Power tool system and wireless communication adapter therefor

Abstract

To provide an electric power tool system which includes a wireless communication device and is formed of a power tool and a battery pack which drives the power tool and is attached to a charging device to be charged.SOLUTION: An electric power tool system 1 comprises: a handheld electric power tool 10; a battery pack 40 configured to be attached to and detached from a housing of the electric power tool; and an adapter 70 which has wireless communication function and can be attached to and detached from the housing of the electric power tool. The adapter 70 performs wireless communication of data with an external device 100 different from a charging device for the battery pack. The data includes at least a control program for the power tool and / or the battery pack.SELECTED DRAWING: Figure 1A

Description

[Technical field]

[0001] cross reference This application claims priority to U.S. Provisional Patent Application Nos. 61 / 511,092, filed July 24, 2011, 61 / 564,513, filed November 29, 2011, 61 / 581,950, filed December 30, 2011, and 61 / 593,533, filed February 1, 2012, the entire contents of which are incorporated by reference herein as if fully set forth herein.

[0002] The present invention relates generally to a power tool system including a power tool and a battery pack. [Background technology]

[0003] Electrical adapters for use with power tools are well known in the art.

[0004] For example, U.S. Patent No. 7,357,526 discloses a combination power tool and an accessory (adapter). The power tool has a number of terminals to which a battery pack or battery assembly can be connected. The accessory (adapter) can be electrically connected to the unused tool terminals that would otherwise be engageable with the battery pack.

[0005] US Patent No. 6,502,949 discloses an adapter designed to be interposed between a power tool and a battery pack, the adapter including additional devices used with the power tool, such as a light, a dust collector, or a hook.

[0006] US Pat. No. 6,577,104 discloses an adapter for connecting a power tool to a battery pack, which provides an alert feature to notify the user that the battery pack needs charging.

[0007] US Pat. No. 7,030,590 discloses an adapter having first electrical contacts for connecting with a battery pack, second electrical contacts for connecting with a battery charger, and a discharge circuit for discharging the rechargeable battery.

[0008] US Pat. No. 7,227,335 discloses an adapter interposed between a charging device and a rechargeable battery pack and having a battery diagnostic device.

[0009] Furthermore, U.S. Patent Application Publication No. 2001 / 0010455A1 discloses a battery pack for a power tool having a memory for storing usage history information about the battery, a reader for uploading the usage history information from the battery or the power tool, and a computer for uploading and analyzing the usage history information uploaded from the reader.

[0010] US 2006 / 0142894 A1 discloses an assistance device that connects to a memory located within a power tool and retrieves information stored therein regarding the model or specification and usage history of the power tool. The assistance device uses this information to determine whether the power tool is being used for a suitable task. If the assistance device determines that the power tool is not suitable for the task, it suggests a power tool that is suitable for the task.

[0011] U.S. Patent Application Publication No. 2003 / 0182916A1 discloses a power tool having a microcontroller and memory that calculates and stores the degree of wear on the power tool based on sensor inputs. When maintenance is performed, the memory is read to determine if any parts have reached a predetermined degree of wear. Summary of the Invention [Problem to be solved by the invention]

[0012] SUMMARY OF THE PRESENT TEACHINGS It is an object of the present teachings to provide an improved power tool system, and in particular to provide a power tool system that includes an adapter. [Means for solving the problem]

[0013] This object is achieved by the invention according to the independent claims. Further refinements of the invention are recited in the dependent claims.

[0014] In one aspect of the present teachings, an adapter for a battery power tool preferably includes at least one central processing unit (CPU), e.g., a controller such as one or more microprocessors, and at least one memory and / or storage device in communication with the controller, in addition to or in place of any of the circuitry or functionality described below. The adapter also preferably includes one or more communication devices configured or adapted to access memory and / or storage devices located on the power tool, the battery pack, or both. Furthermore, the adapter more preferably includes circuitry configured or adapted to read data stored in and / or write data to such memory and / or storage devices.

[0015] Additionally, the adapter is preferably configured or adapted to contribute to a communications path of a power tool system that includes the adapter (ie, battery pack-power tool-adapter).

[0016] In this manner, the adapter does not need to include wiring to conduct current between the battery pack and the power tool, thereby reducing space and manufacturing limitations. Additionally or alternatively, the adapter may be adapted or configured to be more securely attached to the power tool than conventional adapters, such that the adapter is not easily removed from the power tool during operation.

[0017] In preferred embodiments of this aspect of the present teachings, the battery pack, the power tool, and the adapter each preferably include at least one controller, such as at least one microprocessor or microcontroller, and the adapter controller preferably communicates with the battery pack controller via the power tool controller, i.e., the adapter controller preferably communicates indirectly with the battery pack controller.

[0018] In further exemplary embodiments of this aspect of the present teachings, the adapter is preferably configured or adapted to read and / or write one or more of the following types of data or information to one or more memories of the power tool and / or battery pack: a) One or more control programs and / or data for the power tool and / or battery pack. b) Control information for the power tool and / or battery pack. c) Information indicating the status of the battery pack and / or the power tool, such as the charge / discharge status of the battery pack, remaining battery capacity, measured or detected values ​​regarding current, voltage, temperature, etc., the remaining number of operations of the power tool that can be performed using the remaining battery capacity, etc. d) One or more values ​​related to operating parameters of the battery pack and / or the power tool, such as the charge rate of the battery cells, maximum current limit, maximum temperature threshold, maximum charge level, etc. e) Maintenance information, such as usage history, inspection history, and information regarding when to replace one or more worn parts, or any other maintenance information as described below.

[0019] In another aspect of the present teachings, the adapter preferably includes, in addition to or in place of any of the circuits or functions described above or below, a means for wirelessly communicating with an external device (e.g., an external device with a data input device), a controller (computing means, microprocessor, etc.), and / or a display. As will be described later, the method (protocol) of wireless communication is not particularly limited in the present teachings.

[0020] In this aspect of the present teachings, the adapter is preferably further configured or adapted to transmit maintenance information relating to the power tool and / or the battery pack to an external device, and, optionally, the adapter is also preferably configured or adapted to store and / or display such maintenance information.

[0021] The maintenance information may be one or a combination of any two or more of the following: (i) The date of the last maintenance inspection or maintenance service. (ii) The results of the last maintenance inspection or maintenance check. (iii) The cumulative or total usage (operating) hours of the power tool and / or battery pack. (iv) The available charge or state of charge of the battery pack (remaining battery capacity). (v) The number of charge cycles the battery pack has experienced. (vi) The state of one or more battery cells of the battery pack, calculated, for example, from measurements of the internal impedance of the battery cells. (vii) The expected remaining useful life of one or more replaceable parts of the power tool and / or battery pack. (viii) A maintenance schedule for the power tool and / or adapter and / or battery pack. (ix) The usage history of the power tool and / or adapter and / or battery pack. (x) The name of the person responsible for the adapter, battery pack and / or power tool. (xi) Battery pack and / or power tool serial number. (xii) The voltage of one or more (e.g., either individually or in groups of two or more) battery cells. (xiii) The discharge current of one or more (e.g., either individually or in groups of two or more) battery cells. (xiv) The temperature of one or more (e.g., either individually or in groups of two or more) battery cells. (xv) The number of times the battery pack and / or power tool are turned on and / or off. (xvi) The amount of charge or discharge within a given period (e.g., the amount of electricity discharged within the past two hours).

[0022] A power tool according to this aspect of the present teachings may be manufactured with a basic electrical functionality, after which a user may easily select one or more additional electrical functions to be added to the power tool by attaching an appropriate adapter (i.e., an adapter having the desired functionality). In particular, the detachable adapter may communicate one or more of the above-mentioned types of maintenance information related to the power tool.

[0023] That is, in accordance with this aspect of the present teachings, a power tool can be effectively equipped with one or more additional functions depending on the user. Additionally or alternatively, a power tool can be interchangeably equipped with various functions by providing multiple adapters, each adapter having at least one different function than the others.

[0024] Other representative non-limiting examples of functionality that may be implemented by an adapter according to this aspect of the present teachings include the following: - Wirelessly transmitting any of the above or below information to and / or receiving any of the above or below information from the power tool, including, for example, wirelessly communicating with external devices such as base stations, workstations, computers, personal digital assistants, smartphones, etc. Displaying information about the power tool on the display, such as any of the information set out above or below. Measuring, indicating and / or communicating the remaining battery capacity of a battery pack and the estimated number of remaining power tool operations that can be performed with the remaining battery capacity for the same type of operation. · Measuring, displaying and / or communicating one or more operating parameters (e.g., the value of the maximum current limit) that are stored in the battery pack and / or the power tool memory. Measuring, displaying and / or communicating the detected discharge current and / or recommended value of the power tool. - Providing anti-theft features or locks. -Identify or communicate who is responsible for the adapter, battery pack and / or power tool. · Entering, displaying and / or communicating information regarding changes to the charging rate of the battery pack. Measuring, indicating and / or communicating values ​​indicative of the operating status of the battery pack and / or the power tool. Any other features described in U.S. Provisional Patent Application No. 61 / 511,092, which additional features are incorporated herein by reference.

[0025] The features set forth above and below are described separately for purposes of written description, and therefore any one, or any combination of two or more, may be selected separately from the others in future amendments to the specification or claims.

[0026] In a preferred embodiment of the above-described aspects of the present teachings, the power tool system includes a plurality of hand-held power tools, with each adapter preferably attached to the housing of any one of the plurality of hand-held power tools and adapted or configured to provide one or more different or additional functions to the hand-held power tool.

[0027] In another aspect of the present teachings, in addition to or in lieu of any of the circuits or functions described above or below, a power tool system includes a power tool, the power tool preferably comprising a housing having a battery pack interface, an electrically-powered device, and a first connector. The battery pack is adapted or configured to be removably attached (e.g., directly) to the battery pack interface and to provide electrical current to the electrically-powered device. The adapter comprises a second connector configured to be physically and electrically removably attached to the first connector. The adapter is further adapted or configured to (i) receive electrical power from the battery pack via the hand-held power tool, and (ii) provide at least one additional electrical function to the hand-held power tool or perform at least one additional electrical function that the hand-held power tool cannot otherwise perform. The adapter may be any of the adapters described above or below.

[0028] Such an adapter is preferably at least partially disposed, positioned or contained within the space between the housing and the battery pack when the housing and the battery pack are attached to one another, and more preferably, 50% or more, even more preferably 70% or more, even more preferably 85% or more, and even more preferably 100% of the maximum dimension of the adapter is disposed, positioned or contained within the space between the housing and the battery pack when the housing and the battery pack are attached to one another.

[0029] According to the above-mentioned aspect, since at least a portion of the adapter is disposed, located, or housed between the housing and the battery pack, the recessed portion of the adapter is physically protected by the housing and / or the battery pack, for example, when the handheld power tool is dropped or hit by something. Thus, according to this aspect of the present teachings, a robust and durable structure is provided that protects the adapter even in harsh working environments.

[0030] In another aspect of the present teachings, the adapter may include one or more battery terminals configured or adapted to connect to one or more charging terminals of a charger, in addition to or in place of any of the circuits or functions described above or below. According to this aspect of the present teachings, the adapter can be configured to pass charging current from the charger to the battery pack while the battery pack is connected to the power tool, for example.

[0031] In a further refinement of this aspect of the present teachings, the charger is preferably portable and may include a self-contained power source, such as one or more rechargeable battery cells. A means for attaching the charger to a user or carrying the charger, such as a harness, strap, belt or backpack, may also be provided so that the user can wear the charger while performing an operation with the power tool.

[0032] The charger and adapter may be configured to continuously provide charging current to the battery pack when needed, or the charger and adapter may be configured to provide charging current to the battery pack when a user attaches the battery terminals of the adapter to the charging terminals of the charger. For example, the adapter may be provided with a belt hook having the battery terminals. The charging terminals of the charger may be provided on, in, or adjacent to a belt worn by the user. This allows the user to hang the power tool on the tool belt and automatically provide charging current to the battery pack via the adapter when needed.

[0033] The adapter, charger, or battery pack may be provided with charge control circuitry that determines whether or not to provide charging current to the rechargeable battery cells of the battery pack, and if so, determines the magnitude and voltage of the charging current.

[0034] Additionally, a method is provided for charging the battery pack while it is connected to the power tool. The charger is preferably worn or attached to the user, and can perform a charging operation (if desired) each time the user hangs the power tool on his or her tool belt. Charging power can be transferred from the charger to the battery pack via a wired connection or wirelessly.

[0035] In other words, the adapter may have at least one input terminal for receiving or conducting a charging current from a source of energy or power, which may be a charger, a DC power source (e.g., another rechargeable battery pack, etc.), etc. This embodiment allows a user to charge the battery pack through the adapter while the battery pack is attached to the power tool.

[0036] The charger is preferably a cordless charger that includes or is attached to a built-in power source such as a rechargeable battery.

[0037] In any of the above or below described aspects or embodiments of the present teachings, the term "power tool" is intended to encompass a wide range of power tools, including but not limited to power tools for working with metals, power tools for working with wood, power tools for working with stone, and power tools for gardening. Specific examples include but are not limited to power drills, power impact screwdrivers, power impact wrenches, power grinders, power circular saws, power reciprocating saws, power jigsaws, power band saws, power hammers, power cutters, power chainsaws, power planes, power nail guns (including power rivet guns), power staplers, power shears, power hedge trimmers, power lawn pruners, power mowers, power brush cutters, power blowers (leaf blowers), power flashlights, power concrete vibrators, and power vacuum cleaners.

[0038] An adapter in accordance with the present teachings may be usable with more than one of these power tools, thereby allowing the adapter to be used broadly across the power tool product line.

[0039] As another preferred embodiment of this aspect of the present teachings, an adapter according to any of the above-described embodiments or aspects may be provided without the power tool and / or battery pack.

[0040] In each of the above embodiments, the power tool and / or battery pack are preferably configured to be usable with or without an adapter attached.

[0041] In another aspect of the present teachings, the adapter is preferably powered by a battery pack, although the adapter may also be provided with a built-in power source (e.g., a rechargeable battery) that powers the adapter's electronic circuitry, and optionally the adapter may obtain auxiliary power and / or battery charging current from the battery pack as needed.

[0042] Further objects, advantages, features, embodiments and details of the present invention will be readily apparent to those skilled in the art from the following detailed description and claims, taken in conjunction with the accompanying drawings. [Brief description of the drawings]

[0043] [Figure 1A] FIG. 1A shows a schematic diagram of a power tool system according to a first exemplary embodiment of the present teachings, in which an adapter connects directly only to a power tool.

[0044] [Figure 1B] FIG. 1B illustrates in block diagram form a power tool system according to a first exemplary embodiment of the present teachings.

[0045] [Figure 1C] FIG. 1C illustrates a cutaway view of a power tool system according to a first exemplary embodiment of the present teachings.

[0046] [Figure 2A] FIG. 2A shows a schematic diagram of a power tool system according to a second exemplary embodiment of the present teachings, in which the adapter connects directly only to the battery pack.

[0047] [Figure 2B] FIG. 2B illustrates in block diagram form a power tool system in accordance with a second exemplary embodiment of the present teachings.

[0048] [Figure 2C] FIG. 2C illustrates a disconnection of the power tool system in accordance with a second exemplary embodiment of the present teachings.

[0049] [Figure 3A] FIG. 3A shows a schematic diagram of a power tool system according to a third exemplary embodiment of the present teachings, in which an adapter is connected between a battery pack and a power tool.

[0050] [Figure 3B] FIG. 3B illustrates in block diagram form a power tool system according to a third exemplary embodiment of the present teachings.

[0051] [Figure 3C] FIG. 3C illustrates a cutaway view of a power tool system according to a third exemplary embodiment of the present teachings.

[0052] [Figure 4A] FIG. 4A shows a schematic diagram of a power tool system according to a fourth exemplary embodiment of the present teachings, in which an adapter connects to a power tool and has a display.

[0053] [Figure 4B] FIG. 4B illustrates in block diagram form a power tool system in accordance with a fourth exemplary embodiment of the present teachings.

[0054] [Figure 4C] FIG. 4C illustrates a cutaway view of a power tool system according to a fourth exemplary embodiment of the present teachings.

[0055] [Figure 5A] FIG. 5A shows a schematic diagram of a power tool system in accordance with a fifth exemplary embodiment of the present teachings, in which an adapter connects a battery pack and a charger.

[0056] [Figure 5B] FIG. 5B illustrates in block diagram form a power tool system according to a fifth exemplary embodiment of the present teachings.

[0057] [Figure 5C] FIG. 5C illustrates a cutaway view of a power tool system according to a fifth exemplary embodiment of the present teachings.

[0058] [Figure 6A] FIG. 6A shows a schematic diagram of a power tool system according to a sixth exemplary embodiment of the present teachings, in which an adapter connects between the power tool and a charger.

[0059] [Figure 6B] FIG. 6B illustrates in block diagram form a power tool system according to a sixth exemplary embodiment of the present teachings.

[0060] [Figure 6C] FIG. 6C illustrates a cutaway view of a power tool system according to a sixth exemplary embodiment of the present teachings.

[0061] [Figure 7] FIG. 7 shows an external view of a power tool system according to a seventh exemplary embodiment of the present teachings, which is an improved example of the first exemplary embodiment of the present teachings.

[0062] [Figure 8] FIG. 8 illustrates a rear view of a battery pack interface and adapter provided for a power tool system in accordance with a seventh exemplary embodiment of the present teachings.

[0063] [Figure 9]FIG. 9 illustrates a bottom view of a battery pack interface defined or provided on a power tool housing of a seventh exemplary embodiment of the present teachings with no battery pack installed.

[0064] [Figure 10] FIG. 10 illustrates an adapter of the seventh exemplary embodiment of the present teachings removed from a power tool housing.

[0065] [Figure 11] FIG. 11 illustrates a representative example of a wireless communication adapter that can be utilized in the seventh exemplary embodiment of the present teachings.

[0066] [Figure 12] FIG. 12 illustrates a battery pack interface of a seventh exemplary embodiment of the present teachings without the adapter attached.

