Bidirectional motor for gas engine replacement device

Abstract

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

Description

[Technical field]

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

[0002] This application relates to a gas engine replacement motor unit, and more particularly to a gas engine replacement motor unit for use with power equipment. [Background technology]

[0003] A small single or multi-cylinder gasoline engine can be attached to the power equipment to drive the equipment through a power take-off shaft. Summary of the Invention [Means for solving the problem]

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

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

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

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

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

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

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

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

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

[0013] Before describing any embodiment in detail, it is to be understood that the embodiment is not limited in its application to the details of construction and arrangement of components set forth in the following description or illustrated in the following drawings. The embodiments described herein can be practiced or carried out in various ways. It is also to be understood that the phraseology and terminology used herein are for purposes of description and should not be regarded as limiting. The use of "including," "comprising," or "having," and variations thereof herein are meant to encompass the items listed thereafter and equivalents thereof, as well as additional items. The terms "attached," "connected," and "coupled" are used broadly to encompass both direct and indirect attachments, connections, and couplings. Furthermore, "connected" and "coupled" are not limited to physical or mechanical connections or couplings, but can include electrical connections or couplings, whether direct or indirect. Additionally, as used herein in conjunction with a list of items, "and / or" means that the items may be taken all together, as a subset, or as alternatives (e.g., "A, B, and / or C" means A; B; C; A and B; B and C; A and C; or A, B, and C).

[0014] It should be noted that a number of hardware and software-based devices and a number of different structural components may be utilized to implement the embodiments described herein. Moreover, as described in the following paragraphs, the specific configurations shown in the drawings are intended as exemplary embodiments, and other alternative configurations are possible. The terms "processor", "central processing unit", and "CPU" are interchangeable unless otherwise specified. When the terms "processor" or "central processing unit" or "CPU" are used to identify a unit that performs certain functions, it should be understood that, unless otherwise specified, those functions can be performed by a single processor, or by multiple processors arranged in any form, including parallel processors, serial processors, tandem processors, or cloud processing / cloud computing configurations.

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

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

[0017] [Figure 1] FIG. 1 is a perspective view of a gas engine replacement apparatus according to an embodiment. [Diagram 2] FIG. 2 is a plan view of the gas engine replacement device of FIG. 1. [Diagram 3] 2 is a schematic diagram of the gas engine replacement arrangement of FIG. 1; [Figure 4] FIG. 2 is a perspective view of a battery pack of the gas engine replacement device of FIG. 1. [Diagram 5] FIG. 5 is a cross-sectional view of the battery pack of FIG. [Figure 6] FIG. 2 is a cross-sectional view of a battery receptacle of the gas engine conversion device of FIG. 1. [Figure 7] FIG. 2 is a cross-sectional view of the motor of the gas engine exchange device of FIG. 1. [Figure 8] 2 is a schematic diagram of the motor, gear train, and power take-off shaft of the gas engine exchange device of FIG. 1. [Figure 9] FIG. 2 is a block diagram of the gas engine replacement device of FIG. 1. [Figure 10] 2 is a schematic diagram of a power switching network for driving the motor of the gas engine conversion device of FIG. 1; [Figure 11] 11A and 11B illustrate the operation of the power switching network of FIG 10 during forward and reverse motor motion; [Figure 12] FIG. 2 is a flow diagram of a method for bi-directional operation of the gas engine exchange apparatus of FIG. 1. [Figure 13] FIG. 2 is a perspective view of a compactor including the gas engine exchange apparatus of FIG. 1. [Figure 14] FIG. 14 is a plan view of the compactor of FIG. 13. [Figure 15] FIG. 2 is a perspective view of a pump system including the gas engine replacement device of FIG. 1. [Figure 16] 2 is a schematic diagram of an outdoor power equipment including the gas engine exchange apparatus of FIG. 1; [Figure 17] 2 is a schematic diagram of an outdoor power equipment including the gas engine exchange apparatus of FIG. 1; [Figure 18] 2 is a schematic diagram of a compactor including the two gas engine exchange devices of FIG. 1. [Figure 19] FIG. 20 is a flow diagram of a method for operation of the compactor of FIG. 18. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0018] 1 and 2, a gas engine exchange apparatus 10 for use with a piece of power equipment includes a housing 14 having a first side 18, a second side 22 adjacent the first side 18, a third side 26 opposite the second side 22, a fourth side 28 opposite the first side 18, a fifth side 30 extending between the second and third sides 22, 26, and a sixth side 32 opposite the fifth side 30. The gas engine exchange apparatus 10 also includes a flange 34 coupled to the housing 14 at the first side 18, an electric motor 36 located within the housing 14, and a power take-off shaft 38 projecting from the second side 22 and receiving torque from the motor 36. As will be described in more detail below, in some embodiments, the power take-off shaft 38 projects from the first side 18 and the flange 34. 3, the gas engine conversion apparatus 10 also includes control electronics 42 including wiring and a controller 46 positioned within the housing 14 and electrically connected to the motor 36. A similar gas engine conversion apparatus 10 is described and illustrated in U.S. patent application Ser. No. 16 / 551,197, filed Aug. 26, 2019, the entire contents of which are incorporated herein by reference.

