld device's electronics and / or the motor's power is switched off, unless and until it is overwritten by a new pairing procedure (e.g., pairing with a new handheld device).

[0058] Those skilled in the art will understand that, in one or more embodiments, the motor controller may first verify a single RFID tag signal against one or more conditions before completing the pairing process. Furthermore, those skilled in the art will understand that the reception of multiple RFID tag signals during the pairing process outlined above may prompt the user to select such an RFID tag (or handheld device) for pairing and / or may lead to the termination of the pairing process.

[0059] If at least one handheld device has been correctly identified by the motor controller via RFID tag signal, then in conjunction with step 112, the motor controller can complete secure wireless pairing with the handheld device.

[0060] Referring to step 124, the motor controller can determine whether it is receiving a paired wireless signal from the handheld device's wireless transceiver. In one or more embodiments, such a signal is received whenever a magnetic switch at the handheld device is activated, for example by pressing a magnet-containing trigger on the paired handheld device.

[0061] Referring to step 126, in one or more embodiments, the motor controller is in an "ON" state, and the sequence of using the paired handheld device includes activating or starting the power supply, as depicted in step 128. Also referring to step 130, the power supply can provide power to the motor controller. Those skilled in the art will understand that, in addition to providing power to the motor controller, the power supply can also supply power to the motor controller in different ways, such as via AC line power. One or more of steps 126, 128, and 130 can serve as logical or physical prerequisites for proceeding to step 132, in addition to confirming receipt of the paired wireless signal at step 124, which will be described in more detail below.

[0062] Referring to step 132, if the motor controller receives a paired wireless signal from the handheld device, the motor controller can cause its associated electronic components (e.g., driver / half-bridge and / or relay circuitry) to supply power from the power source to the motor, thereby activating the motor and / or placing it in an "ON" and operational state. As described above, in one or more embodiments, one or more of steps 126, 128, and 130 can serve as additional logical or physical prerequisites for achieving step 132 and the "ON" state. Referring to step 134, the DC motor in the "ON" state can cause rotation of the crankshaft or other drivetrain components and subsequent operations of the handheld device (e.g., operation of a high-speed tool on the handheld device).

[0063] Generally, it should be noted that in embodiments of the invention, the "DC motor turn-on" process in step 132 can only proceed if a paired wireless signal is received simultaneously (see step 124). As described above, in one or more embodiments, such a signal can be received as a result of activating a magnetic switch on the handheld device by, for example, squeezing an adjacent corresponding trigger. The switch may include a Hall effect sensor or another sensor configured to respond to and be activated when the proximity of the magnet or ferromagnetic element of the trigger reaches a threshold.

[0064] Referring to step 136, if the motor controller receives a "system off" input (e.g., by user activation of the corresponding switch / button), the motor can be put into an "OFF" state. Upon receiving such an input, in step 138, the power supply can be correspondingly turned off or kept off. Referring to step 140, in step 138, when the power supply is turned off or kept off, the power supply to the motor controller can also be cut off.

[0065] Referring to step 142, if the motor controller does not receive a paired wireless signal from the handheld device, the electronic components associated with the motor controller (e.g., driver / half-bridge and / or relay circuits) will not supply power to the motor, thereby causing the motor to be in a "shutdown" state.

[0066] One or more of steps 136, 138, and 140 may serve as additional or alternative logical or physical preconditions that, when satisfied, will result in or cause the "DC motor off" state of step 142.

[0067] Referring to step 144, when the motor controller determines, or physical conditions require, that the motor should reduce its output or switch from operation to a "shutdown" state, dynamic braking (e.g., via a braking resistor discussed in more detail above) can be used to decelerate the motor. For example, in relation to cutting off power to the leads of a motor with a moving armature, the motor controller can shut off a relay circuit to allow current to flow between the motor and the braking resistor, dissipating energy through the braking resistor (e.g., as heat). It should be noted that a circuit loop can also be added between the braking resistor and the motor. Once the motor output stops, the handpiece will cease operation as described in step 146.

[0068] Now go to Figure 7In one or more embodiments, the motor controller of the power pack may alternatively or additionally implement a watchdog fail-safe mode or algorithm for controlling the operation of the handheld device driven by the power pack. In step 150, the watchdog algorithm may trigger continuous or intermittent monitoring of one or more inputs reflecting system operation; in step 152, an ideal state of the relay circuit of the motor controller that should be determined by said one or more inputs at any given time is determined; and in step 154, it is determined whether the relay circuit has reached or deviated from the ideal state. In step 156, the watchdog algorithm may also cause a switch to electrically disconnect / disconnect the motor from the power supply based on the determination of the deviation. In one or more embodiments, the relay circuit state is binary, i.e., the relay circuit is normally open or normally closed (i.e., the motor is "ON" or "OFF" respectively), and the motor controller will determine whether the relay circuit operates in the expected manner.

