Power tool, battery, charger and methods for their operation

Abstract

Method for operating a power tool (10) comprising a housing (12) holding a motor (28), an on / off switch assembly (74) having a direction switch (76) with trigger (77) and a consumption indicator (118), wherein the method comprises the following operations: Activating the on / off switch assembly (74) by activating the trigger (77) to electrically connect the motor (28) and a battery (200); Measurement of the battery charge level (200) in response to activation of the trigger (77); Displaying the state of charge on the consumption display (118) after activating the trigger (77), wherein the state of charge is measured when the trigger (77) is activated and before the motor (28) and the battery (200) are electrically connected; and Interruption of the charge status display when the trigger (77) is released.

Description

[0001] The present invention relates generally to power tools and more specifically to rotating power tools, for example drills and screwdrivers.

[0002] Power tools, such as rotary power tools, are used to machine or cut various workpieces, for example, metal, wood, drywall, etc. Such tools typically consist of a housing, a motor mounted within the housing and connectable to a power source, and a spindle that is rotatably mounted within the housing and selectively driven by the motor. A tool holder, such as a chuck, is attached to the front end of the spindle, and a tool element, such as a drill bit, is mounted in the chuck so that it rotates with the chuck and spindle to machine a workpiece.

[0003] US Patent 2005 / 0007068A1 discloses a battery charge indicator that may be provided on a battery housing or on a power tool powered by the battery. This indicator is designed to display information about the battery's charge level at the push of a button.

[0004] DE 42 04 420 A1 discloses an electric screwdriver 10 with a motor housing 12, a pistol-grip handle, and a finger-operated trigger. A battery pack 36 with a measuring device 32 featuring an LCD display is attached to the rear to indicate the status. The display unit also has an LED that indicates the switched-on state.

[0005] DE 20 2004 002 422 U1 discloses an electric tool comprising a housing body, a battery pack detachably attached to the housing body, a lamp arrangement attached to the housing body for projecting light onto the work area in front of it, and a power sensing circuit for recording the power storage of the battery pack, whereby the result of the power sensing can be displayed by the lamp arrangement. SUMMARY

[0006] In some embodiments, the invention provides a method for operating a power tool. The power tool comprises a housing that holds a motor, an on / off switch assembly with a directional switch and trigger, and a power consumption indicator. The method includes the operations of activating the on / off switch assembly by activating the trigger to electrically connect the motor and a battery, measuring the battery's state of charge in response to the activation of the trigger, displaying the battery's state of charge on the power consumption indicator after activation of the trigger (measuring the state of charge when the trigger is activated and before the motor and battery are electrically connected), and interrupting the display of the state of charge when the trigger is released.

[0007] In other embodiments, the invention provides a method for operating a power tool comprising a housing that holds a motor and a consumption indicator. The power tool has an on / off switch assembly that can be mounted on the housing and that includes a directional switch with a trigger. The method comprises connecting a battery to the housing, wherein the battery has a resting charge state. It further comprises moving at least the trigger of the on / off switch assembly relative to the housing to measure the resting charge state of the battery in response to activation of the trigger. The method further comprises displaying the resting charge state of the battery on the consumption indicator, activating the motor, and continuing to display the resting charge state of the battery on the consumption indicator for a predetermined time.The on / off switch assembly can be operated in such a way that, as soon as the battery's resting charge level has been measured, the motor and the battery are electrically connected.

[0008] The invention further provides a power tool comprising a movable spindle for holding a tool element and a housing that holds a motor and a drive mechanism driven by the motor. The drive mechanism can be operationally connected to the spindle to cause movement of the spindle relative to the housing. The housing can have a front end that holds the spindle and a rear end. The power tool further comprises a battery connectable to the rear end and a charge indicator mounted on the housing to indicate the battery's resting charge level.The resting charge state is the state of charge of the battery before the battery is affected by drawing current from the motor, and an on / off switch assembly can be operated in such a way that it electrically connects the motor and the battery, and activates the consumption indicator to display the resting charge state of the battery.

[0009] In some embodiments, the invention provides a method for operating a battery charger. The battery charger may have a body that defines an opening and a charging circuit that extends through the body. The method may include the operations of inserting a battery into the opening along an insertion axis, electrically connecting the battery to the charging circuit to charge the battery, and pivoting the battery about the axis relative to the battery charger to secure the battery in the battery charger.

[0010] In other embodiments, the invention provides a method for operating a battery charger. The battery charger can comprise a body and a charging circuit. Either the charger or the battery can have an outwardly extending projection, and the corresponding other part, i.e., the battery or the charger, can provide a recess for receiving the outwardly extending projection. The method can include the operations of electrically connecting the battery and the charging circuit to charge the battery before engaging the projection in the recess to secure the battery to the body of the charger.

[0011] In other embodiments, the invention provides a method for operating a battery charger. The battery charger may comprise a body and a charging circuit extending through the body. The method may include electrically connecting the battery to the charging circuit to charge the battery, and moving the battery relative to the battery charger to secure it to the body while charging continues.

[0012] The invention further provides a combination of a battery and a battery charger. The battery can have a housing and a battery cell held within the housing. The battery charger can have a body and a charging circuit. Either the charger or the battery can have an outwardly extending projection, and the other part, i.e., the battery or the charger, can have a recess for receiving the outwardly extending projection. The battery can be moved relative to the body of the charger between a locked position, in which the projection is in locking engagement with the recess, and an unlocked position, in which the projection is in releasable engagement with the recess. The battery cell can be electrically connected to the charging circuit of the battery charger when the battery is in the locked position and the unlocked position.

