Powering system for battery powered tools

Abstract

A power supply system includes an external power source that is directly connected to a battery pack of a cordless power tool. Power is supplied to the power tool through a connection between the power source and the battery pack. Because the power source is directly connected to the battery pack, the power can be used to charge the batteries of the battery pack when the tool is in an "off" state, and the power can be used to power the tool motor to extend the run time of the tool when the tool is in an "on" state. If the power consumed by the power tool is less than the power available from the power source, the difference in power is used to charge the batteries; if the power consumed by the tool is greater than the power available from the power source, the batteries supplement the additional power needed.

Description

Technical Field

[0001] This invention relates to a power supply system for battery-powered tools. Background Technology

[0002] Battery-powered cordless power tools are favored for their portability and mobility, but their battery packs typically offer limited operating time or "runtime." In contrast, corded power tools can have virtually unlimited runtime as long as they remain connected to AC mains power. While some solutions on the market offer AC-to-DC adapters to allow cordless tools to be powered entirely by AC mains, these solutions can be bulky and relatively expensive. Therefore, there is a need for a power supply system for battery-powered cordless power tools that is moderately or minimally sized and lightweight, while providing extended tool runtime. Summary of the Invention

[0003] The power supply system described herein utilizes an external power source to reduce overall size and weight, and extend the runtime of battery-powered tools. In this system, the external power source is directly connected to the cordless power tool's battery pack. This connection is achieved via a connector, and power is supplied to the power tool through this connector. By directly connecting the power to the battery pack, the power can be used for: 1.) Charge the battery pack while the tool is in the "off" state; and 2.) Power the motor when the tool is in the "on" state to extend the tool's runtime.

[0004] i. If the power consumed by the tool is less than the power supplied by the power source, the difference will be used to charge the battery (charging while running); and ii. If the tool consumes more power than the power supply can provide, the battery will supplement the required additional power.

[0005] The power source and battery from this power supply system can also be used to directly power low-power assistive tools, such as glue pencils. As used herein, the term "low-power" refers to power requirements in the range of 10 to 60 watts. In some embodiments, the power source can be directly connected to and power the assistive tool. The battery can also be used as a portable power source, powering the assistive tool via a charging input connector. The battery pack will include the necessary battery discharge management features, which will keep the assistive tool, especially in terms of electronics, simple and low-cost.

[0006] In some aspects, a multi-functional system for power tools is implemented in a battery pack consisting of at least one electrochemical cell. The system may include a power source, a battery pack, and a cordless power tool. Adaptations or implementations are provided in the battery pack, in the tool itself, or in any combination thereof, enabling the system to perform operating modes such as battery-only discharge, battery-only charging, and charge / load-sharing operation. Information can be exchanged directly or indirectly between these system sub-components to facilitate these operating modes.

[0007] In discharge mode, the battery pack can be discharged through the main interface / connector and / or the secondary interface / connector.

[0008] In charge-only mode, battery discharge is off and the battery pack is charging.

[0009] The on-demand charging / load-sharing mode operates as follows: When the tool load current demand via the primary and / or secondary interfaces can be provided by the power supply at a voltage higher than the battery pack voltage, the power supply provides current to the load and the charging IC, while the charging IC simultaneously charges the battery pack. When the load current demand exceeds the power supply's current limit or causes the power supply voltage to drop below the battery pack voltage, the load current is provided by both the battery pack and the power supply simultaneously. This mode allows for increased output power compared to using either power supply alone.

[0010] The power supply output voltage can either always be higher than the required charging voltage and the charging integrated circuit (IC) will be a buck converter, or the power supply voltage can be lower than, equal to, and / or higher than the cell voltage and the charging IC will be a buck-boost converter or a SEPIC converter. The power supply can be directly connected to the load interface (when providing an acceptable voltage for tool use) or connected to the load interface via a DC-DC converter. The system can be connected to an external DC power supply via a USB-C PD connection, a standard connector, or a dedicated connector. Attached Figure Description

[0011] Figure 1 A first or cordless configuration of the power supply system is shown, in which the battery-powered power tool is powered by a battery pack.

[0012] Figure 2 A second configuration of the power supply system is shown, in which the battery-powered power tools are powered by a battery pack connected to a power source and mains power via a wired connection.