[0067] [Figure 13] FIG. 13 illustrates a vertical cross-sectional view of a seventh exemplary embodiment of a power tool system of the present teachings, including a power tool housing, an adapter, and a battery pack.

[0068] [Figure 14] FIG. 14 shows a rear partial cutaway view of the power tool system of FIG.

[0069] [Figure 15] FIG. 15 illustrates a rear cross-sectional view of the power tool and adapter of FIGS. 13 and 14 without the battery pack installed.

[0070] [Figure 16] FIG. 16 shows a cutaway view of the battery pack interface with the adapter and battery pack attached.

[0071] [Figure 17] FIG. 17 shows the underside of the power tool's electric unit removed from the power tool.

[0072] [Figure 18] FIG. 18 shows an external view of a power tool system according to an eighth exemplary embodiment of the present teachings, which is an improved example of the fourth exemplary embodiment of the present teachings.

[0073] [Figure 19] FIG. 19 illustrates a top perspective view of an adapter of an eighth exemplary embodiment of the present teachings with the power tool removed.

[0074] [Figure 20] FIG. 20 illustrates a bottom perspective view of an adapter of an eighth exemplary embodiment of the present teachings attached to a battery pack interface of a power tool with no battery pack attached.

[0075] [Figure 21] FIG. 21 shows an external view of a power tool system according to a ninth exemplary embodiment of the present teachings.

[0076] [Figure 22] FIG. 22 illustrates a top perspective view of an adapter of a ninth exemplary embodiment of the present teachings removed from a power tool.

[0077] [Figure 23] FIG. 23 shows an external view of a power tool system according to a tenth exemplary embodiment of the present teachings.

[0078] [Figure 24] FIG. 24A illustrates a top perspective view of an adapter of a tenth exemplary embodiment of the present teachings removed from a power tool.

[0079] FIG. 24B illustrates a bottom perspective view of the adapter of the tenth exemplary embodiment of the present teachings removed from the power tool.

[0080] [Diagram 25]FIG. 25 illustrates a bottom perspective view of an adapter of a tenth exemplary embodiment of the present teachings attached to a battery pack interface of a power tool with no battery pack attached.

[0081] [Figure 26] FIG. 26 illustrates a side perspective view of a strap attached to a cylindrical portion of an adapter according to any of the seventh exemplary embodiment through the tenth exemplary embodiment.

[0082] [Figure 27] FIG. 27 shows a side partial cutaway view of a strap attached to the cylindrical portion of the adapter of FIG.

[0083] [Figure 28] FIG. 28 shows a representative circuit diagram of a battery pack, a power tool, and a wireless communication adapter according to a seventh exemplary embodiment of the present teachings, which is a further development of the circuits and functions shown in FIGS. 1A-1C.

[0084] [Figure 29] FIG. 29 shows a representative circuit diagram of a battery pack, power tool, and display adapter according to an eighth exemplary embodiment of the present teachings, which is an improvement over the circuits and functions shown in FIGS. 4A-4C.

[0085] [Diagram 30] FIG. 30 shows a representative circuit diagram of a battery pack, a power tool, and a lighting adapter according to a ninth exemplary embodiment of the present teachings.

[0086] [Diagram 31] 5A-5C depict an exemplary portable charging system using the embodiment of FIGS.

[0087] [Diagram 32] 32A-32C show front, side and rear views of a power tool system including the adapter of FIGS. 6A-6C. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0088] Before describing the presently preferred embodiments in more detail, a further summary of additional features, functions, aspects, advantages, etc. of the present teachings will be provided. As noted above, each of these features, functions, aspects, advantages, etc. can be utilized in any combination with any other features, functions, aspects, advantages, etc. of the other embodiments disclosed herein.

[0089] In some aspects of the present teachings, the adapter is configured or adapted to perform a communication function, such as to enable the battery pack and / or the power tool to communicate, e.g., wirelessly, with one or more external devices.

[0090] In these aspects, methods are also provided for transmitting information to or wirelessly receiving information from the battery pack and / or the power tool, which may allow a wide variety of functions (e.g., any of the functions described above or below) to be performed on the battery pack and / or the power tool from a remote location and / or may allow information regarding the battery pack and / or the power tool to be displayed on an external device, e.g., a portable device such as a smartphone, PDA, tablet computer, laptop computer, or dedicated display device.

[0091] An "external device" according to the present teachings is not particularly limited, so long as it comprises a means for communicating, e.g. wirelessly, with the adapter. The external device may generally comprise circuitry adapted or configured to analyze and / or display information transmitted from the adapter to the external device, and / or transmit information from the external device to the adapter for use by the battery pack or the power tool. The external device may essentially be "dumb" in that it comprises only a communication means and a display, whereby the external device simply displays information calculated or generated by the adapter. Or, the external device may be "smart" in that it comprises a communication means and at least one controller, e.g. one or more microprocessors and one or more memories and / or storage devices, whereby the external device can process and / or analyze data received from the adapter and generate data and / or instructions transmitted via the adapter to the battery pack and / or the power tool. The external device may be capable of directly communicating information to the user, e.g. via a display, or may further communicate information to another external device that serves as a (separate) interface with the user.

[0092] For example, an external device may be a handheld or portable device, such as a mobile phone (e.g., a "smartphone"), a personal digital assistant (PDA), a tablet computer, a portable (laptop) computer, or a dedicated portable electronic device, or it may be a device intended to be fixed in a fixed location, such as a personal (desktop) computer, a server, or a mainframe.

[0093] Alternatively, the external device may be a "dumb" device, such as a dedicated display / input device or a phone, that is not itself capable of running programs to operate the adapter, battery pack, or power tool. For example, the adapter may be configured to send text (SMS) or email messages to a phone, or the adapter may be configured to send information to be displayed on a dedicated display / input device and receive information / commands entered at the dedicated display / input device.

[0094] In either case, the external device and / or adapter may preferably further comprise wireless communication means, such as a Wireless Local Area Network (WLAN) device, e.g., a WiFi network interface controller or access point (i.e., operating in accordance with the wireless communication protocols specified by IEEE 802.11), a Bluetooth® communication device, a cordless telephone or cellular (mobile) network device, a radio frequency (RF) communication device, or any type of known or future developed wireless communication technology.

[0095] In another aspect of the present teachings, the power tool and / or the battery pack may include one or more of these wireless communication means, thereby eliminating the need for an adapter, where the external device communicates directly with the battery pack and / or the power tool.

[0096] According to one embodiment of this aspect of the present teachings, the adapter allows a user to access the memory of one or both of the power tool and the battery pack and to modify and / or update the control programs and / or data stored in the memory of the power tool and / or the battery pack.

[0097] In an exemplary embodiment of the present teachings, the adapter may be adapted or configured to allow a user to change the maximum current limit stored in the power tool memory and / or the battery pack memory. Typically, cordless power tools are designed to operate safely and reliably up to a certain (rated) current threshold. If the actual current exceeds the current threshold, the electric motor, gear transmission and / or battery may be permanently damaged, thereby shortening the useful life of the power tool and / or battery pack.

[0098] Accordingly, some known power tools and / or battery packs include a controller or current limiting device that controls the discharge current of the battery pack (i.e., the power source) to the electric motor of the power tool. The controller or current limiting device performs the discharge current control based on a control program and data stored in a memory of the power tool and / or battery pack. For example, the control program / data may include a current limit value (Ilimit) for the discharge current, and the controller may simply cut off the flow of current to the electric motor when the discharge current reaches the limit value.

[0099] Setting the current limit at a relatively low value can ensure that excessive (damaging) current does not flow to the internal components, maximizing the useful life of the power tool and battery pack. However, if the current limit is set at a relatively low value, the operation of the power tool may be interrupted by reaching the current limit frequently, especially when heavy tasks are being performed. As a result, some power tool tasks may not be able to be performed in a short time, which may significantly reduce the user's productivity.

[0100] On the other hand, setting the current limit to a relatively high value may result in the power tool's operation being interrupted less frequently, thereby increasing the user's productivity, but may also shorten the useful life of the power tool and / or battery pack due to the potentially relatively high currents that may flow through various internal components.

[0101] In short, there is generally an inverse relationship between maximum current limit and convenience of operation (i.e., operation of the power tool without interruptions or tool stalls due to reaching or exceeding the maximum current limit.) However, users do not want to simply operate their power tools with an unalterable current limit that was set at the factory when the tool or battery pack was manufactured, and they would like the freedom to change the maximum current limit.

[0102] As such, in this exemplary embodiment, the system is adapted or configured to allow a user to change the current limit and / or other parameters via the adapter. The instructions may be entered directly at the adapter or may be communicated from an external device via the adapter. For example, the user (or another person) may set a relatively high current limit to avoid excessive interruptions or tool stalls. Alternatively, the user may choose to set a relatively low current limit to extend the useful life of the power tool and battery pack. Of course, the present teachings also contemplate users setting different current limits for different power tool tasks to be performed.

[0103] As one representative example, a user may want to temporarily increase the current threshold when performing a heavy duty power tool task for a short period of time to efficiently perform the heavy duty power tool task, while once the task is completed, the user may want to reduce the current threshold again to protect the power tool system from excessive current that may cause permanent damage.

[0104] In some aspects of the present teachings, the adapter is configured or adapted to allow a user to access a memory of the power tool and / or battery pack to read maintenance information stored in the memory of the power tool and / or battery pack.

[0105] For example, many power tools have parts that are replaced when worn or broken, such as carbon brushes in an electric motor and trigger switches with electrical contacts. In order to avoid sudden and unpredictable failures (breakdowns) of the power tool, which may occur at inopportune times, it is important to periodically inspect the condition of these parts. However, it can be tedious to have to disassemble the power tool to inspect their condition.

[0106] Furthermore, each replaceable part often has a different useful life, which may vary significantly depending on the actual operating time of the power tool and / or the manner in which the power tool is typically used and / or any significant overload conditions experienced by the power tool or battery pack. Thus, even if the condition of the replaceable parts is visually inspected periodically (e.g., once a month), it is often difficult to obtain reliable current information regarding the condition of the various replaceable parts between inspections.

[0107] In view of the above, another aspect of the present teachings provides a power tool system having a memory that can store maintenance information, including, but not limited to, one or more of the following: (i) the date of the last maintenance inspection, (ii) the result of the last maintenance inspection, (iii) the accumulated or total usage (operating) hours of the power tool and / or the battery pack, (iv) the available charge or state of charge (remaining battery capacity) of the battery pack, (v) the number of charging cycles experienced by the battery pack, (vi) the condition of one or more battery cells of the battery pack, calculated, for example, from measurements of the internal impedance of the battery cells, (vii) the predicted remaining useful life of one or more replaceable parts of the power tool and / or the battery pack, (viii) a maintenance schedule for the power tool and / or the adapter ... (ix) usage history of the power tool and / or adapter and / or battery pack, (x) name of a person responsible for the adapter, battery pack and / or power tool, (xi) serial number of the battery pack and / or power tool, (xii) voltage of one or more battery cells (e.g., either individually or in a set of two or more), (xiii) discharge current of one or more battery cells (e.g., either individually or in a set of two or more), (xiv) temperature of one or more battery cells (e.g., either individually or in a set of two or more), (xv) number of times the battery pack and / or power tool has been turned on and / or off, (xvi) amount of charge or discharge within a given period of time (e.g., amount of power discharged within the past two hours). The memory may store only one or any combination of the above, all possible combinations of which are expressly disclosed herein by reference.

[0108] This memory may be located in the power tool and / or battery pack, and / or in the memory of an adapter that provides the communications functionality. The adapter may be configured or adapted to analyze and / or display this information itself, and / or may be configured or adapted to communicate the maintenance information (e.g., raw and / or processed data) to an external device for communication to a user and / or for further analysis and / or processing, if necessary.

[0109] In a preferred embodiment, the user may be able to access the adapter's memory using an external device, such as a smartphone, to check the current status of the replaceable parts. In a further preferred embodiment, an application program ("app") for this function may be available for download from the website of the power tool manufacturer or other provider.

[0110] In another aspect of the present teachings, the adapter may include anti-theft features. For example, one or more of the power tool, battery pack, and battery charger may be equipped with an electronic lock. An electronic lock is a device that prevents or inhibits operation of the power tool and / or battery pack and / or charger unless a "key" such as a passcode or password (e.g., an encrypted password) is received. The adapter may include communication means for communicating the necessary key to the electronic lock to enable and / or disable use of the power tool and / or battery pack.

[0111] For example, an external device, which may be a computer or server connected to a wireless access point (e.g., a wireless router) located in a manufacturing plant or construction site, may wirelessly distribute a key near the work site. Once the adapter receives the key, it communicates the key to the power tool and / or battery pack to enable its use. The power tool and / or battery pack may be configured to operate for a certain period of time, e.g., one hour or one day, after receiving the key, and require the key to be re-entered within the certain period of time for the power tool and / or battery pack to continue operating uninterrupted. If the key is not received in a timely manner, the electronic lock may internally block operation of the power tool and / or battery pack in a non-defeatable manner unless the adapter, battery pack, or power tool again communicates with the external device. Such an embodiment contributes to theft deterrence in that it limits use of the power tool and / or battery pack to the work site where the key is distributed.

[0112] Of course, other means of communicating the key to the power tool and / or battery pack via the adapter may be used, such as a wired connection. In such an embodiment, the adapter may be directly connected to an external device to enable use of the adapter and / or to communicate the key to the adapter. In this case, the adapter may be placed in physical proximity to the external device, or at least an interface of the external device, to obtain the required key.

[0113] In another aspect of the present teachings, the adapter may be provided with the following functionality to allow a construction company and / or manufacturing company to adequately manage a large number of power tools and battery packs that may be used by multiple users, either in common or interchangeably. In particular, an adapter according to this aspect of the present teachings may address the problem of some power tools and battery packs becoming lost or failing prematurely.

[0114] According to this aspect of the present teachings, an administrator can be assigned to each power tool and battery pack, and the maintenance information for each power tool and battery pack preferably includes information identifying the name of the administrator, so that if a power tool or battery pack malfunctions, a tool manager within the company can use an external device, such as a smart phone, to determine who the administrator of the battery pack and / or power tool is to ascertain the cause of the problem.

[0115] In another aspect of the present teachings, the adapter may provide advice or suggestions to a user, administrator, or tool manager, for example, regarding the most appropriate power tool for a particular power tool task.

[0116] For example, the adapter may include circuitry that monitors the discharge current provided to the electric motor of the power tool during operation of the power tool, and the detected discharge current may then be provided to a controller of the adapter for analysis, or the detected discharge current may be communicated to an external device that processes it, either directly by the battery pack or the power tool, or via an adapter connected to one or both of the battery pack and the power tool, and the adapter controller or external device may then determine whether another power tool and / or battery pack having a relatively higher or lower power rating would be better suited for the power tool task being performed.

[0117] The term "detected discharge current" as used herein is intended to include, but is not limited to, the actual transient current measured at any point during a single operation of the power tool, the peak current measured during a single operation of the power tool, the average current delivered during a single operation of the power tool, the profile of the current measured over a single operation of the power tool, the average of the peak currents measured over multiple operations of the power tool, or a peak, average or mean current measured over multiple operations of the power tool.

[0118] In an exemplary embodiment, the "detected discharge current" may be compared to an upper and / or lower current threshold stored in memory in the adapter, the power tool and / or the battery pack. If the detected discharge current is greater than the upper current threshold, the controller may suggest the use of a power tool with a higher rated or nominal power output to ensure that the currently used power tool is not overloaded (which may lead to overheating and therefore permanent damage to the power tool or battery pack). On the other hand, if the detected discharge current is less than the lower current threshold, the controller may suggest the use of a power tool with a lower rated or nominal power output, which may be a lighter tool and therefore less cumbersome and / or tiring to operate.

[0119] In another exemplary embodiment, the detected discharge current may be used as an index into a look-up table (LUT) that contains a combination of multiple power tools and their current ranges. By searching the LUT for a power tool that corresponds to the detected discharge current, the controller may suggest a particular power tool or category of power tools based on their rated power output to be used to perform the current power tool task.

[0120] In other exemplary embodiments, based on the detected discharge current, a temporary (e.g., peak) power or an average power can be determined and used as an index into a look-up table (LUT) containing combinations of multiple power tools and their current ranges.

[0121] Of course, determining the optimal power tool for the current power tool task can be done in a variety of ways, for example, by using an algorithm that calculates the power output required to perform the power tool task based on the detected discharge current and / or power.

[0122] As described below, the optimum power tool recommendation for a particular power tool operation may be communicated to a user, tool administrator, tool manager, or other person via the adapter's display or via the external device's display. Of course, this information may also be communicated audibly, including, for example, sounding an audio alarm if the recommended power tool current or power exceeds the nominal current or power, for example, by a certain percentage.

[0123] In another aspect of the present teachings, the adapter may be configured or adapted so that a user, tool administrator, tool manager, or other person may change the charge rate, charge current, and / or maximum threshold temperature for the battery pack.

[0124] As is well known, the slower the charging speed, the lower the current used and therefore the less damage to the battery cells. Thus, the slower the charging speed, the longer the useful life of the battery cells can be. However, the trade-off is that the longer the charging time, the more likely the user is to wait for the battery pack to be fully charged, which may affect work productivity. On the other hand, the charging speed can be increased, for example by increasing the charging current and / or increasing the battery pack threshold temperature, which may shorten the total charging time, but may also shorten the life of the battery cells.

[0125] Typically, the charging speed is set at the factory and users cannot individually determine the optimal charging speed for the intended use of the battery pack, or the charger only provides two charging operations, i.e., fast charging and slow charging. Therefore, by providing the charging speed function in the adapter, users can freely change the charging speed as needed to maximize productivity and / or maximize battery life.

[0126] The adapter may be configured to vary the charging rate by receiving instructions directly, for example, via a touchpad, touch panel, toggle switch, or push button. Alternatively, the adapter may be configured to receive charging instructions from an external device. Again, an "app" may be downloaded from the tool manufacturer or other provider to provide this functionality to the adapter and / or external device. For example, when the app is downloaded to the external device, the external device executes the app and simply sends instructions to the adapter. Alternatively, the app may be downloaded from the external device to the adapter, in which case the adapter controller may execute the app.