[0013] Other aspects will become clear when considering the detailed description and the attached drawings.

[0014] Before any embodiments of the invention are described in detail, it should be noted that the invention is not limited in its use to the details of embodiments and the arrangement of components specified in the following description or illustrated in the following drawings. The invention can be realized by other embodiments or carried out in various other ways. Furthermore, it should be noted that the terms and concepts used herein serve descriptive purposes and are not to be understood as limiting. The use of "contains," "features," or "has," and their variations, is intended to include the items specified therein, their equivalents, and additional items.Unless specifically stated or otherwise limited, the terms "attached," "connected," "supported," and "coupled," and their variations, shall be interpreted broadly to include both direct and indirect attachments, connections, supports, and couplings. Furthermore, "connected" and "coupled" are not limited to physical or mechanical connections or couplings. BRIEF DESCRIPTION OF THE DRAWINGS Fig. Figure 1 is a front perspective view of a power tool according to an embodiment of the invention. Fig. 2 is a side view from the left of the in Fig. 1 of the power tools shown. Fig. 3 is a supervision of the in Fig. 1 power tool shown. Fig. 4 is a right-hand side view of the Fig. 1 of the power tools shown. Fig. Figure 5 is a sectional view of the power tool along line 5-5 of Fig. 3. Fig. Figure 6 is a perspective view of a battery according to an embodiment of the invention. Fig. 7 an exploded view of the in Fig. 6 shown battery. Fig. 8 is a front view of the in Fig. 6 shown battery. Fig. 9A is a sectional view of the battery along the AA line. Fig. 8. Fig. 9B is a sectional view of the battery along line BB from Fig. 8. Fig. 9C is a sectional view of the battery along line CC of Fig. 8. Fig. 9D is a detailed view of the electrical connection between the battery and the charger, which is shown in Fig. 9C are shown. Fig. Figure 10 is a perspective view of a holder clip. Fig. Figure 11A is a first perspective view of a charger according to an embodiment of the invention. Fig. 11B is a second perspective view of the in Fig. 11A charger shown. Fig. 12 is an exploded view of a battery and the in Fig. 11A charger shown. Fig. 13 is a supervision of the in Fig. 11A charger shown. Fig. 14 is a view from below of the in Fig. 11A charger shown. Fig. 15A is a first perspective view of the in Fig. 11A charger shown, which holds a battery for charging. Fig. 15B is a second perspective view of the in Fig. 11A charger shown, which holds a battery for charging. Fig. 16 is a supervision of the charger and the inserted battery, which is in Fig. 15A are shown. Fig. Figure 17 shows a first cross-sectional view of the assembly consisting of the charger and battery, which is located in the Fig. 15A to 16 is shown. Fig. 18 is a second cross-sectional view of the assembly consisting of the charger and battery, which is located in the Fig. 15A to 16 is shown. Fig. Figure 19 is a third cross-sectional view of the assembly consisting of the charger and battery, which is located in the Fig. 15A to 16 is shown. Fig. 20 is a fourth cross-sectional view of the assembly consisting of the charger and battery, which is located in the Fig. 15A to 16 is shown. Fig. 21 is a schematic representation of the in Fig. 1 of the power tools shown. DETAILED DESCRIPTION

[0015] The Fig. Figures 1-5 show a handheld, battery-operated power tool 10, for example a screwdriver, a drill, or another rotating tool. The power tool 10 can be operated by receiving energy from a battery, for example the battery 200, which is located in the Fig. Figures 6 to 9C are shown. In other embodiments, the power tool 10 can be another handheld power tool, for example a reciprocating saw, a hammer drill, a planer, a circular saw, a grinder, a vibratory sander, etc.

[0016] The power tool 10 has a housing assembly 10 comprising a body 14 and a main actuation handle section or handle 16 connected to a rear section 18 of the body 14.

[0017] The body 14 defines a longitudinal axis 22 and accommodates a drive mechanism 26, a motor 28, and a spindle 30, which is held by a front end 31 of the body 14. Together, the drive mechanism 26, the motor 28, and the spindle 30 can be operated to rotate a tool element (not shown) substantially about a tool axis for machining a workpiece (also not shown). In other embodiments, the drive mechanism 26, the motor 28, and the spindle 30 can also, or alternatively, move the tool element back and forth along the tool axis for machining a workpiece.

[0018] In the illustrated embodiment of the Fig. In embodiments 1-5, the spindle 30 is a tool-free spindle that can receive the tool element and engage it in a locking engagement. The tool element is attached to the spindle 30 by a ball-bearing assembly and requires no tools for insertion or removal. In other embodiments, a chuck, collets, a knife clamp, adapters, or other conventional connecting arrangements can be used to attach a tool element to the spindle 30.

[0019] As in the Fig. As shown in Figures 1-5, the handle 16 is pivotably connected to the rear section 18 of the body 14, behind the motor 28. The handle 16 defines a grip axis 32 and is pivotally mounted relative to the body 14 about a pivot axis 34. In the illustrated embodiment, the pivot axis 34 is essentially perpendicular to both the body axis 22 and the handle axis 32.

[0020] In other embodiments (not shown), the orientation of the axes 22, 32 and 34 may be different, for example, essentially parallel or oblique. Furthermore, the handle 16 may be movable in a different manner, for example, sliding, rotating or pivoting about two axes (i.e., about the pivot axis 34 and about an axis parallel to the body axis 22 and / or the handle axis 32).

