Bidirectional motor for gas engine replacement device

Abstract

To solve problems in the conventional art.SOLUTION: A bidirectional motor (36) is for a gas engine replacement device (10). An embodiment provides a gas engine switching device (10) including: a housing (14); a battery receptacle (54); a motor (36); a power take-off shaft (38) that receives a torque from the motor (36); a power switching network (310) configured to selectively provide electric power to the motor (36); and an electronic processor (302) coupled to the power switching network (310). The electronic processor (302) is configured to rotate the motor (36) in a first direction, and to receive an input for switching a rotational direction of the motor (36). The electronic processor is configured to control the power switching network (310) to stop the motor (36), and to rotate the motor (36) in a second direction after the motor (36) is stopped by controlling the power switching network (310).SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] (Cross - reference to related applications) This application claims the benefit of U.S. Provisional Patent Application No. 62 / 932,715, filed on November 8, 2019, the entire contents of which are incorporated herein by reference.

[0002] This application relates to a motor unit for replacing a gas engine, and more particularly to a motor unit for replacing a gas engine for use with a power device.

Background Art

[0003] A small single - cylinder or multi - cylinder gasoline engine can be attached to a power device and the device can be driven by a power take - off shaft.

Summary of the Invention

Means for Solving the Problems

[0004] One embodiment provides a gas engine replacement device including a housing, a battery receptacle coupled to the housing and configured to removably receive a battery pack, and a motor located within the housing. The gas engine replacement device also includes a power take-off shaft that receives torque from the motor and protrudes from a side surface of the housing, a power switching network configured to selectively provide power from the battery pack to the motor, and an electronic processor coupled to the power switching network and configured to control the power switching network to rotate the motor. The electronic processor is configured to rotate the motor in a first direction and receive an input to switch the rotation direction of the motor. The electronic processor is also configured to control the power switching network to stop the motor by performing one selected from the group consisting of coasting the motor to a stop, applying passive braking to stop the motor, applying active braking to stop the motor, and dynamically pulse driving the motor in a reverse phase from the first direction, and to rotate the motor in a second direction after controlling the power switching network to stop the motor.

[0005] Another embodiment provides an outdoor power equipment including a gas engine replacement device. The gas engine replacement device includes a housing, a battery receptacle coupled to the housing and configured to removably receive a battery pack, and a motor located within the housing. The gas engine replacement device also includes a power take-off shaft that receives torque from the motor and protrudes from a side surface of the housing, a power switching network configured to selectively provide power from the battery pack to the motor, and an electronic processor coupled to the power switching network and configured to control the power switching network to rotate the motor. The outdoor power equipment also includes a first clutch mechanism configured to couple the power take-off shaft to a first equipment bit and to operate the first equipment bit when the motor is rotating in a first direction and to stop the first equipment bit when the motor is rotating in a second direction.

[0006] In some configurations, the outdoor power equipment further includes a second clutch mechanism configured to couple the power take-off shaft to a second equipment bit and to operate the second equipment bit when the motor is rotating in a second direction and to stop the second equipment bit when the motor is rotating in a first direction.

[0007] In some configurations, the first equipment bit is a first vibration mechanism configured to drive a first vibration plate, and the second equipment bit is a second vibration mechanism configured to drive a second vibration plate.

[0008] In some configurations, the outdoor power equipment also includes wheels configured to move the outdoor power equipment forward on the ground, the first equipment bit is a vibration mechanism configured to drive a vibration plate, and the second equipment bit is an axle that drives the wheels.

[0009] Yet another embodiment provides a compactor system including a frame having a handle, a vibration plate supported by the frame, a vibration mechanism configured to drive the vibration plate, and a gas engine exchange device. The gas engine exchange device includes a housing, a battery receptacle coupled to the housing and configured to removably receive a battery pack, and a motor located within the housing. The gas engine exchange device also includes a power switching network configured to selectively provide power from the battery pack to the motor, and a power take-off shaft that receives torque from the motor and protrudes from a side of the housing. The power take-off shaft is connected to the vibration mechanism to drive the vibration mechanism. The gas engine exchange device further includes an electronic processor coupled to the power switching network and configured to control the power switching network to rotate the motor. The electronic processor is configured to rotate the motor in a first direction. The vibration mechanism vibrates the vibration plate to move the compactor system forward when the motor rotates in the first direction. The electronic processor is configured to rotate the motor in a second direction. The vibration mechanism vibrates the vibration plate but does not move the vibration plate forward.

[0010] Yet another embodiment provides a compactor system including a frame having a handle, a first vibrating plate supported by the frame, and a first vibration mechanism configured to drive the first vibrating plate. The compactor system also includes a second vibrating plate supported by the frame, a second vibration mechanism configured to drive the second vibrating plate, and a gas engine replacement device. The gas engine replacement device includes a housing, a battery receptacle coupled to the housing and configured to removably receive a battery pack, and a motor located within the housing. The gas engine replacement device also includes a power switching network configured to selectively provide power from the battery pack to the motor, an electronic processor coupled to the power switching network and configured to control the power switching network to rotate the motor, and a power take-off shaft that receives torque from the motor and protrudes from a side of the housing. The power take-off shaft is connected to the first vibration mechanism to drive the first vibration mechanism via a first clutch mechanism and is connected to the second vibration mechanism to drive the second vibration mechanism via a second clutch mechanism. The first clutch mechanism operably engages the power take-off shaft with the first vibration mechanism when the motor rotates in a first direction, and the first clutch mechanism operably disengages the power take-off shaft from the first vibration mechanism when the motor rotates in a second direction. The second clutch mechanism operably engages the power take-off shaft with the second vibration mechanism when the motor rotates in the second direction, and the second clutch mechanism operably disengages the power take-off shaft from the second vibration mechanism when the motor rotates in the first direction.

[0011] Yet another embodiment provides a compactor system including a frame including a handle, a vibration plate supported by the frame, and a vibration mechanism configured to drive the vibration plate. The compactor system also includes wheels supported by the frame to move the compactor system forward on the ground, and a gas engine replacement device. The gas engine replacement device includes a housing, a battery receptacle coupled to the housing and configured to removably receive a battery pack, and a motor located within the housing. The gas engine replacement device also includes a power switching network configured to selectively provide power from the battery pack to the motor, an electronic processor coupled to the power switching network and configured to control the power switching network to rotate the motor, and a power take-off shaft that receives torque from the motor and protrudes from a side of the housing. The power take-off shaft is connected to the vibration mechanism to drive the vibration mechanism and is connected to the wheels via a clutch mechanism. When the motor rotates in a first direction, the clutch mechanism operably engages the power take-off shaft to the wheels to move the compactor system forward, and when the motor rotates in a second direction, the clutch mechanism operably disengages the power take-off shaft from the wheels.

[0012] Yet another embodiment provides a compactor system including a frame including a handle, a first vibration mechanism configured to drive a first vibration plate, and a first battery-powered gas engine exchange device. The first battery-powered gas engine exchange device includes a first motor, a first electronic processor coupled to the first motor and configured to control rotation of the first motor, and a first power take-off shaft that receives torque from the first motor and is connected to the first vibration mechanism to drive the first vibration mechanism. The compactor system also includes a second vibration mechanism configured to drive a second vibration plate and a second battery-powered gas engine exchange device. The second battery-powered gas engine exchange device includes a second motor, a second electronic processor coupled to the second motor and configured to control rotation of the second motor, and a second power take-off shaft that receives torque from the second motor and is connected to the second vibration mechanism to drive the second vibration mechanism. The compactor system further includes a main electronic processor electrically connected to the first electronic processor and the second electronic processor. The main electronic processor is configured to identify an operating mode of the compactor system, provide a first control signal to the first electronic processor based on the operating mode, and provide a second control signal to the second electronic processor based on the operating mode.

