Battery configuration for a gas engine replacement device

Abstract

To provide a battery-powered gas engine replacement device that increases a run time.SOLUTION: A gas engine replacement device 10 includes a housing, a first battery pack and a second battery pack connected to the housing, a motor 36 in the housing, a power switching circuitry 310 coupled to the motor 36 and the first and second battery packs and driving the motor 36, and an electronic processor 302 configured to sequentially discharge the first battery pack and the second battery pack to the power switching circuitry 310 to drive the motor 36 coupled to the power switching circuitry 310.SELECTED DRAWING: Figure 9

Description

Technical Field

[0001] (Related Application) This application claims the benefit of U.S. Provisional Patent Application No. 62 / 945,697, filed Dec. 9, 2019, the entire contents of which are incorporated herein by reference.

[0002] (Technical Field) This application relates to a battery configuration for a gas engine replacement device.

Background Art

[0003] Outdoor power equipment (e.g., gardening equipment) and construction equipment (e.g., concrete mixers, plate compactors), generally referred to as power equipment, may include a gas engine to operate the equipment. However, gas engines produce exhaust gas and generally are not adaptable to the optimal performance of power equipment.

[0004] Gas engines produce exhaust gas and are not easily configurable for specific applications of various types of equipment. For example, a gas engine replacement device, also called a power head, using a lithium-ion battery pack and an electric brushless motor has several advantages over a gas engine. However, the output density of gasoline is higher than the chemistry of current lithium-ion batteries or other widely available battery technologies. Therefore, in battery-driven gas engine replacement devices, generally the operating time is limited compared to a gasoline-driven engine of the same size. In other words, if the size of a gas engine replacement with a battery pack is comparable to the size of a gas engine with a fuel supply, the attached battery pack that powers the gas engine replacement will be more likely to be completely discharged faster than the gas engine runs out of its gasoline fuel supply.

Summary of the Invention

Problems to be Solved by the Invention

[0005] Therefore, for example, in order to provide the same operating time as a gas engine, it is necessary to increase the operating time of a battery-driven gas engine replacement device.

Means for Solving the Problem

[0006] One embodiment provides a gas engine replacement device including a housing and a power source having a first battery receptacle and a second battery receptacle provided in the housing. The gas engine replacement device also includes a first battery pack received in the first battery receptacle and a second battery pack received in the second battery receptacle. The gas engine replacement device includes a motor within the housing and a power switching network coupled between the motor and the first battery pack and the second battery pack. The first battery pack is coupled to the power switching network through a first switch, and the second battery pack is coupled to the power switching network through a second switch. The gas engine replacement device also includes an electronic processor coupled to the first switch, the second switch, and the power switching network. The electronic processor is configured to connect the first battery pack to the power switching network and determine whether the state of charge of the first battery pack is less than a predetermined threshold. If the state of charge of the first battery pack is less than the predetermined threshold, the electronic processor is further configured to connect the second battery pack to the power switching network and disconnect the first battery pack from the power switching network.

[0007] Another embodiment provides a method for increasing the operating time of a gas engine replacement device. The gas engine replacement device includes a first battery pack coupled to a power switching network through a first switch and a second battery pack coupled to the power switching network through a second switch. The method includes connecting the first battery pack to the power switching network and determining whether the charge state of the first battery pack is less than a predetermined threshold. The method also includes connecting the second battery pack to the power switching network and disconnecting the first battery pack from the power switching network if the charge state of the first battery pack is less than the predetermined threshold.

[0008] Another embodiment provides a gas engine replacement device including a housing and a power source having a battery receptacle and a module port provided in the housing. The gas engine replacement device also includes a first battery pack received in the battery receptacle and a battery module coupled to the module port. A second battery pack is received in the battery module. The gas engine replacement device includes a motor within the housing and a power switching network coupled between the motor and the first battery pack and the module port. The first battery pack is coupled to the power switching network through a first switch, and the battery module is coupled to the power switching network through a second switch. The gas engine replacement device also includes an electronic processor coupled to the first switch, the second switch, and the power switching network. The electronic processor is configured to connect the first battery pack to the power switching network and determine whether the charge state of the first battery pack is less than a predetermined threshold. The electronic processor is further configured to connect the battery module to the power switching network and disconnect the first battery pack from the power switching network if the charge state of the first battery pack is less than the predetermined threshold.

[0009] Another embodiment provides a method for increasing the operating time of a gas engine replacement device. The gas engine replacement device includes a first battery pack coupled to a power switching network through a first switch and a module port coupled to the power switching network through a second switch. The module port is configured to be coupled to a battery module that receives a second battery pack. The method includes connecting the first battery pack to the power switching network and determining whether the charge state of the first battery pack is less than a predetermined threshold. The method also includes, when the charge state of the first battery pack is less than the predetermined threshold, connecting the battery module to the power switching network and disconnecting the first battery pack from the power switching network.

[0010] Another embodiment provides a gas engine replacement device including a housing, a battery receptacle provided in the housing, a battery pack received in the battery receptacle, and an on-board charging circuit for charging the battery pack. The gas engine replacement device includes a motor within the housing and a power switching network coupled between the motor and a first battery pack and a second battery pack. The battery pack is coupled to the power switching network through a discharge switch, and the battery pack is coupled to the on-board charging circuit through a charging switch. The gas engine replacement device also includes a power cord that provides charging power to the on-board charging circuit and an electronic processor coupled to the discharge switch, the charging switch, and the power switching network. The electronic processor is configured to connect the battery pack to the power switching network to operate the motor and to connect the battery pack to the on-board charging circuit to charge the battery pack.

