Power tool battery pack charger and system for controlling charging mode of battery charger

Abstract

A power tool battery pack charger and a system for controlling a charging mode of a battery charger. A system includes: a first microcontroller unit configured to charge a first battery pack via a first power source; a second microcontroller unit configured to charge the second battery pack via a second power source, the second power source being electrically isolated from the first power source; an optical isolation circuit; and an input mechanism. The first microcontroller unit is configured to receive a signal output by the input mechanism, the signal representing a selected charging mode; controlling charging of the first battery pack via the first power supply based on the selected charging mode; and transmitting the selected charging mode to the second microcontroller unit via an optical isolation circuit.

Description

[0001] Related applications

[0002] This application claims priority to U.S. Provisional Application No. 63 / 582,298, filed September 13, 2023, the entire contents of which are incorporated herein by reference. Technical Field

[0003] The embodiments described herein relate generally to battery chargers and, more particularly, to controlling a charging mode of one or more power tool battery packs being charged via the battery charger. Background Art

[0004] The power tool battery charger is configured to support and charge multiple battery packs via multiple battery pack interfaces. Conventional power tool battery chargers are mostly manually controlled charging modes and do not have the function of automatically controlling the charging of the battery packs. Utility Model Content

[0005] Embodiments described herein provide systems and methods for charging a power tool battery pack, for example, controlling a charging mode of a plurality of battery packs connected to a battery charger. One embodiment provides a power tool battery pack charger comprising a first microcontroller unit, a second microcontroller unit, and a plurality of battery pack interfaces for charging the plurality of battery packs. The first microcontroller unit is configured to receive a signal representing a selected charging mode, wherein the selected charging mode comprises a first charging mode or a second charging mode. The first microcontroller unit is further configured to control a charging operation of at least a first battery pack of the plurality of battery packs based on the selected charging mode, and to transmit the selected charging mode to the second microcontroller unit via an optical isolation circuit. At least one of the first microcontroller unit and the second microcontroller unit is configured to control an indicator to indicate the selected charging mode.

[0006] In some embodiments, the charging current of the first charging mode is limited to 3 amps. In some embodiments, the charging current of the first charging mode is limited to 6 amps. In some embodiments, the first microcontroller unit is configured to communicate unidirectionally with the second microcontroller unit via the optical isolation circuit. In some embodiments, the first microcontroller unit is configured to communicate bidirectionally with the second microcontroller unit via the optical isolation circuit. In some embodiments, the first microcontroller unit controls a first power supply of the battery charger and the second microcontroller controls a second power supply of the battery charger, and the first power supply and the second power supply are electrically isolated within the battery charger. In some embodiments, the indicator indicates fast charge mode as the selected charging mode. In some embodiments, the indicator indicates that at least a subset of the plurality of battery pack interfaces is charging the connected battery pack using fast charge mode. In some embodiments, the power tool battery pack charger further includes an input mechanism configured to generate the signal. In some embodiments, the indicator is located on a surface of the battery charger housing, and in some embodiments, the second microcontroller unit is configured to control the indicator to indicate a disruption in communication with the first microcontroller unit. In some embodiments, the optical isolation circuit includes an optocoupler.

[0007] Other embodiments provide a method of operating a battery charger configured to charge a plurality of battery packs. The method includes: controlling, via a first microcontroller unit included in the battery charger, a charging operation of at least a first battery pack among the plurality of battery packs based on a selected charging mode; and transmitting, via an optical isolation circuit included in the battery charger, the selected charging mode to a second microcontroller unit included in the battery charger. The method also includes controlling, via the second microcontroller unit, a charging operation of at least a second battery pack among the plurality of battery packs based on the selected charging mode.

[0008] Another embodiment provides a system for controlling a charging mode of a battery charger. The system includes: a first microcontroller unit configured to charge a first battery pack via a first power source; and a second microcontroller unit configured to charge a second battery pack via a second power source, wherein the second power source is electrically isolated from the first power source. The system also includes an optical isolation circuit and an input mechanism. The first microcontroller unit is configured to receive a signal output by the input mechanism, the signal indicating a selected charging mode, and control charging of the first battery pack via the first power source based on the selected charging mode. The first microcontroller unit is further configured to transmit the selected charging mode to the second microcontroller unit via the optical isolation circuit.

[0009] Before any embodiment is explained in detail, it should be understood that the embodiments are not limited in their application to the configuration details and component arrangements set forth in the following description or shown in the accompanying drawings. The embodiments can be practiced or executed in various ways. In addition, it should be understood that the words and terms used herein are for illustrative purposes and should not be considered restrictive. The use of "including," "comprising," or "having" and variations thereof is meant to encompass the items listed thereafter and their equivalents, as well as additional items. Unless otherwise specified or limited, the terms "mounted," "connected," "supported," and "coupled" and variations thereof are used broadly and encompass both direct mounting, connection, support, and coupling as well as indirect mounting, connection, support, and coupling.

[0010] In addition, 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 only in hardware. However, a person of ordinary skill in the art will recognize, based on reading this detailed description, that in at least one embodiment, the electronic-based aspects may be implemented in software (e.g., stored on a non-transitory computer-readable medium) that may be executed by one or more processing units, such as a microprocessor and / or an application-specific integrated circuit ("ASIC")). Thus, it should be noted that embodiments may be implemented using a plurality of hardware- and software-based devices and a plurality of different structural components. For example, the "server," "computing device," "controller," "processor," etc. described in the specification may include one or more processing units, one or more computer-readable media modules, one or more input / output interfaces, and various connectors (e.g., a system bus) connecting these components.