[0013] Before describing any embodiments in detail, it is to be understood that the embodiments are not limited in their application to the details of the construction and arrangement of components described in the following description or shown in the following drawings. The embodiments described herein can be implemented or executed in various ways. Also, it is to be understood that the expressions and terms used herein are for the purpose of description and should not be regarded as limiting. The use of "including", "comprising", or "having" and their variants herein means including the items listed hereinafter and their equivalents as well as additional items. The terms "attached", "connected", and "coupled" are used in a broad sense and include both direct and indirect attachment, connection, and coupling. Further, "connected" and "coupled" are not limited to physical or mechanical connection or coupling and can include electrical connection or coupling, whether directly or indirectly involved. In addition, as used herein with a list of items, "and / or" means that the items can be taken together, in subsets, or as alternatives (e.g., "A, B, and / or C" means A; B; C; A and B; B and C; A and C; or A, B, and C).

[0014] Note that a plurality of hardware and software-based devices, as well as a plurality of different structural components, may be utilized to implement the embodiments described herein. Further, as described in subsequent paragraphs, the specific configurations shown in the drawings are intended as exemplary embodiments and other alternative configurations are possible. The terms "processor", "central processing unit", and "CPU" are interchangeable unless otherwise specified. When the term "processor" or "central processing unit" or "CPU" is used to identify a unit that performs a particular function, unless otherwise specified, those functions can be performed by a single processor or by a plurality of processors arranged in any form including parallel processors, serial processors, tandem processors, or cloud processing / cloud computing configurations.

[0015] In addition, embodiments may include hardware, software, and electronic components or modules, and it should be understood that for purposes of discussion, these may be illustrated and described as if most of the components were implemented only in hardware. However, those skilled in the art will recognize that based on reading this detailed description, in at least one embodiment, an electronic-based aspect may be implemented in software (e.g., stored on a non-transitory computer-readable medium) executable by one or more processing units such as a microprocessor and / or an application-specific integrated circuit (“ASIC”). Thus, it should be noted that multiple hardware and software-based devices, as well as multiple different structural components, may be utilized to implement embodiments.

[0016] Other features and aspects will become apparent upon consideration of the following detailed description and the accompanying drawings.

Brief Description of the Drawings

[0017]

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Embodiments for Carrying Out the Invention

[0018] As shown in FIGS. 1 and 2, a gas engine replacement device 10 for use with a part of a power plant includes a housing 14 having a first side surface 18, a second side surface 22 adjacent to the first side surface 18, a third side surface 26 facing the second side surface 22, a fourth side surface 28 facing the first side surface 18, a fifth side surface 30 extending between the second and third side surfaces 22, 26, and a sixth side surface 32 facing the fifth side surface 30. The gas engine replacement device 10 also includes a flange 34 coupled to the housing 14 at the first side surface 18, an electric motor 36 positioned inside the housing 14, and a power take-off shaft 38 protruding from the second side surface 22 and receiving torque from the motor 36. As will be described in more detail below, in some embodiments, the power take-off shaft 38 protrudes from the first side surface 18 and the flange 34. As shown in FIG. 3, the gas engine replacement device 10 also includes control electronics 42 including wiring and a controller 46 positioned inside the housing 14 and electrically connected to the motor 36. A similar gas engine replacement device 10 is described and illustrated in U.S. Patent Application No. 16 / 551,197, filed Aug. 26, 2019, the entire contents of which are incorporated herein by reference.

[0019] As shown in FIGS. 1-6, the gas engine replacement device 10 also includes a battery pack 50 that is removably received in a battery receptacle 54 within the housing 14 and transmits current from the battery pack 50 to the motor 36 via the control electronics 42. Referring to FIGS. 4-6, the battery pack 50 includes a battery pack housing 58 having a support portion 62 and a first terminal 66 that is electrically connected to a plurality of battery cells 68 supported by the pack housing 58. The support portion 62 provides a slide-on configuration having a protrusion / recess 70 that cooperates with a complementary protrusion / recess 74 (shown in FIG. 6) of the battery receptacle 54. In the embodiment shown in FIGS. 4-6, the protrusion / recess 70 of the battery pack 50 is a guide rail and the protrusion / recess 74 of the battery receptacle 54 is a guide recess. Similar battery packs are described and illustrated in U.S. Patent Application Publication No. 2019 / 0006980, filed Jul. 2, 2018, the entire contents of which are incorporated herein by reference. In some embodiments, the battery cells 68 have a nominal voltage of up to about 80V. In some embodiments, the battery cells 68 have a nominal voltage of up to about 120V. In some embodiments, the battery pack 50 has a weight of up to about 6 lb. In some embodiments, each of the battery cells 68 has a diameter of up to 21 mm and a length of up to about 71 mm. In some embodiments, the battery pack 50 includes up to 20 battery cells 68. In some embodiments, the battery cells 68 are connected in series. In some embodiments, the battery cells 68 are operable to output a continuous operating discharge current between about 40A and about 60A. In some embodiments, each of the battery cells 68 has a capacity between about 3.0 Ah and about 5.0 Ah.

[0020] FIG. 6 shows the battery receptacle 54 of the gas engine replacement device 10 according to some embodiments. The battery receptacle 54 includes a protrusion / recess 74, a second terminal 78, a latch mechanism 82, and a power cut-off switch 86. The protrusion / recess 74 cooperates with the protrusion / recess 70 of the battery pack 50 to mount the battery pack 50 to the battery receptacle 54 of the gas engine replacement device 10. When the battery pack 50 is mounted to the gas engine replacement device 10, the second terminal 78 and the first terminal 66 are electrically connected. The latch mechanism 82 protrudes from the surface of the battery receptacle 54 and is configured to engage with the battery pack 50 to maintain the engagement between the battery pack 50 and the battery receptacle 54. Accordingly, the battery pack 50 can be connected to and thereby supported by the battery receptacle 54 such that the battery pack 50 can be supported by the housing 14 of the gas engine replacement device 10. In some embodiments, the battery pack receptacle 54 is disposed on the housing 14 at a position that creates a maximum possible separation distance between the motor 36 and the battery pack 50 to suppress vibrations transmitted from the motor 36 to the battery pack 50. In some embodiments, an elastomeric member is disposed on the battery pack receptacle 54 to suppress vibrations transmitted from the motor 36 to the battery pack 50 through the housing 14.

[0021] In other embodiments (not shown), the latch mechanism 82 may be disposed at various positions (e.g., side walls, end walls, upper end walls, etc. of the battery receptacle 54) such that the latch mechanism 82 engages with a corresponding structure on the battery pack 50 to maintain the engagement between the battery pack 50 and the battery receptacle 54. The latch mechanism 82 includes a pivotable actuator or handle 90 that operably engages with a latch member 94. The latch member 94 is slidably disposed within a bore 98 of the receptacle 54 and is biased toward the latched position by a biasing member 102 (e.g., a spring) to protrude through the surface of the battery receptacle 54 into a cavity within the battery pack 50.