[0011] Other features and aspects will become apparent upon consideration of the following detailed description and the accompanying drawings.

Brief Description of the Drawings

[0012]

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DETAILED DESCRIPTION OF THE INVENTION

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

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

[0015] In addition, embodiments can include hardware, software, and electronic components or modules, and it should be understood that for purposes of discussion, these may be illustrated and described as if most of the components were implemented solely in hardware. However, those skilled in the art should recognize that based on reading this detailed description, in at least one embodiment, the electronic-based aspects can be implemented in software (e.g., software 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"). For this reason, note that multiple hardware- and software-based devices, as well as multiple different structural components, can be utilized to implement the embodiments.

[0016] As shown in FIGS. 1 and 2, a gas engine replacement device 10 for use with a power device includes a housing 14 having a first side surface 18, a second side surface 22 adjacent to the first side surface 18, a third side surface 26 on the opposite side of the second side surface 22, a fourth side surface 28 on the opposite side of the first side surface 18, a fifth side surface 30 extending between the second side surface 22 and the third side surface 26, and a sixth side surface 32 on the opposite side of the fifth side surface 30. The gas engine replacement device 10 also includes a flange 34 coupled to the housing 14 at the first side surface 18, an electric motor 36 disposed within the housing 14, and a power take-off shaft 38 that protrudes from the second side surface 22 and receives torque from the motor 36. As will be described in more detail below, in some embodiments, the power take-off shaft 38 protrudes from the first side surface 18 and the flange 34. As shown in FIG. 3, the gas engine replacement device 10 includes control electronics 42 that are disposed within the housing 14, include wiring and a controller 46, and are electrically connected to the motor 36. A similar gas engine replacement device 10 is described and illustrated in U.S. Patent Application Publication No. 16 / 551,197, filed Aug. 26, 2019, the entire contents of which are incorporated herein by reference.

[0017] As shown in FIGS. 1 to 6, the gas engine replacement device 10 includes battery packs 50-1 and 50-2 that are removably received in the battery receptacle 54 of the housing 14 and transmit current from the battery packs 50-1 and 50-2 to the motor 36 via the control electronics 42. The battery packs 50-1 and 50-2 may also be referred to singly as the battery pack 50. Referring to FIGS. 4 to 6, the battery pack 50 includes a battery pack housing 58 having a support portion 62 and a first terminal 66 that is electrically connected to a plurality of battery cells 68 supported by the battery pack housing 58. The support portion 62 provides a slide-on configuration by the cooperation of the protrusion / recess 70 with the complementary protrusion / recess 74 (shown in FIG. 6) of the battery receptacle 54. In the embodiment shown in FIGS. 4 to 6, the protrusion / recess 70 of the battery pack 50 is a guide rail, and the protrusion / recess 74 of the battery receptacle 54 is a guide recess. Similar battery packs are described and illustrated in U.S. Patent Application Publication No. 2019 / 0006980, filed on Jul. 2, 2018, the entire content of which is incorporated herein by reference.

[0018] Figures 4A and 4B illustrate embodiments of the battery pack 50. The battery pack 50 may include one or more cell strings each having several (e.g., 10) battery cells 68 connected in series to provide a desired discharge output (e.g., nominal voltage (e.g., 20V, 40V, 60V, 80V, 120V) and current capacity). FIG. 4A shows a battery pack 50-1 having a 20S2P configuration. The battery pack 50-1 includes two cell strings composed of 20 serially connected cells, and the cell strings are connected in parallel. FIG. 5B is a cross-sectional view of the battery pack 50-1 of FIG. 4A, showing a first cell string 71 and a second cell string 72 separated by a partition 73 of the battery pack housing 58. FIG. 4B shows a battery pack 50-2 having a 20S1P configuration. The battery pack 50-2 includes one cell string composed of 20 serially connected cells. In other embodiments, other combinations of battery cells are possible. FIG. 5A is a cross-sectional view of the battery pack 50-2 of FIG. 4B, showing a cross-sectional view of the cell string in the battery pack housing 58.

[0019] In some embodiments, the battery cell 68 has a nominal voltage of up to about 80V. In some embodiments, the battery cell 68 has a nominal voltage of up to about 120V. In some embodiments, the battery pack 50 has a weight of up to about 6 lb. In some embodiments, each of the battery cells 68 has a maximum diameter of 21 mm and a maximum length of 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 cell 68 is operable to output a continuous operating discharge current between about 40A and about 60A. In some embodiments, each of the battery cells 68 has a capacity of about 3.0 Ah to about 5.0 Ah.

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

[0021] In other embodiments (not shown), the latch mechanism 82 can be disposed at various positions (e.g., side walls, end walls, upper end walls, etc. of the battery receptacle 54) such that the latch mechanism 82 engages with a corresponding structure on the battery pack 50 to maintain the engagement between the battery pack 50 and the battery receptacle 54. The latch mechanism 82 includes a pivotable actuator or handle 90 that operably engages with a latch member 94. The latch member 94 is slidably disposed within the bore 99 of the battery receptacle 54 and is biased toward the latched position by a biasing member 100 (e.g., a spring) to protrude through the surface of the battery receptacle 54 into a cavity within the battery pack 50.