[0127] In another aspect of the present teachings, the adapter, battery pack, and / or power tool may allow a user to set a maximum charge level for the battery pack. As with the previous aspects of the present teachings, the maximum charge level is typically set at the factory, but a user may wish to change this value to optimize the performance and / or useful life of the battery pack for the use for which the user intends the battery pack.

[0128] As used herein, the term "maximum charge level" is intended to mean a value that indicates when a charging operation should be stopped based on the remaining battery capacity of the battery cells.

[0129] For example, a battery pack with a nominal capacity of 2.0 ampere-hours (Ah) may have a "maximum charge level" of 95%, which means that when a 2.0 Ah nominal capacity battery is charged to 1.9 Ah of remaining battery capacity, the battery may be further charged, but the charging operation will end. Similarly, a "maximum charge level" of 80% means that when a 2.0 Ah nominal capacity battery is charged to 1.6 Ah of remaining battery capacity, the charging operation will end.

[0130] Terminating charging at a relatively low charge level may increase the useful life of the battery (e.g., increase or maximize the total number of charge / discharge cycles the battery may be capable of), however, if the battery is not charged to its full capacity, the number or amount of power tool operations that can be performed per charge cycle may also be reduced, and may be significantly reduced if the maximum charge level is set to a relatively low value.

[0131] A user who typically uses a battery pack for relatively short periods of time may wish to extend the useful life of the battery by utilizing a relatively low maximum charge level, whereas a user who uses a battery pack continuously, sometimes throughout a working day, may wish to increase productivity by increasing the amount of work that can be performed between replacing a depleted battery pack with a charged one. In this case, the user may wish to set the maximum charge level relatively high.

[0132] In accordance with the present teachings, a user can change the maximum charge level by entering a new value via an input device on the adapter (e.g., a touch screen, up / down buttons or other push buttons such as a keyboard) or by entering a new value into an external device (e.g., a computer, PDA or phone). In the latter case, the external device can transmit the new value to the battery pack and / or power tool via the adapter or directly to the battery pack and / or power tool.

[0133] In another aspect of the present teachings, the adapter can be configured or adapted to enable the power tool and battery pack to access an external device (e.g., a user's smartphone) for, for example, wirelessly transmitting information indicative of the charging / discharging status of the battery.

[0134] Such an adapter can reliably supply a fully charged battery pack to a user who needs it at the right time, thereby improving the productivity of the worker. In this regard, the storage capacity of a battery pack is not always sufficient to drive a power tool for a whole day, or at least for a time sufficient to charge the battery pack. Therefore, when the battery pack runs out of charge and is no longer able to supply energy to the power tool, the discharged battery pack needs to be replaced with a charged battery pack in order to continue working. In other words, a charged battery pack needs to be available when the battery pack currently in use is no longer able to drive the power tool and may cause a decrease in work productivity.

[0135] Thus, in this aspect of the present teachings, the adapter can be configured to provide useful information regarding the state of charge of the battery pack and enable reliable predictions regarding the estimated time that a currently used battery pack can continue to provide power before being fully discharged. For example, the adapter can analyze the type of task currently being performed by the user (e.g., screwing) while taking into account the remaining battery charge of the battery pack, and output a prediction, for example, regarding how many more screws the current battery pack can be tightened before it needs to be replaced, i.e., before its energy is depleted.

[0136] As described below, the adapter of this embodiment may include a display that directly indicates to the user the state of charge and / or a prediction of the number of remaining operations that can be performed on the power tool, or the adapter may transmit this information, for example wirelessly, to an external device for display thereon.

[0137] Alternatively, the adapter may simply transmit raw data, such as a value indicative of the current battery discharge voltage, or partially processed data, such as a value indicative of the energy output of the current power tool operation, and the external device may then perform the necessary calculations to determine the remaining battery capacity and / or estimate the number of remaining power tool operations that may occur before the battery pack requires recharging.

[0138] The adapter may also transmit information regarding the type of operation currently being performed and / or information indicative of the power consumed by each currently being performed power tool operation. For example, the adapter may dynamically measure the "detected discharge current" (as defined above) to provide a more accurate estimate of the power consumption for each currently being performed power tool operation, since various factors may affect the power consumption of a particular operation, such as threading a screw. That is, the hardness of the material into which the screw is threaded affects the power consumption, with harder materials generally requiring more power for the same size screw. Similarly, the size of the screw affects the power consumption, with larger screws generally consuming more power for the same material. Of course, the presence or absence of a pilot hole also affects the power consumption.

[0139] Therefore, by dynamically measuring the actual power consumption of the power tool operation currently being performed, it is possible to very accurately estimate the remaining number of operations of the same type that the power tool can perform with the remaining battery capacity of the battery pack.

[0140] Additionally or alternatively, the user can input information regarding the current use of the tool and the external device can perform the necessary calculations using average power usage values ​​and remaining battery capacity that it stores in association with the inputted power tool operation.

[0141] Again, an "app" can be downloaded from the tool manufacturer's website or other source to provide this functionality on the external device.

[0142] Additionally or alternatively, the adapter can transmit the raw data (measured discharge voltage) or the calculated remaining battery capacity to a server or a smartphone of the tool manager. In this case, the external device can inform the tool manager or tool manager when to deliver a charged battery pack to a user whose battery pack is running out of charge, for example by performing calculations regarding the remaining number of operations that the power tool can perform. For example, the external device can also store one or more time values ​​indicating an average or typical amount of time (which can be empirically determined) that a particular power tool operation requires, thereby providing an estimate as to the estimated amount of time (e.g., in minutes) that the user can continue to operate the power tool before the currently used battery pack runs out of energy.

[0143] Additionally or alternatively, the adapter may transmit other discharge-related information regarding the power tool and / or battery pack to the tool manager's external device (e.g., a smartphone). For example, the discharge-related information may include a temperature detected within the power tool and / or battery pack. Generally, a power tool that exceeds a certain temperature threshold may indicate that it is currently operating in an overloaded condition. If a user continues to operate the power tool and / or battery pack in an overloaded condition, the power tool and / or battery pack may be permanently damaged by overheating.

[0144] To prevent damage due to overheating (i.e., an overload condition), the adapter may be configured or adapted to send a warning or alarm signal to an external device (e.g., a smartphone) of the user or the tool manager when the power tool and / or battery pack becomes overheated, which can then be communicated to the tool manager to deliver another power tool and / or battery pack to the user, or the alarm can directly alert the user to stop using the overheated power tool system.

[0145] As mentioned above, the power tool system of this aspect of the present teachings may also be configured or adapted to allow a user, tool administrator, tool manager, etc., to change the maximum temperature threshold value via input either through an adapter or an external device.

[0146] In addition or in the alternative to the above-described embodiments and aspects, the adapter may optionally include a display, such as a liquid crystal display (LCD), a light emitting diode (LED) display, including an organic LED (OLED) display, or an organic electroluminescent (EL) display. The display may optionally be a touch pad or touch panel that allows a user to input data into the memory of the power tool and / or battery pack via the adapter.

[0147] In such an embodiment, the adapter is preferably configured or adapted to display information retrieved from the memory of the power tool and / or the battery pack. For example, the adapter's display may visually indicate any of the information or functions described above or below, such as the current charge level (remaining battery capacity) of the battery pack, an overheating warning, an estimate of the number of remaining operations of the power tool that can be performed given the remaining battery capacity of the battery pack, the name of the person in charge of the power tool and battery pack, the maximum charge level, etc.

[0148] The display of the adapter may have the same functions as the display of an external device, for example a smartphone, in the above-mentioned embodiment of the adapter with communication capabilities or in the embodiment described below.

[0149] Another exemplary embodiment according to the present teachings provides a "belt charger." In this embodiment, the charger is configured to be worn or carried by a user while the user is performing an operation on the power tool. Although the charger is currently considered to be worn on the user's belt, the charger may also be attached to a variety of other locations on the user. For example, the charger may be provided with a harness or strap with a detachable connector, such as a Velcro connector, a hook-and-loop fastener, a clasp, a snap-fit ​​connector, or the like, configured to be attached to the user's arm, leg, or torso. Alternatively, the charger may be configured or adapted to be worn on the user's back, such as in a backpack or on a harness that fits over one or both of the user's shoulders.

[0150] The output terminals of the charger (regardless of where the charger is located on the user's body) are preferably located on or adjacent to a belt worn by the user, such as a work belt or tool belt worn during normal power tool operation. The output terminals are configured to transmit or output a charging current and may optionally be located within or on a hook-engaging or hook-receiving device configured or adapted to receive a belt hook located on the side of the adapter (or on the side of the battery pack in embodiments where the adapter is omitted).

[0151] The input terminals for receiving the charging current are disposed in or on the belt hook of the adapter or battery pack in a complementary configuration to the output terminals of the charger, such that when a user hangs the power tool on his or her belt using the belt hook, the output terminals contact the input terminals.

[0152] Thus, whenever the power tool is hung on the tool belt with the input and output terminals in contact, the adapter and / or battery pack are electrically connected to the charger, thereby allowing the battery pack to be charged.

[0153] This embodiment is particularly advantageous for lithium-based rechargeable batteries, which, unlike other types of battery chemistries such as nickel cadmium and nickel metal hydride, do not experience a "memory effect" with repeated charging operations, and therefore, providing intermittent charging current to a lithium-based battery, even when it is nearly fully charged, is not particularly problematic.

[0154] This embodiment also has the advantage that the battery pack attached to the power tool can be charged whenever the power tool is not in use and is hanging on the user's tool belt. Thus, the belt charger embodiment can significantly extend the usage time of the battery pack without requiring its replacement for charging, thereby increasing the productivity of the operator. In fact, the battery pack can be continuously maintained in a fully charged or nearly fully charged state when the user frequently interrupts the operation of the power tool.

[0155] Additionally or alternatively, this embodiment has the advantage that the charging of the battery cells can be stopped at a lower charge level or state (i.e., the upper charge limit or maximum charge level can be lowered or set at a lower level) since the battery pack energy (stored charge) is unlikely to be exhausted during normal power tool operation since the battery cells are frequently charged. That is, if the battery pack is not charged during use, the user may prefer to maximize the amount of stored charge (i.e., increase the upper charge limit or maximum charge level) during the charging operation, thereby maximizing the operating time of the power tool for one charged battery pack. However, when the battery cells are repeatedly charged to their maximum rated (nominal) storage capacity, the useful life of the battery cells is adversely affected. Therefore, by placing an upper limit on the charge below the maximum rated (nominal) storage capacity of the battery cells, the useful life of the battery cells can be increased. Furthermore, frequent charging of the battery cells allows a user to avoid inconvenience by eliminating the need to replace a depleted battery pack with a charged one, even if the battery pack is never charged to its maximum rated (nominal) storage capacity.

[0156] The battery cells of the charger may be of a different battery chemistry and / or capacity than the battery cells of the power tool battery pack. In particular, the charger battery does not need to supply a relatively high current, unlike the power tool battery pack. Thus, the charger battery may use higher capacity battery cells than the power tool battery pack, thereby increasing the power storage density and / or reducing weight limitations for the charger. The charger battery is preferably capable of storing an amount of charge (energy) equivalent to at least one full charge of the power tool battery pack, more preferably at least five charges, and even more preferably at least ten charges. Ergonomic considerations such as the total weight of the belt charger and the battery chemistry (i.e., its power storage density) determine the appropriate balance of charge storage to weight. Of course, the battery chemistry and / or capacity of the battery cells of the charger may be the same as the battery chemistry and / or capacity of the battery cells of the power tool battery pack. High capacity lithium ion cells may be used in the charger and high power lithium ion cells may be used in the battery pack.

[0157] Additionally or alternatively, the adapter of this embodiment need not include a microprocessor or other computing capabilities. For example, the battery pack or power tool may include two sets of battery terminals. A first set of battery terminals is configured or adapted to engage with corresponding battery terminals of the power tool or battery pack. A second set of battery terminals is configured or adapted to engage with charging terminals of a charger. The second set of battery terminals may be provided, for example, on, within, or adjacent to a belt hook, which serves as an adapter in this embodiment. The battery terminals of the belt hook may then be directly connected to charging terminals of a charger provided on a tool belt worn by a user. Thus, charging current is transferred from the charger to the battery pack through the belt hook adapter, which directly connects to the battery pack or power tool.

[0158] Instead of charging terminals for the charger and corresponding battery terminals for the battery pack or adapter, which require a direct or wired connection to transmit (conduct) the charging current, it is also possible to wirelessly transmit power from the charger to the battery pack. In such an embodiment, the charger may include a wireless power transmitting antenna, such as an induction coil, which may be located, for example, on a user's tool belt. The adapter may include a wireless power receiving antenna, such as an induction coil, complementary to the wireless power transmitting antenna, which allows wireless transmission of power by inductive or more preferably resonant inductive coupling.

[0159] In such an embodiment, when the wireless power receiving antenna is in proximity to the wireless power transmitting antenna, power can be transferred wirelessly (e.g., as an oscillating electromagnetic field or magnetic flux) to the adapter (or to the battery pack in an embodiment in which the adapter is omitted). The power received by the adapter can then be converted to a current supplied to the battery cells of the battery pack. The adapter itself may generate an appropriate charging current, or the charging current may be generated within the battery pack, particularly if the adapter is omitted.

[0160] This embodiment has the advantage that the user does not need to directly connect or contact the charging terminals and the battery terminals when performing the charging operation. Instead, the charging operation is automatically initiated (if necessary) as long as the wireless power receiving antenna of the adapter is in close proximity to the wireless power transmitting antenna of the charger. Proximity sensing elements such as mechanical contacts, pressure sensors, radio frequency identification (RFID) devices, magnets (and magnetic sensors such as reed switches or Hall sensors), electrical resistance or capacitance sensors, etc., can be provided on or within one or both of the adapter (or battery pack) and the charger, for example adjacent to the power transmitting and receiving antennas. In this case, the charger wirelessly transmits power only when it is able to transfer charging current to the battery pack, thereby eliminating unnecessary consumption of power.

[0161] As mentioned above, even in such wireless charging embodiments, the adapter may be omitted entirely. For example, the wireless power receiving antenna may be provided on or inside the battery pack. In this case, the wireless power receiving antenna of the battery pack may be adjacent to the wireless power transmitting antenna of the charger when the battery pack (connected to a power tool) is hung on a user's tool belt, for example, so that power may be transferred directly and wirelessly from the charger to the battery pack. In such an embodiment, the wireless power receiving antenna is preferably located on the side of the battery pack that includes the belt hook, so that the charging operation always begins when the belt hook is lowered on the user's tool belt and adjacent to the wireless power transmitting antenna. Thus, the user does not need to take any special measures when orienting the battery pack on the tool belt to ensure that the charging operation is performed.

[0162] In some aspects of the present teachings, it is preferred that the adapter be at least partially disposed, located, or contained within the space between the housing and the battery pack when the housing and battery pack are attached to one another.

[0163] Because the adapter of the above-described aspect is at least partially disposed, located, or housed between the housing and the battery pack, it is physically protected by the housing and / or the battery pack, for example, when the hand-held power tool is dropped or hit by something. Thus, this aspect of the present teachings may provide a robust and durable structure that protects the adapter in harsh working environments.

[0164] In a preferred embodiment of the above-mentioned aspects of the present teachings, the battery pack is preferably adapted or configured to be removably attached to the housing, regardless of whether the adapter is attached to the housing or detached from the housing. The adapter in this embodiment is preferably adapted or configured as an optional accessory or device to the power tool, and is preferably not required for normal operation of the hand-held power tool (i.e., the power tool is operable even without any additional functionality performed or provided by the adapter). Thus, the battery pack can be attached to the housing to supply current to the hand-held power tool, even when the adapter is detached from the housing.

[0165] Moreover, such an embodiment preferably allows a user of the power tool to remove the battery pack from the housing to charge it and then reattach the (or another) charged battery pack to the housing without having to remove the adapter from the housing. This embodiment is particularly advantageous for users who use power tools for relatively long periods of time (e.g., an entire work day) because in such applications a depleted battery pack may be replaced with a charged battery pack several times throughout the day.

[0166] In another preferred embodiment of the above-mentioned aspects of the present teachings, the adapter is preferably adapted or configured to be detachable from the housing only when the battery pack is removed from the housing. The adapter of this preferred embodiment allows a user of the power tool to safely attach and detach the adapter because detaching the adapter requires removing the battery pack from the power tool, so that no power is provided to either the hand-held power tool or the adapter while the adapter is being handled.

[0167] In another preferred embodiment of the above-mentioned aspect of the present teachings, the adapter is preferably adapted or configured to be attached to or detached from the housing along a first direction and the battery pack is preferably adapted or configured to be attached to or detached from the housing along a second direction, the first direction being substantially perpendicular to the second direction. More preferably, the adapter and the battery pack are preferably adapted or configured to be slidably attached to or detached from the power tool housing.

[0168] In another preferred embodiment of the above-described aspect of the present teachings, the housing and the battery pack may define an opening therebetween (e.g., the opening is defined in an exterior surface of the hand-held powered tool and / or the battery pack) that visibly exposes at least a portion of the adapter attached to the housing.

[0169] The adapter of this preferred embodiment allows a power tool user to conveniently view the attached adapter (without removing it from the power tool or otherwise taking the inconvenience of visually inspecting the adapter) to determine what type of adapter is attached to the power tool.

[0170] In other preferred embodiments of the above-described aspects of the present teachings, the adapter is preferably adapted or configured to fit into the opening without significant clearance (e.g., minimal clearance required due to manufacturing tolerances) when the adapter and battery pack are attached to the housing. Such embodiments can prevent dust and moisture from entering the space between the housing and the battery pack, thereby protecting the first connector and the second connector from harmful external influences.