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

[0020] FIG. 6 illustrates the battery receptacle 54 of the gas engine conversion apparatus 10 according to some embodiments. The battery receptacle 54 includes a protrusion / recess 74, a second terminal 78, a latch mechanism 82, and a power disconnect switch 86. The protrusion / recess 74 cooperates with the protrusion / recess 70 of the battery pack 50 to mount the battery pack 50 in the battery receptacle 54 of the gas engine conversion apparatus 10. When the battery pack 50 is mounted in the gas engine conversion apparatus 10, the second terminal 78 and the first terminal 66 are electrically connected. The latch mechanism 82 protrudes from a surface of the battery receptacle 54 and is configured to engage the battery pack 50 to maintain engagement between the battery pack 50 and the battery receptacle 54. Thus, the battery pack 50 is connectable to and supportable by the battery receptacle 54 such that the battery pack 50 is supportable by the housing 14 of the gas engine conversion apparatus 10. In some embodiments, the battery pack receptacle 54 is positioned on the housing 14 at a location that creates the maximum possible separation between the motor 36 and the battery pack 50 to dampen vibrations transmitted from the motor 36 to the battery pack 50. In some embodiments, an elastomeric member is positioned on the battery pack receptacle 54 to dampen vibrations transmitted from the motor 36 through the housing 14 to the battery pack 50.

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

[0022] The latch mechanism 82 also includes a power disconnect switch 86 (e.g., a microswitch) that facilitates electrically connecting / disconnecting the battery pack 50 from the battery receptacle 54 during actuation of the handle 90 to pull the latch member 94 from the battery pack 50. The power disconnect switch 86 may act to electrically disconnect the battery pack 50 from the gas engine conversion apparatus 10 prior to removal of the battery pack 50 from the battery receptacle 54. The power disconnect switch 86 is actuated when the latch member 94 moves from the latched position (i.e., when the latch member 94 is completely within the cavity of the battery pack 50) to an intermediate position. The power disconnect switch 86 is electrically connected to the controller 46 and may generate an interrupt indicating that the battery pack 50 is disconnected from the gas engine conversion apparatus 10. When the controller 46 receives the interrupt, the controller 46 initiates a power disconnect operation to safely power down the control electronics 42 of the gas engine conversion apparatus 10. A similar latch mechanism and disconnect switch is described and illustrated in U.S. Patent Application Publication No. 2019 / 0006980, which is incorporated herein by reference.

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

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

[0025] In some embodiments, the gas engine conversion apparatus 10 includes an on / off indicator (not shown). In some embodiments, the gas engine conversion apparatus 10 includes a filter (not shown) that keeps airborne debris out of the motor 36 and the control electronics 42. In some embodiments, the filter includes a dirt filter sensor (not shown) and a self-cleaning mechanism (not shown). In some embodiments, the motor 36 will mimic a gas engine response when it encounters resistance, such as slowing down or getting stuck in mud. In some embodiments, the gas engine conversion apparatus 10 includes a heat sink 202 in the housing 14 for air cooling the control electronics 42 (FIGS. 1 and 2). In some embodiments, the gas engine conversion apparatus 10 is liquid cooled.