[0022] The latch mechanism 82 also includes a power cut-off switch 86 (e.g., a microswitch) that facilitates electrically connecting / disconnecting the battery pack 50 from the battery receptacle 54 during the operation of the handle 90 that pulls the latch member 94 out of the battery pack 50. The power cut-off switch 86 may act to electrically disconnect the battery pack 50 from the gas engine replacement device 10 before removing the battery pack 50 from the battery receptacle 54. The power cut-off switch 86 operates when the latch member 94 moves from the latched position (i.e., when the latch member 94 is fully inside the cavity of the battery pack 50) to an intermediate position. The power cut-off switch 86 is electrically connected to the controller 46 and may generate an interrupt indicating that the battery pack 50 is disconnected from the gas engine replacement device 10. When the controller 46 receives the interrupt, the controller 46 initiates a power-off operation to safely power off the control electronics 42 of the gas engine replacement device 10. Similar latch mechanisms and cut-off switches are described and illustrated in U.S. Patent Application Publication No. 2019 / 0006980, which is incorporated herein by reference.

[0023] As shown in FIG. 7, the motor 36 includes a motor housing 96 having an outer diameter of 97, a stator 98 having a nominal outer diameter 102 of up to about 80 mm, a rotor 102 having an output shaft 106 and supported for rotation within the stator 98, and a fan 108. A similar motor is described and illustrated in U.S. Patent Application Publication No. 2019 / 0006980, which is incorporated herein by reference. In some embodiments, the motor 36 is a brushless DC motor. In some embodiments, the motor 36 has an electrical power output of at least about 2760 W. In some embodiments, the electrical power output of the motor 36 can drop below 2760 W during operation. In some embodiments, the fan 108 has a diameter 109 that is larger than the diameter 97 of the motor housing 96. In some embodiments, the motor 36 can be stopped by an electronic clutch (not shown) for rapid overload control. In some embodiments, the motor 36 has a volume of up to about 443,619 mm 3 . In some embodiments, the motor has a weight of up to about 4.6 lb. The housing 14 includes an inlet vent and an outlet vent such that the motor fan 108 draws air along the control electronics 42 through the inlet vent and cools the control electronics 42 before the air is discharged through the outlet vent. In the embodiment shown in FIG. 7, the motor 36 is an internal rotor motor, but in other embodiments, the motor 36 can be an external rotor motor having a nominal outer diameter (i.e., the nominal outer diameter of the rotor) of up to about 80 mm.

[0024] Referring to FIG. 8, the motor 36 can transmit torque to the power take-off shaft 38 in various configurations. In some embodiments, the output shaft 106 is also the power take-off shaft 38 such that the motor 36 drives the power take-off shaft 38 directly without any intermediate gear train. For example, the motor 36 may be a direct drive multi-pole motor. As shown in FIG. 8, in other embodiments, the gas engine replacement device 10 includes a gear train 110 that transmits torque from the motor 36 to the power take-off shaft 38. In some embodiments, the gear train 110 can include a mechanical clutch (not shown) that interrupts the transmission of torque from the motor 36 to the power take-off shaft 38. In some embodiments, the gear train 110 may include a planetary transmission that transmits torque from the output shaft 106 to the power take-off shaft 38, and the axis of rotation of the output shaft 106 is coaxial with the axis of rotation of the power take-off shaft 38. In some embodiments, the gear train 110 includes a spur gear that engages the output shaft 106 of the rotor such that the axis of rotation of the output shaft 106 is offset from and parallel to the axis of rotation of the power take-off shaft 38. In some embodiments, the gear train 110 includes bevel gears such that the axis of rotation of the output shaft 106 is perpendicular to the axis of rotation of the power take-off shaft 38. In other embodiments that utilize bevel gears, the axis of rotation of the output shaft 106 is not perpendicular, parallel, or coaxial with the axis of rotation of the power take-off shaft 38, and the power take-off shaft 38 projects from the flange 34.

[0025] In some embodiments, the gas engine replacement device 10 includes an on / off indicator (not shown). In some embodiments, the gas engine replacement device 10 includes a filter (not shown) to prevent airborne debris from entering the motor 36 and the control electronics 42. In some embodiments, the filter includes a dirty filter sensor (not shown) and a self-cleaning mechanism (not shown). In some embodiments, the motor 36 will mimic the gas engine response when encountering resistance such as deceleration or getting stuck in mud. In some embodiments, the gas engine replacement device 10 includes a heat sink 202 in the housing 14 for air-cooling the control electronics 42 (Figs. 1 and 2). In some embodiments, the gas engine replacement device 10 is liquid-cooled.

[0026] In some embodiments, the output shaft 106 of the rotor 102 has the ability to move both forward and backward, as will be further described below. In some embodiments, the forward and backward capabilities are controllable without shifting the gears of the gear train 110 as compared to a gas engine where the forward / backward capability cannot be achieved without additional gears and time delays. Accordingly, the gas engine replacement device 10 provides higher speed, lighter weight, and lower cost. The gas engine replacement device 10 has fewer moving parts and no combustion system compared to a gas engine, thus providing additional speed, weight, and cost advantages.

[0027] The gas engine replacement device 10 can operate in any orientation (vertical, horizontal, upside down) with respect to the ground for an extended period of time, providing an advantage over a four-stroke gas engine that can only operate for a short time in one orientation and with a slight tilt. The gas engine replacement device 10 does not require gas, oil, or other fluids, and thus can be operated, transported, and stored upside down or on any given side without leaking or overflowing.

[0028] During operation, the gas engine replacement device 10 can be used to replace the gas engine system. Specifically, the gas engine replacement device 10 can be attached to a part of the power equipment having the second bolt pattern by aligning the first bolt pattern defined by a plurality of apertures in the flange 34 with the second bolt pattern. In some embodiments, the flange 34 may include one or more intermediate mounting members or adapters disposed between the flange 34 itself and the flange of a part of the power equipment having the second bolt pattern such that the adapter couples the flange 34 to the power equipment. In these embodiments, the adapter includes both a second bolt pattern and a first bolt pattern such that the first bolt pattern of the flange 34 aligns with the first bolt pattern of the adapter and the second bolt pattern of the adapter aligns with the second bolt pattern defined in a part of the power equipment, thereby enabling the flange 34 of the gas engine replacement device 10 to be coupled to a part of the power equipment.

[0029] Alternatively, the gas engine replacement device 10 can be connected to a part of the power equipment using a belt system by providing a belt that operably connects the power take-off shaft and the equipment bit. Accordingly, the power take-off shaft 38 of the gas engine replacement device 10 can be used to drive the equipment.

[0030] During operation, the housing 14 of the gas engine replacement device 10 is relatively much cooler than the housing of the internal combustion unit because there is no combustion in the gas engine replacement device 10. Specifically, during operation of the gas engine unit, the housing of the gas engine unit reaches 220 °C or higher. In contrast, during operation of the gas engine replacement device 10, all of the outer surfaces of the housing 14 are less than 95 °C. Tables 1 and 2 below list more specifically the temperature limits of various components on the housing 14 of the gas engine replacement device 10.

[0031] Table 1 below lists the temperature limits of Underwriter’s Laboratories (UL) for various components commonly used in power tools, depending on whether those components are formed from metal, plastic, rubber, wood, porcelain, or glass. For example, in at least some embodiments, the rated temperature of the plastic is not exceeded by the gas engine exchange device 10.