[0171] In another preferred embodiment of the above-mentioned aspects of the present teachings, the power tool system may further include a dummy adapter, preferably adapted or configured to be removably attached to the housing instead of the adapter. More preferably, the dummy adapter may be designed to fit into the opening without creating a substantial gap when the dummy adapter and the battery pack are attached to the housing. A user of the power tool may insert the dummy adapter into the first (adapter) connector of the power tool housing when not requiring use of the (functional) adapter of the above aspects and / or embodiments to prevent dust and moisture from entering the first (adapter) connector.

[0172] In another preferred embodiment of the above-mentioned aspects of the present teachings, the dummy adapter is preferably adapted or configured to cover the first connector when attached to the housing, such that the first connector is protected from dust and moisture even when the battery pack is removed from the housing.

[0173] In another preferred embodiment of the above-mentioned aspect of the present teachings, the first connector is preferably a female connector having at least one contact pin and a peripheral wall surrounding the at least one contact pin, and the second connector is preferably a male connector having at least one bore configured to receive the at least one contact pin and at least one contact plate located within the at least one bore and adapted or configured to make physical and electrical contact with the at least one contact pin.

[0174] With regard to this embodiment, a female connector is generally considered to be less expensive to manufacture than a male connector. Therefore, in order to avoid increasing the manufacturing cost of the power tool, the power tool may preferably employ a female connector (contact pins) and the adapter may preferably employ a male connector (contact terminals). Since the adapter is considered to be an optional accessory, some users may not require the adapter. According to this embodiment, the manufacturing cost of the power tool can be kept low.

[0175] In another preferred embodiment of the above-mentioned aspects of the present teachings, the adapter may be attachable to the housing via a threaded fastener (e.g., a screw or a bolt), such that the adapter can be rigidly secured to the housing such that the connection between the first connector and the second connector is stable and securely maintained.

[0176] In another preferred embodiment of the above-mentioned aspect of the present teachings, the adapter may be first positioned relative to the housing by mating the first connector and the second connector, and then positioned relative to the housing by tightening the threaded fasteners.

[0177] In another preferred embodiment of the above-described aspects of the present teachings, the adapter may have a cylindrical portion into which a threaded fastener may be inserted to tighten and secure the adapter to the power tool housing.

[0178] Further, the cylindrical portion may optionally be exposed through an exterior surface of the power tool. Additionally or alternatively, the cylindrical portion may optionally be adapted or configured to have a strap attached thereto. According to this embodiment, the cylindrical portion is reinforced and thus prevented from breaking by a threaded fastener extending through the cylindrical portion. Additionally or alternatively, a strap (e.g., a carrying strap) may be easily attached to the adapter via the cylindrical portion.

[0179] In another preferred embodiment of the above-described aspects of the present teachings, the power tool system preferably includes a plurality of adapters, each preferably attached to the housing and adapted or configured to provide the hand-held power tool with at least one other or additional electrical function (i.e., an electrical function not natively possessed by the hand-held power tool) or to perform at least one different or additional electrical function.

[0180] According to this embodiment, a variety of different electrical functions can be provided to the power tool by creating a variety of adapters. Any of the electrical functions described in or below in U.S. Provisional Patent Application No. 61 / 511,092 can be implemented in an adapter according to the present teachings, and therefore, all descriptions of the functions and circuits referred to in U.S. Provisional Patent Application No. 61 / 511,092 are incorporated herein by reference.

[0181] In another aspect of the present teachings, the adapter may include a lighting device, such as an incandescent lamp, a fluorescent lamp, and / or one or more light emitting diodes, in addition to or in place of any of the circuits or functions described above. In such an embodiment, the lighting device may be connected to the base of the adapter, preferably via a flexible yet rigid cord, so that the lighting device may be positioned and held in any position relative to the power tool housing, but preferably in the orientation in which the power tool is operating on a workpiece.

[0182] Representative, non-limiting examples of the present invention are described in detail below. This detailed description is merely intended to teach those skilled in the art further details for implementing preferred aspects of the present teachings, and is not intended to limit the scope of the present invention. Furthermore, each of the additional features and teachings disclosed above and below can be used individually or in combination with other features and teachings to provide improved adapters, battery packs connected to the adapters, power tools connected to the adapters, power tool systems, chargers, and methods of making and using the same.

[0183] Moreover, the combinations of features and steps disclosed in the following detailed description are not necessarily required in terms of practicing the invention in its broadest sense, but are merely taught to illustrate exemplary embodiments of the invention. Moreover, various features of the exemplary examples described below, as well as the various independent and dependent claims that follow, can be combined in ways not specifically and explicitly recited to further realize useful embodiments of the present teachings.

[0184] All features disclosed in the specification and / or claims are intended to be disclosed separately and independently for purposes of the original written disclosure, not only for the purpose of limiting the claimed subject matter, but also independent of the particular combination of features in the embodiment and / or claim. Furthermore, all numerical range or aggregate indications are intended to disclose all possible intermediate values ​​or intermediate entities for purposes of the original written disclosure, not only for the purpose of limiting the claimed subject matter.

[0185] It is expressly understood that the functionality described above or below (or claimed) may be implemented in any of the exemplary embodiments described below, for example, by appropriately programming the controller of the adapter, battery pack, power tool, charger, and / or external device. Alternatively, as will be readily appreciated by one of ordinary skill in the art upon reading this disclosure, some or all of the functionality described above may be implemented in any of the exemplary embodiments described below by analog circuitry, dedicated digital circuitry, e.g., state machines, or mixed dedicated circuitry. EXAMPLES

[0186] 1A-1C, a first exemplary embodiment (Example 1) of a power tool system 1 according to the present teachings will now be described in further detail. The power tool system 1 may generally include a cordless (battery-operated) power tool 10, a battery pack 40, an adapter 70, and an external device 100.

[0187] The power tool 10 according to this exemplary embodiment generally includes a controller 12, a discharge information detector 14, a memory 16, and a communication unit 18. For example, as is well known in the art, power is supplied to the power tool 10 via two battery terminals 22 by opening and closing a power FET 20 using pulse width modulation techniques to drive an electric motor M. The operation of the motor M is manually controlled by a switch 28, which may be a trigger switch, as is well known in the art. As shown in FIG. 1C, the motor M is enclosed in a housing 32 and drives a tool chuck 30 to which a suitable tool, such as a screw bit, may be connected. Optionally, a reduction gear (not shown) may be interposed between the motor M and the tool chuck 30.

[0188] The battery pack 40 according to this exemplary embodiment generally includes a controller 42, a charge / discharge information detector 44, a memory 46, a communication unit 48, and at least one battery cell 50. Power is provided to the power tool 10 via two battery terminals 52 to drive the electric motor M. As shown in Figures 1A and 1C, a cut-off switch 58 may be provided to disconnect the battery cell 50 from the battery terminals 52 when the remaining battery capacity reaches a lower limit, for example as determined by the controller 42, thereby preventing further use of the battery pack 40 until it is charged.

[0189] Adapter 70 according to this exemplary embodiment generally comprises at least one controller 72, one or more communication terminals (ports) 74, one or more power terminals 75, at least one memory 76, and at least one communication unit 78. As further described in further embodiments below, which are incorporated by reference into this embodiment, adapter 70 may optionally further comprise a display.

[0190] The external device 100 generally comprises at least one controller 102 , at least one display 104 , at least one memory 106 and at least one communication unit 108 .

[0191] Each device controller 12, 42, 72, 102 preferably includes at least one processor, such as a microprocessor or microcontroller as are well known in the art, configured to operate according to instructions or program code and data stored in memory 16, 46, 76, 106, respectively.

[0192] The memory 16, 46, 76, 106 of each device preferably comprises mechanically addressable memory, such as one or more of non-volatile read-only memory (ROM) and / or re-writable memory, such as EEPROM and flash memory, or a hard drive (e.g., specifically for external device 100). The memory 16, 46, 76, 106 may also comprise volatile memory, such as RAM, DRAM, and SRAM. The type and / or configuration of the memory 16, 46, 76, 106 of any of the devices is not particularly limited by the present teachings.

[0193] Each communication portion 18, 48, 78, 108 of the devices may comprise at least one or both of: (i) one or more wired input / output (I / O) ports (i.e., one or more connection terminals); and (ii) a wireless communication device, such as a wireless local area network (WLAN) device, such as WiFi (i.e., operating according to the wireless communication protocols enumerated by IEEE 802.11), a Bluetooth device, a cordless telephone or cellular (mobile) network device, a radio frequency (RF) communication device, or any other type of known or future developed wireless communication technology. Again, the configuration of any communication portion 18, 48, 78, 108 of the devices is not particularly limited by the present teachings.

[0194] Power is supplied to the adapter 70 via the power terminals 25 and 75 .

[0195] The display (80, see FIG. 4A) of adapter 70 and / or display 104 of external device 100 may also comprise any device capable of visually conveying information to a user, such as, but not limited to, a liquid crystal display (LCD), a light emitting diode (LED) display, including an organic LED (OLED) display, or an organic electroluminescent (EL) display. Plasma or CRT are also possibilities for display 104.

[0196] The discharge information detector 14 of the power tool 10 and the charge / discharge information detector 44 of the battery pack 40 may comprise any type of analog, digital or hybrid circuitry configured to detect current values, voltage values, battery cell temperature and / or resistance (impedance) values, as is well known in the art.

[0197] For example, in one exemplary embodiment, the charge / discharge information detector 44 of the battery pack 40 may include a comparator configured to compare a measured voltage value V (which may be a voltage across the battery cell 50 or a voltage value indicative of a current I passing through the battery cell 50) with a reference voltage value. The comparator may output a signal to the controller 42 when the voltage across the battery cell 50 drops below a predetermined threshold (as represented by the reference value), thereby providing information regarding the remaining battery capacity of the battery cell 50. Additionally or alternatively, the comparator may output another signal when the current passing through the battery cell 50 exceeds a predetermined current limit (threshold), thereby indicating that the power tool system 1 is in an overloaded state. Additionally or alternatively, the comparator may output another signal when, for example, a temperature (Temp.) measured by a temperature sensor in the battery pack 10 or the power tool 10 exceeds a predetermined temperature limit (threshold), thereby indicating that the battery pack 40 or the power tool system 1 is in an overloaded state.

[0198] Additionally or alternatively, the discharge information detector 14 of the power tool 10 may comprise a comparator configured to compare a measured voltage value V with a reference voltage value, such as a voltage value indicative of a current I passing through the electric motor M. The comparator may output a signal to the controller 12 if the current passing through the motor M exceeds a predetermined current limit (threshold), thereby indicating that the tool system 1 is in an overloaded condition. Additionally or alternatively, the comparator may output another signal if the temperature (Temp.), e.g. as determined by a temperature sensor, exceeds a predetermined temperature limit (threshold), thereby also indicating that the tool 10 or the power tool system 1, as the case may be, is in an overloaded condition.

[0199] Each of these thresholds may be stored in memory 46 of battery pack 40, memory 16 of power tool 10 and / or memory 76 of adapter 70. As mentioned above, one aspect of the present teachings allows a user to change various thresholds or operating parameters to optimize performance of battery pack 40 and power tool 10 by communicating new thresholds via adapter 70. Alternatively, new values ​​may be entered directly into adapter 70 when adapter 70 includes input devices such as a touch pad, push buttons, keyboard, toggle switches, etc.

[0200] Thus, in one aspect of the present teachings, an operator (e.g., a user, a tool administrator, a tool manager, etc.) can change one of the thresholds or operating parameters stored in memory 16, 46 or 76 by inputting a new value into external device 100 via an input device, such as a keyboard or a display 104 configured as a touchpad. Communication unit 108 transmits the new value to communication unit 78 of adapter 70, wirelessly or via a wired connection. As described above, the new value is stored in memory 76 of adapter 70 and, optionally, accessed by battery controller 42 via power tool 10 or by tool controller 12 via communication terminals 24, 74. If desired, the new value may be communicated to battery pack 40 via communication terminals 26, 56 and, optionally, stored in memory 46.

[0201] Fig. 1B shows other functions that are optionally performed by and provided to each device or subunit within each device, and Fig. 1C shows an external view of the power tool system 1 and a cutaway view of some of the internal circuit blocks mentioned above. EXAMPLES

[0202] The second exemplary embodiment (Example 2) shares many overlapping features, functions, circuits and structures with the first exemplary embodiment. Therefore, the circuits and structures that operate similarly or substantially similarly are assigned the same reference numbers and need not be further described. For any features, functions, circuits or structures that are not explicitly described in the second exemplary embodiment and are incorporated by reference in this embodiment, please refer to the first exemplary embodiment.

[0203] The power tool system 1' of the exemplary embodiment 2 shown in Figure 2A differs from the first exemplary embodiment mainly in that the adapter 70' is configured to connect directly to the battery pack 40' instead of directly to the power tool 10'. The external device 100 communicates with the adapter 70' and operates similarly to the first exemplary embodiment.

[0204] Thus, in this exemplary embodiment, the communication path is as follows: external device 100, adapter 70', battery pack 40', power tool 10'. In particular, adapter 70' communicates information and / or data via its communication terminals 74 to communication terminals 54 located on battery pack 40', which then communicates directly with controller 42 via communication portion 48.

[0205] In all other respects, however, the adapter 70' may be configured or adapted to perform any one or any combination of the functions set forth above or below.

[0206] Figure 2B shows other functions that are optionally performed by and provided to each device or subunit within each device, and Figure 2C shows an external view of the power tool system 1' and shows in cutaway some of the internal circuit blocks mentioned above.

[0207] The first and second exemplary embodiments have the advantage that the adapter 70, 70' is not interposed between the power tool 10, 10' and the battery pack 40, 40'. This eliminates the need to conduct motor drive current from the battery pack 40, 40' through the adapter 70, 70' to the power tool 10, 10', thereby eliminating the need to provide wiring and other protection within the adapter 70, 70' that can safely conduct large currents.

[0208] However, in some embodiments, as discussed in the exemplary embodiments below, it may be advantageous to insert an adapter between the power tool and the battery pack. EXAMPLES

[0209] The third exemplary embodiment (Example 3) also shares many overlapping features, functions, circuits and structures with the first exemplary embodiment and the second exemplary embodiment. Therefore, the circuits and structures that operate similarly or substantially similarly are assigned the same reference numbers and further description thereof is unnecessary. For any features, functions, circuits or structures that are not explicitly described in the third exemplary embodiment and are incorporated by reference in this embodiment, please refer to the first exemplary embodiment or the second exemplary embodiment.

[0210] The power tool system 1'' of the third exemplary embodiment shown in FIG. 3A differs from the first and second exemplary embodiments primarily in that an adapter 70'' is configured to directly connect to both the battery pack 40 and the power tool 10'. The external device 100 communicates with the adapter 70'' and operates similarly to the first and second exemplary embodiments.

[0211] Thus, in this exemplary embodiment, the external device 100 communicates with the adapter 70'', which in turn can communicate with one or both of the battery pack 40 and the power tool 10'. In particular, the adapter 70'' can communicate information and / or data, such as new program code, via its communication terminals 74 to the communication terminals 54 located on the battery pack 40 and / or via its communication terminals 74 to the communication terminals 24 located on the power tool 10'.

[0212] Additionally, the current for driving the electric motor M flows through the adapter 70'' via respective battery terminals 82 which connect with the battery terminals 52 of the battery pack 40 on one side and the battery terminals 22 of the power tool 10' on the other side.

[0213] In all other respects, however, the adapter 70'' may be configured or adapted to perform any one or any combination of the functions set forth above or below.

[0214] Fig. 3B shows other functions that are optionally performed by and provided to each device or subunit within each device. Fig. 3C shows an external view of the power tool system 1" and shows in cutaway some of the internal circuit blocks mentioned above. EXAMPLES

[0215] The fourth exemplary embodiment (Example 4) also shares many overlapping features, functions, circuits and structures with the first exemplary embodiment, the second exemplary embodiment and the third exemplary embodiment. Therefore, the circuits and structures that operate similarly or substantially similarly are assigned the same reference numbers and further description thereof is unnecessary. For any features, functions, circuits or structures that are not explicitly described in the fourth exemplary embodiment that are incorporated by reference in this embodiment, please refer to the first exemplary embodiment, the second exemplary embodiment and the third exemplary embodiment.

[0216] The fourth exemplary embodiment of the power tool system 1''' shown in FIG. 4A differs from the first exemplary embodiment mainly in that the adapter 70''' includes a display 80 but does not include a dedicated communication unit for communicating with an external device. The power tool 10 and the battery pack 40 operate similarly to the first embodiment. As will be appreciated, this embodiment can be modified to include communication means (e.g. wireless communication means) according to any of the previous embodiments.

[0217] As mentioned above, the display 80 of adapter 70''' may comprise any device capable of visually conveying information to a user, such as, by way of example and not limitation, a liquid crystal display (LCD), a light emitting diode (LED) display, including an organic LED (OLED) display, or an organic electroluminescent (EL) display. Preferably, the display 80 may be configured as a touchpad that allows a user to directly input instructions into the adapter 70'''. However, if desired, the adapter 70''' may be optionally provided with any type of input device (not shown), such as a keyboard, push button pad, toggle switches, etc., for inputting information.

[0218] The display 80 is preferably configured or adapted to display any of the information described above or below, including, but not limited to, the remaining battery capacity, the number of remaining power tool operations that can be performed due to the remaining battery capacity, the current limit threshold, the battery discharge threshold, etc.

[0219] Figure 4B shows other functions that are optionally performed by and provided to each device or subunit within each device. Figure 4C shows an external view of the power tool system 1''', with a cutaway view of some of the internal circuit blocks mentioned above. EXAMPLES

[0220] The fifth exemplary embodiment (Example 5) also shares many overlapping features, functions, circuits and structures with the first exemplary embodiment, the second exemplary embodiment, the third exemplary embodiment and the fourth exemplary embodiment. Therefore, the circuits and structures that operate similarly or substantially similarly are assigned the same reference numbers and further description thereof is unnecessary. For any features, functions, circuits or structures not explicitly described in the fifth exemplary embodiment that are incorporated by reference in this embodiment, please refer to the first exemplary embodiment, the second exemplary embodiment, the third exemplary embodiment and the fourth exemplary embodiment.