[0013] Figure 3 A third configuration of the power supply system is shown, in which the low-power tool without a battery is powered by... Figure 2 Power supply and mains power supply.

[0014] Figure 4 The fourth configuration of the power supply system is shown, in which Figure 3Battery-free, low-power tools Figure 1 Powered by a battery pack.

[0015] Figure 5 This is a schematic diagram of the first embodiment of the battery pack of the power supply system.

[0016] Figure 6 This is a schematic diagram of a second embodiment of the battery pack of the power supply system.

[0017] Figure 7 This is a schematic diagram of a third embodiment of the battery pack in the power supply system.

[0018] Figure 8 This is a schematic diagram of an electric tool with an integrated battery system. Detailed Implementation

[0019] refer to Figure 1 and Figure 5 The power supply system 1 includes four configurations for powering power tools. The power supply system 1 can be used to power a battery-powered cordless power tool 2 (also referred to as "main tool" 2). Additionally, the power supply system 1 can be used to power a low-power power tool 3 (also referred to as "auxiliary tool" 50).

[0020] like Figure 1 As seen, the first power supply configuration for powering the battery-powered cordless power tool 2 is a cordless configuration, including the cordless power tool 2 and a battery pack 12 directly connected to the power tool 2. Specifically, the battery interface 4 of the power tool 2 is electrically and mechanically engaged with the tool interface 16 (e.g., power output connector 16) of the battery pack 12. In the first power supply configuration, the cordless power tool 2 can simply be used as a typical battery-powered tool.

[0021] The battery-powered cordless power tool 2 can be any power tool that can be connected to a standard battery pack (e.g., sander, drill, rotary tool, etc.). The cordless power tool 2 can use more than 100W of power and includes battery discharge management (BDS), which incorporates BDS electronics contained within the tool 2.

[0022] The battery pack 12 may include a battery 26, a charging management electronic control unit (CM ECU) 24, a discharge control device 22, a microcontroller (microcontroller or MCU) 20 for controlling the battery pack components, and a power input connector 14 and a power output connector 16. The power output connector 16 contains battery contact pins and battery pack signal information used by the main tool 2. The battery pack also includes the power input connector 14, which allows the battery pack 12 to be electrically and mechanically connected to perform two functions. The first function of the power input connector 14 is to provide a charging port for the battery 26 of the battery pack 12, and the second function of the power input connector 14 is to provide power to the auxiliary tool 3, as described below.

[0023] Battery 26 may include one or more electrochemical cells. The cells may be, for example, lithium-ion cylindrical cells, lithium polymer pouch cells, or any other type of cell suitable for a given application.

[0024] The CM ECU 24 is used to safely charge the cells of the battery 26. The CM ECU 24 regulates the charging current, battery voltage, and single-cell monitoring, and operates only within the battery temperature limits, and can be implemented using readily available charging management integrated circuits (ICs). When the main tool 2 is connected to the battery pack 12, the CM ECU 24 can supply a current up to the allowable charging current of the battery 26 to a load (e.g., to the tool motor 6).

[0025] The discharge control device 22 can be an electronic switch (e.g., MOSFET) controlled by the MCU 20, used for discharge management of the power supplied to the auxiliary tool. The MCU 20 communicates with the CM ECU 24 to provide discharge management control and can also communicate with the connected main tool 2.

[0026] refer to Figure 2 The second power supply configuration for battery-powered cordless power tools includes Figure 1 The cordless power tool 2 and the battery pack 12 are included. Furthermore, a second power supply configuration includes a power source 40 directly connected to the battery pack 12. Specifically, the connector 42 of the power source 40 is electrically and mechanically engaged with the connector 14 of the battery pack 12.

[0027] In the illustrated embodiment, power supply 40 is an AC / DC converter that steps down the mains voltage to a DC voltage usable by the cordless power tool 2 and / or charging circuitry. In the illustrated embodiment, power supply 40 is a 60W power supply (12.6 volts, 4.87 amps), as this power is commonly found in laptops and is therefore readily available. Power supply 40 includes a connector 42 that mates with a corresponding power input connector 14 in the battery pack 12.