[0069] In one or more embodiments, the relay circuit is activated to a first or second state corresponding to the state of the motor. For example, the relay circuit may be activated to a first state (corresponding to the motor "ON" state), wherein the relay circuit can electrically connect the motor to a power source. When the motor is connected to the power source, the relay circuit can be turned on. In another example, the relay circuit may be activated to a second state (corresponding to the motor "OFF" state), wherein the relay circuit can disconnect the motor from the power source (in this case, the relay circuit may alternatively electrically connect the motor to a braking resistor). When the motor is disconnected from the power source, the relay circuit can be turned off.

[0070] Referring again to step 154, determining the deviation may include identifying that some portions of the input data generated by the electrical components of the power pack are insufficient to establish normal operation. For example, this input data may be insufficient to establish normal operation due to a communication failure between one or more components in the system. In another example, this input data may be insufficient to establish normal operation because the input data was corrupted during transmission between components.

[0071] In one or more embodiments, the watchdog algorithm may be implemented in conjunction with the steps described above for wireless control, and may represent a complete or independent condition or a set of conditions that lead to the DC motor OFF step 142 described above.

[0072] Determining the ideal state of a relay circuit at any given time may involve analyzing one or more inputs against one or more conditions. For example, in one or more implementations, the ideal state of the relay circuit would not allow the motor to operate at 100% duty cycle.

[0073] In another example, the control signals of the power pack's driver / half-bridge, as well as the output level of the driver / half-bridge, can be monitored. A fail-safe watchdog algorithm can determine at any given time whether the difference between the output level and the expected value corresponding to the control signal is small enough (i.e., within a predetermined threshold range). Therefore, the algorithm can determine the ideal state and the deviation from it. In other words, the algorithm can determine that at a given moment or within a certain time range, the relay circuit has not reached the ideal state due to insufficient driver / half-bridge output and should be shut down.

[0074] In another example, the reception of paired wireless signals and the status of the relay circuit can be monitored. The watchdog algorithm can determine at any given time whether the relay circuit is "open" when the corresponding wireless signal is not received, and whether it is "closed" when the corresponding wireless signal is received. Therefore, the algorithm can determine the ideal state and the deviation from it. That is, the algorithm can determine whether the relay circuit has reached its ideal state at a given time or within a certain time range based on the paired wireless signals received by the motor controller.

[0075] In either case, when the watchdog algorithm determines that the relay circuit has not reached one or more ideal states, it can instruct the power supply to the motor to be cut off or the relay circuit to be turned off, and / or stop the operation of the motor and / or handpiece (see step 156).

[0076] An ideal state can be a threshold representing the permissible deviation between the power supply output level (from the motor) and the corresponding output specified in the control signal managing the power supply. It should be noted that one or more ideal states of a relay circuit can be based at least in part on predefined states. These predefined states can be a set of conditions, operating data, identification information, etc., associated with the relay circuit, or ideal states previously used by the handheld device.

[0077] Additionally, one or more ideal states of the relay circuit may at least partially include variable ideal states. Variable ideal states may change based on normal wear-related variations that gradually occur during prolonged use of the handheld device and the resulting changes in the expected values ​​of measured variables. Other factors that may cause or affect variable ideal states include the duration of connection between the handheld device and the power pack and the duration of motor operation. In one or more preferred embodiments of the invention, the relay circuit may be configured to send a signal indicating the current relay state to at least one processor of the motor controller.

[0078] It should also be noted that one or more ideal states may represent the ideal value range of one or more data types, or the relationship between the values ​​of two or more data types. Data types may include power output levels, control signals for power supplies, indications of the ideal state of relay circuits, motor operation durations, timestamps related to the use of one or more components, records of paired wireless communication signals, or associated ideal states. Those skilled in the art will understand that additional data types or relationships between data types may be used to determine one or more ideal states without departing from the spirit of the invention.

[0079] The preferred embodiments of the present invention described above are for illustrative purposes only and should not be construed as limiting the scope of the invention. Those skilled in the art can readily make obvious modifications to the exemplary embodiments described above without departing from the spirit of the invention.

[0080] Additional considerations

[0081] In this specification, references to "one embodiment," "an embodiment," or "multiple embodiments" mean that one or more features referenced are included in at least one embodiment of the present technology. Individual references to "one embodiment," "an embodiment," or "multiple embodiments" in this specification do not necessarily refer to the same embodiment and are not mutually exclusive unless so stated and / or will be apparent to those skilled in the art as described herein. For example, features, structures, actions, etc., described in one embodiment may also be included in other embodiments, but are not necessarily included. Therefore, the present technology may include various combinations and / or integrations of the embodiments described herein.