[0221] The fifth exemplary embodiment of the power tool system 1'''' shown in FIG. 5A mainly differs from the second exemplary embodiment in that the adapter 70'''' comprises a charging circuit and a charger 120 is also provided. The power tool 10' and the battery pack 40' generally operate similarly to the second embodiment, except that the battery pack 40' can receive a charging current from the charger 120 via the adapter 70''''. This exemplary embodiment can also be modified to comprise (wireless) communication means and / or a display according to any of the previous embodiments.

[0222] As discussed above with respect to the various charging embodiments, the adapter 70'''' according to this exemplary embodiment may generally include at least one controller 72, at least one memory 76, and at least one communication unit 78. The controller 72 is configured or adapted to execute at least a charging program or protocol stored in the memory 76 or stored in the memory 46 and communicated to the controller 72 via the communication terminals 54, 74. The charging program is not particularly limited in the present teachings and any charging program suitable for charging the battery cells 50 located in the battery pack 40' may be utilized. Additionally, the controller 72 may be configured to perform any of the functions described above or other functions described below.

[0223] The charger 120 according to this exemplary embodiment includes at least one controller 122, at least one memory 126, at least one communication unit 128, and a power source 130. The controller 122 can execute a charging program stored in the memory 126. For example, the charging program is communicated to the memory 126 via the communication terminals 86, 124 and the communication unit 128, or is stored in the memory 126, or is programmed after manufacture by an external device.

[0224] Each of the battery pack 40', adapter 70'''' and charger 120 includes a shut-off switch 58, 88, 138 (see also FIG. 5C) controlled by the respective controller 42, 72, 122. The shut-off switch 58 is closed when initiating power tool operation with the power tool 10' and is opened to protect the internal circuitry when an overload or other adverse condition is detected. The shut-off switches 88, 138 are closed when initiating a charging operation and are opened to protect the internal circuitry when an overload or other adverse condition is detected or when the charging operation is completed. The adapter 70'''' may include a diode 90 to protect against reverse current that could damage the internal circuitry.

[0225] Power source 130 may be an AC power source, such as alternating current provided by a utility AC power source or a generator, or an external DC power source such as a vehicle battery system. However, in a preferred embodiment, power source 130 is a DC power source 140 that is contained within charger 120 or attached to charger 120, such as directly or via a flexible power cord 142 as shown in FIG. 31. Power source 130 preferably comprises one or more rechargeable battery cells, such as lithium-based battery cells, which, as discussed above, preferably have a relatively high charge storage capacity, e.g., higher than battery cells 50.

[0226] The power tool system 1'''' according to this embodiment can be operated according to the "belt charging" embodiment described above. With further reference to FIG. 31, the charger 120 includes a DC power source 140 that can be carried by the user while working. A belt 144, or alternatively a harness, strap, backpack, or other means for attaching the charger 120 to the user can be utilized. This allows the user to easily and comfortably wear or carry the charger 120 on their body, e.g., on a limb, torso, or back. The charging terminal 132 (not shown in FIG. 31) is preferably provided in or on the belt hook receptacle 146 of the belt 140, which will be described further below.

[0227] 5A, the adapter 70'''' preferably includes a portion that connects directly to the battery pack 40' via the charging terminals 84. The charging terminal receptacle 85 is configured to connect directly to the charging terminals 132 of the charger 120 and is preferably disposed within or on the belt hook, which will be described in a sixth exemplary embodiment below. The belt hook and the belt hook receptacle 146 are preferably configured with complementary shapes so that they can interlock, interfere or fit together when a user engages the belt hook of the adapter 70'''' (or the battery pack 40') with the belt hook receptacle 146 and hangs the power tool 10' from his or her belt 144.

[0228] When the terminals 85, 132 make contact, thereby enabling the passage of charging current from the charger 120 through the adapter 70'''', one or more of the controllers 42, 72, 122 can sense or detect the connection and begin providing charging current. For example, when a user removes the power tool 10' from his or her tool belt 144 and the terminals 85, 132 become separated from one another, one or more of the controllers 42, 72, 122 can sense or detect the disconnection and terminate the supply of charging current, thereby conserving power.

[0229] Additionally, the charge detector 44 can continuously or intermittently sense the state of charge of the battery cells 50 during the charging operation. Upon determining that the battery cells 50 are fully charged, the controller 42 of the battery pack 40' can send a signal to the adapter 70'''' and / or the charger 120 to stop providing charging current, thereby avoiding power waste.

[0230] As discussed above, the adapter 70'''' in this embodiment need not include the charger controller 72, memory 76, or communications unit 78. Instead, the adapter 70'''' may simply be configured as a belt hook, which may include a charging terminal receptacle 85 that is physically connected to the battery pack 40' and configured to connect directly to the charging terminals 132. Thus, the belt hook may simply serve to conduct charging current from the charger 120 to the battery pack 40' and may not perform any other function.

[0231] Furthermore, as mentioned above, the charging current (power) does not have to be transmitted from the charger 120 to the adapter 70'''' by a wired or direct connection. Instead, the charging terminal 132 of the charger 120 can be replaced with a wireless power transmitting antenna, such as an induction coil, and the charging terminal receptacle 85 of the adapter 70'''' (or belt hook) can be replaced with a wireless power receiving antenna, such as an induction coil. In this case, when the wireless power receiving antenna is in close proximity to the wireless power transmitting antenna, which is detected by a proximity sensor, such as a pressure sensor, a magnetic sensor, an RFID device (tag and interrogator), an electrical resistance or capacitance sensor, the wireless power transmitting antenna of the charger 120 can begin to emit a fluctuating or oscillating electromagnetic field, such as a magnetic flux, so that a current flows in the wireless power receiving antenna of the adapter 70''''. This current can then be converted into an appropriate charging current to be supplied to the battery cell 50.

[0232] In this embodiment, the wireless power transmitting antenna only needs to be close to the wireless power receiving antenna to perform the charging operation, and therefore there is no need to check that the charging terminal receptacle 85 on or inside the belt hook is engaged with the charging terminal 132 on or inside the belt hook receptacle 146, which is advantageous in that it may be more convenient for the user.

[0233] This wireless embodiment may also be implemented using a complementary belt hook and belt hook receptacle 146 housing a wireless power receiving antenna and a wireless power transmitting antenna, respectively, such that when a user places the power tool 10' on his tool belt 144 by placing a belt hook located on the adapter 70'''' or battery pack 40' within or on (i.e., at least adjacent or proximate to) the belt hook receptacle 146, a proximity sensor detects the presence of the belt hook and causes the charger 120 to begin wirelessly transmitting power, for example, by applying an oscillating current to the wireless power transmitting antenna (e.g., an induction coil).

[0234] As mentioned above, the adapter 70'''' of this wireless embodiment also need not include a controller 72, memory 76, or communication unit 78. Instead, the adapter 70'''' can simply be configured as a belt hook, which is physically connected to the battery pack 40' and includes a wireless power receiving antenna (e.g., an induction coil) that absorbs or harvests the power being wirelessly transmitted by the charger 120. The belt hook or basic circuitry that provides current to the battery pack 40' can also be included. The controller 42 of the battery pack 40 can execute a charging program stored in the memory 46 to charge the battery cells 50. Thus, the belt hook only serves to provide current to the battery pack 40' and need not perform any other functions.

[0235] Further teachings regarding wireless transmission of power to charge power tool batteries are provided in U.S. Provisional Patent Application No. 61 / 511,089, the contents of which are incorporated by reference herein as if fully set forth herein.

[0236] Figure 5B shows other functions that are optionally performed by and provided to each device or subunit within each device. Figure 5C shows an external view of power tool system 1"" and shows in cutaway some of the internal circuit blocks mentioned above. EXAMPLES

[0237] The sixth exemplary embodiment (Example 6) also shares many overlapping features, functions, circuits and structures with the first exemplary embodiment, the second exemplary embodiment, the third exemplary embodiment, the fourth exemplary embodiment and the fifth exemplary embodiment. Therefore, the circuits and structures that operate similarly or substantially similarly are assigned the same reference numbers and further description thereof is unnecessary. For any features, functions, circuits or structures not explicitly described in the sixth exemplary embodiment that are incorporated by reference in this embodiment, please refer to the first exemplary embodiment, the second exemplary embodiment, the third exemplary embodiment, the fourth exemplary embodiment and the fifth exemplary embodiment.

[0238] The sixth exemplary embodiment of the power tool system 1''''' shown in FIG. 6A differs from the fifth exemplary embodiment mainly in that the adapter 70''''' is configured to connect to the power tool 10, similar to the first exemplary embodiment described above. The power tool 10 and the battery pack 40 generally operate similarly to the first exemplary embodiment, except that the battery pack 40 is capable of receiving a charging current from the charger 120 via the adapter 70'''''' and the power tool 10. Again, this exemplary embodiment can be modified to include (wireless) communication means and / or a display according to any of the previous embodiments.

[0239] Additionally, the charger 120 and adapter 70''''' can operate similarly to that described above with respect to the fifth exemplary embodiment, such that the general description of the charger 120 and adapter 70''''' need not be repeated in this embodiment. Rather, the teachings of the fifth exemplary embodiment are incorporated in their entirety into this embodiment.

[0240] 32A-32C, the charging terminal receptacle 85 of the adapter 70''''' is configured to connect directly to the charging terminals 132 of the charger 120 (located in the belt hook receptacle 146 shown in FIG. 31) and is preferably located within or on the belt hook 148. As mentioned above, the belt hook 148 and the belt hook receptacle 146 are preferably configured with complementary shapes so that when a user engages the belt hook 148 of the adapter 70'''' (or battery pack 40') with the belt hook receptacle 146 to suspend the power tool 10' from his or her belt 144, they can engage by interlocking, interference or mating with each other.

[0241] Figure 6B shows other functions that are optionally performed by and provided to each device or subunit within each device. Figure 6C shows an external view of power tool system 1''''', with cutaway views of some of the internal circuit blocks mentioned above.

[0242] Although the fifth and sixth exemplary embodiments show that the charging function is implemented by connecting the adapter to only one of the power tool or the battery pack, it is understood that the charging function can also be implemented in the adapter that connects to both the power tool and the battery pack, as in the fourth exemplary embodiment, that is, it is clearly understood that embodiments in which the adapter is interposed between the power tool and the battery pack and includes the charging function described in the fifth and sixth exemplary embodiments are included within the scope of the present teachings. EXAMPLES

[0243] 7 shows an external view of a power tool system according to a seventh exemplary embodiment of the present teachings, which is an improvement of the first exemplary embodiment described above. Thus, in the seventh exemplary embodiment, the same reference numbers are used for the same elements as in the first exemplary embodiment, and the description thereof is incorporated by reference in the seventh exemplary embodiment.

[0244] The power tool system shown in Fig. 7 includes a hand-held power tool 10 and a battery pack 40. The battery pack 40 is configured to be removably attached to a battery pack interface 34 provided on the power tool housing 32. The attached battery pack 40 supplies current to the power tool 10, such as an electric motor M housed therein, which functions as a motor-driven device. However, other motor-driven devices, such as lights and radios, can also be driven by the present teachings.

[0245] 8 shows a rear view of the battery pack interface 34 provided with an adapter 70 for the power tool system 1. The adapter 70 is located between the power tool housing 32 and the battery pack 40. The adapter 70 shown in FIG. 8 is an example of a wireless communication adapter (described in detail above) that is relatively small in size. In this embodiment, the entire adapter 70 is located between the power tool housing 32 and the battery pack 40, such that no part of the adapter 70 protrudes beyond the exterior surface or contours of the power tool housing 32 and the battery pack 40.

[0246] Furthermore, the power tool 10 and battery pack 40 are configured such that at least a portion of the adapter 70 is visibly exposed by the opening 36, thereby allowing a power tool user to visually check in a simple manner what type of adapter (i.e., what function it provides) is currently attached to the power tool 10. A specific indicia, such as a name, letter or code, e.g., "1", may be provided on the outer surface of the communications adapter 70 to indicate the type of adapter.

[0247] 9 shows a bottom view of the battery pack interface 34 defined or provided on the power tool housing 32 without the battery pack 40 attached. The adapter 70 is configured to be removably attached to the power tool housing 32. In this embodiment, both the battery pack 40 and the adapter 70 can be attached to the power tool housing 32. That is, the adapter 70 is not directly connected to the battery pack 40. Furthermore, the battery pack 40 can be attached to the power tool housing 32 (i.e., to its battery pack interface 34) such that current is provided to the power tool 10 regardless of whether the adapter 70 is present (connected) or not.

[0248] 10 shows the adapter 70 removed from the power tool housing 32. The adapter 70 in this embodiment is attached to and detached from the battery pack interface 34 from the lower or bottom side of the battery pack interface 34. Thus, in this embodiment, the adapter 70 can only be attached or detached when the battery pack 40 is removed (disconnected) from the power tool 10. With the battery pack 40 removed and no power being supplied to the power tool 10 and the adapter 70, a user can safely attach (and detach) the adapter 70 to (and from) the power tool housing 32.

[0249] Additionally, the underside of the adapter 70 is supported by the battery pack 40. Thus, the adapter 70 is prevented from being accidentally or unintentionally removed from the power tool housing 32. As shown in Figures 8 and 10, the adapter 70 may optionally be attached to the housing 32 by a threaded fastener 92, such as a screw or bolt. Alternatively, a rod-like latch device may be inserted into the hollow cylindrical portion 91 (described further below) and coupled to the power tool housing 32 by an interference fit or a connection other than a threaded connection.

[0250] 11 illustrates a representative example of a wireless communication adapter 70 in isolation. The adapter 70 includes a male connector 94 configured to connect to the power tool 10. The male connector 94 of the adapter 70 includes a plurality of holes 96 (an example of "at least one hole"), with contact terminals 97 disposed on protrusions 98 within each of the holes 96. The adapter 70 further includes a hollow cylindrical portion 91 within which a threaded fastener 92 is disposed for fastening or attaching the adapter 70 to the power tool housing 32. As will be further described below, the cylindrical portion 91 also serves as a post or bracket for attaching a strap 150.

[0251] 10 and 11, the adapter 70 may be provided with ribs 93 on either side thereof that may slide within corresponding slots 33 defined in the power tool housing 32, thereby providing structural support to the adapter 70 when attached to the power tool 10.

[0252] 12 illustrates the battery pack interface 34 without the adapter 70, with a space 35 between the power tool housing 35 and the battery pack 40 for receiving at least a portion of the adapter 70. A female connector 37 is provided inside the battery pack interface 34 and is configured to receive (engage with) a male connector 94 of the adapter 70. The female connector 37 includes contact pins 38 within a recess defined by a peripheral wall 39. When the female connector 37 receives the male connector 94 of the adapter 70, the contact pins 38 of the female connector 37 enter holes 96 of the male connector 94 and make physical and electrical contact with contact terminals 97 of the male connector 94. The peripheral wall 39 of the female connector 37 surrounds the contact pins 38 to prevent the contact pins 38 from coming into contact with a user's fingers or other objects.

[0253] 13-15 show cross-sectional and cutaway views of an exemplary power tool system including the power tool housing 32, the adapter 70, and the battery pack 40. It will be appreciated that in FIGURES 13-15, the adapter 70 is shown disposed entirely within the outer shell of the power tool system, and no portion of the adapter 70 protrudes beyond the outer contour of the power tool housing 32 and / or the outer contour of the battery pack 40. However, it will be apparent that the adapter 70 may be modified to protrude partially or substantially beyond the outer contour of the power tool housing 32 and / or the outer contour of the battery pack 40.

[0254] 16 illustrates a cutaway view of the battery pack interface 34, with some elements of the power tool 10 omitted for clarity of illustration.

[0255] 13-16, the power tool 10 includes an electronic unit 11 along with a circuit board 13. The female connector 37 may be integrally formed with the electronic unit 11, and the contact pins 38 extend from the circuit board 13. Similarly, the adapter 70 includes a circuit board 73, and the contact terminals 97 are disposed on the circuit board 73.

[0256] The cross-section shown in Figure 13 illustrates in greater detail the connection between the male connector 94 and the female connector 37. In particular, the vertically extending contact pins 38 contact the contact terminals 97. This establishes a communication path between the power tool 10 (and in particular the controller 12 disposed therein) and the adapter 70 (and in particular the controller 72 disposed therein), as described above in Figures 1A-1C and below in Figure 28.

[0257] The electronic unit 11 of the power tool 10 preferably includes a controller 12, a memory 16, a communication section 18, and the like, which perform the electronic functions of the power tool 10. One or more of these electronic circuits may preferably be provided on a circuit board 13.

[0258] 14 and 15 show a cross section of the adapter 70 as viewed from the front of the power tool housing 32. The electrical connections between the contact terminals 97 and the contact pins 38 are clearly shown.

[0259] 16 shows the electronic unit 11 of the power tool 10 positioned above the battery pack 40 and the adapter 70. The contact pins 38 are exposed. A strap 150 can optionally be attached to the adapter 70 via the cylindrical portion 91, as described below.

[0260] 17 shows the electronic unit 11 removed from the power tool 10. The female connector 37 is formed integrally with the electronic unit 11. A peripheral wall 39 surrounds the contact pins 38. EXAMPLES

[0261] 18-20 illustrate another representative embodiment of an adapter 70''' according to the present teachings, which is a variation of the fourth exemplary embodiment described above. In this eighth exemplary embodiment, the same reference numbers are used for the same elements as in the fourth exemplary embodiment, and the descriptions thereof are incorporated by reference in the eighth exemplary embodiment.

[0262] The adapter 70''' is an example of a medium size adapter and is a display adapter having a display 80. Such an adapter 70''' is partially located or disposed outside the power tool housing 32 (i.e., a portion of the adapter 70''' protrudes from the outer wall or outer contour of the power tool housing 32 and / or battery pack 40).

[0263] The display adapter 70''' may also include the male connector 94, the cylindrical portion 91, and the ribs 93 according to the previous embodiment. That is, the mounting structure may be the same as the mounting structure provided on the wireless communication adapter 70. Furthermore, in order to identify the type of adapter, the outer surface of the display adapter 70'' may be provided with a specific indication such as a name, letter, or symbol, for example, "2."