[0011] Relative terms used in conjunction with quantities or conditions, such as "about," "approximately," "substantially," and the like, will be understood by those of ordinary skill in the art to include the stated value and have the meaning dictated by the context (e.g., the term includes at least the degree of error associated with measurement accuracy, the tolerance associated with a particular value [e.g., manufacturing, assembly, use, etc.], etc.). Such terms should also be considered to disclose a range defined by the absolute values ​​of the two endpoints. For example, the expression "from about 2 to about 4" also discloses a range "from 2 to 4." Relative terms can refer to positive and negative percentages of the indicated value (e.g., 1%, 5%, 10%, or more).

[0012] Unless the context of their usage clearly indicates otherwise, the articles "a," "an," "the," and "said" should not be construed as meaning "one" or "only one." Instead, these articles should be construed as meaning "at least one" or "one or more" and can be used interchangeably with "a," "an," "the," and "said" without implying a different meaning.

[0013] Furthermore, it should be understood that, unless explicitly stated otherwise, the components shown may be combined or separated into separate software, firmware, and / or hardware. For example, the logic and processing described herein may be distributed across multiple electronic processors, rather than being located within and executed by a single electronic processor. Similarly, even if the embodiments described or illustrated herein have a single such device or element, one or more memory modules and communication channels or networks may be used. Moreover, regardless of how they are combined or divided, the hardware and software components may be located on the same computing device or may be distributed across multiple different devices. Therefore, in the claims, if a device, method, or system is claimed, for example, including a controller, control unit, electronic processor, computing device, logic element, module, memory module, communication channel or network, or other element that is configured in some manner to, for example, perform multiple functions, then the claim or claim element should be interpreted as meaning one or more such elements, wherein any one of the one or more elements is configured, as claimed, to, for example, perform any one or more of the multiple functions listed, such that the one or more elements, as a set, collectively perform the multiple functions. Similarly, components described as performing a particular function may also perform additional functions not described herein. For example, a device or structure that is "configured" in a certain way is configured in at least that way, but may also be configured in ways that are not expressly listed.

[0014] Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1A is a perspective view of a multi-bay battery charger according to some embodiments described herein.

[0016] Figure 1B is a top view of another multi-bay battery charger according to some embodiments described herein.

[0017] Figure 2 According to some embodiments described herein Figure 1A or Figure 1B A perspective view of a multi-bay battery charger charging a battery pack.

[0018] Figure 3According to some embodiments described herein Figure 1A or Figure 1B Block diagram of the charger control system.

[0019] Figure 4 is a block diagram of a charging mode switching interface according to some embodiments described herein.

[0020] Figure 5 is a block diagram of an alternative charging mode switching interface according to some embodiments described herein.

[0021] Figure 6 According to some embodiments described herein Figure 4 or Figure 5 Schematic diagram of the charging mode switching interface.

[0022] Figure 7 is used according to the embodiments described herein Figure 4 or Figure 5 The process of selecting the charging mode through the charging mode switching interface. DETAILED DESCRIPTION

[0023] Figure 1A A battery charger 10 is illustrated, configured to support and charge multiple battery packs 14A-F via multiple battery pack interfaces, wherein such a battery charger 10 may be referred to herein as a "multi-bay" battery charger, referring to the multiple battery pack interfaces. In the illustrated embodiment, the battery charger 10 supports and charges up to six battery packs 14A-F. In other embodiments, the battery charger 10 is configured to support and charge fewer or more battery packs 14A-F. The battery packs 14A-F are, for example, 18-volt lithium-ion power tool battery packs. In other embodiments, the battery packs 14A-F may have different voltages (e.g., 8 volts, 12 volts, 16 volts, 28 volts, 48 ​​volts, etc.) and / or different chemistries (e.g., NiMH, NiCd, etc.). The illustrated charger 10 includes a base 18 and a housing 22. The base 18 is coupled to a bottom portion of the housing 22. The base 18 is typically larger (e.g., wider and longer) than the housing 22 to increase the stability of the charger 10.

[0024] Housing 22 extends outwardly from base 18 and includes four side surfaces 46, 50 (side surfaces 54, 58 are not shown, but are located opposite one of side surfaces 46 and 50) and an upper surface 62. Side surfaces 46, 50, 54, 58 are arranged perpendicular to each other in a generally rectangular pattern. Upper surface 62 is spaced apart from base 18 and extends generally perpendicular to side surfaces 46, 50, 54, 58. In some embodiments, housing 22 is comprised of two clamshell halves that are connected together to define surfaces 46, 50, 54, 58, 62 of housing 22. Thus, the clamshell halves enclose the internal components of charger 10. In other embodiments, housing 22 can be formed as a single piece that is connected to base 18.

[0025] When the charger 10 is supported on a surface by the base 18, the side surfaces 46, 50, 54, 58 are generally oriented vertically. In some embodiments, each side surface 46, 50, 54, 58 supports at least one battery pack interface. In other embodiments, one or more of the side surfaces 46, 50, 54, 58 may support two or more battery pack interfaces. Furthermore, in some embodiments, the charger 10 may include only a single battery pack interface for charging a single battery pack. Thus, the embodiments described herein are not limited to multi-bay chargers.

[0026] In the illustrated embodiment, housing 22 also includes a handle 82 extending from upper surface 62. Handle 82 is centrally located on charger 10 such that a central axis defined by side surfaces 46, 50, 54, 58 of housing 22 extends through handle 82. Handle 82 defines a longitudinal axis that is generally parallel to side surfaces 46, 54 and generally perpendicular to side surfaces 50, 58. Thus, handle 82 defines an elongated grip that is generally parallel to and spaced apart from upper surface 62 to facilitate lifting and carrying charger 10.

[0027] In some embodiments, each battery pack interface of the charger 10 includes a connection structure and electrical contacts. In some embodiments, the connection structure includes one or more guide rails configured to receive a sliding battery pack ( Figure 2 In other embodiments, the connection structure can be configured to receive different types of battery packs, such as tower-style battery packs.

[0028] In some embodiments, the electrical contacts of the battery pack interface of charger 10 are coupled to a charging circuit. The charging circuit is located within housing 22 and charges battery packs 14A-F when they are connected to the battery pack interface.