[0082] In this specification, multiple instances can implement components, operations, or structures described as a single instance. While the individual operations of one or more methods are shown and described as separate operations, one or more of these operations may be executed concurrently, and the order in which they are executed is not required. Structures and functionalities presented as separate components in the example configuration can be implemented as composite structures or components. Similarly, structures and functionalities presented as single components can be implemented as separate components. These and other variations, modifications, additions, and improvements fall within the scope of this document.

[0083] Some embodiments described herein include logic or multiple routines, subroutines, applications, or instructions. These can constitute software (e.g., code embodied on a machine-readable medium or in transmitted signals) or hardware. In hardware, routines, etc., are tangible units capable of performing certain operations and can be configured or arranged in a certain way. In example embodiments, one or more computer systems (e.g., standalone, client, or server computer systems) or one or more hardware modules (e.g., processors or processor groups) of a computer system can be configured by software (e.g., applications or application portions) to operate to perform certain operations as described herein.

[0084] In various embodiments, computer hardware such as a processing element can be implemented as dedicated or general-purpose. For example, a processing element may include dedicated circuitry or logic permanently configured to perform certain operations, such as an application-specific integrated circuit (ASIC), or dedicated circuitry or logic infinitely configured to perform certain operations, such as an FPGA. A processing element may also include programmable logic or circuitry temporarily configured by software to perform certain operations (e.g., included within a general-purpose processor or other programmable processor). It should be understood that the decision to implement a processing element as dedicated, dedicated, and permanently configured circuitry, or as general-purpose (e.g., software-configurable), may be driven by cost and time considerations.

[0085] Therefore, the term "processing element" or its equivalent should be understood to encompass tangible entities, whether physically constructed, permanently configured (e.g., hardwired) or temporarily configured (e.g., programmed), that operate or perform certain operations described herein. Consider an implementation where processing elements are temporarily configured (e.g., programmed), each of the processing elements need not be configured or instantiated at any one time instance. For example, in the case where the processing elements include a general-purpose processor configured using software, the general-purpose processor may be configured as a corresponding different processing element at different times. The software may accordingly configure the processing elements to constitute a specific hardware configuration at one time instance and a different hardware configuration at different time instances.

[0086] Computer hardware components, such as transceiver elements, memory elements, and processing elements, can provide information to and receive information from other computer hardware components. Therefore, the described computer hardware components can be considered communicatively coupled. When multiple such computer hardware components exist simultaneously, communication can be achieved through signal transmission connecting the computer hardware components (e.g., via appropriate circuitry and buses). In embodiments where multiple computer hardware components are configured or instantiated at different times, communication between such computer hardware components can be achieved, for example, by storing and retrieving information in a memory structure accessible to the multiple computer hardware components. For example, one computer hardware component can perform an operation and store the output of that operation in a communicatively coupled memory device. Another computer hardware component can then access the memory device at a later time to retrieve and process the stored output. Computer hardware components can also initiate communication with input or output devices and can operate on resources (e.g., collections of information).

[0087] The various operations of the example methods described herein can be performed, at least in part, by one or more processing elements that are temporarily configured (e.g., by software) or permanently configured to perform the relevant operations. Whether temporarily or permanently configured, such processing elements can constitute modules implemented by processing elements that operate to perform one or more operations or functions. In some example embodiments, the modules mentioned herein may include modules implemented by processing elements.

[0088] Similarly, the methods or routines described herein may be implemented by at least some of the processing elements. For example, at least some operations of the method may be performed by one or more processing elements or hardware modules implemented by processing elements. The execution of some operations may be distributed across one or more processing elements, residing not only within a single machine but also deployed across multiple machines. In some example embodiments, the processing elements may be located in a single location (e.g., in a home environment, an office environment, or as a server farm), while in other embodiments, the processing elements may be distributed across multiple locations.

[0089] Unless otherwise expressly stated, the use of terms such as “processing,” “computing,” “operation,” “determining,” “presenting,” and “displaying” in this document may refer to the actions or processes of a machine (e.g., a computer having processing elements and other computer hardware components) that manipulates or transforms data represented as physical (e.g., electronic, magnetic, or optical) quantities within one or more memories (e.g., volatile memory, non-volatile memory, or combinations thereof), registers, or other machine components that receive, store, transmit, or display information.

[0090] As used herein, the terms "comprising," "including," "having," or any other variations thereof are intended to cover non-exclusive inclusion. For example, a process, method, article, or apparatus that includes a list of elements is not necessarily limited to those elements, but may include other elements not expressly listed or inherent to such a process, method, article, or apparatus. Furthermore, unless expressly stated to the contrary, "or" means inclusive, not exclusive. For example, any of the following satisfies condition A or B: A is true (or exists) and B is false (or does not exist); A is false (or does not exist) and B is true (or exists); and both A and B are true (or exist).