[0264] Display 80 is preferably an LCD (liquid crystal display), although the present teachings are not specifically limited thereto and other types of display technologies may be advantageously utilized with the present teachings, as claimed above or below.

[0265] The electronic functions of adapter 70''' may be performed by the circuitry shown in FIGS. 4A-4C above, or as described below with reference to FIG. EXAMPLES

[0266] 21 and 22 show another exemplary embodiment (Example 9) of the adapter 70'''''' according to the present teachings. The adapter 70'''''' is an example of a large-sized adapter, which is a lighting adapter having a light 152 supported by a flexible arm 154. The adapter 70'''''' is also partially located outside the power tool 10, similar to the previous embodiment. The lighting adapter 70'''''' may include the common mounting structure, i.e., the male connector 94, the cylindrical portion 91, and the rib 93, according to the previous embodiment. To identify the type of adapter, the outer surface of the display adapter 70'''''' may be provided with a specific indicia, such as a name, letter, or symbol, for example, "3."

[0267] The flexible arm 154 is preferably flexible to allow a user to change the illumination direction of the light 152, while also being rigid to maintain the orientation of the light 152 in a desired orientation set by the user. A manual on / off switch 156 can be provided on the exterior of the adapter 70'''''' to allow a user to selectively illuminate the light 152.

[0268] The electronic functionality of adapter 70'''''' may be realized by a circuit described below with reference to FIG.

[0269] Light 152 is preferably embodied with one or more LEDs, although other lighting technologies, such as incandescent or fluorescent lights, may be used interchangeably in this embodiment of the present teachings. EXAMPLES

[0270] 23 to 25 show a dummy adapter 170. The dummy adapter is a part made of plastic and has the same outer shape or contour as the previous adapters (all of which can perform at least one electrical function). The dummy adapter 170 can be attached to the power tool housing 32 to replace the functional adapters described above. Thus, a user can attach the dummy adapter 170 to the power tool 10 when there is no need to insert any functional adapter into the adapter slot. The dummy adapter 170 fits into the opening 36 formed on the outer surface of the power tool 10 to prevent dust and moisture from entering. Furthermore, the dummy adapter 170 has a dummy male connector 94 that is coupled to the female connector 37 of the power tool 10, and can protect the female connector 37 and the contact pins 38. The dummy adapter 170 can also have a cylindrical portion 91 for attaching the dummy adapter 170 to the power tool housing 32 via a threaded fastener 92. EXAMPLES

[0271] 26 and 27 show the strap 150 attached to the cylindrical portion 91 of the adapter 70 (or the adapter of any one of the previously described embodiments). A user can easily attach and detach the strap 150 to and from the cylindrical portion 91 by removing the adapter 70 or the like. A space is provided between the cylindrical portion 91 and the power tool housing 32 to freely or pivotally support the strap 150. Because the threaded fastener 92 extends through the hollow cylindrical portion 91, the cylindrical portion 91 is reinforced against breakage.

[0272] FIG. 28 illustrates a representative circuit diagram of the battery pack 40, power tool 10, and wireless communication adapter 70 according to the seventh exemplary embodiment. This circuit provides the same basic electronic functions as the circuits and diagrams shown in FIGS. 1A-1C. Accordingly, elements in FIG. 28 that are the same as those in FIGS. 1A-1C are given the same reference numerals, and their descriptions are incorporated herein by reference. For a description of any elements shown in FIG. 28 but not explicitly described below, please refer to the description associated with FIGS. 1A-1C above.

[0273] The adapter 70 includes an MPU (microprocessor unit) or CPU 72 and an RF (radio frequency) module 78 that communicate electronically. The communication terminals 74 of the adapter 70, i.e., the "+" terminal, the "SW" terminal, the "Tx" terminal, the "Rx" terminal, the "BS" terminal, and the "-" terminal, correspond to or are constituted by the contact terminals 97 provided on the male connector 94. Correspondingly, the communication terminals 24 of the power tool 10, i.e., the "+" terminal, the "SW" terminal, the "Tx" terminal, the "Rx" terminal, the "BS" terminal, and the "-" terminal, correspond to or are constituted by the contact pins 38 provided on the female connector 37. The communication adapter 70 is electrically connected to the battery pack 40 via the power tool 10. The MPU 72 of the adapter 70 communicates with the MPU 42 of the battery pack 40 via the MPU 12 of the power tool 10. The RF signal generated by the RF module (communication unit) 78 is wirelessly transmitted to an external device (according to the above-mentioned embodiment) via an antenna 79.

[0274] Although a wireless communication adapter has been disclosed above, it will be appreciated that a wired communication adapter may also be embodied. In this case, the RF module 78 may be replaced with a wired connector. The wired connector may be any type of plug and socket connector known in the art, such as, but not limited to, a USB connector, that may provide serial or parallel communication between a processor of the power tool and / or battery pack and a processor of an external device (e.g., a computing bus).

[0275] FIG. 29 illustrates a representative circuit diagram of a battery pack 40, power tool 10, and display adapter 70''' according to an eighth exemplary embodiment. This circuit provides the same basic electronic functionality as the circuits and diagrams shown in FIGS. 4A-4C. In FIG. 29, elements that are the same as in FIGS. 4A-4C are given the same reference numerals, and their descriptions are incorporated herein by reference. For a description of any elements shown in FIG. 29 but not explicitly described below, please refer to the description associated with FIGS. 4A-4C above.

[0276] Display adapter 70''' comprises an MPU (or CPU) 72, an LCD control IC (integrated circuit) or LCD driver 81, and an LCD panel 80. LCD panel 80 can be driven by LCD driver 81 based on a video signal generated by MPU 72 in a manner well known in the art.

[0277] FIG. 30 illustrates an exemplary circuit diagram of a battery pack 40, a power tool 10, and a lighting adapter 70'''''' according to a ninth exemplary embodiment. The lighting adapter 70'''''' includes an MPU or CPU 72, a number of LEDs 153, a constant current circuit (e.g., a current regulator) 155, and a manual on / off switch 156. When the manual switch 156 is activated, the MPU 72 turns on a FET 158, thereby illuminating the LEDs 153. The constant current circuit 155 adjusts the brightness of the LEDs 153 by varying the amount of current flowing through the LEDs 153 according to instructions from the MPU 72, in a manner well known in the art.

[0278] Other circuits and elements in Figure 30 operate in the same manner as in Figures 28 and 29 described above, and therefore need not be described again.

[0279] The use of lithium-based battery cells, and particularly lithium-ion battery cells, is currently preferred in the adapters and chargers of the present teachings, although the present teachings are not particularly limited in this regard and any other suitable battery chemistries may be utilized, such as, for example, lithium metal oxide, lithium polymer, lithium metal phosphate, lithium sulfur, lithium sulfide, and lithium sulfate.

[0280] Additionally, while elements 91-94 have been described as one preferred means for engaging the adapter 70, 70''', 70'''', 70''''' to the power tool 10, the present teachings are not particularly limited in this regard. For example, the present teachings may interchangeably utilize a variety of other interlocking, form-fit, press-fit, or fastener connections, such as one or more slide rails, plug-and-socket mechanisms, other types of threaded connections (e.g., screws or bolts that fasten the adapter to an exterior or interior portion of the power tool housing and / or to the battery pack), one or more clamps, one or more clasps, etc., to physically engage the adapter with the power tool and / or battery pack. In short, any type of element or set of elements that allows the adapter to be detachably attached to the power tool housing and / or battery pack should be understood to be included in the expression "means for detachably connecting" to the battery pack and / or power tool.

[0281] The present specification discloses further embodiments, including, but not limited to, the following:

[0282] 1. An adapter for a power tool powered by a removable battery pack, comprising: means for releasably connecting to said power tool only; a controller, such as at least one microprocessor; At least one memory or storage device in communication with the controller; at least one communication port configured to be in electrical communication with a controller located on the power tool, such as at least one microprocessor; An adapter comprising:

[0283] 2. An adapter according to embodiment 1, wherein when a battery pack having a controller, such as at least one microprocessor, is connected to the power tool, a communication path is established such that the controller of the battery pack communicates with the controller of the adapter via the power tool controller.

[0284] 3. An adapter for a power tool powered by a removable battery pack, comprising: means for detachably connecting to only the battery pack; a controller, such as at least one microprocessor; At least one memory or storage device in communication with the controller; at least one communication port configured to electrically communicate with a controller located in the battery pack, such as at least one microprocessor; An adapter comprising:

[0285] 4. An adapter according to embodiment 3, wherein when the battery pack is connected to a power tool having a controller, such as at least one microprocessor, a communication path is established such that the power tool's controller communicates with the adapter's controller via the battery pack's controller.

[0286] 5. An adapter for a power tool powered by a removable battery pack, comprising: a first means for removably connecting to the battery pack; second means for releasably connecting to the power tool; a controller, such as at least one microprocessor; At least one memory or storage device in communication with the controller; at least one first communication port configured to electrically communicate with a controller located in the battery pack, such as at least one microcontroller; at least one second communication port configured to electrically communicate with a controller located on the power tool, such as at least one microcontroller; An adapter comprising:

[0287] 6. An adapter according to embodiment 5, wherein when the adapter is connected to the battery pack and the power tool, a communication path is established such that the battery pack controller communicates with the adapter controller and the adapter controller communicates with the power tool controller.

[0288] 7. The adapter according to any of the preceding embodiments, wherein the adapter is configured or adapted to measure remaining battery capacity of a battery pack.

[0289] 8. The adapter according to any of the preceding embodiments, wherein the adapter is configured or adapted to measure a discharge voltage of a battery cell located in the battery pack.

[0290] 9. An adapter according to embodiment 7 or 8, wherein the adapter is further configured or adapted to estimate the number of remaining operations that the power tool can perform based on the measured remaining battery capacity and / or the measured discharge voltage of the battery cell.

[0291] 10. An adapter according to embodiment 9, wherein the at least one memory stores a set of energy values ​​associated with a plurality of power tool operations, and the controller is configured or adapted to calculate, based on the measured remaining battery capacity and / or the measured discharge voltage of the battery cell, the remaining number of operations that the power tool can perform by dividing the measured remaining battery capacity by the stored energy value associated with the currently being performed power tool operation.

[0292] 11. An adapter according to embodiment 9 or 10, wherein at least one of the adapter, power tool or battery pack is further configured or adapted to dynamically measure energy consumed during the performance of an operation of the power tool, and the controller of the adapter is configured to calculate, based on the measured remaining battery capacity and / or the measured discharge voltage of the battery cell, the remaining number of operations that the power tool can perform for the same type of operation by dividing the measured remaining battery capacity by a measured amount of energy consumed during the operation of the power tool.

[0293] 12. The controller of the adapter storing in memory measurements of energy consumption for a plurality of power tool operations; calculating the number of remaining operations of the power tool by dividing the measured remaining battery capacity by a representative or average measured amount of energy consumed for the plurality of power tool operations; An adapter according to embodiment 11, configured as follows:

[0294] 13. An adapter according to any of the preceding embodiments, configured or adapted to modify one or more operating parameters stored in a memory of the battery pack and / or the power tool, such as a value relating to a maximum current limit.

[0295] 14. An adapter according to embodiment 13, configured or adapted to receive instructions from an external device regarding the modification of said operating parameters.

[0296] 15. An adapter according to any of the preceding embodiments configured or adapted to store, display, and / or transmit, for example to an external device, maintenance information relating to the power tool and / or battery pack.

[0297] 16. The maintenance information is (i) The date of the last maintenance inspection or maintenance service; (ii) The results of the last maintenance inspection and maintenance check; (iii) The cumulative or total usage (operating) hours of the power tool and / or battery pack; (iv) the available charge or state of charge of the battery pack (remaining battery capacity); (v) the number of charge cycles the battery pack has experienced; (vi) the state of one or more battery cells of the battery pack, e.g., calculated from measurements of the internal impedance of the battery cells; (vii) The expected remaining useful life of one or more replaceable parts of the power tool and / or battery pack; (viii) a maintenance schedule for the power tool and / or adapter and / or battery pack; (ix) The usage history of the power tool and / or adapter and / or battery pack; (x) The name of the person responsible for the adapter, battery pack, and / or power tool; (xi) The serial number of the battery pack and / or the power tool; (xii) the voltage of one or more (e.g., either individually or in a group of two or more) battery cells; (xiii) the discharge current of one or more (e.g., either individually or in a group of two or more) battery cells; (xiv) the temperature of one or more (e.g., either individually or in groups of two or more) battery cells; (xv) the number of times the battery pack and / or the power tool are turned on and / or off; (xvi) The amount of charge or discharge within a given period (e.g., the amount of electricity discharged within the past two hours); 16. An adapter according to embodiment 15, wherein the adapter is one of the following or any combination thereof:

[0298] 17. The adapter according to embodiment 15 or 16, configured or adapted to enable the external device to access maintenance information stored in the adapter.

[0299] 18. An adapter according to any of the preceding embodiments, configured or adapted to dynamically detect a discharge current supplied to an electric motor of the power tool during operation and to store the detected discharge current.

[0300] 19. The adapter according to embodiment 18, further configured or adapted to compare the detected discharge current with an upper discharge current limit and / or a lower discharge current limit, and optionally use the comparison result to suggest a different power tool for performing operation of the power tool.

[0301] 20. The adapter according to embodiment 18 or 19, further configured or adapted to transmit the detected discharge current and / or the power tool suggestions to an external device.

[0302] 21. The adapter according to any preceding embodiment, further configured or adapted to change a maximum charge level of the battery pack.

[0303] 22. An adapter according to any of the preceding embodiments, further configured or adapted to perform an anti-theft function.

[0304] 23. The adapter according to embodiment 22, wherein the anti-theft functionality includes communication of a key sent from an external device to an electronic lock located on the battery pack and / or the power tool.

[0305] 24. The adapter according to any of the preceding embodiments, further configured or adapted to store information regarding a person responsible for the adapter, the battery pack and / or the power tool.

[0306] 25. The adapter according to any of the preceding embodiments, further configured or adapted to vary the charging rate of the battery pack, for example based on instructions manually entered into the adapter or based on instructions sent by an external device.

[0307] 26. The adapter according to embodiment 25, wherein the instructions include increasing a charging current and / or increasing a battery pack temperature threshold.

[0308] 27. The adapter according to any of the preceding embodiments, further configured or adapted to measure one or more values ​​indicative of an operating condition of the battery pack and / or the power tool, such as temperature, current and / or voltage.

[0309] 28. The adapter according to embodiment 27, further configured or adapted to display a value indicative of an operational status of the battery pack and / or the power tool.

[0310] 29. The adapter according to embodiment 27 or 28, further configured or adapted to transmit a value indicative of an operational status of the battery pack and / or the power tool to an external device.

[0311] 30. The adapter of any preceding embodiment, further comprising means for wirelessly communicating information relating to the power tool and / or the battery pack to an external device.

[0312] 31. The means for wirelessly transmitting the information comprises: Wireless local area network (WLAN) devices, e.g., wireless communication devices such as WiFi (i.e., operating according to the wireless communication protocols enumerated by IEEE 802.11); Bluetooth devices, Radio Frequency (RF) communications devices, or Cellular or mobile phone devices An adapter according to embodiment 30, comprising one or more of the following:

[0313] 32. The information to be communicated is: the measured remaining battery capacity and / or the remaining number of operations that the power tool can perform with the remaining battery capacity to perform the same type of operation according to any one of embodiments 7 to 12; According to embodiment 13, one or more operating parameters stored in a memory of the battery pack and / or the power tool, such as a value of a maximum current limit; Maintenance information according to embodiment 15 or 16; Proposal of a detected discharge current and / or a power tool according to embodiments 18 to 20; The anti-theft function or lock according to embodiment 22 or 23; A person responsible for the adapter, the battery pack and / or the power tool according to embodiment 24; Information for modifying a charging rate of the battery pack according to embodiment 25 or 26; A value indicative of an operating state of the battery pack and / or the power tool according to embodiment 27 or 28. 32. An adapter according to embodiment 30 or 31, which is one of the following or any combination thereof:

[0314] 33. The adapter according to embodiment 30, 31 or 32, wherein the communicated information is a value indicating a new maximum charge level for the battery pack.

[0315] 34. The adapter according to embodiment 33, wherein the maximum charge level determines when to terminate charging of the battery pack.

[0316] 35. The adapter according to any one of embodiments 25 to 34, wherein the external device is a smartphone.

[0317] 36. The adapter according to any one of embodiments 25 to 34, wherein the external device comprises a portable computing device, such as a PDA, a tablet computer, or a laptop computer.

[0318] 37. The adapter according to any one of embodiments 25 to 34, wherein the external device comprises a desktop computer, a server, or a mainframe computer.

[0319] 38. The adapter according to any of the preceding embodiments, further comprising an input device configured or adapted to input the commands, the data, the information, the operating parameters and / or the user preferences directly into the adapter.

[0320] 39. An adapter according to embodiment 38, wherein the input device includes a touchpad, a touch screen, up / down buttons, push buttons and / or toggle switches.

[0321] 40. An adapter according to any preceding embodiment, further comprising a display.

[0322] 41. The adapter according to embodiment 40, wherein the display comprises a liquid crystal display (LCD), a light emitting diode (LED) display such as an organic light emitting diode (OLED) display, or an organic electroluminescent (EL) display.

[0323] 42. The adapter according to embodiment 40 or 41, wherein the display is a touchpad or touch panel.

[0324] 43. An adapter according to embodiment 40, 41 or 42, wherein the display is configured to visually display any of the information, values ​​or functions described in the previous or following embodiments, such as the charge level (remaining battery capacity) of the battery pack, an alarm indicating overheating, an estimate of the number of remaining operations that the power tool can perform of the same type of operation with the remaining battery capacity of the battery pack, the name of the person responsible for managing the power tool and the battery pack, the maintenance information, the charge rate value, the detected discharge current value, the operating parameters, or any values ​​indicative of the operating status of the battery pack and / or power tool.