[0029] In the illustrated embodiment, the battery charger 10 also includes one or more indicator lights 106A-F that can be coupled to the charging circuit. The indicator lights 106A-F are illustrated as light emitting diodes (LEDs). Figure 1A As shown, LEDs 106A-F can extend from the upper surface 62 of the housing 22. In some embodiments, each battery pack interface of the charger 10 can be associated with one or more indicator lights, so that each indicator light can indicate the operating status of the associated battery pack interface. These indicators can be controlled to provide various visual indications of the operating status of the battery pack interface (e.g., various colors, icons or symbols, text, flashing patterns, etc.). For example, a continuous red light output via the indicator light can indicate that the battery pack connected to the associated battery pack interface is charging, a continuous green light output via the indicator light can indicate that the battery pack connected to the associated battery pack interface is fully charged, and a flashing red and / or green light output via the indicator light can indicate that an error has occurred with the battery pack connected to the associated battery pack interface or with the battery pack interface itself. In some examples, in response to one battery pack being connected to a battery pack interface while another battery pack is already charging via one of the other battery pack interfaces, one of the indicator lights (e.g., a red LED) can flash to indicate that charging is in progress and will begin after the other battery pack completes charging. Additionally or alternatively, the indicator lights can be configured to indicate the charge rate of one or more battery packs.

[0030] As described in more detail below, in some embodiments, the charger 10 includes a user interface for receiving user input to adjust parameter settings related to charging one or more battery packs 14A-F (i.e., one or more battery pack interfaces). The user interface may include one or more input mechanisms, such as a screen (e.g., a touch screen), one or more buttons, knobs, etc., or a combination thereof. The user interface may be located on one or more surfaces of the housing 22, such as the upper surface 62.

[0031] It should be understood that the multi-bay battery charger 10 can take various forms (e.g., sizes and shapes) and configurations. For example, Figure 1B Another embodiment of a multi-bay battery charger 10 is illustrated that is configured to support and charge multiple battery packs 14A-F via multiple battery pack interfaces (not shown), in accordance with some embodiments. Figure 1B The charger 10 is shown to include a first battery pack interface 70 and a second battery pack interface 72. In this example, both interfaces 70 and 72 are located on a top surface 74 of the housing 22 of the charger 10. However, other locations and configurations of interfaces 70 and 72 may be used. In some embodiments, each battery pack interface 70 and 72 of the charger 10 includes a connection structure and electrical contacts. In some embodiments, the connection structure includes one or more rails configured to receive a sliding battery pack (see FIG. Figure 2 ). In other embodiments, the connection structure can be configured to receive different types of battery packs, such as tower battery packs. In addition, although Figure 1B The charger 10 is shown to include two battery pack interfaces 70 on the same surface of the housing 22 , but the charger 10 may include more than two interfaces, and the interfaces may be located at different locations and on different surfaces of the housing 22 .

[0032] like Figure 1B As shown, the charger 10 also includes one or more indicator lights 78 (similar to the above description of Figure 1A The charger 10 shown depicts lights 106A-F), which can be coupled to the charging circuitry. The indicator light 78 can be a light emitting diode (LED) and can be located on the top surface 74 of the housing 22. In some embodiments, each battery pack interface 70 and 72 of the charger 10 can be associated with one or more indicator lights, and each indicator light can indicate the operating status of the associated battery pack interface. For example, a continuous red light output via the indicator light can indicate that the battery pack connected to the associated battery pack interface is charging, a continuous green light output via the indicator light can indicate that the battery pack connected to the associated battery pack interface is fully charged, and a flashing red and / or green light output via the indicator light can indicate that an error has occurred with the battery pack connected to the associated battery pack interface or with the battery pack interface itself. Again, it should be understood that the indicator light can provide indications in various forms, such as via color, text, an icon or symbol, a flashing pattern, etc. In some examples, in response to one battery pack being connected to a battery pack interface while another battery pack is already charging via one of the other battery pack interfaces, one of the indicator lights (e.g., a red LED) can flash to indicate that charging is in progress and will begin after the other battery pack has completed charging. Additionally or alternatively, the indicator light can be configured to indicate the charge rate of one or more battery packs. For example, in some embodiments, the charger 10 is configured to provide a fast charge current to one or more interfaces 70 and 72, and can provide the fast charge current automatically, in response to user input, or a combination thereof. The value of the fast charge current (e.g., a 9 amp charging current) is greater than the standard charge current value (e.g., a 6 amp charging current). When the charger 10 provides a fast charge current to one or both of the interfaces 70 and 72, the charger 10 can activate a first indicator 79A (e.g., a lightning symbol illuminates) to indicate that the charger 10 is fast charging the battery pack. In some embodiments, a second indicator 79B (e.g., an arrow) is activated to indicate which of the interfaces 70 and 72 is receiving the fast charge current.

[0033] As described in more detail below and as Figure 1BAs shown, in some embodiments, the housing 22 of the charger 10 (e.g., the top surface 74 of the housing 22) further includes one or more user interfaces for receiving user input to adjust parameter settings related to charging one or more battery packs being charged by the charger 10. The one or more user interfaces may include one or more input mechanisms, such as one or more screens (e.g., touch screens), one or more buttons, knobs, etc., or a combination thereof. For example, Figure 1B As shown, in some embodiments, the charger 10 includes a button 80 for each interface 70 and 72, wherein a user can select (e.g., press, slide, toggle, etc.) the button 80 to manually control the charging provided by the corresponding interface (e.g., start or stop charging, change the charging mode, etc.). For example, in some embodiments, the charger 10 may include a separate power supply for each interface 70 and 72, wherein these power supplies are electrically isolated from each other and controlled by separate controllers. Thus, in such a configuration, a separate button 80 may be provided for each interface 70 and 72. As described in more detail below, in some embodiments, only a single button 80 is provided for controlling charging (e.g., controlling or selecting a charging mode). The button(s) 80 may include a push button and may allow a user to manually switch between different charging modes.