[0021] In some embodiments, the body 14 consists of two body halves 14a, 14b (see Fig. 3) Accordingly, the handle 16 consists of two handle halves 16a, 16b (also in Fig. 3 shown). In these embodiments, a first end 40 of the handle 16 sandwiches the rear section 18 of the body 14. A pivot pin 42, which defines the pivot axis 34, extends through the first end 40 of the handle 16 and through the rear section 18 of the body 14 to pivotally connect the handle 16 to the body 14.

[0022] The handle 16 can move relative to the body 14 between a first position (shown in Fig. 1), in which the body axis 22 and the handle axis 32 are essentially aligned and run essentially parallel, and a second position (shown in Fig. 2) move the handle 16 in such a way that the handle axis 32 is not aligned with the body axis 22. In the second position, the handle 16 is arranged such that the handle axis 32 and the body axis 22 form an angle α between approximately 90° and approximately 135°. The handle 16 can further be moved into one or more positions between the first and second positions.

[0023] Furthermore, the handle 16 is designed to pivot relative to the body 14 in order to change the length of the power tool 10, measured from a front end 31 of the body 14 to the rear end 44 of the handle 16. In the Fig. In the position shown in Figure 1, the power tool 10 has a first length, measured between the front end 31 of the body 14 and the rear end 44 of the handle 16. In the Fig. In the position shown in Figure 2, the power tool 10 has a second, shorter length, measured between the front end 31 of the body 14 and the rear end 44 of the handle 16.

[0024] Regarding the in the Fig. In the embodiment shown in Figures 1-5, the motor 28 is an electric motor which is connected to a power supply source, for example the battery 200, by an electrical circuit 310 (shown schematically in Figure 1-5). Fig. 21) is connectable. The battery 200 is detachably held in a battery chamber 56, which extends through the rear end 44 of the handle 16, and is slidably attached to the handle 16 in a direction substantially parallel to the handle axis 32. In other embodiments, the handle 16 can hold two or more batteries 200 in a battery chamber 56, or alternatively, a sliding connection can be made with an external engagement surface of the handle 16 to the battery or batteries 200.

[0025] The power tool 10 has an on / off switch assembly 74 which can be actuated to connect the motor 28 to the power supply source. In the Fig. In the embodiment shown in Figures 1-5, the switch assembly 74 includes a direction switch 76 (shown in Figure 1-5). Fig. 21) which is provided with a trigger 77 mounted on a side surface 78 of the body 14, for actuation by the thumb or finger of an operator who is either right-handed or left-handed. In the illustrated embodiment, the trigger 77 is arranged towards the rear of the body 14, near the handle 16. As shown in the Fig. As shown in Figures 1-5, at least one section of the switch assembly 74, for example the trigger 77, can move together with the body 14 relative to the handle 16 during a pivoting movement of the handle 16.

[0026] In other embodiments (not shown), the power supply and the direction of rotation of the motor 28 can be controlled by other elements and structures. In such an alternative embodiment, a single trigger can be actuated to cause the motor shaft 58 to rotate relative to the body 14. The direction of rotation of the motor shaft 58 can be controlled by a separate direction switch, which can be actuated between a "forward" and a "reverse" position, and in this case, an additional locking device can be provided to prevent actuation of the trigger and the supply of power to the motor 28.

[0027] In some embodiments, the power tool 10 may have a speed control mechanism 82 which can be actuated to adjust the speed of a tool element held by the power tool 10 and / or the speed of the spindle 30 between two or more different speeds (for example, a high speed, a low speed, and a medium speed). As shown in the Fig. As shown in Figures 1-5, the speed control mechanism 82 can be mounted on an upper surface 84 of the body 14 and can be operated to move the drive mechanism 26 between a first configuration in which elements of the drive mechanism 26 are oriented such that a tool element and / or the spindle 30 is rotated about the tool axis at a first speed, and a second configuration in which elements of the drive mechanism 26 are oriented such that they rotate a tool element about the tool axis at a second, different speed. In other embodiments, the speed control mechanism 82 can be operated to control the energy supplied to the motor 28 by the power supply source (for example, the battery 200) so that the motor shaft 58 rotates at a first speed and a second, different speed.

[0028] As in the Fig. As shown in Figures 1-5, the power tool 10 further comprises a locking assembly 110 for locking the handle 16 in a position relative to the body 14. The locking assembly 110 is operable between a locked position, in which the handle 16 is fixed in its position relative to the body 14, and an unlocked position, in which the position of the handle 16 relative to the body 14 is adjustable. In some embodiments, the locking assembly 110 may be substantially the same as that described in U.S. Patent Application No. 09 / 704914, filed on November 2, 2000, and / or in U.S. Patent Application No. 10 / 796365, filed on March 9, 2004, the entirety of which is incorporated by reference into the present application.

[0029] In the illustrated embodiment, the locking assembly 110 has a locking arrangement between the handle 16 and the body 14 to enable effective engagement between the handle 16 and the body 14. The locking assembly 110 has a locking part 112, a section of which can be selectively engaged in a first recess to secure the handle 16 in the first position relative to the body 14, and a second recess to secure the handle 16 in the second position relative to the body 14. The locking assembly 110 may further have additional recesses into which the locking part 112 can be engaged to secure the handle 16 in additional positions relative to the body 14.