[0032] [Table 1]

[0033] Table 2 below lists the UL temperature limits of various components of the battery pack housing 58 of the battery pack 50, depending on whether those components are formed from metal, plastic, or rubber. For example, in at least some embodiments, the rated temperature of the plastic is not exceeded by the gas engine exchange device 10.

[0034] [Table 2]

[0035] FIG. 9 shows a simplified block diagram of a gas engine replacement device 10 according to an exemplary embodiment. As shown in FIG. 9, the gas engine replacement device 10 includes an electronic processor 302, a memory 306, a battery pack 50, a power switching network 310, a motor 36, a rotor position sensor 314, a current sensor 318, a user input device 322 (e.g., a trigger or a power button), a transceiver 326, and an indicator 330 (e.g., a light emitting diode). In some embodiments, the gas engine replacement device 10 includes fewer or additional components than those shown in FIG. 9. For example, the gas engine replacement device 10 may include a battery pack fuel gauge, a work light, additional sensors, a kill switch, a power cut-off switch 86, etc. In some embodiments, one or more of the elements of the gas engine replacement device 10 shown in FIG. 9, including the electronic processor 302, the memory 306, the power switching network 310, the rotor position sensor 314, the current sensor 318, the user input device 322 (e.g., a trigger or a power button), the transceiver 326, and the indicator 330 (e.g., a light emitting diode), form at least a part of the control electronics 42 shown in FIG. 3, and the electronic processor 302 and the memory 306 form at least a part of the controller 46 shown in FIG. 3.

[0036] The memory 306 includes a read-only memory (ROM), a random access memory (RAM), other non-transitory computer-readable media, or a combination thereof. The electronic processor 302 is configured to communicate with the memory 306 to store data and retrieve the stored data. The electronic processor 302 is configured to receive instructions and data from the memory 306 and, in particular, execute instructions. Specifically, the electronic processor 302 executes instructions stored in the memory 306 to perform the methods described herein.

[0037] As described above, in some embodiments, the battery pack 50 is removably attached to the housing of the gas engine replacement device 10 such that different battery packs 50 can be removed from and attached to the gas engine replacement device 10 to provide different amounts of power to the gas engine replacement device 10. Further description of the battery pack 50 (e.g., nominal voltage, continuous operating discharge current, size, number of cells, operation, etc.) and the motor 36 (e.g., output, size, operation, etc.) is provided above with respect to FIGS. 1-8.

[0038] The power switching network 310 enables the electronic processor 302 to control the operation of the motor 36. Generally, when the user input device 322 is depressed (or otherwise actuated), current is supplied from the battery pack 50 to the motor 36 via the power switching network 310. When the user input device 322 is not depressed (or otherwise not actuated), current is not supplied from the battery pack 50 to the motor 36. In some embodiments, the amount by which the user input device 322 is depressed is related to or corresponds to the desired rotational speed of the motor 36. In other embodiments, the amount by which the user input device 322 is depressed is related to or corresponds to the desired torque. In other embodiments, a separate input device (e.g., slider, dial, etc.) that communicates with the electronic processor 302 to provide a desired rotational speed or torque to the motor 36 is included in the gas engine replacement device 10.

[0039] In response to the electronic processor 302 receiving a drive request signal from the user input device 322, the electronic processor 302 activates the power switching network 310 to supply power to the motor 36. Through the power switching network 310, the electronic processor 302 controls the amount of current available to the motor 36, thereby controlling the speed and torque output of the motor 36. The power switching network 310 may include a number of field effect transistors (FETs), bipolar transistors, or other types of electrical switches. For example, the power switching network 310 may include a 6-FET bridge (see FIG. 10) that receives a pulse width modulation (PWM) signal from the electronic processor 302 to drive the motor 36.

[0040] The rotor position sensor 314 and the current sensor 318 are coupled to the electronic processor 302 and transmit various control signals indicative of different parameters of the gas engine exchanger 10 or the motor 36 to the electronic processor 302. In some embodiments, the rotor position sensor 314 includes one hall sensor or a plurality of hall sensors. In other embodiments, the rotor position sensor 314 includes a quadrature phase encoder attached to the motor 36. The rotor position sensor 314 outputs motor feedback information, such as an indicator (e.g., a pulse) when the magnet of the rotor of the motor 36 rotates across the face of the hall sensor, to the electronic processor 302. In still other embodiments, the rotor position sensor 314 includes a voltage or current sensor that provides an indicator of, for example, the back electromotive force (back emf) generated in the motor coil. The electronic processor 302 may identify the rotor position, rotor speed, and rotor acceleration based on the back emf signal received from the rotor position sensor 314, i.e., the voltage or current sensor. The rotor position sensor 314 can be combined with the current sensor 318 to form a current and rotor position composite sensor. In this example, the composite sensor provides current flowing through the active phase coils of the motor 36 and also provides current in one or more non-active phase coils of the motor 36. The electronic processor 302 measures the current flowing through the motor based on the current flowing through the active phase coils and measures the motor speed based on the current in the non-active phase coils.

[0041] Based on the motor feedback information from the rotor position sensor 314, the electronic processor 302 can identify the position, speed, and acceleration of the rotor. In response to the motor feedback information and the signal from the user input device 322, the electronic processor 302 transmits a control signal to control the power switching network 310 and drive the motor 36. For example, by selectively enabling and disabling the FETs of the power switching network 310, the power received from the battery pack 50 is selectively applied periodically to the stator windings of the motor 36 to rotate the rotor of the motor 36. The motor feedback information is used by the electronic processor 302 to ensure the appropriate timing of the control signal to the power switching network 310 and, in some cases, to provide closed-loop feedback to control the speed of the motor 36 to a desired level. For example, to drive the motor 36, using the motor positioning information from the rotor position sensor 314, the electronic processor 302 identifies where the rotor magnet is relative to the stator windings and (a) excites the next stator winding pair (or pairs) in a predetermined pattern to apply a magnetic force to the rotor magnet in the desired direction of rotation, and (b) demagnetizes the previously excited stator winding pair (or pairs) to prevent the application of a magnetic force to the rotor magnet in the direction opposite to the direction of rotation of the rotor.

[0042] The current sensor 318 monitors or detects the current level of the motor 36 during the operation of the gas engine exchanger 10 and provides a control signal indicating the detected current level to the electronic processor 302. The electronic processor 302 may use the detected current level to control the power switching network 310 as described in more detail below.

[0043] The transceiver 326 enables communication between the electronic processor 302 and an external device (e.g., a smartphone, a tablet, or a laptop computer) via a wired or wireless communication network 334. In some embodiments, the transceiver 326 may comprise separate transmit and receive components. In some embodiments, the transceiver 326 may comprise a wireless adapter attached to the gas engine exchanger 10. In some embodiments, the transceiver 326 is a wireless transceiver that encodes information received from the electronic processor 302 into a carrier radio signal and transmits the encoded wireless signal to the external device 338 via the communication network 334. The transceiver 326 also decodes information from the wireless signal received from the external device 338 via the communication network 334 and provides the decoded information to the electronic processor 302.

[0044] The communication network 334 provides a wired or wireless connection between the gas engine exchanger 10 and the external device 338. The communication network 334 may comprise a short-range network, e.g., a BLUETOOTH (registered trademark) network, a Wi-Fi network, etc., or a long-range network, e.g., the Internet, a cellular network, etc.