[0091] The patent claims at the end of this patent application are not intended to be interpreted in accordance with 35 U.SC §112(f) unless they expressly describe conventional means plus function language, such as “means for…” or “steps for…” as expressly stated in one or more claims.

[0092] Although the invention has been described with reference to embodiments shown in the accompanying drawings, it should be noted that equivalents may be used and substitutions may be made herein without departing from the scope of the invention as described in the claims.

Claims

1. A power pack for power tools, the power pack comprising: An electric motor, configured to engage with the power tool in a driving manner; Braking resistor; A relay circuit electrically communicating with the electric motor, the relay circuit including a switch capable of selectively connecting to the braking resistor, the relay circuit being configured such that the electrical connection from the electric motor to the braking resistor allows electrical energy from the electric motor to be dissipated at least partially as heat by the braking resistor; as well as A non-transitory computer-readable storage medium storing computer-executable instructions for monitoring the operation of an electric motor, wherein when executed by at least one processor, the computer-executable instructions cause the at least one processor to perform the following operations: The system monitors input data related to the operation of the electric motor, the data type of which includes one or more of the following: power output level, control signals to the power supply, paired wireless communication signals received from the power tool, motor operation duration, and motor operation duty cycle. The system determines, at least in part, that the motor operation has deviated from an ideal state based on the input data. Based on the determination of the deviation, the relay circuit is activated to electrically connect the motor to the braking resistor.

2. The power pack according to claim 1, The relay circuit has at least a first state and a second state, the first state and the second state corresponding to the motor's on state and off state, respectively.

3. The power pack according to claim 2, wherein, Based on the determination of the deviation, the relay circuit is activated to the second state.

4. The power pack according to claim 3, wherein, In the first state, the relay circuit electrically connects the motor to the power supply.

5. The power pack according to claim 1, wherein, Determining the deviation involves determining whether the motor is already operating or will be operating at 100% duty cycle.

6. The power pack according to claim 1, further comprising a housing, The relay circuit and the motor are both located within the housing.

7. The power pack according to claim 1, wherein, The braking resistor functions when the relay circuit is closed. Activation of the relay circuit includes a signal that turns the relay circuit off.

8. The power pack according to claim 1, wherein, The relay circuit is configured to send a signal to the at least one processor indicating the current state of the relay circuit.

9. The power pack according to claim 8, wherein, The current relay circuit state is determined at least in part based on a variable ideal state that can be configured by the at least one processor.

10. The power pack according to claim 1, wherein, Determining the deviation involves identifying that some portions of the input data generated by the electrical components of the power pack are insufficient to establish normal operation.

11. A system for selectively powering a power tool, the system comprising: Power tools; An electric motor, configured to engage with the power tool in a drive configuration; Braking resistor; A relay circuit electrically communicating with the electric motor, the relay circuit including a switch capable of selectively connecting to the braking resistor, the relay circuit being configured such that the electrical connection from the electric motor to the braking resistor allows electrical energy from the electric motor to be dissipated at least partially as heat by the braking resistor; as well as A non-transitory computer-readable storage medium having stored thereon computer-executable instructions, wherein when executed by at least one processor, the computer-executable instructions cause the at least one processor to perform the following operations: Fault conditions are determined based on deviations of one or more of the following input data types from the ideal state: power output level, power supply control signals, paired wireless communication signals received from the power tool, motor operation duration, and motor operation duty cycle. Based on the fault condition determination result, the relay circuit is activated to electrically connect the motor to the braking resistor.

12. The system according to claim 11, wherein, The power tool includes a rotary cutter.

13. The system according to claim 11, wherein, The braking resistor includes a power resistor.

14. The system according to claim 13, wherein, The power resistor enables dynamic braking of the electric motor.

15. The system according to claim 14, wherein, The power resistor is configured for dynamic braking, thereby causing the motor to decelerate at a variable rate.

16. The system according to claim 11, wherein, The relay circuit allows electrical connection between the motor and the braking resistor, such that activation of the relay circuit by the at least one processor includes failure to send an operation signal to the relay circuit.

17. The system according to claim 11, wherein, The computer-readable instructions, when executed by the at least one processor, also cause the at least one processor to perform the following operations: Receive user input, The output of the motor is changed based on the user input.

18. The system according to claim 11, wherein, The power tool has an output that is proportional to the operating rate of the electric motor.

19. The system according to claim 11, wherein, The motor is directly connected to the relay circuit and the grounding terminal of the relay circuit or another device.

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