[0030] The locking assembly 110 can further move an actuating element 114 to move the locking part 112 between the locked and unlocked positions. In the Fig. In the embodiment shown in Figures 1-5, the actuating element 114 is arranged on an upper surface 84 of the body 14 for actuation by the thumb or finger of either a right-handed or left-handed operator. A section of the actuating element 114 extends through the housing 12 and can be selectively engaged with the locking element 112 to move the locking element 112 between the locked and unlocked positions. In some embodiments, the locking assembly 110 may include a preloading element, such as a spring, to preload the locking element 112 toward the locked position, or alternatively, to preload the locking element 112 toward the unlocked position.

[0031] To move the handle 16 relative to the body 14, the actuating element 114 is actuated to disengage the locking projection 114 from the recesses. The handle 16 is then moved relative to the body 14 to a position corresponding to the engagement of the locking projection 114 with one of the recesses. When the handle 16 is in the desired position, the locking projection 114 is moved into the corresponding recess (for example, by a spring).

[0032] In other embodiments (not shown), the locking assembly 110 can have a different locking arrangement, for example, a frictional engagement between the handle 16 and the body 14. In such an embodiment, the locking assembly 110 can further have a true engagement arrangement, for example, mutually engaging teeth provided on the body 14 and the handle 16, which engage when the locking assembly 110 is in the locked state.

[0033] The locking assembly 110 may further include a pivot lock that prevents the handle 16 from pivoting about the pivot axis 34 relative to the body 14 when the motor 28 is in operation and / or when the switch assembly 74 is activated.

[0034] The power tool 10 may also have a consumption indicator 118 to display the charge level of the battery 200, which is held in the battery compartment 56. As in the Fig. 1 and Fig. As shown in Figure 2, the consumption indicator 118 can have a display 120 arranged on one side of the handle 16. In some embodiments, for example in the Fig. 1 and Fig. In the embodiment shown in Figure 2, the display 120 can have a group of indicator lights 122 (for example, light-emitting diodes) arranged to form a scale. In this embodiment, a number of indicator lights 122 can be illuminated when the battery charge level is high, and one or no lights can be illuminated to indicate that the battery charge level is low. In other embodiments, one light can flash to indicate that the battery charge level is low. In further embodiments, the display 120 can have other display screens and / or indicator lights that have different relative orientations and positions, and can have indicator lights of different colors (for example, green, blue, yellow, orange, and red) to indicate the charge level of the battery 200.In other embodiments, the display 120 can be used to inform the user about other conditions, for example an abnormal (high or low) battery temperature, an electrical fault in the electrical circuit 310, or other information relating to the battery 200 or the tool 10.

[0035] In some embodiments, for example those that are in Fig. As shown in Figure 21, the electrical circuit 310 includes a controller 320. The controller 320 can perform various functions in the tool 10, such as measuring different battery states (e.g., the state of charge of battery cell 208), controlling various components present in the circuit 310 (e.g., the consumption indicator 118), controlling the operation of the power tool 10, and collecting and storing data relating to tool operation, battery states, and the operation of components in the circuit 310. In other embodiments, the controller 320 and / or the electrical circuit 310 may include similar components and / or perform similar functions to the battery controllers and electrical circuits described in U.S. Patent Application No. 10 / 720027, filed on November 20, 2003, and U.S. Patent Application No. 11 / 138070, filed on [date missing].May 2005, shown and described, the entire content of which is included in the present application by reference.

[0036] In some embodiments, the controller 320 is programmed to measure the state of charge in response to the activation of the trigger 77, as explained below. In these embodiments, the battery state of charge data is measured before the motor 28 is activated, i.e., before the battery state of charge is affected by the current drawn and supplied to the motor 28. This measurement of the battery state of charge represents a resting state of charge of the battery 200. In these embodiments, only the resting state charge measurements are displayed on the consumption indicator 118. In some embodiments, the state of charge data is displayed for a predetermined time after the trigger 77 is actuated. In one design, the predetermined time is approximately two (2) seconds. In other designs, the predetermined time may be greater than two (2) seconds.In other configurations, the predetermined time may be less than two (2) seconds. After the predetermined time has elapsed, display 120 can be cleared. In one configuration, display 120 is cleared when the predetermined time has elapsed, regardless of whether trigger 77 is still activated. In some configurations, display 120 is cleared when the predetermined time has elapsed, regardless of the activity of trigger 77. In still other configurations, display 120 is cleared before the predetermined time has elapsed (for example, two (2) seconds) if trigger 77 is released.

[0037] Circuit 310 further includes a direction switch 76, which controls and / or selects the direction of rotation of the motor shaft 58. Circuit 310 also includes an on / off switch 330, a brake 335, a mechanical torque clutch 340, and a temperature measuring device or thermistor 350. In some embodiments, the on / off switch 310 and the brake 335 may include a field-effect transistor, for example, a MOSFET.

[0038] The on / off switch 330 is controlled by the controller 320 and activated by the controller 320 under various conditions. For example, the controller 320 activates the on / off switch 330 to the conducting state so that energy is supplied to the motor 28 in response to the activation of the trigger 77. The controller 320 can also activate the switch 330 to a non-conducting state to interrupt the power supply to the motor 28 when the charge level of the battery 200 reaches a cutoff threshold, or when an overload condition is detected by the controller 320. In some embodiments, an overload condition can occur when the temperature of the battery 200, which is detected by the controller 320 via the thermistor 350, reaches a high-temperature threshold, or when the current supplied to the motor 320 reaches an overcurrent threshold.In these embodiments, the controller 320 can indicate to a user that an overload condition has occurred via the display 120, for example by flashing one or more lights 122.