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

[0023] As shown in FIG. 7, the motor 36 includes a motor housing 96 having an outer diameter of 97, a stator 98 having a nominal outer diameter 101 of up to about 80 mm, a rotor 102 having an output shaft 106 and supported for rotation within the stator 98, and a fan 108. A similar motor is described and illustrated in U.S. Patent Application Publication No. 2019 / 0006980, which is incorporated herein by reference. In some embodiments, the motor 36 is a brushless DC motor. In some embodiments, the motor 36 has an electrical power output of at least about 2760 W. In some embodiments, the electrical power output of the motor 36 may drop below 2760 W during operation. In some embodiments, the fan 108 has a diameter 109 that is the larger diameter 97 of the motor housing 96. In some embodiments, the motor 36 can be stopped by an electronic clutch (not shown) for rapid overload control. In some embodiments, the motor 36 has a volume of up to about 443,619 mm 3 3. In some embodiments, the motor 36 has a weight of up to about 4.6 lb. The housing 14 includes an inlet vent and an outlet vent, whereby the motor fan 108 draws air along the control electronics 42 through the inlet vent and cools the control electronics 42 before the air is discharged through the outlet vent. In the embodiment shown in FIG. 7, the motor 36 is an internal rotor motor, but in other embodiments, the motor 36 can be an external rotor motor having a nominal outer diameter of up to about 80 mm (i.e., the nominal outer diameter of the rotor 102).

[0024] Referring to FIG. 8, motor 36 can transmit torque to power take-off shaft 38 in various configurations. In some embodiments, output shaft 106 is also a power take-off shaft 38 such that motor 36 drives power take-off shaft 38 directly without any intermediate gear train. For example, motor 36 can be a direct drive multi-pole motor. As shown in FIG. 8, in other embodiments, gas engine replacement device 10 includes a gear train 110 that transmits torque from motor 36 to power take-off shaft 38. In some embodiments, gear train 110 can include a mechanical clutch (not shown) that interrupts the transmission of torque from motor 36 to power take-off shaft 38. In some embodiments, gear train 110 can include a planetary transmission that transmits torque from output shaft 106 to power take-off shaft 38, and the axis of rotation of output shaft 106 is coaxial with the axis of rotation of power take-off shaft 38. In some embodiments, gear train 110 includes spur gears that engage output shaft 106 of rotor 102 such that the axis of rotation of output shaft 106 is offset from and parallel to the axis of rotation of power take-off shaft 38. In some embodiments, gear train 110 includes bevel gears such that the axis of rotation of output shaft 106 is perpendicular to the axis of rotation of power take-off shaft 38. In other embodiments that utilize bevel gears, the axis of rotation of output shaft 106 is not perpendicular, parallel, or coaxial with the axis of rotation of power take-off shaft 38, and power take-off shaft 38 projects from flange 34.

[0025] In some embodiments, the gas engine replacement device 10 includes an on / off indicator (not shown). In some embodiments, the gas engine replacement device 10 includes a filter (not shown) that prevents airborne debris from entering the motor 36 and the control electronics 42. In some embodiments, the filter includes a dirty filter sensor (not shown) and a self-cleaning mechanism (not shown). In some embodiments, the motor 36 mimics the gas engine response when it encounters resistance such as decelerating or becoming immobile. In some embodiments, the gas engine replacement device 10 includes a heat sink 202 within the housing 14 for air-cooling the control electronics 42 (FIGS. 1 and 2). In some embodiments, the gas engine replacement device 10 is liquid-cooled.

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

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

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

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

[0030] During operation, the housing 14 of the gas engine replacement device 10 is relatively much cooler than the housing of an internal combustion unit because there is no combustion in the gas engine replacement device 10. Specifically, during operation of the gas engine unit, the housing of the gas engine unit reaches 220 °C or higher. In contrast, during operation of the gas engine replacement device 10, all of the outer surfaces of the housing 14 are less than 95 °C.

[0031] FIG. 9 shows a simplified block diagram of a gas engine replacement device 10 according to one exemplary embodiment. As shown in FIG. 9, the gas engine replacement device 10 includes an electronic processor 302, a memory 306, a power supply 308, a power switching network 310, a motor 36, a rotor position sensor 314, a current sensor 318, a voltage sensor 320, a user input device 322 (e.g., a trigger or a power button), a transceiver 326, and an indicator 330 (e.g., a light emitting diode). In some embodiments, the gas engine replacement device 10 includes fewer or additional components than those shown in FIG. 9. For example, the gas engine replacement device 10 may include a battery pack fuel gauge, a work light, additional sensors, a kill switch, a power cut-off switch 86, etc. In some embodiments, one or more of the elements of the gas engine replacement device 10 shown in FIG. 9, including the electronic processor 302, the memory 306, the power switching network 310, the rotor position sensor 314, the current sensor 318, the voltage sensor 320, the user input device 322 (e.g., a trigger or a power button), the transceiver 326, and the indicator 330 (e.g., a light emitting diode), form at least a part of the control electronics 42 shown in FIG. 3, and the electronic processor 302 and the memory 306 form at least a part of the controller 46 shown in FIG. 3.

[0032] The memory 306 includes a read-only memory (ROM), a random access memory (RAM), other non-transitory computer-readable media, or a combination thereof. The electronic processor 302 is configured to communicate with the memory 306 to store data and retrieve the stored data. The electronic processor 302 is configured to receive instructions and data from the memory 306 and, in particular, to execute instructions. Specifically, the electronic processor 302 executes instructions stored in the memory 306 to perform the methods described herein. The memory 306 also stores firmware including configurable device settings of the gas engine replacement device 10. The electronic processor 302 accesses the firmware stored in the memory 306 and controls the motor 36 according to the device settings in the firmware.

[0033] As described above, in some embodiments, power source 308 may include one or more battery packs 50 received in battery receptacle 54 on housing 14. Power source 308 may also include one or more battery modules 158 coupled to gas engine replacement device 10.