[0034] User interface(s) (including Figure 1B The button(s) 80 shown in the user interface allow a user to manually control the charging mode implemented by the charger 10. For example, at a certain time of day (e.g., at night), when multiple chargers are plugged in, using a fast charging mode of a particular charger may cause a circuit breaker to trip or negatively impact power usage. Therefore, in such situations or other situations where there is ample time for battery charging, the user can use the user interface to manually switch to a slower or lower charging mode (e.g., a 3 amp charging mode).

[0035] In some embodiments, in addition to providing manual charging control, the charger 10 can also automatically charge the battery packs 14A-F using various parameters. For example, in some embodiments, the charger 10 can charge the battery packs 14A-F in series, such that only one battery pack 14A-F is charged at a time. Thus, in such embodiments, the charger 10 can be referred to as a "sequential charger." The charging circuitry in the sequential charger can sequentially cycle through the battery pack interfaces to determine parameters related to the battery packs 14A-F connected to each interface. These parameters may include the presence of a battery pack and which battery pack, if any, requires charging (e.g., based on the battery pack's current state of charge). In response to detecting that multiple battery packs connected to the charger 10 require charging, the charging circuitry charges the battery packs sequentially, starting with the battery pack connected to the lowest (e.g., relative to physical location on the charger 10) battery pack interface (e.g., the first battery pack interface) to the battery pack connected to the highest battery pack interface (e.g., the sixth battery pack interface). In response to completing charging of the battery pack connected to a particular battery pack interface, the charging circuitry begins charging the battery pack connected to the next battery pack interface in sequence (i.e., based on physical location). The charger 10 repeats this process until there are no more connected battery packs that require charging. In response to not detecting a connected battery pack at one of the battery pack interfaces or if the battery pack and / or battery pack interface encounters an error, the charging circuitry may skip that particular interface and proceed to the next battery pack interface. It should be understood that other sequences may be used to perform charging, and that such sequential charging is not limited to moving from the lowest (by location) battery pack interface to the highest (by location) battery pack interface, as the charger 10 may apply any particular sequence. Furthermore, alternatively or additionally, in some embodiments, the charger 10 may charge one or more battery packs 14A-F simultaneously, such that one or more connected battery packs are charged simultaneously.

[0036] In some embodiments, the charger 10 determines additional parameters (e.g., regarding the battery packs 14A-F, the charger's operating environment, the charger 10, or a combination thereof) and can optimize charging operations accordingly (e.g., rather than executing a simple sequential charging sequence). For example, the parameters can include charger rate / current, state of charge at which charging ends (e.g., a battery state of charge setpoint at which charging stops), ambient temperature, battery temperature, battery capacity, battery voltage, battery condition / life, battery charging characteristics, battery chemistry, maximum charge current for the battery, number of batteries on one charger, number of batteries on one power outlet, number of batteries on multiple connected devices, maximum available AC power, or a combination thereof. The charger 10 uses these parameters to generate a charging profile that provides operating settings for the charger 10 and / or the battery packs 14A-F.

[0037] In some embodiments, in addition to or independently of the battery parameters, charger parameters, and environmental parameters described above, the charger 10 is further configured to use one or more user-defined settings to generate a charging configuration. The charger 10 may use the user-defined settings in conjunction with other parameters (e.g., the battery pack interface, the battery pack, the operating environment of the charger 10, and / or parameters of the charger 10) when generating a charging configuration, or alternatively, may use the user-defined settings to override other parameters. User-defined settings allow users to configure the charger 10 to meet their needs and usage scenarios and manage (e.g., adjust) battery cycle life, rather than being forced to accept default charging parameters set by the manufacturer or supplier (e.g., the battery pack). User-defined settings may include maximum charger rate / current, state of charge at which charging ends, and the like. For example, setting the charge rate may allow multiple chargers to be connected to a single outlet (e.g., a 120V AC outlet) and limit the charger rate to allow simultaneous charging. Similar controls can be used for sequential chargers to allow simultaneous charging of battery packs connected to the charger. Additionally, setting the state of charge at which charging ends allows charging to be stopped in response to the battery state of charge reaching a set point (e.g., 70%, 75%, 80%, 85%, 90%, 95%, 98%, etc.). Thus, user-defined settings allow the user to choose whether to obtain full capacity from the battery pack or to stop charging early to extend the life of the battery pack. Similarly, user-defined settings can include a maximum charge rate and / or current (which can be used to extend battery life); a maximum battery voltage (which can also be used to extend battery life); a preferred charging sequence for multiple chargers or multiple battery pack interfaces on a charger (e.g., charging two battery packs to maximum capacity as quickly as possible while charging other connected batteries at a slower rate; setting the order or sequence in which the battery packs are charged; charging available batteries to maximum capacity in the shortest time, etc.), and the like.

[0038] Figure 2 The battery pack 200 is shown, which represents Figure 1AThe battery pack 200 includes a housing 205, a user interface portion 210 for providing a state of charge indication for the battery pack 200, and a device interface portion 215 for connecting the battery pack 200 to a device (e.g., a power tool or charger 110). In some embodiments, the battery pack 200 includes a plurality of battery cells within the housing 205. In other embodiments, the battery pack 200 includes a communication interface and a memory that includes default and / or user-defined parameters for a charging configuration (e.g., battery parameters, environmental parameters). In some embodiments, the battery pack 200 can provide stored parameter settings to the charger 10 for charging according to the charging configuration (e.g., via the communication interface), and the stored user-defined parameters can be initially received from the charger 10 or a separate device. For example, similar to how a remote device can communicate with the charger 10 to provide user-defined settings, the user-defined settings can be transmitted directly from the remote device to the battery pack (e.g., using the battery pack's communication interface).