[0039] The brake 335 is controlled by the control unit 320, and activated by the control unit 320 when the torque of the motor 28 exceeds the torque setting of the tool 10, as detected by the control unit 320, via the clutch 340.

[0040] As in the Fig. As shown in Figures 1-10, the battery 200 in the illustrated embodiment is essentially cylindrical and has a substantially circular cross-section. In other embodiments, the battery 200 may have any other shape and / or cross-sectional shape, including, without limitation, a rectangular, oval, polygonal, irregular, etc. shape.

[0041] During the Fig. In the embodiment shown in Figures 1-10, the battery 200 comprises a battery sleeve or battery housing 204 and a battery cell 208, which is held in the battery housing 204. The battery 200 may further comprise a cap 206, which can be attached to a second end 205 of the battery housing 204 to substantially enclose the battery cell 208. In other embodiments, the battery 200 may comprise two or more battery cells 208, which are arranged in various combinations of series and parallel connections.

[0042] During the Fig. In the embodiment shown in Figures 1-10, the battery 200 comprises a single battery cell 208, which has a nominal voltage of approximately 4.0 volts (V) and a capacity of about 3.0 ampere-hours (Ah). In this embodiment, the battery cell 208 has a lithium-based chemical structure, for example, based on lithium ions. The lithium-based chemistry can include various lithium-ion chemistries, such as lithium-cobalt, lithium-manganese (“Li-Mn”) spinel, or Li-Mn nickel.

[0043] As in the Fig. As shown in Figures 6-9D, contact recesses 216a, 216b extend radially through a first end 203 of the housing 204. In the illustrated embodiment, the contact recesses 216a, 216b are essentially L-shaped. In other embodiments, one or both of the contact recesses 216a, 216b may have other shapes and may be arranged at other locations along the battery housing 204.

[0044] The battery 200 further comprises a first (e.g., negative) battery terminal 202a and a second (e.g., positive) battery terminal 202b, sections of which are accessible through the contact recesses 216a, 216b to electrically connect the battery cell 208 to the associated electrical terminals (not shown) of the power tool 10, or alternatively to the electrical terminals (not shown) of a battery charger. In some embodiments, the battery terminals 202a and 202b can also, or alternatively, at least partially, physically connect the battery 200 to the handle 16 of the power tool 10.

[0045] As in the Fig. As shown in Figures 6-9D, the battery terminals 202a and 202b are equidistant in the circumferential direction (for example, approximately 180° apart) around a front end of the battery cell 208. In other embodiments, the battery terminals 202a and 202b may have different orientations and locations, depending in part on the location and orientation of the contact recesses 216a and 216b.

[0046] In the illustrated embodiment, when a battery 200 is inserted into the battery chamber 56 of a power tool 10, the battery 200 can be pivoted about the battery axis 201, which can coincide with the handle axis 32, so that the first battery terminal 202a of the battery 200 sweeps over the electrical terminal of the power tool, thus cleaning the battery terminal 202a of the battery 200 and the corresponding power tool terminal before an electrical connection is established between the battery 200 and the power tool 10.

[0047] Accordingly, the second battery terminal 202b of the battery 200 can brush against the electrical terminal of the power tool, thereby cleaning the electrical connector 202b of the battery 200 and the corresponding power tool terminal. In this way, the first and second battery terminals 202a and 202b of the battery 200, respectively, and the first and second terminals of the power tool can be cleaned each time a battery 200 is electrically connected to the power tool 10, and / or each time a battery 200 is removed from the power tool 10.

[0048] During the Fig. In the embodiment shown in Figures 6 to 9D, a retaining clip 210 is held in the battery housing 204 and can be actuated to position and hold the battery terminals 202a, 202b and the battery cell 208 in their respective locations and orientations within the battery housing 204. In the illustrated embodiment, the retaining clip 210 has a radially outwardly extending projection 211 that can be engaged with a recess (not shown) in the battery housing 204 to align the retaining clip 210 in a predetermined orientation within the battery housing 204.

[0049] As in Fig. As shown in Figure 10, the retaining clip 210 can also have two recesses 212, 213 for receiving sections of the battery terminals 202a and 202b, respectively. When assembled with the retaining clip 210, the battery terminals 202a, 202b are therefore secured in a predetermined circumferential orientation with respect to the battery housing 204.

[0050] During the Fig. In the embodiment shown in Figures 6-9D, an insulator 214 (for example, a foam insert) is arranged between a front end of the battery cell 208 and the cap 206. In this embodiment, the cap 206 is positioned over the insulator 214 and attached to the battery housing 204 by a pair of cap-retaining barbs 215 extending radially outward from the housing 204. In other embodiments, the cap 206 can be attached to the housing 204 by screws, bolts, nails, rivets, pins, pillars, clips, clamps, and / or other conventional fasteners; by mutually engaging elements on the cap 206 and the housing 204 (for example, tongues, flanges, or other extensions inserted into slots, grooves, or other openings, etc.); by an adhesive or cohesive bonding material; or in any other suitable manner.

[0051] In some embodiments, the battery 200 has a locking arrangement 220 for locking the battery 200 in the battery chamber 56 of the power tool 10. In the embodiment described in the Fig. In the embodiment shown in 6-9D, the locking arrangement 220 has first and second projections 222a, 222b which extend radially outwards from the housing 204 of the battery 200.