[0028] Power source 40 is connected to mains voltage via conductive wire 44, for example, by connecting to a public power outlet 5. Depending on the size of power source 40, it can charge battery 26 of battery pack 12, power motor 8 of power tool 2, or both. This configuration extends the tool's runtime compared to a power tool powered solely by battery pack 12.

[0029] refer to Figure 3 The third power supply configuration for battery-powered cordless power tools includes Figure 2 The power supply 40 and a low-power auxiliary tool 3, such as a glue pen, are provided. The auxiliary tool 3 can be compact, have limited electronic functions, and may or may not include a battery. In the third power supply configuration, the auxiliary tool 3 is directly connected to the power supply 40 via connector 42. Since the auxiliary tool 3 does not contain a battery, the power supply 40 powers the auxiliary tool 3 entirely.

[0030] refer to Figure 4 The fourth power supply configuration for battery-powered cordless power tools includes Figure 3 Low-power auxiliary tools 3 and Figure 1 The battery pack 12 is configured for use with the main tool 2, and therefore can provide more power than the auxiliary tool 3 requires. In a fourth power supply configuration, the auxiliary tool 3 is directly powered by the battery pack 12 via a power input connector 14, or "charging port," located on the battery pack 12. As previously mentioned, the battery pack 12 includes a lithium-ion battery discharge control device 22 to maintain the low cost of the auxiliary tool.

[0031] Refer again Figure 5 The first exemplary power supply system 1 includes a separate battery pack 12, a main tool 2, and an external power supply 40. Optionally, the power supply system 1 may also include an auxiliary tool 3. This is an example of a 12V system, but the power supply system 1 can also be adapted to work with other voltages, such as 4V, 8V, 18V, etc.

[0032] Battery pack 12 provides a path 32 for delivering power from power source 40 to main tool 2. In power delivery path 32, power flows from power input connector 14 to CM ECU 24, from CM ECU 24 to battery 26, and from battery 26 to power output connector 16.

[0033] In power supply system 1, the power supplied to the main tool 2 by battery 26 can be supplemented by power source 12. For example, when battery pack 12 is connected to power source 40 (which in this example has 60 watts / 12.6 volts / 5 amps), if the main tool 2 consumes two amps of current, battery pack 12 is configured to supply two amps of current to the main tool 2 and three amps of current to battery 26, thereby charging battery 26. In a second example, if the current consumed by the main tool 2 is greater than the current supplied by power source 40, or causes the power supply voltage to drop below the battery pack voltage, then battery 26 supplies additional current to the main tool 2. In other words, the load current is supplied simultaneously by both battery pack 12 and power source 40.

[0034] Battery pack 12 provides another path 36 for supplying power to the auxiliary tool 3. In this embodiment, the auxiliary tool 3 is directly powered by battery pack 12 via a power input connector 14, or "charging port," located on battery pack 12. In power supply path 36, power flows from battery 26 to discharge control device 22 and from discharge control device 22 to power input connector 14. In some embodiments, conductive wire 9 provides the connection between power input connector 14 and auxiliary tool 3.

[0035] refer to Figure 6 The second exemplary power supply system 100 and Figure 5 The system is similar, the difference being... Figure 6 The power supply system 100 includes a battery pack 112 according to an alternative embodiment. Figure 6 Battery pack 112 and Figure 5 The battery pack 112 differs from the main tool 2 in that it includes a power isolation device 28 located between the battery 26 and the power source 40. The power isolation device 28 allows power to be directly transferred to the main tool 2 without the need for regulation by the CM ECU 24. This addition allows the power source 40 to still supply power to the main tool 2 even when battery charging is not permitted due to charging temperature limitations, and allows the use of a higher-power power source. The power isolation device 28 works in conjunction with the microcontroller, charging circuitry, and DC power supply. It contains at least one ideal diode, implemented using a FET and an ideal diode or ORing controller (or gate controller), with the anode at the positive terminal of the battery pack and the cathode at the load interface (main battery interface block).

[0036] Battery pack 112 provides two distinct and parallel paths 132 and 134 for delivering power from power source 40 to main tool 2. In the first power delivery path 132, power flows from power input connector 14 to CM ECU 24, from CM ECU 24 to battery 26, and from battery 26 to power output connector 16. In the second power delivery path 134, power flows from power input connector 14 to power isolation device 28, and from power isolation device 28 to power output connector 16. Therefore, battery pack 112 is configured to allow power to bypass CM ECU 24 and be delivered to main tool 2 via power isolation device 28, thereby allowing a larger power source (e.g., greater than 60W) to be connected to battery pack 112. As in the previous embodiment, both battery 26 and power source 40 simultaneously power main tool 2.