[0026] In some embodiments, the output shaft 106 of the rotor 102 has both forward and reverse capabilities, as described further below. In some embodiments, the forward and reverse capabilities are controllable without shifting gears in the gear train 110, as compared to gas engines, which cannot achieve forward / reverse capabilities without extra gears and time delays. Thus, the gas engine conversion apparatus 10 provides higher speed, lower weight, and lower cost. The gas engine conversion apparatus 10 also provides additional speed, weight, and cost advantages, as compared to gas engines, because it has fewer moving parts and does not have a combustion system.

[0027] The gas engine conversion device 10 is capable of operating in any orientation (vertical, horizontal, upside down) relative to the ground for extended periods of time, providing an advantage over four-stroke gas engines which can only operate in one orientation and at a slight tilt for short periods of time. Because the gas engine conversion device 10 does not require gas, oil, or other fluids, it can be operated, transported, and stored upside down or on any given side without leaking or spilling.

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

[0029] Alternatively, the gas engine conversion apparatus 10 can be connected to a piece of power equipment using a belt system by providing a belt operatively connecting the power take-off shaft and the equipment bit. Thus, the power take-off shaft 38 of the gas engine conversion apparatus 10 can be used to drive the equipment.

[0030] During operation, the housing 14 of the gas engine conversion apparatus 10 is comparatively much cooler than the housing of an internal combustion unit due to the absence of combustion in the gas engine conversion apparatus 10. Specifically, the housing of the gas engine unit is above 220° C. during operation of the gas engine unit. In contrast, all of the exterior surfaces of the housing 14 are below 95° C. during operation of the gas engine conversion apparatus 10. Tables 1 and 2 below further list the temperature limitations of various components on the housing 14 of the gas engine conversion apparatus 10.

[0031] Table 1 below lists the Underwriter's Laboratories (UL) temperature limits for various components commonly used in power tools, whether those components are made from metal, plastic, rubber, wood, porcelain, or vitreous. For example, in at least some embodiments, the temperature ratings of plastics are not exceeded by the gas engine conversion apparatus 10.

[0032] [Table 1]

[0033] Table 2 below lists the UL temperature limits of various components of the battery pack housing 58 of the battery pack 50 with respect to whether those components are made of metal, plastic, or rubber. For example, in at least some embodiments, the temperature ratings of plastics are not exceeded by the gas engine conversion apparatus 10.

[0034] [Table 2]

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

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

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

[0038] The power switching network 310 allows the electronic processor 302 to control the operation of the motor 36. In general, when the user input device 322 is pressed (or otherwise actuated), current is provided from the battery pack 50 to the motor 36 via the power switching network 310. When the user input device 322 is not pressed (or otherwise actuated), current is not provided from the battery pack 50 to the motor 36. In some embodiments, the amount that the user input device 322 is pressed is related to or corresponds to a desired rotational speed of the motor 36. In other embodiments, the amount that the user input device 322 is pressed is related to or corresponds to a desired torque. In other embodiments, the gas engine conversion apparatus 10 includes a separate input device (e.g., a slider, dial, etc.) that communicates with the electronic processor 302 to provide the desired rotational speed or torque for the motor 36.

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

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

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

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

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

[0044] The communications network 334 provides a wired or wireless connection between the gas engine exchange apparatus 10 and external devices 338. The communications network 334 may comprise a short-range network, such as a BLUETOOTH network, a Wi-Fi network, etc., or a long-range network, such as the Internet, a cellular network, etc.

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

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

[0047] 10 illustrates one embodiment of a power switching network 310 for driving the motor 36 of the gas engine conversion device 10. The power switching network 310 includes three high-side FETs H1, H2, and H3 and three low-side FETs L1, L2, and L3, each having a first, or conducting, state and a second, or non-conducting state. The power switching network 210 is used to selectively apply power from the battery pack 50 to the motor 36. Exemplary manners in which the high-side and low-side switches are controlled to operate the motor 36 in forward and reverse directions are described below.