[0034] Power switching circuitry 310 enables electronic processor 302 to control the operation of motor 36. Generally, when user input device 322 is depressed (or otherwise actuated), current is supplied from battery pack 50 to motor 36 through power switching circuitry 310. When user input device 322 is not depressed (or otherwise actuated), current is not supplied from battery pack 50 to motor 36. In some embodiments, the amount by which user input device 322 is depressed is related to or corresponds to the desired rotational speed of motor 36. In other embodiments, the amount by which user input device 322 is depressed is related to or corresponds to the desired torque. In other embodiments, a separate input device (e.g., a slider, a dial, etc.) that communicates with electronic processor 302 to provide a desired rotational speed or torque to motor 36 is included in gas engine replacement device 10.

[0035] In response to receiving a drive request signal from user input device 322, electronic processor 302 actuates power switching circuitry 310 to provide power to motor 36. Through power switching circuitry 310, electronic processor 302 controls the amount of current available to motor 36, thereby controlling the speed and torque output of motor 36. Power switching circuitry 310 may include a number of field effect transistors (FETs), bipolar transistors, or other types of electrical switches. For example, power switching circuitry 310 may include a 6-FET bridge that receives a pulse width modulation (PWM) signal from electronic processor 302 to drive motor 36.

[0036] The rotor position sensor 314, the current sensor 318, and the voltage sensor 320 are coupled to the electronic processor 302 and transmit various control signals indicative of different parameters of the gas engine replacement device 10, the motor 36, the power supply 308, or combinations thereof to the electronic processor 302. In some embodiments, the rotor position sensor 314 includes one or more Hall sensors. In other embodiments, the rotor position sensor 314 includes a quadrature phase encoder attached to the motor 36. The rotor position sensor 314 outputs motor feedback information, such as an indicator (e.g., a pulse), to the electronic processor 302 when the magnets of the rotor of the motor 36 rotate across the face of the Hall sensor. In still other embodiments, the rotor position sensor 314 includes a voltage or current sensor that provides an indicator of, for example, the back electromotive force (back emf) generated in the motor coil. The electronic processor 302 can identify the rotor position, rotor speed, and rotor acceleration based on the back emf signal received from the rotor position sensor 314, i.e., the voltage or current sensor. The rotor position sensor 314 can be combined with the current sensor 318 to form a current and rotor position composite sensor. In this example, the composite sensor provides current flowing through the active phase coils of the motor 36 and also provides current in one or more non-active phase coils of the motor 36. The electronic processor 302 measures the current flowing through the motor based on the current flowing through the active phase coils and measures the motor speed based on the current in the non-active phase coils.

[0037] Based on the motor feedback information from the rotor position sensor 314, the electronic processor 302 can identify the position, speed, and acceleration of the rotor. In response to the motor feedback information and the signal from the user input device 322, the electronic processor 302 transmits a control signal to control the power switching circuitry 310 to drive the motor 36. For example, by selectively enabling and disabling the FETs of the power switching circuitry 310, the power received from the battery pack 50 is selectively applied periodically to the stator windings of the motor 36 to rotate the rotor 102 of the motor 36. The motor feedback information is used by the electronic processor 302 to ensure the appropriate timing of the control signal to the power switching circuitry 310 and, in some cases, to provide closed-loop feedback to control the speed of the motor 36 to a desired level. For example, to drive the motor 36, using the motor positioning information from the rotor position sensor 314, the electronic processor 302 identifies where the rotor magnet is relative to the stator windings and (a) excites the next stator winding pair (or pairs) in a predetermined pattern to apply a magnetic force to the rotor magnet in the desired direction of rotation, and (b) demagnetizes the previously excited stator winding pair (or pairs) to prevent the application of a magnetic force to the rotor magnet in the direction opposite to the direction of rotation of the rotor.

[0038] The voltage sensor 320 is configured to measure the voltage of the power supply 308 corresponding to the charge state of the power supply 308 and provide a signal indicating the charge state to the electronic processor 302. In some embodiments, the voltage sensor 320 is incorporated into the power supply 308, and the power supply 308 (e.g., the electronic processor of the power supply 308) transmits a signal indicating the charge state of the power supply 308. If the power supply 308 includes multiple battery packs, the voltage sensor is configured to measure the voltage of each pack and provide a signal indicating the corresponding charge state of each pack.

[0039] Transceiver 326 enables communication between electronic processor 302 and external device 338 (e.g., smartphone, tablet, or laptop computer) via wired or wireless communication network 334. In some embodiments, transceiver 326 may include separate transmit and receive components. In some embodiments, transceiver 326 may include a wireless adapter attached to gas engine replacement device 10. In some embodiments, transceiver 326 is a wireless transceiver that encodes information received from electronic processor 302 into a carrier radio signal and transmits the encoded wireless signal to external device 338 via communication network 334. Transceiver 326 also decodes information from the wireless signal received from external device 338 via communication network 334 and provides the decoded information to electronic processor 302.

[0040] Communication network 334 provides a wired or wireless connection between gas engine replacement device 10 and external device 338. Communication network 334 may include a short-range network, such as a BLUETOOTH® network, Wi-Fi network, etc., or a long-range network, such as the Internet, cellular network, etc.

[0041] As shown in FIG. 9, the indicator 330 is also coupled to the electronic processor 302, receives control signals from the electronic processor 302, and turns on and off or otherwise conveys information based on different states of the gas engine replacement device 10. The indicator 330 includes, for example, one or more light-emitting diodes ("LEDs") or a display screen. The indicator 330 can be configured to display the state of the gas engine replacement device 10 or information related thereto. For example, the indicator 330 is configured to indicate measured electrical characteristics of the gas engine replacement device 10, the state of the gas engine replacement device 10, the mode of the gas engine replacement device 10, the state of the battery pack 50, and the like. The indicator 330 can also include elements that convey information to the user through audible or tactile output. In some embodiments, the indicator 330 includes an eco indicator that indicates the amount of power being used by the load during operation.