[0037] CM ECU 24 can prevent battery charging under certain operating conditions. For example, if the ambient temperature of the battery pack 12 exceeds the charging temperature range of the battery 26 (i.e., exceeds the range of 0 degrees Celsius to 45 degrees Celsius), CM ECU 24 will prevent battery charging. In another example, CM ECU 24 will prevent battery charging in the event of a system malfunction. Even when CM ECU 24 prevents battery charging, the main tool 2 can still be supplied with power via the second power delivery path 134.

[0038] Similar to the previous embodiment, the battery pack 112 provides a path 36 for supplying power to the auxiliary tool 3. In this embodiment, the auxiliary tool 3 is directly powered by the battery pack 112 via a power input connector 14 disposed on the battery pack 12. In the power supply path 36, power flows from the battery 26 to the discharge control device 22 and from the discharge control device 22 to the power input connector 14. In some embodiments, a conductive wire 9 provides a connection between the power input connector 14 and the auxiliary tool 3.

[0039] refer to Figure 7 The third exemplary power supply system 200 is similar to the previously described systems 1 and 100, and another variation is shown in which the power supply 40 is omitted and a Universal Serial Bus (USB) device 240 (e.g., having USB Power Delivery (USB PD)) is used. ® USB Type-C ® (Instead of the device). By doing so, the battery pack 212 can be supplied with higher power than the power source 40 could provide. For example, in the illustrated embodiment, the USB-C device 240 can provide 240 watts / 5V - 48V / 5 amps.

[0040] The third power supply system 200 differs from the first and second power supply systems 1 and 100 described above in that the battery pack 212 includes a USB Type-C connector 214 as a power input connector. To accommodate the voltages supported by USB PD, a DC-DC converter 30 is required to handle various voltages. In some embodiments, the DC-DC converter 30 is configured to handle voltages in the range of 5 volts to 48 volts from the USB device 240, and to provide a fixed output voltage from the battery 26 to the auxiliary tool 3. Furthermore, the third power supply system includes an MCU 220 modified to accommodate USB connectivity.

[0041] Battery pack 112 provides two distinct and parallel paths 232 and 234 for delivering power from a power source (e.g., USB device 240) to main tool 2. In the first power delivery path 232, power flows from USB Type-C connector 214 to DC-DC converter 30, from DC-DC converter 30 to CM ECU 24, from CM ECU 24 to battery 26, from battery 26 to power isolation device 28, and from power isolation device 28 to power output connector 16. In the second power delivery path 234, power flows from USB Type-C connector 214 to DC-DC converter 30, from DC-DC converter 30 to power isolation device 28, and from power isolation device 28 to power output connector 16. Therefore, battery pack 112 is configured to allow power to bypass CM ECU 24 and be delivered to main tool 2 via power isolation device 28, thereby allowing a larger power source (e.g., greater than 60W) to be connected to battery pack 112. As in the previous embodiment, battery 26 and USB device 240 can simultaneously power main tool 2.

[0042] The battery pack 112 can be used to charge the auxiliary tool 3 via the battery 26, the discharge management device 22, the DC-DC converter 30 and the USB-C connector 214.

[0043] refer to Figure 8 The fourth exemplary power supply system 300 is similar to the previously described systems 1, 100, and 200, and another variation is shown in which a USB-C port with power delivery can be used in a tool with an integrated battery. For this system, an integrated battery device 310, similar to the battery packs 12, 112, and 212 described above, is incorporated into the main tool 302. In the illustrated embodiment, the integrated battery device 310 includes a USB Type-C connector 214, a DC-DC converter 30, a CM ECU 24, an MCU 220 modified to accommodate USB connectivity, a power isolator 28, and a battery 26.