[0045] As shown in FIG. 9, indicator 330 is also coupled to electronic processor 302, receives control signals from electronic processor 302, and is turned on and off based on different states of gas engine exchanger 10, or otherwise conveys information. Indicator 330 includes, for example, one or more light emitting diodes ( "LEDs"), or a display screen. Indicator 330 may be configured to display the state of gas engine exchanger 10 or information related thereto. For example, indicator 330 is configured to indicate measured electrical characteristics of gas engine exchanger 10, the state of gas engine exchanger 10, the mode of gas engine exchanger 10, etc. Indicator 330 may also include elements that convey information to the user via audible or tactile output. In some embodiments, indicator 330 includes an eco indicator that indicates the amount of power being used by the load during operation.

[0046] The connections shown between the components of gas engine exchanger 10 are simplified in FIG. 9. In reality, the wiring of gas engine exchanger 10 is more complex because the components of the gas engine exchanger are interconnected by several wires for power and control signals. For example, each FET of power switching network 310 is separately connected to electronic processor 302 by a control line, each FET of power switching network 310 is connected to the terminals of motor 36, and the power line from battery pack 50 to power switching network 310 includes a positive wire and a negative / ground wire, etc. In addition, the power lines can have a large gauge / diameter to handle increased current. Further, although not shown, additional control signals and power lines are used to interconnect additional components of gas engine exchanger 10.

[0047] FIG. 10 shows an example of a power switching network 310 for driving a motor 36 of the gas engine replacement device 10. The power switching network 310 includes three high-side FETs H1, H2, and H3 and three low-side FETs L1, L2, and L3, each having a first, i.e., conducting state, and a second, i.e., non-conducting state. The power switching network 210 is used to selectively apply power from the battery pack 50 to the motor 36. An exemplary method for controlling the high-side switches and the low-side switches to operate the motor 36 in the forward and reverse directions will be described below.

[0048] The high-side switch and the low-side switch may be controlled using (pulse-width modulation) PWM commutation, center-line commutation, or other commutation methods. FIG. 11A shows a simple PWM commutation for controlling the motor 36 to rotate in the forward direction. As shown in FIG. 11A, each of the high-side FETs H1, H2, and H3 conducts periodically throughout the commutation phase. When one of the FETs H1, H2, and H3 stops conducting, the next high-side FET starts conducting. Similarly, each of the low-side FETs L1, L2, and L3 conducts periodically throughout the commutation phase. When one of the FETs L1, L2, and L3 stops conducting, the next low-side FET starts conducting. However, one or both of the high-side or low-side FETs may operate only for a period of the commutation phase (e.g., by a PWM signal having a duty ratio of 75%, 50%, 25%, or another duty ratio) based on the desired speed of the motor 36 or the load on the motor 36. In the illustrated embodiment, to drive the motor 36 in the forward direction, the high-side and low-side FETs operate in a predetermined pair and in a predetermined sequence. In the embodiment shown in FIG. 11A, H1 and L2 operate first, then H2 and L3 operate, and then H3 and L1 operate. This sequence continues during the operating time of the motor 36 in the forward operation. FIG. 11B shows a simple PWM commutation for controlling the motor 36 to rotate in the reverse direction. In the embodiment shown in FIG. 11B, H1 and L3 operate first, then H3 and L2 operate, and then H2 and L1 operate. This sequence continues during the operating time of the motor 36 in the reverse operation. In some embodiments, one or more variations to the sequence can be made based on the desired motor operation. For example, one or both of the high-side and low-side FETs may be switched at a certain frequency during their operating phases to control the speed of the motor. Additionally, the operating phases of the high-side and low-side FETs may be shifted to create an overlap with other operations to achieve different control (e.g., field-oriented control).

[0049] FIG. 12 is a flowchart of an exemplary method 400 for bidirectional operation of motor 36. Method 400 includes rotating motor 36 in a first direction (at block 405). Depending on the desired function of the power equipment, motor 36 may be rotated in the forward or reverse direction. For example, electronic processor 302 provides a PWM control signal as shown in FIG. 11A to rotate the motor in the forward direction (e.g., the first direction). Electronic processor 302 may adjust the duty cycle of the PWM signal to adjust the operating speed.

[0050] Method 400 also includes receiving an input to switch the rotation direction of motor 36 (at block 410). The user may provide the input via user input device 322. For example, user input device 322 may be a forward / reverse switch actuated by the user, or a mode selection switch that enables the user to select an operating mode. User input device 322 provides a control signal to electronic processor 302 to switch the rotation direction of motor 36 based on the actuation of user input device 322. In some embodiments, the input may be received from one or more sensors of gas engine exchanger 10 or the power equipment coupled to gas engine exchanger 10. In some embodiments, the input may be received from a smartphone, for example, via communication network 334.

[0051] Method 400 further includes controlling the power switching network 310 to stop the motor 36 (at block 415). The electronic processor 302 may use several techniques to stop the motor 36. In one embodiment, the electronic processor 302 turns off all the high-side and low-side FETs, allowing the motor 36 to coast to a stop. When the FETs are turned off, current is no longer supplied to the motor 36, and the motor 36 stops due to the friction or load acting on it. In other embodiments, passive or active braking may be used to stop the motor 36. During passive braking, the electronic processor 302 provides control signals to the high-side and low-side FETs to connect the motor to a braking load (e.g., a braking coil or resistor coupled between one or more stator coils and ground), quickly dissipating the energy in the motor 36 and braking the motor 36. During active braking, the electronic processor 302 turns off the high-side FET and controls the low-side FET to be on, short-circuiting the motor coil to ground and dissipating the remaining energy in the coil to ground. In other embodiments, the electronic processor 302 provides control signals to the high-side and low-side FETs to perform regenerative braking, returning the energy in the motor 36 to the battery pack 50 via the power switching network 310. In yet another embodiment, dynamic pulsing may be used to brake the motor 36. The electronic processor 302 may provide control signals to the high-side and low-side FETs to provide an electric braking force to the rotor of the motor 36. The electronic processor 302 may monitor the rotor position sensor 314 and actuate the phase (i.e., the corresponding pair of high-side and low-side FETs) when the rotor just passes through a phase. For example, the rotor position sensor 314 indicates that the rotor has just rotated past the phase corresponding to FETs H1 and L2. In response, the electronic processor 302 may actuate FETs H1 and L2 to drive current through the stator coil, generating a magnetic field that provides a braking force to the rotor in the direction opposite to the rotation direction of the rotor to stop the rotation.The electronic processor 302 may continue to operate the FET pair at a timing based on the rotor position information from the rotor position sensor 314 such that, although in a sequence similar to that of FIG. 11A, the magnetic field resulting from the coupled stator coils continues to provide a braking force that stops the rotation.

[0052] Method 400 also includes controlling the power switching network 310 to rotate the motor 36 in a second direction after stopping the motor (at block 420). For example, the electronic processor 302 provides a PWM control signal as shown in FIG. 11B to rotate the motor in the reverse direction (e.g., the second direction). The electronic processor 302 may adjust the duty cycle of the PWM signal to adjust the operating speed. Method 400 may be repeated whenever a change in the direction of rotation is desired.