[0039] Figure 3 A control system for the charger 10 is schematically illustrated. The control system includes a controller 300. The controller 300 is electrically and / or communicatively connected to various modules or components of the charger 10. For example, the controller 300 is shown electrically connected to a battery pack interface 410, one or more sensors or sensing circuits 415, one or more indicators 416, a user interface 420, a communication controller or interface 425, and a power control module 430. The controller 300 includes a combination of hardware and software operable to, among other things, control the operation of the charger 10, monitor the operation of the charger 10, activate one or more indicators 416 (e.g., LEDs), and the like.

[0040] The controller 300 includes a plurality of electrical and electronic components that provide power, operational control, and protection to the components and modules within the controller 300, the charger 10, and / or the battery pack 200. For example, the controller 300 includes, among other things, a processing unit 440 (e.g., a microprocessor, a microcontroller, an electronic processor, an electronic controller, or another suitable programmable device), a memory 445, an input unit 450, and an output unit 455. The processing unit 440 includes, among other things, a control unit 460, an arithmetic logic unit (ALU) 465, and a plurality of registers 470 (shown as a set of registers), and is implemented using a known computer architecture (e.g., a modified Harvard architecture, a von Neumann architecture, etc.). The processing unit 440, the memory 445, the input unit 450, and the output unit 455, as well as the various modules or circuits connected to the controller 300, are connected via one or more control buses and / or data buses (e.g., a common bus 475). For illustrative purposes, the common bus 475 is used to connect the components of the controller 300 to the computer 300. Figure 3The control bus and / or data bus are generally shown in FIG. In view of the invention described herein, it will be known to those skilled in the art to use one or more control buses and / or data buses for interconnection and communication between various modules, circuits and components.

[0041] The memory 445 is a non-transitory computer-readable medium and includes, for example, a program storage area and a data storage area. The program storage area and the data storage area may include a combination of different types of memory, such as read-only memory ("ROM"), random access memory ("RAM") (e.g., dynamic RAM ["DRAM"], synchronous DRAM ["SDRAM"], etc.), electrically erasable programmable ROM ("EEPROM"), flash memory, a hard drive, an SD card, or other suitable magnetic, optical, physical, or electronic storage devices. The processing unit 440 is connected to the memory 445 and is configured to execute software instructions, which may be stored in the RAM of the memory 445 (e.g., during execution), in the ROM of the memory 445 (e.g., on a generally permanent basis), or in another non-transitory computer-readable medium such as another memory or disk. The software included in embodiments of the charger 10, battery pack 200, and controller 300 may be stored in the memory 445 of the controller 300. The software includes, for example, firmware, one or more application programs, program data, filters, rules, one or more program modules, and other executable instructions. The controller 300 is configured to retrieve from the memory 445 and execute, among other things, instructions related to the control processes and methods described herein. In other embodiments, the controller 300 includes additional components, fewer components, or different components.

[0042] The battery pack interface 410 includes a combination of mechanical components (e.g., rails, grooves, latches, etc.) and electrical components (e.g., one or more terminals) that are configured and operable to interface (e.g., mechanically, electrically, and communicatively connect) the charger 10 with a battery pack (e.g., battery pack 200). For example, the power provided by the charger 10 to the battery pack 200 is provided from the power input 405 to the battery pack interface 410 via the power control module 430. The power control module 430 includes a combination of active and passive components to regulate or control the power received from the power input 405 before providing the power to the controller 300. The battery pack interface 410 also provides power from the power input 405 to the battery pack 200. The battery pack interface 410 also includes, for example, communication lines 495 for providing a communication line or link between the controller 300, the battery pack interface 410, and the battery pack 200.

[0043] The sensors 415 include, for example, one or more voltage sensors, one or more current sensors, one or more temperature sensors, and / or one or more additional sensors for measuring electrical characteristics and / or other characteristics of the charger 10 and / or the battery pack 200. Each of the sensors 415 generates one or more output signals that are provided to the controller 300 for processing and evaluation. The indicator 416 includes, for example, one or more light emitting diodes ("LEDs"). The indicator 416 can be configured to display the condition of the charger 10 or information associated with the charger. For example, the indicator 416 is configured to indicate the measured electrical characteristics of the charger 10, the status of the charger 10, etc. The indicator 416 can also include the above-mentioned Figure 1A and Figure 1B The indicator lights 106A-F and 78 are described.

[0044] The user interface 420 is operably coupled to the controller 300 and receives user input, including, for example, selection of an operating mode (charging mode selection), adjustment of charger parameter settings (i.e., one or more user-defined settings as described above), or a combination thereof. In some embodiments, the user interface 420 includes a combination of digital and analog input or output devices required to achieve the desired level of operation of the charger 10, such as one or more knobs, one or more dials, one or more switches, one or more buttons, etc. The user interface 420 may include the user input described above with respect to Figure 1A and Figure 1B In some examples, the user interface 420 includes a button pad 500, such as a button pad 501. Figures 4 and 5 As shown and described in detail below. The button pad 500 includes a mode button 525 for selecting an operating mode, and a mode LED 530 for indicating the selected operating mode. In some examples, the mode LED 530 is included in the Figure 1A and Figure 1B The indicator lights 106A-F and 78 are shown. In other examples, the mode LED 530 is separate from the indicator lights 106A-F.

[0045] The controller 300 is configured to implement a charging configuration by determining whether a specific condition exists and generating one or more control signals related to the condition. For example, the sensing circuit 415 includes one or more current sensors, one or more voltage sensors, one or more temperature sensors, etc., and the controller 300 receives data from the sensing circuit 415, which the controller 300 uses to detect whether a specific condition exists. The controller 300 calculates or stores in memory 445 predetermined operating thresholds and limits for the operation of the charger 10 and / or a battery pack connected to the charger 10, which the controller 300 can compare with the data from the sensing circuit 415 (or data derived from such data) to detect or predict (e.g., using static rules, historical data, machine learning, etc.) a condition. For example, in response to detecting or predicting that a temperature (e.g., of a battery pack connected to the charger 10, etc.) is out of range, the controller 300 can limit or interrupt power to the connected battery pack (via the power control module 430) until the temperature decreases.