[0052] As in the Fig. As shown in Figures 6-8, the first and second approaches 222a and 222b, respectively, each have a substantially rectangular cross-sectional shape, and the first approach 222a has larger dimensions than the second approach 222b. In other embodiments, the first and second approaches 222a, 222b may have any other shape and / or cross-sectional shape, including, without limitation, round, oval, polygonal, irregular, etc.

[0053] Corresponding slots extend axially along the sides of the battery chamber 56 of the power tool 10. One of these slots has such dimensions and shape that it accommodates the first projection 222a, and the other slot has such dimensions and shape that it accommodates the second projection 222b, thus ensuring that the battery 200 can be inserted into the power tool 10 in only one desired orientation (i.e., such that the battery terminals 202a, 202b of the battery 200 are aligned with and electrically connected to corresponding terminals of the power tool 10).

[0054] In some such embodiments, the slots extend axially along the inner wall of the battery chamber 56 of the power tool 10 and have lower ends that extend circumferentially around at least a section of the inner wall of the battery chamber 56. In these embodiments, the slots are essentially L-shaped. In this way, after the battery 200 has been inserted axially into the battery chamber 56 of the power tool 10, the battery 200 can be pivoted about the battery axis 201 and relative to the housing 12 to engage in a locking connection with the projections 222a, 222b in the respective L-shaped receiving grooves, thus locking the battery 200 to the power tool 10. In other embodiments (not shown), the locking arrangement 220 can have a single projection and a single receiving slot.

[0055] As in the Fig. As shown in Figures 6-9D, the battery 200 can further have axially extending projections 224 located at the front end of the battery 200 opposite the cap 206. The projections 224 can engage with one or more appropriately shaped parts in the battery chamber 56 to provide tactile and / or audible feedback to the user after rotation of the battery 200 relative to the handle 16. In other embodiments, the battery 200 can have a single projection 224, or more than two projections 224, which may be arranged at different locations on the battery housing 204, for engagement with the battery chamber 56.In other embodiments, the projection 224 can engage with one or more adapted part(s) in a battery charger 400 to provide tactile and / or audible feedback to the user after rotation of the battery 200 relative to the battery charger 400.

[0056] As in the Fig. As shown in Figures 11A to 20, the battery 200 can be connected to a battery charger 400, which can be operated to charge one or more batteries 200. In some embodiments, alternating current from a power supply source (i.e., a power grid) can be supplied to a battery 200 mounted on the charger 400 via a charging circuit 401. In some embodiments, the charging circuit 401 can convert alternating current energy into direct current energy. In other embodiments, the battery charger 400 can supply energy to the battery 200 from an unconventional power supply source, including auxiliary batteries and various alternating current and direct current sources.In some such embodiments, the charging circuit 401 may include AC / DC converter components and may alternatively provide current and / or voltage limiting functions, signal conditioning and the like.

[0057] The charging circuit 401 may have the same components and implement the same charging algorithms as the charging circuits described in US patent application No. 10 / 719680, filed on November 20, 2003, US patent application No. 11 / 113020, filed on May 24, 2005, and US patent application No. 11 / 266007, filed on November 2, 2005, the entire contents of which are incorporated by reference into the present application.

[0058] During the Fig. In the embodiment shown in Figure 11A-20, the charger 400 has a charger housing or charger body 402, which has an upper section 402a and a lower section 402b. As shown in the Fig. As shown in Figures 11A to 20, the housing 402 can define a battery chamber 403 and can have an opening 404 for receiving batteries 200. In the illustrated embodiment, the opening 404 is located substantially towards the front end 406 of the charger 400. A rear section 408 of the charger 400 is provided with a socket 410 for electrical current to receive a cable or plug.

[0059] As most clearly seen from the Fig. 11A and Fig. As shown in Figure 11B, a first and a second receiving slot 418a and 418b, respectively, extend through the charger housing 402 on opposite sides of the opening 404 and have dimensions such that they engage with sections of the battery 200 to hold the battery 200 in the charger 400 and to align the battery 200 with respect to the charger 400. In some embodiments, the receiving slots 418a, 418b are formed with the same dimensions, the same shape, and the same relative orientation to the receiving slots in the battery chamber 56 of the power tool 10.

[0060] In some embodiments, the receiving slots 418a, 418b may have different dimensions, so that the battery 200 can only be inserted into the battery chamber 403 in a required orientation (i.e., so that the battery terminals 202a, 202b engage with the respective terminals 420a, 420b of the battery charger 400).

[0061] During the Fig. In the embodiment shown in Figures 11A-20, the receiving slots 418a, 418b are essentially L-shaped. In this way, after a battery 200 has been inserted axially through the opening 404 and into the battery chamber 403, the battery 400 can be pivoted about the battery axis 201 and relative to the housing 402, from an unlocked position, in which the battery 200 can move axially out of the opening 404, to a locked position, in which the engagement between the projections 222a, 222b and the receiving slots 418a, 418b prevents the battery 200 from moving axially out of the battery chamber 403.

[0062] As in the Fig. As shown in Figures 12, 13, and 15A-16, the charger 400 may include an indicator 419 located on an outer surface of the housing 402, and the battery 200 may have a corresponding indicator 223. In this way, if the indicator 419 of the charger 400 and the indicator 223 of the battery 200 are not properly aligned, the user can confirm that the battery 200 is in the unlocked position. Similarly, if the indicator 419 of the charger 400 and the indicator 223 of the battery 200 are aligned, the user can confirm that the battery 200 is in the locked position.