[0053] FIG. 13 shows a compactor 576 including a frame 580 that supports a gas engine exchanger 10 such that the gas engine exchanger 10 can drive a vibration mechanism 588 to drive a vibration plate 584, the vibration plate 584, and the vibration mechanism 588 intermediate the gas engine exchanger 10 and the vibration plate 584. The frame 580 includes a handle 592 and also supports a water tank 596 having a valve 600 through which water or other liquid can be applied to a surface for tightening or to the vibration plate 584. In some embodiments, the compactor 576 includes a paint sprayer 604 for spraying and delineating lines or boundaries within and around the tightening operation.

[0054] During operation, the operator can grip the handle 592 and operate the gas engine replacement device 10 to drive the vibrating plate 584 to compact soil or asphalt containing a granular mixed material that is mostly non-sticky. During operation, in some applications, the operator can control the valve 600 so that water from the water tank 596 can be applied to the compacted surface, allowing the particles to form a paste with water and bond to each other to form a denser or tighter finished surface. Further, the water from the water tank 596 prevents asphalt or other materials from adhering to the vibrating plate 584 during operation.

[0055] The compactor 576 can be used in the construction of parking lots, highways, or bridges. In particular, the compactor 576 can be used in construction areas adjacent to structures, curbs, and abutments. The compactor 576 can also be used for landscaping for compacting roadbeds and paving materials. The compactor 576 including the gas engine replacement device 10 has advantages over conventional compactors with internal combustion engines, some of which are described below. For example, the motor 36 of the gas engine replacement device 10 can rotate in the forward or reverse direction, allowing the operator to shift the directional bias of the vibration mechanism 588. Accordingly, the vibration mechanism 588 is configured to move forward or backward or "walk" itself depending on how the operator shifts the directional bias of the vibration mechanism 588.

[0056] FIG. 14 shows another embodiment of a compactor 700 that includes a frame 704 that supports a gas engine replacement device 10 such that the gas engine replacement device 10 can drive a vibration mechanism 712 to drive a vibration plate 708, the vibration plate 708, and the vibration mechanism 712 intermediate the gas engine replacement device 10 and the vibration plate 708. The frame 704 includes a handle 716 for a user to hold and move the compactor 700. The gas engine replacement device 10 is connected to the vibration mechanism 712 using a belt 720. The belt 720 couples the power take-off shaft 38 to the vibration mechanism 712 such that when the power take-off shaft 38 rotates, the belt 720 rotates with the power take-off shaft 38 to excite the vibration mechanism 712. The vibration mechanism 712, in turn, vibrates the vibration plate 708.

[0057] Generally, a gas engine plate compactor includes only one operating mode. In particular, the gas engine may rotate the motor in only one direction, which limits the function of the plate compactor. In contrast, the compactor 700 includes a gas engine replacement device 10 that includes a motor 36 that can rotate in both forward and reverse directions. Therefore, the compactor 700 is adapted to perform different functions based on the rotation direction of the motor. When the electronic processor 302 rotates the motor 36 in the first direction (e.g., as in block 405), the vibration mechanism 712 may drive the vibration plate 708 to provide both forward tightening and movement of the compactor 700. The vibration mechanism 712 is, for example, an asymmetric rotating mass. As the mass rotates about the axis, the mass applies a non-uniform force to the axis, which is then transmitted to the vibration plate 708. The vibration mechanism 712 may be located in front of the vibration plate 708, for example, in front of the center of mass of the vibration plate 708, to enable forward movement of the vibration plate 708. During rotation, the mass of the vibration mechanism first transmits a rotational force to the vibration plate 708 in an upward movement that lifts the front face of the vibration plate 708. The mass then transmits a forward movement force that drives the vibration plate 708 forward. That is, when the mass rotates in the first direction, the vibration plate 708 is lifted during the upward movement of the mass, and the vibration plate 708 moves forward during the forward movement of the mass. The phase or vibration of the vibration mechanism 712 may be controlled to provide the dual functions of tightening and movement as described above. The phase may be controlled to advance the compactor 700 forward at a slow walking pace. Therefore, the user may operate the compactor 700 to easily navigate the work area while also providing tightening. Such operation reduces the user's physical stress.

[0058] When the electronic processor 302 rotates the motor 36 in the second direction (e.g., as in block 420), the vibration mechanism 712 may drive the vibration plate 708 to provide only tightening without moving the compactor 700 in the reverse direction. When the mass body of the vibration mechanism 712 rotates in the second direction, the mass body, as described above, lifts the front surface of the vibration plate 708 during the upward movement of the mass body. In addition, the mass body may also transmit the backward movement of the mass body to the vibration plate 708. However, since the rear part of the vibration plate 708 does not lift, the friction between the ground and the vibration plate 708 prevents the compactor 700 from moving backward. The phase or vibration of the vibration mechanism 712 may be controlled to provide only the tightening function as described above. Thus, the user may operate the compactor 700 in an area where additional tightening is desired, e.g., in a narrow space. Thereby, the user can keep the compactor 700 in place where additional tightening is desired when the compactor 700 would otherwise tend to move forward when operating in the forward direction and the user needs to prevent such forward movement. A typical gas engine plate compactor requires a complex mechanical clutch and linkage mechanism to drive the vibration mechanism 712 in the reverse direction. For example, a gas engine plate compactor may use two vibration mechanisms to achieve the reverse operation as described above. In contrast, the compactor 700 provides reverse operation with only a single vibration mechanism 712 without the need for a complex mechanical clutch.

[0059] FIG. 15 shows a pump system 520 including a frame 524 that supports the gas engine replacement device 10 and a pump 528, and the gas engine replacement device 10 is operable to drive the pump 528. The illustrated pump 528 is a centrifugal pump having an impeller positioned within a housing 532 of the pump 528 that is rotatable about an axis to move material from an inlet 536 of the pump 528 to an outlet 540 of the pump 528. Specifically, the pump 528 is a "trash pump" that includes a sufficient clearance (e.g., 8 millimeters) between the impeller of the pump 528 and the housing 532 to provide a mixture of liquid (e.g., water) and debris (e.g., solid materials such as mud, pebbles, leases, sand, sludge, etc.) that passes through the pump 528 from the inlet 536 to the outlet 540 without debris being trapped within the pump 528 and degrading the performance of the pump system 520.

[0060] Generally, a gas engine pump includes only one operating mode. In particular, the gas engine may rotate the motor in only one direction, which limits the function of the pump. In contrast, the pump system 520 includes a gas engine replacement device 10 that includes a motor 36 that can rotate in both forward and reverse directions. Accordingly, the pump system 520 is adapted to perform different functions based on the rotation direction of the motor. When the electronic processor 302 rotates the motor 36 in a first direction (e.g., as in block 405), the pump 528 may drive the impeller in the forward direction to move the material from the inlet 536 of the pump 528 to the outlet 540 of the pump 528. When the electronic processor 302 rotates the motor 36 in a second direction (e.g., as in block 420), the pump 528 may drive the impeller to remove a clog (without using a transmission including a forward gear and a reverse gear) or clean the pump 528 if debris is clogged inside the pump 528. In some embodiments, the motor 36 may be controlled by the electronic processor 302 to rotate in the second direction at a speed slower than the first direction to remove a clog in the pump 528. For example, the electronic processor 302 may provide a PWM signal with a higher duty ratio for driving in the first direction than the duty ratio for driving in the second direction to rotate the motor 36 in the first direction at a higher speed than the second direction to the FET of the power switching network 310.