[0046] The communication interface 425 can communicate with the network 435 and enable the controller 300 to communicate with one or more peripheral (remote) devices, such as smartphones, tablet computers, smart wearable devices, other charging devices, servers, or combinations thereof, that are also connected to the network 435. As described in more detail below, the controller 300 includes a combination of hardware and software that is configured to, among other things, control the operation of the power control module 430 and the associated power input 405, communicate over the network 435, receive input from a user via the user interface 420, provide information to the user via the user interface 420 (e.g., a display), and so on.

[0047] Although the controller 300 Figure 3 10 is shown as one controller, but the controller 300 may include multiple controllers that are configured to work together to achieve a desired level of control over the charger 10. Therefore, any control functions and processes described herein with respect to the controller 300 may also be performed by two or more controllers operating in a distributed manner, where the two or more controllers, as a set, collectively perform the control functions and processes described herein. For example, as described above, in some embodiments, the charger includes separate power supplies for different battery pack interfaces or groups of battery pack interfaces, and the power supplies may be electrically isolated from each other and controlled by separate controllers. In such embodiments, the controller 300 may include, for example, Figures 4 and 51 and described below. The motherboard 505 may include one or more microcontroller units (MCUs), such as a left MCU 510 and a right MCU 515. In some examples, each MCU 510, 515 may be responsible for charging a different battery pack 200 connected to the charger 10 using power from, for example, a different electrically isolated power source. During operation of the charger 10, the MCUs 510, 515 (or alternatively, the controller 300) are configured to monitor voltages, currents, and / or other signals received from the various components described above. More generally, the MCUs 510, 515 are configured to monitor and / or control the flow of power to and from the components of the charger 10 described above, which are electrically and communicatively coupled to the charger 10.

[0048] As described above, in some embodiments, the MCUs 510 and 515 may not communicate, and therefore, a separate button or other user interface may be provided on the charger 10 to control charging provided via a specific interface or subset of interfaces. Alternatively, in some embodiments, a single button may be provided to control charging of multiple (e.g., two) power supplies (e.g., to switch the maximum charge rate). Therefore, in this configuration, the MCUs 510 and 515 need to communicate while maintaining electrical isolation.

[0049] Figure 4 FIG is a block diagram of a charging mode switching interface 400 of the charger 10 according to some embodiments, wherein the interface 400 provides a single button to control multiple power supplies used by the charger 10. Figure 4 As shown, the charging mode switching interface 400 includes a mainboard 505, which includes a first (e.g., left) MCU 510, a second (e.g., right) MCU 515, and an octo-isolator (also known as an optical isolation circuit 520). An optical isolator (also known as an optocoupler, photocoupler, or optical isolator) is an electrical component that uses light to transmit an electrical signal between two isolated circuits, thereby preventing high voltages from affecting the system receiving the signal. The optical isolator can include an LED and a phototransistor in an opaque package, but other combinations are possible (e.g., an LED-photodiode, an LED-LASCR, or a lamp-photoresistor pair).

[0050] like Figure 4As shown, the charging mode switching interface 400 further includes a button panel 500, which includes a mode button 525 and a mode LED 530. In some examples, a user can select the charging rate of the charger 10 via the mode button 525. For example, when the mode button 525 is pressed, a mode selection signal is output from the mode button 525 and input to the left MCU 510. The MCU 510 is configured to output a control signal to the optical isolation circuit 520 in response to receiving the mode selection signal. The control signal drives the optical isolation circuit 520 (e.g., drives the LED of the circuit 520), which in turn drives an input signal (e.g., digital) to the right MCU 515.

[0051] The mode / charge rate of the charger 10 can be transmitted as a constant high or low signal or a modulated signal (e.g., a series of "tones") to indicate the selected charging mode. For example, a 1 Hz signal can be associated with a first charging mode, a 2 Hz signal can be associated with a second charging mode, and so on. It should be understood that various frequencies can be used, and in some embodiments, more than two charging modes can be used, and additional frequencies can be used to specify one of the available modes. It should also be understood that different data can be transmitted between the left MCU 510 and the right MCU 515 to indicate the selected charging mode. For example, the transmitted data can include an identifier of the mode, an identifier of the charge rate, or a combination thereof.

[0052] In some examples, the left MCU 510 is configured as a “master” MCU and controls a first power supply, while the right MCU 515 is configured as a “secondary” MCU and controls a separate power supply, and the optical isolation circuit 520 allows the left MCU 510 to communicate with the right MCU 515 while remaining electronically isolated from each other.

[0053] In some examples, such as Figure 4 In the example shown, the communication between the MCUs 510 and 515 is unidirectional. For example, the left MCU 510 can transmit a control signal to the right MCU 515, but the right MCU 515 may not transmit a signal back to the left MCU 510. When communication is implemented as unidirectional, the right MCU 515 can also be configured to control the mode LED 530 to flash a fault code when the right MCU 515 stops receiving communication. For example, when the left MCU 510 controls the LED 530, the left MCU 510 may not be able to recognize whether the communication with the right MCU 515 has been interrupted (i.e., based on unidirectional communication). In some examples, the mode button 525 is configured to output a mode selection signal to the left MCU 510 and is also configured to output a control signal to the optical isolation circuit 520.