[0325] 44. The adapter according to any one of embodiments 40 to 43, wherein the display is configured to visually indicate a maximum charge level of the battery pack.

[0326] 45. The adapter according to any of the preceding embodiments, further comprising means for obtaining power from a charger and configured to provide current to the battery pack for charging one or more battery cells located in the battery pack.

[0327] 46. ​​An adapter according to embodiment 45, wherein the means for obtaining power from the charger includes at least one charging terminal receptacle configured to connect to at least one charging terminal of the charger and conduct current from the charger to the adapter.

[0328] 47. An adapter according to embodiment 45, wherein the means for obtaining power from the charger includes at least one wireless power receiving antenna, such as an induction coil, configured to generate a current when in proximity to at least one wireless power transmitting antenna, such as an induction coil, of the charger.

[0329] 48. An adapter according to embodiment 45, 46 or 47, further comprising a belt hook configured to hang from a tool belt worn by a user, the means for obtaining power from the charger being disposed within or on the belt hook.

[0330] 49. An adapter according to any one of embodiments 45 to 48, further comprising a proximity sensor, such as a mechanical contact, a pressure sensor or switch, a radio frequency identification (RFID) device, a magnet or a magnetic field sensor such as a reed switch or a Hall sensor, and / or an electrical resistance or capacitance sensor, configured to output a signal, e.g., a start charging signal, when the charger is in proximity to the adapter.

[0331] 50. A portable battery pack charging system comprising an adapter according to any one of embodiments 45 to 49 and a charger.

[0332] 51. A portable battery pack charging system according to embodiment 50, wherein the charger comprises at least one charging terminal configured to electrically connect to at least one charging terminal receptacle of the adapter.

[0333] 52. A portable battery pack charging system according to embodiment 50, wherein the charger includes a wireless power transmitting antenna, such as an induction coil, configured to wirelessly transmit power to a wireless power receiving antenna, such as an induction coil, of the adapter.

[0334] 53. A portable battery pack charging system according to any one of embodiments 50 to 52, wherein the charger comprises or is attached to an internal power source.

[0335] 54. A portable battery pack charging system according to embodiment 53, wherein the built-in power source comprises a plurality of rechargeable battery cells.

[0336] 55. A portable battery pack charging system according to embodiment 54, wherein the rechargeable battery cells of the charger have a higher charge storage capacity and a lower nominal current than the battery cells of the battery pack.

[0337] 56. The portable battery pack charging system according to any one of embodiments 50 to 55, further comprising a means for attaching the charger to a user.

[0338] 57. A portable battery pack charging system according to embodiment 56, wherein the attachment means comprises a harness configured to removably attach the charger to a user's limb, torso or back, such as a strap having a removable hook and loop fastener, e.g., Velcro®, a strap having a removable clasp or fastener, a belt or a backpack.

[0339] 58. The means of attachment are: (i) a belt hook receptacle having at least one charging terminal configured to connect to at least one charging terminal receptacle of the adapter; or (ii) the wireless power transmitting antenna configured to wirelessly transmit power to a wireless power receiving antenna of the adapter; 58. A portable battery pack charging system according to embodiment 56 or 57, further comprising one of the following:

[0340] 59. A portable battery pack charging system according to embodiment 58, wherein the belt hook receiver or the wireless power transmitting antenna is configured to be attached to a tool belt worn by a user or is integral to the tool belt.

[0341] 60. The portable battery pack charging system according to any one of embodiments 50 to 59, further comprising a charging control circuit configured to determine a charging current provided to the battery pack.

[0342] 61. A portable battery pack charging system according to embodiment 60, wherein the charging control circuit is located in the adapter and / or the battery pack.

[0343] 62. The portable battery pack charging system according to embodiment 60, wherein the charging control circuit is located in the charger.

[0344] 63. A portable battery pack charging system according to any one of embodiments 50 to 62, wherein the charger stores sufficient energy to fully charge the battery pack at least 1 time, more preferably at least 5 times, and even more preferably at least 10 times.

[0345] 64. The portable battery pack charging system according to any one of embodiments 50 to 63, wherein the charger further comprises a proximity sensor, such as a mechanical contact, a pressure sensor or switch, a radio frequency identification (RFID) device, a magnet or a magnetic field sensor such as a reed switch or a Hall sensor, an electrical resistance or capacitance sensor, etc., configured to output a signal, e.g., a start charging signal, when the charger, or at least its charging terminals or wireless power transmitting antenna, is in proximity to the adapter.

[0346] 65. A portable battery pack charging system according to embodiment 64, wherein the proximity sensor is disposed within or on a belt hook receiver of the charger.

[0347] 66. The portable battery pack charging system according to embodiment 64 or 65, wherein the proximity sensor comprises a magnetic field sensor connected to a controller of the charger, and the adapter comprises a magnet.

[0348] 67. A portable battery pack charging system according to embodiment 64 or 65, wherein the proximity sensor includes an RFID interrogator connected to a controller of the charger, and the adapter is equipped with an RFID tag.

[0349] 70. A portable system for charging a battery pack of a power tool, e.g., a hand-held power tool, comprising: a charger configured or adapted to provide power to charge at least one battery cell of the battery pack; means for attaching said charger to a user; A portable system comprising:

[0350] 71. The portable system according to embodiment 70, wherein the charger comprises or is attached to an internal power source.

[0351] 72. The portable system according to embodiment 71, wherein the built-in power source comprises a plurality of rechargeable battery cells.

[0352] 73. The portable system according to embodiment 72, wherein the rechargeable battery cells of the charger have a higher charge storage capacity and a lower nominal current than the battery cells of the battery pack.

[0353] 74. A portable system according to any one of embodiments 70 to 73, wherein the attachment means comprises a harness configured to removably attach the charger to a user's limbs, torso or back, such as a strap with a removable hook and loop fastener, e.g. Velcro®, a strap with a removable clasp or fastener, a belt or a backpack.

[0354] 75. The means for attaching comprises: (i) a belt hook receptacle having at least one charging terminal configured to connect to at least one charging terminal receptacle of the adapter; or (ii) the wireless power transmitting antenna configured to wirelessly transmit power to a wireless power receiving antenna of the adapter; 75. The portable system according to any one of embodiments 70 to 74, further comprising one of the following:

[0355] 76. The portable system according to embodiment 75, wherein the wireless power transmitting antenna includes an induction coil.

[0356] 77. A portable system according to embodiment 75 or 76, wherein the belt hook receiver or the wireless power transmitting antenna is configured to be attached to a tool belt worn by a user or is integral to the tool belt.

[0357] 78. The portable system according to any one of embodiments 75 to 77, wherein the belt hook receiver is configured or adapted to engage with a belt hook attached to the battery pack.

[0358] 79. The portable system according to embodiment 78, wherein the belt hook receiver further comprises a proximity sensor configured to output a signal, e.g., a charging start signal, when the charging terminal or the wireless power transmitting antenna is in proximity to a belt hook attached to the battery pack, the proximity sensor including, but not limited to, a mechanical contact, a pressure sensor or switch, a radio frequency identification (RFID) device, a magnet or a magnetic field sensor such as a reed switch or a Hall sensor, an electrical resistance or capacitance sensor.

[0359] 80. The portable system according to any one of embodiments 70 to 79, further comprising a battery pack connected to a belt hook comprising one of the charging terminal receptacle or the wireless power transmitting antenna.

[0360] 81. The portable system according to embodiment 80, wherein the wireless power receiving antenna includes an induction coil.

[0361] 82. The portable system according to embodiment 80 or 81, wherein the belt hook is attached to an adapter that is electrically connected to at least one battery cell of the battery pack.

[0362] 83. The portable system according to embodiment 82, wherein the adapter comprises a wire configured or adapted to conduct a charging current from the charger to the battery pack.

[0363] 84. The portable system according to embodiment 83, wherein the adapter further comprises a controller and memory configured or adapted to control battery charging operations.

[0364] 85. The portable system according to any one of embodiments 70 to 84, further comprising a charging control circuit configured to determine a charging current supplied to the battery pack.

[0365] 86. The portable system according to embodiment 85, wherein the charging control circuit is located in the charger.

[0366] 87. The portable system according to embodiment 85, wherein the charging control circuitry is located in the battery pack or in an adapter electrically connected to the battery pack.

[0367] 88. The portable system according to any one of embodiments 80 to 87, wherein the charger stores sufficient energy to fully charge the battery pack at least one time, more preferably at least five times, and even more preferably at least ten times.

[0368] 90. A method of charging a battery pack, comprising: attaching a portable charger to a user, the portable charger having or attached to an internal power source, and a first charging port of the portable charger being positioned on a belt worn by the user; hanging the battery pack on a belt while the battery pack is physically engaged and electrically connected to a power tool; starting to transfer power from the charger to the battery pack when the first charging port is in proximity to a second charging port electrically connected to at least one battery cell of the battery pack; The method includes:

[0369] 91. The method according to embodiment 90, wherein the first charging port and the second charging port have complementary terminals configured or adapted to conduct current, more preferably charging current, from the charger to at least one battery cell of the battery pack.

[0370] 92. The method according to embodiment 90, wherein the first charging port includes a wireless power transmitting antenna and the second charging port includes a wireless power receiving antenna.

[0371] 93. The method according to embodiment 92, wherein each of the wireless power transmitting antenna and the wireless power receiving antenna includes an induction coil.

[0372] 94. The method according to embodiment 92 or 93, wherein the transmission of power is performed by inductive coupling, more preferably by resonant inductive coupling.

[0373] 95. The method according to any of embodiments 90 to 94, further comprising detecting proximity of the first charging port to a second charging port and initiating the transfer of power when the proximity is detected.

[0374] 96. The method according to embodiment 95, further comprising terminating the transfer of power upon detecting separation of the first charging port from the second charging port.

[0375] 97. The method according to embodiment 95 or 96, wherein the proximity is detected based on a magnetic field, pressure, a radio signal, electrical resistance or capacitance, or mechanical movement.

[0376] 98. A method according to any of embodiments 90 to 97, wherein the second charging port is disposed on or within a belt hook attached to the battery pack.

[0377] 99. The method according to embodiment 98, wherein the belt hook is attached to an adapter that physically engages the battery pack or the power tool.

[0378] 100. The method according to embodiment 98, wherein the adapter controls the charging operation.

[0379] 101. The method according to embodiment 98, wherein the belt hook is attached directly to the battery pack.

[0380] 102. The method according to embodiment 101, wherein the charger controls the charging operation.

[0381] 103. The method according to embodiment 101, wherein a controller of the battery pack controls a charging operation.

[0382] 105. A method of charging a battery pack, comprising: transmitting power from the charger to the battery pack when a first charging port of the charger is adjacent to a second charging port electrically connected to at least one battery cell of the battery pack attached to the power tool; The method includes:

[0383] 106. The method according to embodiment 105, wherein the first charging port and the second charging port are positioned on or adjacent to a surface of a belt worn by a user.

[0384] 107. A method according to embodiment 105 or 106, wherein the charger is attached to a user while the user is performing operation of the power tool and has or is attached to a built-in DC power source.

[0385] 110. An adapter for a power tool powered by a removable battery pack, comprising: at least one communication port configured to electrically communicate with a controller, such as at least one microprocessor, located on the power tool and / or the battery pack; means for wirelessly communicating information regarding the power tool and / or the battery pack to an external device; An adapter comprising:

[0386] 111. Means of wirelessly transmitting information include: Wireless local area network (WLAN) devices, e.g., wireless communication devices such as WiFi (i.e., operating according to the wireless communication protocols enumerated by IEEE 802.11); Bluetooth devices, Radio Frequency (RF) communications devices, or Cellular or mobile phone devices An adapter according to embodiment 110, comprising one or more of the following:

[0387] 112. The information to be communicated is: the measured remaining battery capacity and / or the remaining number of operations that the power tool can perform with the remaining battery capacity to perform the same type of operation according to any one of embodiments 7 to 12; According to embodiment 13, one or more operating parameters stored in a memory of the battery pack and / or the power tool, such as a value of a maximum current limit; Maintenance information according to embodiment 15 or 16; Proposal of a detected discharge current and / or a power tool according to embodiments 18 to 20; The anti-theft function or lock according to embodiment 22 or 23; A person responsible for the adapter, the battery pack and / or the power tool according to embodiment 24; Information for modifying a charging rate of the battery pack according to embodiment 25 or 26; A value indicative of an operating state of the battery pack and / or the power tool according to embodiment 27 or 28. The adapter according to embodiment 100 or 101, wherein the adapter is one of the following or any combination thereof:

[0388] 113. The adapter according to any one of embodiments 110 to 112, wherein the external device is a smartphone.

[0389] 114. The adapter according to any one of embodiments 110 to 112, wherein the external device includes a portable computing device, such as a PDA, a tablet computer, or a laptop computer.

[0390] 115. The adapter according to any one of embodiments 110 to 112, wherein the external device includes a desktop computer, a server, or a mainframe computer.

[0391] 116. An adapter according to any one of embodiments 110 to 115, further comprising an input device, such as a touch pad, a touch screen, a push button and / or a toggle switch, configured or adapted to enable a user to input commands directly into the adapter.

[0392] 117. The adapter according to any one of embodiments 110 to 116, further comprising a display.

[0393] 118. The adapter according to embodiment 117, wherein the display comprises a liquid crystal display (LCD), a light emitting diode (LED) display such as an organic light emitting diode (OLED) display, or an organic electroluminescent (EL) display.

[0394] 119. The adapter according to embodiment 117 or 118, wherein the display is a touchpad or touch panel.

[0395] 120. An adapter according to any one of embodiments 117 to 119, wherein the display is configured to visually display any of the information, values ​​or functions described in the preceding or following embodiments, such as the charge level (remaining battery capacity) of the battery pack, an alarm indicating overheating, an estimate of the number of remaining operations that the power tool can perform of the same type of operation with the remaining battery capacity of the battery pack, the name of the person responsible for managing the power tool and the battery pack, the maintenance information, the charging rate value, the detected discharge current value, the operating parameters, or any value indicative of the operating status of the battery pack and / or power tool.

[0396] 121. The adapter according to any one of embodiments 110 to 120, further comprising means for obtaining power from a charger and configured to provide current to the battery pack to charge one or more battery cells located in the battery pack.

[0397] 122. The adapter according to embodiment 121, wherein the means for obtaining power from the charger includes at least one charging terminal receptacle configured to connect to at least one charging terminal of the charger and conduct current from the charger to the adapter.

[0398] 123. An adapter according to embodiment 121, wherein the means for obtaining power from the charger includes at least one wireless power receiving antenna, such as an induction coil, configured to generate a current when in proximity to at least one wireless power transmitting antenna, such as an induction coil, of the charger.

[0399] 124. An adapter according to any one of embodiments 121 to 123, further comprising a belt hook configured to hang from a tool belt worn by a user, the means for obtaining power from the charger being disposed in or on the belt hook.

[0400] 125. An adapter according to any one of embodiments 121 to 124, further comprising a proximity sensor, such as a mechanical contact, a pressure sensor or switch, a radio frequency identification (RFID) device, a magnet or a magnetic field sensor such as a reed switch or a Hall sensor, and / or an electrical resistance or capacitance sensor, configured to output a signal, e.g., a start charging signal, when the charger is in proximity to the adapter.

[0401] 126. An adapter according to any one of embodiments 110 to 125, configured to be at least partially located in a space between the power tool housing and the battery pack when the power tool housing and the battery pack are attached to one another.

[0402] 127. The adapter according to any one of embodiments 110 to 126, configured to be detachable from the housing of the power tool only when the battery pack is removed from the housing.

[0403] 128. The adapter is configured to be slidably attached to and detached from the housing of the power tool along a first direction, preferably along a longitudinal direction of the handle of the power tool; the battery pack is configured to be slidably inserted into and removed from the housing of the power tool along a second direction, preferably lateral to the handle of the power tool; An adapter according to any one of embodiments 110 to 127, wherein the first direction is substantially perpendicular to the second direction.

[0404] 129. An adapter according to any one of embodiments 110 to 128, which is attachable to the housing via a threaded fastener, e.g., a screw or bolt, and optionally has a cylindrical portion into which the threaded fastener can be inserted to tighten the adapter to the power tool housing.

[0405] 130. A method comprising wirelessly communicating information between an external device and one of a power tool and a battery pack.

[0406] 131. The method according to embodiment 130, wherein the information is communicated via an adapter physically and electrically connected to the power tool and / or battery pack.

[0407] 132. The method according to embodiment 131, wherein the adapter receives a wireless signal from the external device and communicates an electrical signal to the power tool and / or battery pack.

[0408] 133. The method according to any one of embodiments 130 to 132, wherein the external device is a smartphone.

[0409] 134. The method according to any one of embodiments 130 to 132, wherein the external device includes a portable computing device, such as a PDA, a tablet computer, or a laptop computer.

[0410] 135. The method according to any one of embodiments 130 to 132, wherein the external device includes a desktop computer, a server, or a mainframe computer.

[0411] 136. A method according to any one of embodiments 130 to 135, wherein the communicated information includes a measured remaining battery capacity and / or an estimate of the number of remaining operations the power tool can perform of the same type of operation with the remaining battery capacity.

[0412] 137. A method according to any one of embodiments 130 to 136, wherein the communicated information includes one or more values ​​corresponding to one or more operating parameters, e.g., a maximum current limit, stored in memory of the battery pack and / or the power tool.

[0413] 138. The method according to any one of embodiments 130 to 137, wherein the communicated information includes maintenance information for the power tool and / or the battery pack.

[0414] 139. A method according to embodiment 138, wherein the maintenance information includes the date and / or results of the last maintenance inspection / check.