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

[0049] 12 is a flow diagram of an example method 400 for bidirectional operation of the motor 36. The method 400 includes rotating the motor 36 in a first direction (at block 405). Depending on the desired function of the powered device, the motor 36 may rotate in a forward or reverse direction. For example, the electronic processor 302 may provide a PWM control signal as shown in FIG. 11A to rotate the motor in a forward direction (e.g., a first direction). The electronic processor 302 may adjust the duty cycle of the PWM signal to adjust the operating speed.

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

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

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

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

[0054] During operation, an operator can grasp the handle 592 and activate the gas engine exchange apparatus 10 to drive the vibrating plate 584 to compact soil or asphalt, including granular mixed materials that are largely non-sticky. During operation, the operator may control the valve 600 to allow water from the water tank 596 to be applied to the compacted surface, such that in some applications, the water allows the particles being compacted to form a paste and bond together, forming a denser or tighter finished surface. Additionally, the water from the water tank 596 prevents asphalt or other materials from sticking to the vibrating plate 584 during operation.

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

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

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

[0058] When the electronic processor 302 rotates the motor 36 in a second direction (e.g., as in block 420), the vibration mechanism 712 may drive the vibration plate 708 to provide only compaction without moving the compactor 700 in the reverse direction. When the mass of the vibration mechanism 712 rotates in the second direction, the mass lifts the front of the vibration plate 708 during the upward movement of the mass, as described above. In addition, the mass may also transmit the rearward movement of the mass to the vibration plate 708. However, because the rear of the vibration plate 708 does not lift, friction between the ground and the vibration plate 708 prevents the compactor 700 from moving backward. The phase or vibration of the vibration mechanism 712 may be controlled to provide only the compaction function as described above. Thus, a user may operate the compactor 700 in areas where additional compaction is desired, such as tight spaces. This allows a user to park the compactor 700 in a location where additional compaction is desired when operating in a forward direction and would otherwise need to restrain the compactor 700 from moving forward. Typical gas engine plate compactors require complex mechanical clutches and linkages to drive the vibrating mechanism 712 in the reverse direction. For example, a gas engine plate compactor may use two vibrating mechanisms to achieve reverse motion as described above. In contrast, the compactor 700 provides reverse motion with only a single vibrating mechanism 712 and without the need for complex mechanical clutches.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

[0073] The several outdoor power equipment described above that are powered by gas engine converter 10 include many advantages over conventional equipment powered by internal combustion engines, some of which are described below.

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

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

[0076] In some embodiments, an operator or original equipment manufacturer (OEM) is allowed limited access to control the speed of the gas engine conversion device 10 through the electronic processor 302 via an interface, such as a controller area network (CAN). In some embodiments, the electronic processor 302 allows a wider range of speed selection than a gasoline engine with a single gear set in the gear train 110. For example, the control electronics 42 is configured to drive the motor 36 at less than 2,000 RPM, which is lower than any speed a gasoline engine is capable of, thereby allowing the associated equipment to have a greater overall run time over the full discharge of the battery pack 50 than a gasoline engine. In addition, the control electronics 42 is configured to drive the motor at more than 3,600 RPM, which is higher than any speed a gasoline engine is capable of and capable of outputting more torque. The wider speed range of the motor 36 provides greater efficiency and capacity than a gasoline engine. In some embodiments, the operator may have access to control the current drawn by the motor 36 in addition to the speed.