[0054] Figure 5is a block diagram of an alternative configuration of the charging mode switching interface 550 according to some embodiments described herein. Figure 4 The charging mode switching interface 400 is similar. Figure 5 The alternative configuration shown includes a mainboard 505 that includes an MCU 510, an MCU 515, and an optical isolation circuit 520. However, in this configuration, the communication between the MCUs 510, 515 is bidirectional. Figure 5 As shown, in interface 550 , the left MCU 510 (as the master MCU) can receive input from the mode button 525 and also control the LED 530 , as the left MCU 510 can confirm or track communications with the right MCU 515 using two-way communication.

[0055] Figure 6 FIG6 is a schematic diagram 600 of a charging mode switching interface 400 or 550 according to some embodiments. Schematic diagram 600 includes a button circuit 605 and a communication circuit 610. The button circuit 605 includes a switch 615 configured to generate a mode selection signal, wherein the switch 615 is included as part of the mode button 525 described above. The mode selection signal is then transmitted as an MCU input 620 to the left MCU 510 ( Figure 6 (not shown in the figure). Figure 6 As shown, the button circuit 605 may further include a resistor 626 (e.g., a 10k ohm resistor), a resistor 627 (e.g., a 1k ohm resistor), a diode 628, and a capacitor 629 (e.g., a 0.1μ capacitor) located on a power line (e.g., a 5 volt power line). It should be understood that other circuit configurations may be used to obtain an input representing the selected charging mode and transmit the selected charging mode to the MCU 510, and Figure 6 The configuration shown in is only an example.

[0056] The left MCU 510 is configured to output a control signal as an MCU output 625 to an optocoupler 630, which is included as an optical isolation circuit 520 and Figure 6 The optical coupler 630 is configured to transmit the control signal as MCU input 635 to the right MCU 515 (not shown). Figure 6 As shown, the communication circuit 610 may further include a resistor 636 (e.g., a 1.58k ohm resistor) located on a power line (e.g., a 5 volt power line), a resistor 637 (e.g., a 10k ohm resistor), a resistor 638 (e.g., a 10k ohm resistor) located on a power line (e.g., a 5 volt power line), a resistor 639 (e.g., a 1k ohm resistor), and a capacitor 640 (e.g., a 0.1μ capacitor). It should be understood that Figure 6The circuitry configuration of the communication circuit 610 shown in FIG. 5 is provided as an example only, and other circuit configurations may be used to communicate the selected charging mode to the right MCU 515 while maintaining electrical isolation of the MCUs 510 and 515 and the power supplies controlled by each MCU.

[0057] Figure 7 FIG7 is a flow chart illustrating a process 700 for selecting a charging mode using the charging mode switching interface 400 or 550 according to some embodiments described herein. Process 700 can be executed by the charger 10 to charge one or more battery packs 200. Process 700 includes receiving and / or determining a selected charging mode (block 705). As described above, in some embodiments, an input signal received from an input mechanism can indicate the selected charging mode. For example, a signal from a mode selection button (e.g., mode button 525) can indicate the selected charging mode and can be received at the left MCU 510 (e.g., the main MCU). The charging mode can be, for example, a slow charging mode or a fast charging mode. In some examples, the slow charging mode can limit the current provided to the battery pack to 3 amps, while the fast charging mode can limit the current provided to the battery pack to 6 amps. In some examples, the current limit of the slow charging mode or the fast charging mode can be another current limit. For example, the slow charging mode can alternatively limit the current to between 1 amp and 3 amps, while the fast charging mode can limit the current to between 1 amp and 12 amps. While it is described herein that the mode button 525 can be used to select a charging mode for each power supply used by the charger 10, the mode button 525 (or similar user input / interface) can be used to select a charging mode configuration, where different charging modes can be selected for different power supplies and / or different charging interfaces (batteries). For example, a user can select two battery packs to charge in a slow charging mode and select a third battery pack to charge in a fast charging mode. In some embodiments, a different button or other user input / interface can be provided to select such a mode configuration. Alternatively or additionally, the mode button 525 can allow the user to cycle through the available configurations and select one of them.

[0058] Although mode selection is described herein as being based on a mode button 525 (or a similar type of user input / interface), in some embodiments, the charger 10 (e.g., the left MC 510) is configured to automatically determine or select a charging mode. Automatic selection of a charging mode can be determined based on one or more battery pack parameters, charger parameters, and operating environment parameters, such as battery pack voltage, battery pack temperature, battery pack condition / life, battery pack charge capacity, ambient temperature, maximum available power, time remaining for a charger bulk charge (e.g., time based on the desired remaining charge in the battery pack), current charger settings (e.g., charger configuration), time of day, number of batteries connected to the charger 10, and the like. For example, the charger 10 can be configured to select a fast charging mode when the battery pack temperature is at or below 60° C., and to select a slow charging mode when the battery pack temperature is above 60° C. (as determined by the sensing circuit 415). Therefore, it should be understood that block 705 can include receiving a selected charging mode, automatically determining a selected charging mode, or a combination thereof, and that process 700 can operate similarly depending on whether the charging mode selection is received from a user input / interface or automatically determined. As described above, in some embodiments, a charging mode or charging mode configuration can be automatically determined, and one or more user inputs can also be received and applied to modify or override the determined charging mode or charging mode configuration. As described above, in some embodiments, one or more battery parameters can be transmitted from the battery pack (e.g., battery pack life and / or condition, charging mode, etc.), or can be automatically determined using, for example, various sensors and sensing circuitry (e.g., battery temperature).

[0059] The process 700 also includes controlling the charging operation of the first battery pack based on the selected charging mode (e.g., setting charging parameters based on the selected charging mode) (at block 710). As described above, the main MCU can receive the selected charging mode (selected via user input and / or automatically determined) and can control the charging of the first battery pack (of the plurality of battery packs interfaced with the charger 10) based on the selected charging mode. The processor 700 also includes transmitting the selected charging mode to another MCU included in the charger via the optical isolation circuit 520 (block 715). For example, as described with respect to Figure 4 and Figure 5 As described above, the mode button 525 transmits the selected charging mode to at least one MCU, such as the left MCU 510 of the main board 505, and the left MCU 510 transmits the selected charging mode to the right MCU 515 via the optical isolation circuit 520. As also described above, the optical isolation circuit 520 allows the MCUs 510 and 515 to communicate while maintaining electrical isolation of the power supply and related circuits established with the MCUs 510 and 515.