[0042] The connections shown between the components of the gas engine replacement device 10 are simplified in FIG. 9. In reality, the wiring of the gas engine replacement device 10 is more complex because the components of the gas engine replacement device 10 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, and the power lines from the battery pack 50 to the power switching network 310 include a positive wire and a negative / ground wire, and so on. Additionally, the power lines can have a large gauge / diameter to handle increased current. Further, although not shown, additional control signals and power lines are used to interconnect additional components of the gas engine replacement device 10.

[0043] As described above, the gas engine alternative device 10 has a shorter operation time than a gas engine of the same size. FIGS. 10 to 18 show some battery configurations of the gas engine alternative device 10 that increase the operation time of the gas engine alternative device 10. As shown in FIGS. 10, 11A, and 11B, a plurality of battery receptacles 54 are provided in the housing 14 of the gas engine alternative device 10 and can receive a plurality of battery packs 50. In FIG. 10, the plurality of battery receptacles 54 include a first battery receptacle 54A and a second battery receptacle 54B, and are individually labeled as the first battery receptacle 54A and the second battery receptacle 54B. The plurality of battery packs 50 include a first battery 50A and a second battery 50B, and are individually labeled as the first battery 50A and the second battery 50B.

[0044] As shown in FIG. 10, the battery receptacle 54 is provided on the housing 14 that extends between the upper surface (the fourth side surface 28) and the side surfaces (the fifth side surface 30 and the sixth side surface 32). The first battery receptacle 54A extends between the fourth side surface 28 and the fifth side surface 30, and the second battery receptacle 54B extends between the fourth side surface 28 and the sixth side surface 32. In some embodiments, the battery pack 50 can be received from the fourth side surface 28 such that the battery pack 50 slides downward into the battery receptacles 54A and 54B from the upper part of the housing 14. In some embodiments, the battery pack 50 can be received from the fifth side surface 30 and the sixth side surface 32 respectively such that the battery pack 50 slides upward into the battery receptacles 54A and 54B from the side surfaces of the housing 14. In other embodiments, the battery pack 50 can be received from the second side surface 22 and / or the third side surface 26 such that the battery pack 50 slides into the battery receptacles 54A and 54B from the second side surface 22 to the third side surface 26 or vice versa. The battery pack 50 protrudes outside the housing 14 at the fourth side surface 28, the fifth side surface 30, and the sixth side surface 32.

[0045] As shown in FIGS. 11A and 11B, the housing 14 includes a first handle 150A and a second handle 150B that extend from a fifth side surface 30 to a sixth side surface 32. The first handle 150A is provided closer to the second side surface 22, and the second handle 150B is provided closer to the third side surface 26. The first battery receptacle 54A and the second battery receptacle 54B are provided between the first handle 150A and the second handle 150B at the fifth side surface 30 and the sixth side surface 32, respectively. The battery pack 50 is attached from the fourth side surface 28 such that the battery pack 50 slides downward into the battery receptacles 54A and 54B from the upper part of the housing 14. The battery pack 50 is received in recesses provided in the fifth side surface 30 and the sixth side surface 32. Thus, the battery pack 50 does not extend beyond the housing 14 at the fifth side surface 30 and the sixth side surface 32. The battery pack 50 projects beyond the upper part of the housing 14 at the fourth side surface 28. A support portion 154 may be provided at the upper part of the housing 14 that extends substantially equal to the length of the portion of the battery pack 50 that projects beyond the upper part of the housing 14. The support portion 154 provides additional support for the battery pack 50 that suppresses vibrations generated by the gas engine replacement device 10. The battery pack 50 and the support portion 154 do not extend beyond the first handle 150A and the second handle 150B. The first handle 150A and the second handle 150B provide additional protection for the battery pack 50 during a drop event.

[0046] FIG. 12 is a simplified block diagram of a power supply 308 according to one exemplary embodiment. The power supply 308 includes a first battery pack 50A and a second battery pack 50B, corresponding to the plurality of battery pack gas engine replacement devices 10 of FIGS. 10-11B. The power switching network 310 is coupled to the first battery pack 50A through a first switch 350 and to the second battery pack 50B through a second switch 354. The first switch 350 and the second switch 354 are FETs, for example, controlled to be enabled and disabled by an electronic processor 302. When the first switch 350 is enabled, the first switch 350 allows current to flow from the first battery pack 50A to the power switching network 310. When the first switch 350 is disabled, the first switch 350 cuts off the current from the first battery pack 50A to the power switching network 310. Similarly, the second switch 354 is controlled by the electronic processor 302 to allow and cut off current from the second battery pack 50B to the power switching network 310.

[0047] During operation, the electronic processor 302 may connect only one of the first battery pack 50A and the second battery pack 50B to the power switching circuitry 310 at any given time during operation (except for temporarily overlapping during switching between packs) in some embodiments. The electronic processor 302 discharges the first battery pack 50A and the second battery pack 50B sequentially to increase the operating time of the gas engine replacement device 10. FIG. 13 is a flowchart of an exemplary method 400 for increasing the operating time of the gas engine replacement device 10. In the illustrated example, method 400 includes connecting the first battery pack 50A to the power switching circuitry 310 using the first switch 350 (at block 404). The electronic processor 302 controls the first switch 350 so that current can flow from the first battery pack 50A to the power switching circuitry 310. Before enabling the first switch 350, the electronic processor 302 may determine whether the first battery pack 50A has been received in the first battery receptacle 54A and whether the charge state of the first battery pack 50A exceeds a predetermined threshold.