[0077] In some embodiments, the electronic processor 302 is configured to record and report data. For example, the electronic processor 302 is configured to provide wired or wireless diagnostics to monitor and read the status of the gas engine conversion apparatus 10. For example, the electronic processor 302 can monitor and record the run time of the gas engine conversion apparatus 10, for example, in a rental scenario. In some embodiments, the motor 36 and the electronic processor 302 use regenerative braking to charge the battery pack 50. In some embodiments, the gas engine conversion apparatus 10 includes a DC output for lighting or accessories. In some embodiments, the electronic processor 302 can detect anomalies or malfunctions of the gas engine conversion apparatus 10 via voltage, current, motion, speed, and / or thermocouples. In some embodiments, the electronic processor 302 can detect unintended use or shutdown of the gas engine conversion apparatus 10. If the equipment driven by the gas engine conversion apparatus 10 is not operating with the intended characteristics or is not being used correctly or safely, the electronic processor 302 can detect the anomaly and shut down the gas engine conversion apparatus 10. For example, the gas engine conversion apparatus 10 may include one or more accelerometers that sense whether the gas engine conversion apparatus 10 and the equipment are in an intended orientation, and if the electronic processor 302 determines that the gas engine conversion apparatus 10 is not in an intended orientation (i.e., the equipment has tipped over), the electronic processor 302 may shut down the gas engine conversion apparatus 10.

[0078] In some embodiments, the gas engine conversion apparatus 10 includes an accessible sensor port (not shown) that electrically connects with a user-selected sensor for use with a piece of power equipment, such as an accelerometer, gyroscope, GPS unit, or real-time clock, allowing the operator to customize the variables sensed and detected by the electronic processor 302. In some embodiments, the electronic processor 302 can indicate to the operator the status of the battery pack 50, such as when the battery is depleted, via a visual, audible, or tactile notification. In some embodiments, the electronic processor 302 can operate an auxiliary motor separate from the motor 36 to drive an auxiliary device, such as a winch. The auxiliary motor can be internal or external to the gas engine conversion apparatus 10.

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

Claims

1. A power device, a first device for replacing a gas engine in the power machine; a second device for replacing the gas engine in the power machine; a controller coupled to the first device and the second device; The first device is A first motor; a first power take-off shaft for direct or indirect connection with a first exciter of the power machine to receive torque from the first motor; a first power switching network configured to selectively provide battery power to the first motor; The second device is A second motor; a second power take-off shaft for direct or indirect connection with a second exciter of the power machine to receive torque from the second motor; a second power switching network configured to selectively provide battery power to the second motor; The controller: providing a first control signal to the first device to drive the first motor; providing a second control signal to the second device to drive the second motor; It is configured as follows: Power equipment.

2. The power machine of claim 1 , wherein the first exciter is positioned intermediate the first device and a first vibrating plate.

3. 3. The power machine of claim 2, wherein the first exciter includes a first vibration mechanism, and the first device drives the first motor to drive the first vibration mechanism to drive the first vibration plate.

4. 2. The power machine of claim 1, wherein the first device is connected to the first exciter via a first belt coupling the first power take-off shaft to the first exciter.

5. The power machine of claim 1 , wherein the second exciter is positioned intermediate the second device and a second vibratory plate.

6. 6. The power machine of claim 5, wherein the second exciter includes a second vibration mechanism, and the second device drives the second motor to drive the second vibration mechanism to drive the second vibration plate.

7. 2. The power machine of claim 1, wherein the second device is connected to the second exciter via a second belt coupling the second power take-off shaft to the second exciter.

8. 10. The power machine of claim 1, wherein the power machine is a double exciter compactor.

9. 2. The power equipment of claim 1, wherein the controller is configured to provide the first control signal to a first electronic processor included in the first device and to provide the second control signal to a second electronic processor included in the second device.

10. The power machine of claim 1 , wherein the first control signal and the second control signal control a speed, a direction, and a phase offset of the first device and the second device, respectively.

11. The controller: further configured to determine an operating mode of the powered equipment; providing the first control signal to the first device includes providing the first control signal to the first device based on the operational mode; providing the second control signal to the second device includes providing the first control signal to the second device based on the operational mode. The power device according to claim 1 .

12. The power equipment of claim 11 , wherein the controller further comprises a memory that stores a mapping between the operating modes and controls for the first device and the second device.

13. The power equipment of claim 11 , wherein the controller determines the operational mode based on one or more user inputs received through a user input device of the power equipment.

14. The power equipment of claim 11 , wherein the controller determines the operational mode based on one or more user inputs received over a communications network from an external device providing a graphical user interface.