[0060] Based on the transmitted charging mode, each MCU receiving the transmitted charging mode (which may include a second MCU, or, in embodiments where the charger 101 includes more than two MCUs, more than one MCU) sets charging parameters for controlling the charging of another battery pack (e.g., a second battery pack) interfaced with the charger 10 based on the selected charging mode (block 720). For example, when a slow charging mode is selected / determined, the battery charging parameters are set to the selected slow charging mode (e.g., 6 amps). In this example, battery charging is limited to the operating range of the charger 10 based on the selected charging mode. In some embodiments, the controller 300 may store the selected charging mode (and / or the received settings) in the memory 445 of the charger 10.

[0061] like Figure 7 As shown, in some embodiments, when bidirectional communication is implemented via an optical isolation circuit, the MCU (e.g., the second MCU) that receives the transmitted selected charging mode may transmit an acknowledgment confirming receipt of the transmitted selected charging mode (also referred to herein as a "communication acknowledgment") (at block 718). This acknowledgment may be transmitted to the master MCU to allow the master MCU to track and confirm communication with the MCU and take appropriate action if a communication failure or error occurs (e.g., a failure or error occurs in the optical isolation circuit) or a failure or error occurs in the operation of another MCU or related power supply and charging operation.

[0062] Process 700 also includes controlling one or more indicators to indicate the selected charging mode (block 725). For example, the selected charging mode may be indicated on the mode LED 530. Additionally or alternatively, the selected charging mode may be indicated on the charger 10 or on another type of user output / interface remote from the charger 10. The selected charging mode may be indicated in a variety of ways, such as by turning on an LED, illuminating (activating) an icon, controlling an LED to output light in a particular color, pattern, or blinking rate, etc. As described above, the mode LED 530 (and / or other indicators included in the charger 10) may also be controlled to indicate an error condition, a power condition, the state of charge of one or more connected battery packs 200, etc. As described with respect to FIG. Figure 4 and Figure 5 As mentioned, in some embodiments, the right or secondary MCU 515 is configured to control an indicator, such as LED 530. However, in other embodiments, the left or primary MCU 510 is configured to control the indicator (e.g., when two-way communication is used). Furthermore, in some embodiments, the left MCU 510 and the right MCU 515 can each be configured to control its own (multiple) indicators.

[0063] Thus, the present disclosure provides, among other things, methods and systems for selecting a charging mode for a battery charging system.Various features and advantages of the present disclosure are set forth in the following claims.

Claims

1. A power tool battery charger, characterized in that: include: a first microcontroller unit; a second microcontroller unit; as well as Multiple battery pack interfaces for charging multiple battery packs, The first microcontroller unit is configured to: receiving a signal indicating a selected charging mode, the selected charging mode comprising a first charging mode or a second charging mode, controlling a charging operation of at least a first battery pack of the plurality of battery packs based on the selected charging mode, and transmitting the selected charging mode to the second microcontroller unit via an optical isolation circuit, At least one of the first microcontroller unit and the second microcontroller unit is configured to control an indicator to indicate a selected charging mode.

2. The power tool battery pack charger according to claim 1, wherein: The charging current of this first charging mode is limited to 3 amps.

3. The power tool battery pack charger according to claim 1, wherein: The charging current of this first charging mode is limited to 6 amps.

4. The power tool battery pack charger according to claim 1, wherein: The first microcontroller unit is configured to bidirectionally communicate with the second microcontroller unit via the optical isolation circuit.

5. The power tool battery pack charger according to claim 1, wherein: The first microcontroller unit is configured to control a first power supply of the power tool battery pack charger, and the second microcontroller unit is configured to control a second power supply of the power tool battery pack charger, wherein the first power supply and the second power supply are electrically isolated within the power tool battery pack charger.

6. The power tool battery pack charger according to claim 1, wherein: This indicator indicates fast charge mode.

7. The power tool battery pack charger according to claim 1, wherein: The indicator indicates that at least a subset of the plurality of battery pack interfaces are charging a connected battery pack using a fast charge mode.

8. The power tool battery pack charger according to claim 1, wherein: Further included is an input mechanism configured to generate the signal.

9. The power tool battery pack charger according to claim 1, wherein: The indicator is located on a surface of the power tool battery pack charger housing.

10. The power tool battery pack charger according to claim 1, wherein: The second microcontroller unit is configured to control the indicator to indicate interruption of communication with the first microcontroller unit.

11. The power tool battery pack charger according to claim 1, wherein: The optical isolation circuit includes an optical coupler.

12. A system for controlling a charging mode of a battery charger, characterized in that: The system includes: a first microcontroller unit configured to charge a first battery pack via a first power source; a second microcontroller unit configured to charge a second battery pack via a second power source, the second power source being electrically isolated from the first power source; Optical isolation circuit; and Input mechanism, The first microcontroller unit is configured to: receiving a signal output by the input mechanism, the signal indicating a selected charging mode; controlling charging of the first battery pack via the first power source based on the selected charging mode; and The selected charging mode is transmitted to the second microcontroller unit via the optical isolation circuit.

13. The system of claim 12, wherein: The second microcontroller unit is configured to transmit a communication confirmation to the first microcontroller unit via the optical isolation circuit.

14. The system of claim 12, wherein: An indicator is further included, wherein at least one of the first microcontroller unit and the second microcontroller unit is configured to control the indicator to indicate the selected charging mode.

15. The system of claim 14, wherein: This indicator indicates when the selected charging mode is fast charging mode.

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