[0063] In embodiments of the charger 400, for example those described in the Fig. In embodiments 11A-20, which have L-shaped receiving slots 418a, 418b, the terminals 420a, 420b of the battery charger 400 can extend circumferentially around at least a section of the battery chamber 403, so that the battery terminals 202a, 202b can be electrically connected to the respective terminals 420a, 420b of the battery charger 400 when the battery 200 is in the locked and unlocked positions.

[0064] In some such embodiments, the charger 400 can be operated to charge the battery 200 while the battery 200 is either in the locked or unlocked position. This can be convenient for users, some of whom wish to quickly insert the battery 200 for charging without having to move it into a locked position. Alternatively, in applications where the charger 400 is mounted on a wall or other vertical surface (i.e., such that the battery chamber 403 is open in a direction substantially parallel to the ground), a user can insert the battery 200 into the battery chamber 403 and pivot the battery 200 into the locked position so that it can be charged and will not fall out of the charger 400 during charging.

[0065] As in Fig. As shown in Figure 14, the charger 400 can have mounting receptacles 428 for attaching the charger 400 to a wall or other inclined surface, or alternatively for attaching the charger 400 to a work cart, a horizontal surface, a worktable or workbench, and the like. In some embodiments, for example ... work table, a workbench, or a worktable, and the like. Fig. In the embodiment shown in Figure 14, the charger 400 can still have feet 413 for holding the charger 400.

[0066] As in Fig. As shown in Figure 13, the charger 400 can further have locking devices 422 for engaging with the projections 224 on the battery 200 to provide tactile and / or audible feedback to the user, indicating that the user has moved the battery 200 to the locked position, or alternatively to the unlocked position. In the embodiment shown in the Fig. As shown in Figure 11A-20, the locking devices 422 are elastically deformable and extend horizontally over the lower end of the battery chamber 403. In other embodiments, the locking devices 422 may have different relative orientations and positions. For example, in some embodiments, the locking devices 422 may extend circumferentially around the side walls of the battery chamber 403 to engage with corresponding battery projections 224 located on the sides of the battery 200.

[0067] A charge indicator 412 (for example, a light-emitting diode (LED) or another light) can be mounted on the upper charger housing 402a to display charging data to a user (for example, remaining charging time, current charging progress, charging complete, etc.). In other embodiments, the charger 400 may additionally or alternatively have other indicators or display devices.

[0068] The operation of the power tool is governed by the following: Fig. 1, Fig. 2 and Fig. 21 explained.

[0069] To operate, a user grasps the handle 16 with one hand and the body 14 with a second hand, and pivots the handle 16 about the pivot axis 34 from the first position (shown in Fig. 2) into the second position (shown in Fig. 2).

[0070] When the locking assembly 110 is in the locked position, the user can move the actuating element 114 relative to the housing 12 to move the locking part 112 from the locked position to the unlocked position, before and / or during the pivoting movement of the body 14 and the handle 16. When a desired alignment between the body 14 and the handle 16 is achieved, the user can insert a tool into the spindle 30.

[0071] The user can also insert battery 200 into battery compartment 56 to supply power to the power tool 10. The user can then move trigger 77 into an actuated position, which in turn engages the direction switch 76. When trigger 77 is activated, energy is supplied to the electrical circuit 310 from battery 200, waking the controller 320 from a low-energy state. The controller 320 then enters a state in which the charge of battery 200 is read, stores the read value in the controller's internal memory (not shown), and activates the consumption indicator 118 to display the current in the battery 200's resting state.

[0072] Once the battery's resting state of charge has been measured, the controller 320 switches the normally non-conductive on / off switch 330 to the conductive state, so that current from battery cell 208 is supplied to motor 28, according to the setting of the direction switch 76, causing motor 28 to rotate spindle 30 and the tool element. The controller 320 continues to display the state of charge reading via the consumption indicator 118 until the predetermined period has elapsed.

[0073] The user can then move the handle 16 from the second position back to the first position, or alternatively to an intermediate position (not shown), to align the power tool 10 so that it operates in a confined workspace and / or performs a different operation. Alternatively or additionally, a user can pivot the handle 16 about the pivot axis 34 and relative to the body 14 by a pivoting movement of the wrist and / or by grasping either the handle 16 or the body 14 with one hand and pressing the other part, i.e., the body 14 or the handle 16, against their body.

[0074] In one embodiment, as soon as the trigger 77 is released, the on / off switch 330 is set to the non-conductive state, and the controller 320 begins counting down the waiting period. In this embodiment, if the user activates the trigger 77 before the waiting period has elapsed, the controller 320 approximates the current state of charge of the battery based on the previous state of the charge measurement and the duration for which the motor 28 ran, and displays this approximation. In some embodiments, if the duration for which the motor 28 ran is longer than a predetermined period, the controller 320 does not calculate or approximate the current state of charge of the battery and does not display a battery state of charge reading on the consumption indicator 118.

[0075] If the user activates the trigger after the waiting period has elapsed, the controller 320 determines a different resting charge state value of the battery before the activation of the on / off switch 330 and before the power supply to the motor 28, as explained above.

[0076] After operating the power tool 10 and the battery 200, the user can remove the battery 200 from the power tool 10 and insert it into the charger 400 to recharge it. In some embodiments, the user can insert the battery 200 axially into the battery chamber 403 of the battery charger 400 to initiate charging. Alternatively or additionally, the user can pivot the battery 200 into a locked position so that it is securely attached to the battery charger 400 during charging.