[0048] Method 400 includes determining whether the charge state of the first battery pack 50A is less than a predetermined threshold (at block 408). In some embodiments, the gas engine replacement device 10 includes a voltage sensor (e.g., voltage sensor 320) that measures the voltage of the first battery pack 50A and / or the second battery pack 50B. The electronic processor 302 determines the charge state of the first battery pack 50A using the voltage sensor. In other embodiments, the first battery pack 50A includes an internal voltage sensor that determines the charge state of the first battery pack 50A. The electronic processor 302 communicates with the battery electronics processor of the first battery pack 50A and receives the charge state of the first battery pack 50A from the battery electronics processor. For example, the first battery pack 50A provides charge state information to the electronic processor 302 during group readout.

[0049] When the state of charge of the first battery pack 50A exceeds a predetermined threshold, method 400 returns to block 404 and continues to operate the gas engine replacement device 10 using the first battery pack 50A. When the state of charge of the first battery pack 50A is less than the predetermined threshold, method 400 includes (at block 412) connecting the second battery pack 50B to the power switching network 310 using the second switch 354. The electronic processor 302 controls the second switch 354 so that current can flow from the second battery pack 50B to the power switching network 310. Similar to what was described above, before enabling the second switch 354, the electronic processor 302 may determine whether the second battery pack 50B has been received in the second battery receptacle 54B and whether the state of charge of the second battery pack 50B exceeds a predetermined threshold.

[0050] Method 400 also includes (at block 416) disconnecting the first battery pack 50A from the power switching network 310 using the first switch 350. The electronic processor 302 controls the first switch 350 to interrupt the current from the first battery pack 50A to the power switching network 310. In the example shown in FIG. 13, connecting the second battery pack 50B is performed before disconnecting the first battery pack 50A. However, it should be understood that these steps may be performed in the reverse order. That is, the electronic processor 302 may disconnect the first battery pack 50A from the power switching network 310 before connecting the second battery pack 50B to the power switching network 310. Further, in some embodiments, the electronic processor 302 may disconnect the first battery pack 50A from the power switching network 310 at the same time as connecting the second battery pack 50B to the power switching network 310.

[0051] In some embodiments, the electronic processor 302 can activate an indicator 330 to indicate to the user the state of the battery pack 50. For example, the electronic processor 302 can use the indicator 330 to indicate that the battery pack 50 has been connected, disconnected, and / or discharged. In one example, the electronic processor 302 can turn on different indicators 330 associated with each of the above states, or can turn on the indicator 330 associated with the battery pack 50 in different colors based on the state of the battery pack 50. Thereafter, the user can replace the depleted battery pack 50 with a fully or partially charged battery pack 50 so that method 400 can repeat connecting the first battery pack 50A when the second battery pack 50B is depleted. Thereby, method 400 enables the user to continuously operate the gas engine alternative device 10 while alternating the battery pack 50 during operation. Such applications are useful, for example, when the gas engine alternative device 10 is used for pumps (requiring continuous operation), material handling carts / buggies (where the depleted battery pack 50 can be replaced when the user is near the charger), concrete mixers, and flat concrete saws.

[0052] FIG. 13 generally describes an embodiment in which either the first battery pack 50A or the second battery pack 50B is connected to the power switching circuit network 310 at a given time during the operation of the gas engine replacement device 10, but not both packs. In other embodiments, both the battery packs 50A and 50B are connected to the power switching circuit network. For example, the battery packs 50A and 50B can be connected in parallel to the power switching circuit network when the charge state of each pack exceeds a predetermined threshold. When the charge state of either the battery pack 50A or 50B drops below the predetermined threshold, that battery pack 50A or 50B is disconnected from the power switching circuit network 310 via its respective first switch 350 or second switch 354. At this time, the gas engine replacement device 10 is still powered by the remaining connected battery pack 50A or 50B, and the user can replace the depleted battery pack 50A or 50B with a fully or partially charged battery pack 50. When replaced, the electronic processor 302 can control the associated first switch 350 or second switch 354 to connect the newly inserted battery pack 50 in parallel to the power switching circuit network 310 with the battery pack 50A or 50B that was not removed. In another example, the battery packs 50A and 50B are coupled in series to the power switching circuit network to provide a higher supply voltage by the gas engine replacement device 10. In some embodiments of the battery packs 50A and 50B connected in series, a single switch 350 can be provided in series with the battery packs 50A and 50B. Also, when the charge state of either the battery pack 50A or 50B drops below a predetermined threshold, the switch 350 opens to disconnect both the battery packs 50A and 50B.

[0053] FIG. 14 shows several battery modules 158 that can be daisy-chain connected to a battery receptacle 54 in a housing 14 of the gas engine replacement device 10. The gas engine replacement device 10 includes module ports 162 (e.g., on the housing 14) for connecting to one or more of the battery modules 158. Each battery module 158 includes a module housing 164 that includes a module battery receptacle 166. The module battery receptacle 166 is similar to the battery receptacle 54 in the housing 14 of the gas engine replacement device 10, and each module battery receptacle 166 includes an electrical and mechanical interface for engaging a battery pack 50. The battery pack 50 is received in the module battery receptacle 166. The module housing 164 includes an output connector port 170 and an input connector port 174. A first cord 178A is used to couple a first battery module 158A to the gas engine replacement device 10. The first cord 178A couples the output connector port 170 to the module port 162 to provide operating current from a first battery pack 50A received in the first battery module 158A to the gas engine replacement device 10. A second cord 178B is used to couple a second battery module 158B to the first battery module 158A to provide operating current from a second battery pack 50B received in the second battery module 158B to the first battery module 158A. The first battery module 158A passes the operating current from the second battery module 158B, along with the operating current from the first battery pack 50A, through the first cord 178A to the gas engine replacement device 10. In some embodiments, the battery module 158 can be directly attached to the gas engine replacement device 10 or to a power device powered by the gas engine replacement device 10.