15. 12. The powered machine of claim 11, wherein the operating modes include one selected from the group consisting of forward compaction, reverse compaction, and neutral compaction, each operating mode corresponding to a particular control of the first device and the second device.

16. 16. The powered machine of claim 15, wherein in response to the operating mode being forward compaction, the first control signal and the second control signal control the first device and the second device to compact and advance the powered machine in a forward direction.

17. 17. The power machine of claim 16, wherein in response to the operating mode being forward compaction, the first control signal and the second control signal control the first motor and the second motor to rotate in a first direction.

18. 18. The powered machine of claim 17, wherein in response to the operating mode being reverse compaction, the first control signal and the second control signal control the first device and the second device to compact and advance the powered machine in a rearward direction.

19. 20. The power machine of claim 18, wherein in response to the operating mode being reverse compaction, the first control signal and the second control signal control the first motor and the second motor to rotate in a second direction opposite the first direction.

20. 20. The powered machine of claim 19, wherein in response to the operating mode being neutral compaction, the first control signal and the second control signal control the first device and the second device to perform compaction while remaining stationary.

21. 21. The power machine of claim 20, wherein in response to the operating mode being neutral compaction, the first control signal and the second control signal control the first motor and the second motor to rotate in opposite directions.

22. 12. The powered machine of claim 11, wherein the controller is further configured to repeat providing the first control signal to the first device and providing the second control signal to the second device for each mode change of the powered machine.

23. The power machine of claim 1 , wherein the controller is included in one of the first device and the second device.

24. 1. A method of operating a power device, comprising: determining, using a controller included in the powered machine, an operating mode of the powered machine; providing a first control signal for controlling a first motor of a first device included in the power machine based on the operating mode, the first device replacing a gas engine of the power machine and including the first motor, a first power take-off shaft receiving torque from the first motor for direct or indirect connection with a first exciter of the power machine; providing a second control signal to control a second motor of a second device included in the power equipment based on the operating mode, the second device replacing a gas engine of the power equipment and including the second motor, a second power take-off shaft receiving torque from the second motor for direct or indirect connection with a second exciter of the power equipment; method.

25. 25. The method of claim 24, wherein providing the first control signal and the second control signal based on the operational mode includes accessing a memory that stores a mapping between the operational mode and controls for the first device and the second device.

26. 25. The method of claim 24, wherein the first control signal and the second control signal control a speed, a direction, and a phase offset of the first device and the second device, respectively.

27. 25. The method of claim 24, wherein determining the operational mode includes determining the operational mode based on one or more user inputs received through a user input device of the powered equipment.

28. 25. The method of claim 24, wherein determining the operational mode includes determining the operational mode based on one or more user inputs received over a communications network from an external device that provides a graphical user interface.

29. 25. The method of claim 24, wherein the operating modes include one selected from the group consisting of forward compaction, reverse compaction, and neutral compaction, each operating mode corresponding to a particular control of the first device and the second device.

30. 30. The method of claim 29, wherein in response to the operating mode being forward compaction, the first control signal and the second control signal control the first device and the second device to compact and advance the powered equipment in a forward direction.

31. 31. The method of claim 30, wherein in response to the operating mode being forward compaction, the first control signal and the second control signal control the first motor and the second motor to rotate in a first direction.

32. 32. The method of claim 31 , in response to the operating mode being reverse compaction, the first control signal and the second control signal control the first device and the second device to compact and advance the powered equipment in a rearward direction.

33. 33. The method of claim 32, wherein in response to the operating mode being reverse compaction, the first control signal and the second control signal control the first motor and the second motor to rotate in a second direction opposite the first direction.

34. 34. The method of claim 33, wherein in response to the operating mode being neutral compaction, the first control signal and the second control signal control the first device and the second device to perform compaction while remaining stationary.

35. 35. The method of claim 34, wherein in response to the operating mode being neutral compaction, the first control signal and the second control signal control the first motor and the second motor to rotate in opposite directions.

36. 25. The method of claim 24, further comprising repeating providing the first control signal to the first device and providing the second control signal to the second device for each mode change of the powered equipment.

37. The method of claim 24 , wherein the controller is included in one of the first device and the second device.

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