[0061] FIG. 16 shows an example of an outdoor power equipment 750 including a gas engine replacement device 10, a first equipment bit 754, and a second equipment bit 758. The first equipment bit 754 is coupled to the power take-off shaft 38 of the gas engine replacement device 10 using a first clutch mechanism 762. In the illustrated example, the first clutch mechanism 762 includes a first one-way clutch 766 attached to the power take-off shaft 38. A first belt 770 couples the first one-way clutch 766 to the first equipment bit 754. The first one-way clutch 766 is, for example, a sprag bearing or the like that transmits rotational motion to the first belt 770 when the power take-off shaft 38 is rotating in a first direction, but does not transmit rotational motion to the first belt 770 when the power take-off shaft 38 is rotating in a second opposite direction. Accordingly, the first clutch mechanism 762 activates the first equipment bit 754 when the motor 36 is rotating in the first direction and stops the first equipment bit 754 when the motor 36 is rotating in the second direction. The first one-way clutch 766 and the first belt 770 are an example of the first clutch mechanism 762. In some implementations, different mechanical components may be used to implement the first clutch mechanism 762 that activates the first equipment bit 754 only when the rotor is rotating in the first direction.

[0062] The second device bit 758 is coupled to the power take-off shaft 38 of the gas engine replacement device 10 using a second clutch mechanism 778. In the illustrated embodiment, the second clutch mechanism 778 includes a second one-way clutch 782 that is attached to the power take-off shaft 38. A second belt 786 couples the second one-way clutch 782 to the second device bit 758. The second one-way clutch 782 is, for example, a sprag bearing or the like that transmits rotational motion to the second belt 786 when the power take-off shaft 38 is rotating in the second direction, but does not transmit rotational motion to the second belt 786 when the power take-off shaft 38 is rotating in the first direction. Accordingly, the second clutch mechanism 778 actuates the second device bit 758 when the motor 36 is rotating in the second direction and stops the second device bit 758 when the motor 36 is rotating in the first direction. The second one-way clutch 782 and the second belt 786 are one example of the second clutch mechanism 778. In some implementations, different mechanical components may be used to implement the second clutch mechanism 778 that actuates the second device bit 758 only when the rotor is rotating in the second direction.

[0063] The outdoor power equipment 750 is, for example, a double exciter plate compactor. In this embodiment, the first device bit 754 is a first vibration mechanism configured to drive a first vibration plate, and the second device bit 758 is a second vibration mechanism configured to drive a second vibration plate. When the motor 36 rotates in the first direction, power is transmitted to the first vibration mechanism via the first clutch mechanism 762. The first vibration mechanism thereby drives the first vibration plate and advances the plate compactor, for example, forward. When the motor 36 rotates in the second direction, power is transmitted to the second vibration mechanism via the second clutch mechanism 778. The second vibration mechanism thereby drives the second vibration plate and advances the plate compactor, for example, in the reverse direction.

[0064] FIG. 17 shows another exemplary outdoor power equipment 750 (e.g., a wheeled plate compactor). In the illustrated embodiment, the outdoor power equipment 750 includes wheels 790 for propelling the outdoor power equipment 750 on the ground. In this embodiment, the first equipment bit 754 is a vibration mechanism configured to drive a vibrating plate, and the second equipment bit 758 is configured to drive an axle 794 coupled to the wheels 790. When the motor 36 rotates in a first direction, power is transmitted to the vibration mechanism via the first clutch mechanism 762. The vibration mechanism thereby drives the vibrating plate. When the motor 36 rotates in a second direction, power is transmitted to the wheels 790 via the second clutch mechanism 778. The wheels 790 can be used to drive the outdoor power equipment 750.

[0065] FIG. 18 shows an exemplary double exciter compactor 800 including a frame 804 that supports two gas engine exchangers 10 labeled as a first gas engine exchanger 10A and a second gas engine exchanger 10B. The frame further supports a first vibrating plate 808 and a first vibration mechanism 812 (e.g., a first exciter) intermediate the first gas engine exchanger 10A and the first vibrating plate 808 such that the first gas engine exchanger 10A can drive the first vibration mechanism 812 to drive the first vibrating plate 808. The first gas engine exchanger 10A is connected to the first vibration mechanism 812 using a first belt 816. The first belt 816 couples the power take-off shaft 38A of the first gas engine exchanger 10A to the first vibration mechanism 812 such that when the power take-off shaft 38A rotates, the first belt 816 rotates with the power take-off shaft 38A to excite the first vibration mechanism 812. The first vibration mechanism 812, in turn, vibrates the first vibrating plate 808.

[0066] The double exciter compactor 800 also includes a second gas engine replacement device 10B, a second vibration plate 820, and a second vibration mechanism 824 (e.g., a second exciter) intermediate the second gas engine replacement device 10B and the second vibration plate 820 such that the second gas engine replacement device 10B can drive the second vibration mechanism 824 to drive the second vibration plate 820. The second gas engine replacement device 10B is connected to the second vibration mechanism 824 using a second belt 828. The second belt 828 couples the second power take-off shaft 38B to the second vibration mechanism 824 such that when the second power take-off shaft 38B rotates, the second belt 828 rotates with the second power take-off shaft 38B to excite the second vibration mechanism 824. The second vibration mechanism 824, in turn, vibrates the second vibration plate 820.

[0067] The double exciter compactor 800 further includes a main controller 832 coupled to the first gas engine replacement device 10A to provide a control signal to the first electronic processor 302A of the first gas engine replacement device 10A and coupled to the second gas engine replacement device 10B to provide a control signal to the second electronic processor 302B of the second gas engine replacement device 10B. The main controller 832 may be implemented similarly to the electronic processor 302 and provides control signals to the first electronic processor 302A and the second electronic processor 302B based on a selected operating mode or desired operation of the double exciter compactor 800.

[0068] FIG. 19 is a flow diagram of an exemplary method 850 for the operation of a double exciter compactor 800. The method 850 includes identifying an operating mode of the compactor 800 (at block 855) using a main controller 832. The main controller 832 may receive user input via a user input device of the compactor 800 (e.g., a mode selector slider, dial, or push button), or via a communication network from an external device 338 based on input received via a graphical user interface on the external device 338. The user input indicates an operating mode of the compactor 800. The operating modes of the compactor 800 include, for example, forward tamping, reverse tamping, neutral tamping. Each mode may correspond to specific control of a first gas engine switching device 10A and a second gas engine switching device 10B. The mapping between the operating mode and the control for the first gas engine switching device 10A and the second gas engine switching device 10B may be stored in the memory of the main controller 832.

[0069] Method 850 also includes using main controller 832 to provide a first control signal to first electronic processor 302A based on the operating mode (at block 860), and using main controller 832 to provide a second control signal to second electronic processor 302B based on the operating mode (at block 865). As discussed above, main controller 832 may identify specific controls for first gas engine exchanger 10A and second gas engine exchanger 10B based on the operating mode, and provide corresponding control signals to first gas engine exchanger 10A and second gas engine exchanger 10B. For example, if the user selects forward tightening, main controller 832 may provide the first and second control signals to control the speed, direction, and phase offset of first gas engine exchanger 10A and second gas engine exchanger 10B. By controlling the speed, direction, and / or phase offset of first gas engine exchanger 10A and second gas engine exchanger 10B, vibration plates 808, 820 may provide tightening and be controlled to move forward. In one embodiment, forward tightening may be achieved by controlling motors 36 of first gas engine exchanger 10A and second gas engine exchanger 10B to rotate in a first direction.