[0054] FIG. 15 is a simplified block diagram of a power supply 308 according to another exemplary embodiment. The power supply 308 includes a battery pack 50 and a module port 162 and corresponds to the gas engine replacement device 10 of FIG. 14. A power switching network 310 is coupled to the battery pack 50 through a first switch 350 and to the module port 162 through a second switch 354. The module port 162 is used to connect one or more battery modules 158 to the gas engine replacement device 10. The first switch 350 and the second switch 354 are FETs that are controlled to be enabled and disabled, for example, by an electronic processor 302. When the first switch 350 is enabled, the first switch 350 allows current to flow from the battery pack 50 to the power switching network 310. When the first switch 350 is disabled, the first switch 350 interrupts the current from the battery pack 50 to the power switching network 310. Similarly, the second switch 354 is controlled by the electronic processor 302 to allow and interrupt current flow from one or more battery modules 158 to the power switching network 310.

[0055] During operation, the electronic processor 302 can connect only one of the battery pack 50 and one or more battery modules 158 to the power switching network 310. The electronic processor 302 discharges the battery pack 50 and one or more battery modules 158 sequentially to increase the operating time of the gas engine alternative device 10. FIG. 16 is a flowchart of an exemplary method 430 for increasing the operating time of the gas engine alternative device 10. In the illustrated example, method 430 includes connecting the battery pack 50 to the power switching network 310 using a first switch 350 (at block 434). The electronic processor 302 controls the first switch 350 so that current can flow from the battery pack 50 to the power switching network 310. Before enabling the first switch 350, the electronic processor 302 can determine whether the battery pack 50 has been received in the battery receptacle 54 and whether the charge state of the battery pack 50 exceeds a predetermined threshold.

[0056] Method 430 includes determining whether the charge state of the battery pack 50 is less than a predetermined threshold (at block 438). In some embodiments, the gas engine alternative device 10 includes a voltage sensor (e.g., voltage sensor 320) that measures the voltage of the battery pack 50. The electronic processor 302 uses the voltage sensor to determine the charge state of the battery pack 50. In other embodiments, the battery pack 50 includes an internal voltage sensor that determines the charge state of the battery pack 50. The electronic processor 302 communicates with the battery electronics processor of the battery pack 50 to receive the charge state of the battery pack 50 from the battery electronics processor. For example, the battery pack 50 provides charge state information to the electronic processor 302 during group read.

[0057] When the state of charge of the battery pack 50 exceeds a predetermined threshold, method 430 returns to block 434 and continues to operate the gas engine replacement device 10 using the battery pack 50. When the state of charge of the battery pack 50 is less than the predetermined threshold, method 400 includes (at block 442) using a second switch 354 to connect a module port 162 to a power switching network 310. The electronic processor 302 controls the second switch 354 so that current can flow from the module port 162 to the power switching network 310. In other words, when a battery module 158 having an attached battery pack 50 is coupled to the module port 162 and the module port 162 is connected to the power switching network 310 via the second switch 354, power from the battery pack 50 of the battery module 158 is connected to the power switching network 310 to supply power to the gas engine replacement device 10. Similar to what was described above, before enabling the second switch 354, the electronic processor 302 can determine whether a battery module 158 including the battery pack 50 is connected to the module port 162 and whether the state of charge of the battery pack 50 received by the battery module 158 exceeds a predetermined threshold.

[0058] Method 430 also includes disconnecting the battery pack 50 from the power switching network 310 using the first switch 350 (at block 446). The electronic processor 302 controls the first switch 350 to interrupt the current from the battery pack 50 to the power switching network 310. In the example shown in FIG. 16, connecting the module port 162 is performed before disconnecting the battery pack 50. However, these steps may be performed in the reverse order. That is, the electronic processor 302 may disconnect the battery pack 50 from the power switching network 310 before connecting the module port 162 to the power switching network 310. Further, in some embodiments, the electronic processor 302 may disconnect the battery pack 50 from the power switching network 310 at the same time as connecting the module port 162 to the power switching network 310.

[0059] Thereby, method 430 enables a user to continuously operate the gas engine replacement device 10 while daisy-chain connecting an additional battery pack 50 without removing the currently attached battery pack 50 during operation. Such applications are useful, for example, in stationary applications such as pumps, concrete / mortar mixers, where the battery module 158 is attached to the power equipment. Method 430 also provides the advantage of maximum flexibility for implementing more batteries. In particular, the user can determine the number of batteries required for the task. Additionally, in this embodiment, an additional battery receptacle 54 is not required in the housing 14 of the gas engine replacement device 10, thereby providing a better form factor for the gas engine replacement device 10.

[0060] FIG. 16 generally describes an embodiment in which the battery pack 50 or the module port 162 is connected to the power switching network 310 at a given time during the operation of the gas engine alternative device 10, but not both packs are connected. In other embodiments, both the battery pack 50 and the module port 162 are connected to the power switching network. For example, the battery pack 50 and the module port 162 can be connected in parallel or in series, similar to the alternative embodiments described above with respect to FIG. 13.