[0415] 140. The maintenance information is the cumulative or total usage (operation) time of the power tool and / or the battery pack (40); the available charge or state of charge of the battery pack (e.g., remaining battery capacity); The number of charge cycles performed on the battery pack; and / or a state of one or more battery cells of the battery pack, e.g., calculated from internal impedance measurements of the battery cells; 139. The method according to embodiment 138 or 139, comprising:

[0416] 141. The maintenance information is the expected remaining useful life of one or more replaceable components of the power tool and / or the battery pack; a maintenance schedule for the power tool and / or the adapter and / or the battery pack; a usage history of the power tool and / or the adapter and / or the battery pack; The name of the person responsible for the adapter, the battery pack, and / or the power tool; and / or A serial number of the battery pack and / or the power tool; The method according to any one of embodiments 138 to 140, comprising:

[0417] 142. The maintenance information is the voltage of one or more (e.g., either individually or in groups of two or more) battery cells; the discharge current of one or more (e.g., either individually or in groups of two or more) battery cells; and / or the temperature of one or more (e.g., either individually or in groups of two or more) battery cells; The method according to any one of embodiments 138 to 141, comprising:

[0418] 143. The method according to any one of embodiments 138 to 142, wherein the maintenance information includes the number of times the battery pack and / or the power tool have been turned on and / or off.

[0419] 144. The method according to any one of embodiments 138 to 143, wherein the maintenance information includes the amount of charge or discharge within a given period of time, such as the amount of power discharged within the past two hours.

[0420] 145. The method according to any one of embodiments 130 to 144, wherein the communicated information includes the detected discharge current and / or power tool suggestions generated based on the detected discharge current.

[0421] 146. The method according to any one of embodiments 130 to 145, wherein the communicated information includes an anti-theft feature or a key.

[0422] 147. The method according to any one of embodiments 130 to 146, wherein the communicated information includes a person responsible for managing the adapter, the battery pack, and / or the power tool.

[0423] 148. The method according to any one of embodiments 130 to 147, wherein the communicated information includes instructions to modify a charging rate of the battery pack, for example, by increasing a charging current and / or a battery pack temperature threshold.

[0424] 149. A method according to any one of embodiments 130 to 148, wherein the communicated information includes one or more values ​​indicative of an operational status of the battery pack and / or the power tool.

[0425] 150. The method according to any one of embodiments 130 to 149, wherein the communicated information includes one or more values ​​indicative of a maximum charge level of the battery pack.

[0426] 151. A hand-held power tool comprising a housing having a battery pack interface, an electric device, and a first connector; a battery pack adapted or configured to be connected, for example directly to, the battery pack interface and to supply electrical current to the electrically powered device; an adapter including a second connector configured to be physically and electrically removably connected to the first connector; the adapter is configured to receive power from the battery pack via the hand-held power tool and to provide at least one additional electrical function to the hand-held power tool or to perform at least one additional electrical function that the hand-held power tool cannot naturally perform; A power tool system, wherein at least a portion of the adapter is disposed in a space between the housing and the battery pack when the housing and the battery pack are attached to each other.

[0427] 152. A power tool system according to embodiment 151, wherein the battery pack is configured to be detachable from the housing regardless of whether the adapter is attached to or detached from the housing.

[0428] 153. A power tool system according to embodiment 151 or 152, wherein the adapter is configured to be detachable from the housing only when the battery pack is removed from the housing.

[0429] 154. The adapter is configured to be slidably attached to and detached from the housing of the power tool along a first direction, preferably along a longitudinal direction of the handle of the power tool; the battery pack is configured to be slidably inserted into and removed from the housing of the power tool along a second direction, preferably lateral to the handle of the power tool; A power tool system according to any one of embodiments 151 to 153, wherein the first direction is substantially perpendicular to the second direction.

[0430] 155. A power tool system according to any one of embodiments 151 to 154, wherein the housing and the battery pack define an opening therebetween that visibly exposes at least a portion of the adapter attached to the housing (e.g., an opening is defined on an exterior surface of the hand-held power tool and / or the battery pack).

[0431] 156. A power tool system according to embodiment 155, wherein the adapter is configured to fit into the opening without significant gaps (e.g., with minimal gaps required due to manufacturing tolerances) when the adapter and the battery pack are attached to the housing.

[0432] 157. A power tool system according to embodiment 155 or 156, further comprising a dummy adapter configured to be removably attached to the housing in place of the adapter, the dummy adapter being configured to fit into the opening without creating a substantial gap when the dummy adapter and the battery pack are attached to the housing.

[0433] 158. The power tool system according to embodiment 157, wherein the dummy adapter is configured to cover the first connector when attached to the housing.

[0434] 159. The first connector is a female connector having at least one contact pin and a peripheral wall surrounding the at least one contact pin; The second connector is a male connector having at least one hole configured to receive at least one contact pin, and at least one contact plate (contact terminal) located within the at least one hole and configured to make physical and electrical contact with the at least one contact pin. A power tool system according to any one of embodiments 151 to 158.

[0435] 160. The power tool system according to any one of embodiments 151 to 159, wherein the adapter is attachable to the housing via a threaded fastener, such as a screw or bolt.

[0436] 161. A power tool system according to embodiment 160, wherein the adapter is firstly positioned relative to the housing by mating of the first connector and the second connector, and secondly positioned relative to the housing by a tightened threaded fastener.

[0437] 162. A power tool system according to embodiment 160 or 161, wherein the adapter has a cylindrical portion into which the threaded fastener can be inserted to tighten the adapter to the housing of the power tool.

[0438] 163. A power tool system according to embodiment 162, wherein the cylindrical portion is exposed through an outer surface of the power tool and configured to allow a strap to be attached.

[0439] 164. With multiple adapters, A power tool system according to any one of embodiments 151 to 163, wherein each adapter is attached to the housing and configured to provide at least one different electrical function to the hand-held power tool or to perform at least one different electrical function.

[0440] 165. A power tool system according to any one of embodiments 151 to 164, wherein the adapter is configured or adapted to wirelessly communicate information, such as any of the information listed above or below, to and / or from the power tool while wirelessly communicating with an external device, such as a base station, a workstation, a computer, a personal digital assistant, or a smartphone.

[0441] 166. A power tool system according to any one of embodiments 151 to 165, wherein the adapter is configured or adapted to display information about the power tool on a display, such as any of the information listed above or below.

[0442] 167. A power tool system according to any one of embodiments 151 to 166, wherein the adapter is configured or adapted to measure and / or display and / or communicate an estimate of the remaining battery capacity of the battery pack and / or the number of remaining operations that the power tool can perform of the same type of operation with the remaining battery capacity.

[0443] 168. A power tool system according to any one of embodiments 151 to 167, wherein the adapter is configured or adapted to measure and / or display and / or communicate values ​​corresponding to one or more operating parameters, e.g., a maximum current limit, stored in a memory of the battery pack and / or the power tool.

[0444] 169. A power tool system according to any one of embodiments 151 to 168, wherein the adapter is configured or adapted to measure and / or display and / or communicate: (i) the date of the last maintenance inspection, (ii) the result of the last maintenance inspection, (iii) the accumulated or total usage (operating) time of the power tool and / or the battery pack, (iv) the available charge or state of charge (remaining battery capacity) of the battery pack, (v) the number of charging cycles experienced by the battery pack, (vi) the condition of one or more battery cells of the battery pack, calculated, for example, from measurements of the internal impedance of the battery cells, (vii) the predicted remaining useful life of one or more replaceable parts of the power tool and / or the battery pack, and (viii) a maintenance schedule for the power tool and / or the adapter and / or the battery pack.

[0445] 170. A power tool system according to any one of embodiments 151 to 169, wherein the adapter is configured or adapted to measure and / or display and / or communicate the detected discharge current and / or the power tool's suggestions.

[0446] 171. A power tool system according to any one of embodiments 151 to 170, wherein the adapter is configured or adapted to provide an anti-theft feature or lock.

[0447] 172. A power tool system according to any one of embodiments 151 to 171, wherein the adapter is configured or adapted to identify or communicate with a person responsible for managing the adapter, the battery pack, and / or the power tool.

[0448] 173. A power tool system according to any one of embodiments 151 to 172, wherein the adapter is configured or adapted to input and / or display and / or communicate information regarding changing the charging rate of the battery pack.

[0449] 174. A power tool system according to any one of embodiments 151 to 173, wherein the adapter is configured or adapted to measure and / or display and / or communicate values ​​indicative of an operating status of the battery pack and / or the power tool.

[0450] 175. The power tool system according to any one of embodiments 151 to 174, further comprising a light coupled to the body of the adapter via a flexible arm.

[0451] 176. The adapter comprises: and wirelessly communicating information to and / or from the power tool, such as any of the information set forth above or below, while wirelessly communicating with an external device, such as a base station, a workstation, a computer, a personal digital assistant, or a smartphone; displaying information about the power tool on a display, such as any of the information set forth above or below; measuring and / or displaying and / or communicating an estimate of the remaining battery capacity of the battery pack and / or the number of remaining operations that the power tool can perform with the remaining battery capacity to perform the same type of operation; measuring and / or displaying and / or communicating a value corresponding to one or more operating parameters stored in a memory of the battery pack and / or the power tool, e.g., a maximum current limit; (i) the date of the last maintenance inspection; (ii) the result of the last maintenance inspection; (iii) the cumulative or total usage (operating) hours of the power tool and / or battery pack; (iv) the available charge or state of charge (remaining battery capacity) of the battery pack; (v) the number of charging cycles experienced by the battery pack; (vi) the condition of one or more battery cells of the battery pack, calculated, for example, from measurements of the internal impedance of the battery cells; (vii) the predicted remaining useful life of one or more replaceable parts of the power tool and / or battery pack; and (viii) a maintenance schedule for the power tool and / or adapter and / or battery pack; Measuring and / or displaying and / or communicating the detected discharge current and / or power tool proposal; Provide anti-theft features or locks; Identifying or communicating with a person responsible for managing the adapter, the battery pack, and / or the power tool; inputting and / or displaying and / or communicating information regarding changes to the charging rate of the battery pack; and / or measuring and / or indicating and / or communicating values ​​indicative of an operational state of the battery pack and / or the power tool; and / or Perform any other function described in the specification above. 165. A power tool system according to any one of embodiments 151 to 164, configured or adapted to:

[0452] 177. Equipped with multiple hand-held power tools; A power tool system according to any one of embodiments 151 to 176, wherein each adapter is configured to be attached to the housing of any one of the hand-held power tools and to provide different functions to the hand-held power tool.

[0453] 178. A power tool system according to any one of embodiments 151 to 177, not including the power tool and the battery pack.

[0454] 181. An adapter for a hand-held power tool powered by a battery pack, comprising: a connector configured to be removably connected physically and electrically to a corresponding connector on the hand-held power tool; means for receiving power from the battery pack via the hand-held power tool and the connector; means for performing at least one additional electrical function that the handheld power tool cannot otherwise perform; Equipped with An adapter, at least a portion of which is located in a space between a housing of the hand held power tool and the battery pack when the housing and the battery pack are attached to one another.

[0455] 182. The adapter according to embodiment 181, configured to be attached to and detached from the housing only when the battery pack is removed from the housing.

[0456] 183. The adapter is configured to be slidably attached to and detached from the housing along a first direction, preferably along a longitudinal direction of the handle of the power tool; the battery pack is configured to be slidably inserted into and removed from the housing along a second direction, preferably lateral to the handle of the power tool; An adapter according to embodiment 181 or 182, wherein the first direction is substantially perpendicular to the second direction.

[0457] 184. An adapter according to any one of embodiments 181 to 183, wherein at least a portion of the adapter is configured to be visibly exposed through an opening defined by the housing and the battery pack while the adapter is attached to the housing (e.g., the opening is defined on an exterior surface of a hand-held power tool and / or a battery pack).

[0458] 185. An adapter according to embodiment 184, configured to fit into an opening without significant gaps (e.g., with minimal gaps required due to manufacturing tolerances) when the adapter and the battery pack are attached to the housing.

[0459] 186. The connector is a female connector having at least one contact pin and a peripheral wall surrounding the at least one contact pin; An adapter according to any one of embodiments 181 to 185, wherein the corresponding connector is a male connector having at least one hole configured to receive at least one contact pin and at least one contact plate (contact terminal) positioned within the at least one hole and configured to make physical and electrical contact with the at least one contact pin.

[0460] 187. An adapter according to any one of embodiments 181 to 186, configured to be attachable to the housing via a threaded fastener, such as a screw or bolt.

[0461] 188. An adapter as in embodiment 187, configured to be first positioned relative to the housing by coupling the connectors together, and then positioned relative to the housing by tightening the threaded fasteners.

[0462] 189. The adapter according to embodiment 187 or 188, having a cylindrical portion into which the threaded fastener can be inserted to tighten the adapter to a power tool housing.

[0463] 190. The adapter as in embodiment 189, wherein the cylindrical portion is exposed through an exterior surface of the power tool and is configured to allow a strap to be attached.

[0464] 191. An adapter as in any one of embodiments 181 to 190, further comprising the features of any one of the adapters according to embodiments 1, 2, or 7 to 49.

[0465] 192. The adapter as in any one of embodiments 181 to 191, further comprising a light coupled to the body of the adapter via a flexible arm. [Explanation of symbols]

[0466] 1, 1', 1'', 1''', 1'''', 1'''': Power tool system 10, 10': Cordless power tools 11: Electronic unit 12: Controller 13: Circuit board 14: Discharge detector 16: Memory 18: Communications Department 20: Power FET 22: Battery terminal 24: Adapter communication terminal 25: Adapter power terminal 26: Battery pack communication terminal (I / O terminal) 28: Trigger switch 30: Tool chuck 32: Housing 33: Slot 34: Battery pack interface 35: Space between the power tool housing and the battery pack 36: Opening 37: Female connector 38: Contact pin 39: Peripheral wall 40, 40': Battery pack 42: Controller 44: Charge / discharge detector 46: Memory 48: Communications Department 50: Battery cell 52: Battery terminal 54: Adapter communication terminal 55: Adapter power terminal 56: Power tool communication terminal (I / O terminal 58: Switch 60: Charging terminal 70, 70', 70'', 70'''', 70'''', 70'''''':Adapter 72: Controller 73: Circuit board 74: Communication terminal 75: Power terminal 76: Memory 78: Communications Department 79: Antenna 80: Display 81: LCD driver 82: Battery terminal 84:Charging terminal 85: Charging terminal holder 86: Charger communication terminal (I / O terminal 88: Switch 90: Diode 91: Cylindrical part 92: Screw parts 93: Rib 94: Male connector 96: Hole 97: Contact terminal 98: Projection body 100: External device 102: Controller 104: Display 106: Memory 108: Communications Department 120: Charger 122: Controller 124: Adapter communication terminal 126: Memory 128: Communications Department 130: Power supply 132: Charging terminal 138: Switch 140:DC power supply 142: Flexible power cord 144: Belt 146: Belt hook holder 148: Belt hook 150: Strap 152: Light 153: LED 154: Flexible arm 155: Constant current generator 156: ON / OFF switch 158:FET 170: Dummy adapter M: Electric motor of power tool

Claims

1. Power tools and a battery pack that is attached to the power tool to drive the power tool and that is attached to a charger to be charged; a wireless communication adapter that is detachably attached to the power tool and wirelessly transmits data between the power tool and an external device other than the charger, when the wireless communication adapter is attached to the power tool, no part of the wireless communication adapter protrudes beyond an outer surface or contour of the power tool and the battery pack; The data includes at least: (d) values ​​related to operational parameters of the power tool and / or the battery pack; the operating parameters include a limit value for a discharge current from the battery pack to the power tool; Power tool system.

2. The power tool system of claim 1 , wherein the data further includes: (e) maintenance information regarding the power tool and / or the battery pack.

3. The power tool system according to claim 2 , wherein the maintenance information includes a name of a person responsible for managing the battery pack and / or the power tool.

4. Power tools and a battery pack that is attached to the power tool to drive the power tool and that is attached to a charger to be charged; a wireless communication adapter that is detachably attached to the power tool and wirelessly transmits data between the power tool and an external device other than the charger, when the wireless communication adapter is attached to the power tool, no part of the wireless communication adapter protrudes beyond an outer surface or contour of the power tool and the battery pack; The data includes at least: (e) maintenance information relating to the power tool and / or the battery pack; The maintenance information includes a name of a person responsible for managing the battery pack and / or the power tool. Power tool system.

5. The power tool system according to claim 2 , wherein the maintenance information includes an accumulated operating time of the power tool and / or the battery pack.

6. The power tool system of claim 1 , wherein the data further includes: (a) a control program for the power tool and / or the battery pack.

7. The power tool system of claim 1 , wherein the data further includes (b) management information for the power tool and / or the battery pack.

8. The power tool system according to claim 1 , wherein the data further includes (c) information indicating a status of the power tool and / or the battery pack.

9. The power tool system according to claim 8 , wherein the status information includes a measured or detected value relating to a remaining battery capacity of the battery pack.

10. The power tool system according to claim 8 or 9, wherein the information indicating the state includes a warning or alarm signal transmitted when the power tool or the battery pack overheats or is overloaded.

11. the external device is a smartphone, The power tool system according to claim 1 , wherein the smartphone has an application program that enables reception and / or transmission of the data between the smartphone and the wireless communication adapter.

12. Power tools and a battery pack that is attached to the power tool to drive the power tool and that is attached to a charger to be charged; a wireless communication adapter that is detachably attached to the power tool and wirelessly transmits data between the power tool and an external device other than the charger, when the wireless communication adapter is attached to the power tool, no part of the wireless communication adapter protrudes beyond an outer surface or contour of the power tool and the battery pack; the external device is a smartphone, the smartphone has an application program that enables reception and / or transmission of the data between the smartphone and the wireless communication adapter; Power tool system.

13. 13. An application program for the power tool system according to claim 11 or 12, comprising: An application program that, when executed by the smartphone, enables the data to be received and / or transmitted between the smartphone and the wireless communication adapter.

14. 1. A wireless communication adapter for a power tool system, comprising: The power tool system includes: Power tools and a battery pack that is attached to the power tool to drive the power tool and that is attached to a charger to be charged; The wireless communication adapter includes: a charger that is detachably attached to the power tool and configured to wirelessly communicate data with an external device other than the charger; when attached to said power tool, no part of said power tool protrudes beyond the exterior surface or contour of the power tool and battery pack; Wireless communication adapter.

Images