[0070] In another example, if the user selects reverse tightening, main controller 832 may provide the first and second control signals to control the speed, direction, and phase offset of first gas engine exchanger 10A and second gas engine exchanger 10B. By controlling the speed, direction, and / or phase offset of first gas engine exchanger 10A and second gas engine exchanger 10B, vibration plates 808, 820 may provide tightening and be controlled to move backward. In one embodiment, reverse tightening may be achieved by controlling motors 36 of first gas engine exchanger 10A and second gas engine exchanger 10B to rotate in a second direction.

[0071] In yet another embodiment, when the user selects neutral tightening, the main controller 832 may provide a first control signal and a second control signal to control the speed, direction, and / or phase offset of the first gas engine exchanger 10A and the second gas engine exchanger 10B. By controlling the speed, direction, and / or phase offset of the first gas engine exchanger 10A and the second gas engine exchanger 10B, the vibration plates 808, 820 may be controlled to provide tightening while remaining stationary. In one embodiment, neutral tightening may be achieved by controlling the motors 36 of the first gas engine exchanger 10A and the second gas engine exchanger 10B to rotate in opposite directions. That is, control the motor 36 of the first gas engine exchanger 10A to rotate in the forward direction, control the motor 36 of the second gas engine exchanger 10B to rotate in the reverse direction, or vice versa.

[0072] Method 850 is repeated for each mode selection or mode change of the compactor 800. Those skilled in the art will correctly recognize that the main controller 832 may be used to operate the double-exciter compactor 800 in some other modes not explicitly described herein. Additionally, in some embodiments, the functionality of the main controller 832 is incorporated into one of the electronic processors of the first or second gas engine exchangers 10A, 10B, and the main controller 832 is not included within the double-exciter compactor 800.

[0073] Some of the outdoor power equipment described above that is driven by the gas engine exchanger 10 includes many advantages over conventional equipment driven by internal combustion engines, some of which are described below.

[0074] In some embodiments, the gas engine replacement device 10 can be fitted with new equipment, and the memory 306 can be reprogrammed to optimize the gas engine replacement device 10 for operation with the new equipment. In some embodiments, the electronic processor 302 automatically recognizes what type of new equipment the gas engine replacement device 10 is fitted with and manages the operation of the gas engine replacement device 10 accordingly. In some embodiments, the electronic processor 302 can automatically detect what equipment the gas engine replacement device 10 is fitted with via radio frequency identification (RFID) communication with the new equipment.

[0075] In some embodiments, the memory 306 is reprogrammable via either the BLUETOOTH or Wi-Fi communication protocol. In some embodiments, the electronic processor 302 has control modes for different uses of the same equipment. The control modes may be preset or user-programmable and may be programmed remotely via BLUETOOTH or Wi-Fi. In some embodiments, the electronic processor 302 utilizes master / slave device communication and cooperation so that the gas engine replacement device 10 can perform one-way control over the equipment, or so that an operator can perform one-way control over the gas engine replacement device 10 using a smartphone application.

[0076] In some embodiments, an operator or an original equipment manufacturer (OEM) is permitted limited access to control the speed of the gas engine replacement device 10 through the electronic processor 302 via an interface such as, for example, a controller area network (CAN). In some embodiments, the electronic processor 302 enables a wider range of speed selections than a gasoline engine by means of a single gear set within the gear train 110. For example, the control electronics 42 is configured to drive the motor 36 at speeds below 2,000 RPM, which is lower than any speed possible with a gasoline engine, thereby enabling the associated equipment to have a greater total run time than a gasoline engine over a full discharge of the battery pack 50. Additionally, the control electronics 42 is configured to drive the motor at speeds exceeding 3,600 RPM, which is higher than any speed possible with a gasoline engine and has the ability to output more torque. The wider speed range of the motor 36 provides higher efficiency and capabilities than a gasoline engine. In some embodiments, the operator can have access to control the current drawn by the motor 36 in addition to the speed.

[0077] In some embodiments, the electronic processor 302 is configured to record and report data. For example, the electronic processor 302 is configured to provide wired or wireless diagnostics for monitoring and reading the state of the gas engine exchanger 10. For example, the electronic processor 302 can monitor and record the runtime of the gas engine exchanger 10, for example, in a rental scenario. In some embodiments, the motor 36 and the electronic processor 302 use regenerative braking to charge the battery pack 50. In some embodiments, the gas engine exchanger 10 includes a DC output for lighting or accessories. In some embodiments, the electronic processor 302 can detect abnormalities or malfunctions of the gas engine exchanger 10 via voltage, current, movement, speed, and / or thermocouples. In some embodiments, the electronic processor 302 can detect unauthorized use or stoppage of the gas engine exchanger 10. If the equipment driven by the gas engine exchanger 10 is not operating with the intended characteristics, or is not being used correctly or safely, the electronic processor 302 can detect the abnormality and stop the gas engine exchanger 10. For example, the gas engine exchanger 10 can include one or more accelerometers that sense whether the gas engine exchanger 10 and the equipment are in the intended orientation. Also, if the electronic processor 302 determines that the gas engine exchanger 10 is not in the intended orientation (i.e., the equipment has fallen over), the electronic processor 302 can stop the gas engine exchanger 10.

[0078] In some embodiments, the gas engine replacement device 10 includes an accessible sensor port (not shown) that is electrically connected to a user-selectable sensor, such as an accelerometer, gyroscope, GPS unit, or real-time clock, for use with a portion of the power equipment, enabling an operator to customize the variables sensed and detected by the electronic processor 302. In some embodiments, the electronic processor 302 can indicate to the operator the state of the battery pack 50, such as when the battery is depleted, via visual, auditory, or tactile notifications. In some embodiments, the electronic processor 302 can operate an auxiliary motor separate from the motor 36 to drive an auxiliary device such as a winch. The auxiliary motor may be inside or outside the gas engine replacement device 10.

[0079] In some embodiments, the gas engine replacement device 10 can include digital control on a customizable user interface, such as a touch display or a combination of knobs and buttons. In contrast, an analog gasoline engine does not include such digital control. In some embodiments, the user interface for the gas engine replacement device 10 can be modular, wired, or wireless, and can be attachable to the gas engine replacement device 10 or handheld. In some embodiments, the gas engine replacement device 10 can be controlled remotely and includes a status indicator for certain characteristics of the gas engine replacement device 10, such as the charge and temperature of the battery pack 50. In some embodiments, the gas engine replacement device 10 can provide a status display by a remote programmable device.

Claims

Claim 1 A power device, a first device for replacing a gas engine in the power device, a second device for replacing the gas engine in the power device, and a controller coupled to the first device and the second device, wherein the first device includes a first motor, a first power take-off shaft that receives torque from the first motor for direct or indirect connection to a first exciter of the power device, and a first power switching network configured to selectively provide battery power to the first motor, wherein the second device includes a second motor, a second power take-off shaft that receives torque from the second motor for direct or indirect connection to a second exciter of the power device, and a second power switching network configured to selectively provide battery power to the second motor, wherein the controller is configured to provide a first control signal to the first device to drive the first motor, and provide a second control signal to the second device to drive the second motor, such that the power device.

Images