[0044] The integrated battery device 310 provides two distinct and parallel paths 332 and 334 for delivering power from a power source (e.g., USB device 240) to the main device 2. In the first power path 332, power flows from the USB Type-C connector 214 to the DC-DC converter 30, from the DC-DC converter 30 to the CM ECU 24, from the CM ECU 24 to the battery 26, from the battery 26 to the power isolation device 28, and from the power isolation device 28 to the motor electronic control unit (motor ECU) 6. In the second power path 334, power flows from the USB Type-C connector 214 to the DC-DC converter 30, from the DC-DC converter 30 to the power isolation device 28, and from the power isolation device 28 to the motor electronic control unit (motor ECU) 6. Therefore, the battery pack 212 is configured to allow power to bypass the CM ECU 24 and be delivered to the motor 8 via the power isolation device 28, thereby allowing a larger power source (e.g., greater than 60W) to be connected to the motor 8. As in the previous embodiment, both battery 26 and power supply 240 can supply power to main tool 2 simultaneously.

[0045] The integrated battery device 310 can be used to charge the auxiliary tool 3 via the USB-C connector 214.

[0046] The foregoing has described in detail selective illustrative embodiments of the system and associated devices. It should be understood that only structures deemed necessary to illustrate the system and associated devices have been described herein. Other conventional structures, as well as auxiliary and accessory components of the system, are considered to be known and understood by those skilled in the art. Furthermore, while working examples of the system and associated devices have been described above, the system and associated devices are not limited to the above-described working examples, but various design changes can be made without departing from the system and associated devices set forth in the claims.

Claims

1. A battery-powered system, comprising: power supply; The battery pack includes a first connector and a second connector; as well as Cordless battery-powered power tools The battery-powered system is configured to operate in the following mode: In the first mode, the battery pack can discharge via the first connector, the second connector, or both the first connector and the second connector. In the second mode, the battery pack is not discharging and the battery pack is charging. In the third mode, And among them, when running in the third mode and When the current demand generated by the tool load through the first connector and / or the second connector can be provided by the power source at a voltage higher than the battery pack voltage, the power source simultaneously provides current to the tool and charges the battery pack. When the current demand generated by the tool load through the first connector and / or the second connector exceeds the current limit of the power supply or causes the voltage of the power supply to drop below the voltage of the battery pack, the battery pack and the power supply simultaneously supply current to the tool.

2. A battery pack for supplying power to a battery-powered device, the battery pack comprising: The input interface is configured to connect to a power source. The output interface is configured to connect to a battery-powered device. The first power supply path transmits power from the input interface to the output interface, and The second power supply path transmits power from the input interface to the output interface. in, The first power supply path is different from the second power supply path, and The first power supply path and the second power supply path operate in parallel.

3. The battery pack according to claim 2, wherein, The first power supply path includes: A charging management electronic control unit (CM ECU) connected to the input interface; and The battery is located in the path between the CM ECU and the output interface.

4. The battery pack according to claim 3, wherein, The battery is configured to be charged by the power source when the power source is connected to the input interface.

5. The battery pack according to claim 3, wherein, The battery pack includes a discharge controller that receives power from the battery and delivers the power to the input interface.

6. The battery pack according to claim 5, wherein, The discharge controller is configured to provide at least one of undervoltage protection and overcurrent protection for the battery.

7. The battery pack according to claim 2, wherein, The second power supply path includes: A power isolation device is disposed between the input interface and the output interface.

8. A power supply system, comprising: power supply; Battery-powered equipment; as well as The battery pack includes: An input interface, configured to be connected to the power supply, An output interface is configured to connect to the battery-powered device. The first power supply path transmits power from the input interface to the output interface, and The second power supply path transmits power from the input interface to the output interface. in, The first power supply path is different from the second power supply path, and The first power supply path and the second power supply path operate in parallel.

9. The power supply system according to claim 8, wherein, The first power supply path includes: A charging management electronic control unit (CM ECU) connected to the input interface; and The battery is located in the path between the CM ECU and the output interface.

10. The power supply system according to claim 9, wherein, The battery is configured to be charged by the power source when the power source is connected to the input interface.

11. The power supply system according to claim 9, wherein, The battery pack includes a discharge controller that receives power from the battery and delivers the power to the input interface.

12. The power supply system according to claim 11, wherein, The discharge controller is configured to provide at least one of undervoltage protection and overcurrent protection for the battery.

13. The power supply system according to claim 8, wherein, The second power supply path includes: A power isolation device is disposed between the input interface and the output interface.

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