[0077] Once charging is complete (i.e., after a predetermined charging time, or when data indicating a full charge is displayed on the charger 400's display 412), the user can remove the battery 200 from the charger 400 and insert the newly charged battery 200 into the battery compartment 56 of the power tool 200. To confirm that the battery 200 is fully charged, the user can press down trigger 77, which will cause charge status data to be displayed on the display 120.

[0078] Some or more of the foregoing features and other independent features and advantages are specified in the following patent claims.

Claims

[1] Method for operating a power tool (10) comprising a housing (12) holding a motor (28), an on / off switch assembly (74) comprising a direction switch (76) with trigger (77) and a consumption indicator (118), wherein the method comprises the following operations: Activating the on / off switch assembly (74) by activating the trigger (77) to electrically connect the motor (28) and a battery (200); Measurement of the battery charge level (200) in response to activation of the trigger (77); Displaying the state of charge on the consumption display (118) after activating the trigger (77), wherein the state of charge is measured when the trigger (77) is activated and before the motor (28) and the battery (200) are electrically connected; and Interruption of the charge status display when the trigger (77) is released. [2] Method according to claim 1, wherein the display of the charge state comprises the display of a rest charge state of the battery (200). [3] Method according to claim 1, which further comprises operating the motor (28), wherein the state of charge of the battery (200) changes during operation of the motor (28), and wherein during operation of the motor (28) the consumption indicator (118) continuously displays the state of charge that was measured before operation of the motor (28). [4] The method of claim 1, further comprising: Calculation of a second state of charge of the battery (200), wherein the second state of charge differs from the first state of charge; and Display of the second charge level before the motor (28) and battery (200) are reconnected. [5] Method according to claim 1, which further comprises alerting a user when the motor (28) is overloaded. [6] Method according to claim 5, wherein alerting the user includes activating the display. [7] Method according to claim 5, which further comprises stopping the motor (28) when the motor (28) is overloaded. [8] Method for operating an electric tool (10) comprising a housing (12) holding a motor (28) and a consumption indicator (118); wherein the power tool (10) has an on / off switch assembly (74) which can be mounted on the housing (12) and which has a direction switch (76) with trigger (77); the procedure includes the following operations: Connecting a battery (200) to the housing (12), wherein the battery (200) has a resting charge state; Furthermore, it is planned to move at least the trigger (77) of the on / off switch assembly (74) relative to the housing (12) in order to measure the resting charge state of the battery (200) in response to activation of the trigger (77); Furthermore: Displaying the battery's resting charge level (200) on the consumption display (118); and Activating the motor (28) and continuing to display the battery's resting charge level (200) on the consumption display (118) for a predetermined time, wherein the on / off switch assembly (74) can be operated in such a way that as soon as the rest state of charge of the battery (200) has been measured, the motor (28) and the battery (200) are electrically connected. [9] Method according to claim 8, wherein moving the section of the on / off switch assembly (74) relative to the housing (12) comprises electrically connecting the motor (28) and the battery (200) to the on / off switch assembly (74), and further comprises removing the quiescent charge state at the consumption indicator (118) before electrically disconnecting the battery (200) and the motor (28) through the on / off switch assembly (74). [10] Method according to claim 8, wherein the display of the rest state of charge of the battery (200) on the consumption display (118) comprises displaying the rest state of charge of the battery (200) before activating the motor (28). [11] Method according to claim 8, wherein the display of the rest state of charge of the battery (200) on the consumption indicator (118) comprises displaying the rest state of charge approximately 2 seconds after movement of at least one section of the on / off switch assembly (74) in relation to the housing (12). [12] Method according to claim 8, which further comprises alerting a user when the motor (28) is overloaded. [13] Method according to claim 12, wherein the alerting of the user comprises displaying an alarm on the consumption indicator (118). [14] Method according to claim 12, which further comprises switching off the motor (28) when the motor (28) is overloaded. [15] Method according to claim 12, which further comprises interrupting the display of the rest charge state of the battery (200) on the consumption display (118) before the motor (28) is switched off. [16] Method according to claim 8, which further comprises operating the motor (28) and changing a charge state of the battery (200), wherein the continuation of the display of the rest charge state of the battery (200) comprises displaying the rest charge state recorded before the operation of the motor (28). [17] Power tool (10) which includes: a movable spindle (30) for holding a tool element; a housing (12) that holds a motor (28) and a drive mechanism (26) which is driven by the motor (28), wherein the drive mechanism (26) is operationally connected to the spindle (30) to cause a movement of the spindle (30) relative to the housing (12), wherein the housing (12) has a front end (31) that holds the spindle (30) and a rear end (44); a battery (200) that can be connected to the rear end (44); a consumption indicator (118) mounted on the housing (12) to display a resting charge state of the battery (200), wherein the resting charge state is a charge state of the battery (200) before the battery (200) is affected by drawing current through the motor (28); and an on / off switch assembly (74) operable to electrically connect the motor (28) and the battery (200) and activate the consumption indicator (118) to display the resting charge state of the battery (200). [18] Power tool according to claim 17, in which the consumption indicator (118) can be operated in such a way that it displays the rest charge state during the further operation of the motor (28). [19] Power tool according to claim 17, wherein the consumption indicator (118) can be operated in such a way that it displays the idle charge approximately 2 seconds after activation of the motor (28).

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