[0061] In some embodiments, when the electronic processor 302 is switched between power sources, the motor 36 can be temporarily stopped and the operation of the motor 36 can be temporarily restricted. For example, after determining that the first battery pack 50A or the battery pack 50 is depleted, the electronic processor 302 can control the power switching network 310 to stop the motor 36. Then, after enabling the first switch 350 and disabling the second switch 354, the electronic processor 302 resumes the operation of the motor 36. In some embodiments, instead of stopping the motor 36, the electronic processor 302 can operate the motor 36 inertially while switching between power sources.

[0062] Figures 17A - 17B each show two daisy chain circuits 450A and 450B that connect a daisy chain - connected battery pack 50 to the module ports 162 of FIGS. 14 and 15 so as to be able to supply power to the power - switching circuit network 310 and thus to the gas engine replacement device 10. In FIG. 17A, the module port 162 is coupled to two module housings 164 (each individually identified as 164A and 164B) each having a respective battery pack 50. As shown, cords 178A and 178B form a DC bus link to the module port 162, whereby the battery pack 50 of module housing 164A is coupled to the bus link via a third switch 452, and the battery pack 50 of module housing 164B is coupled to the bus link 178 via a fourth switch 454. The third switch 452 and the fourth switch 454 are selectively controlled by an electronic processor 302. Thus, the respective battery packs 50 of module housing 164A and module housing 164B can be selectively coupled to the module port 162 and thus to the power - switching circuit network 310. Returning to block 442 of FIG. 16, when the module port 162 is connected to the power - switching circuit network 310 via the second switch 354, the electronic processor 302 may further provide a control signal to the third switch 452, the fourth switch 454, or both, to select one or both of the batteries 50 coupled to module housings 164A - B to provide power to the power - switching circuit network 310. The control signal may be provided from the electronic processor 302 through the data lines of cords 178A - B via the module port. For example, a control line may be provided for each module housing 164, or a shared control line may be used by a control signal having an associated address that identifies the module housing 164 for receiving the control signal. Next, the module housing 164 (or each switch of module housing 164) operates in response to a control signal targeted at itself and may exclude control signals targeted at other module housings 164.

[0063] In FIG. 17B, module port 162 is also coupled here to two module housings 164 (each individually identified as 164A and 164B) each having a respective battery pack 50. As shown, cords 178A and 178B form a DC bus link to module port 162, whereby the battery packs 50 of module housings 164A and 165B are coupled to the bus link. Instead of including individual switches within module housings 164A - B, a multipole switch 456 is included as part of the module port 162 of the gas engine alternative 10. In some embodiments, the multipole switch 456 can be incorporated within one of the module housings 164. The DC bus link includes one separate power supply line connecting the module port 162 to the module housing 164, one for each module housing 164. The multipole switch 456 is selectively controlled by the electronic processor 302 to select one of the power supply lines of the DC bus link. Thus, each respective battery pack 50 of module housing 164A and module housing 164B can be selectively coupled to the module port 162 and thus to the power switching network 310. Returning to block 442 of FIG. 16, when the module port 162 is connected to the power switching network 310 via the second switch 354, the electronic processor 302 can further provide a control signal to the multipole switch 456 to select one or both of the batteries 50 coupled to module housings 164A - B to provide power to the power switching network 310.

[0064] Three power supply lines and a 3 - to - 1 multipole switch are shown as part of the cords 178A and 178B of FIG. 17B, but in some embodiments, fewer or more power supply lines are included and a multipole switch 456 having a corresponding number of inputs is provided. Generally, for each power supply line included, one additional module housing 164 having a battery pack 50 can be coupled to the module port 162 in a daisy - chain fashion.

[0065] In connection with the embodiments of FIGS. 17A and 17B, the electronic controller 302 may select a battery 50 from a plurality of daisy-chain connected batteries 50 based on the state of charge of the battery 50. The battery pack 50 may include a voltage sensor or other sensor that measures its respective state of charge and provides the measured state of charge to the electronic controller 302 via the data lines of codes 178A and 178B. The gas engine alternative device 10 may include a voltage sensor or other sensor that measures the state of charge of any battery pack 50 coupled via the module port 162. In some embodiments, when the module port 162 is selected to provide power (e.g., in step 442 of FIG. 16), the electronic controller 302 determines the state of charge of each battery pack 50 connected to the module port 162 via the daisy chain and selects the battery pack 50 having the highest state of charge. Thereafter, the electronic controller 302 monitors the state of charge of the selected battery pack 50 and may switch to the battery pack 50 having the highest state of charge at that time if the state of charge drops below a predetermined threshold. In some embodiments, other selection criteria and techniques for the battery pack 50 are used to select from the battery packs 50 coupled to the module port 162.

[0066] In some embodiments, as shown in FIGS. 18 and 19, the gas engine alternative device 10 includes an on-board charging circuit 460 that charges the battery pack 50 connected to the gas engine alternative device 10. The gas engine alternative device 10 includes a power cord 464 that can be plugged into a power outlet (e.g., a 120VAC / 60Hz wall outlet or other standard power outlet) to receive charging power to charge the battery pack 50. The on-board charging circuit 460 receives charging power from the power cord 464 and, when enabled, provides a charging current to charge the battery pack 50.

[0067] FIG. 19 is a simplified block diagram of a power supply 308 according to another exemplary embodiment. The power supply 308 includes a battery pack 50 and an on-board charging circuit 460 that charges the battery pack 50. The battery pack 50 is coupled to a power switching network 310 through a discharge switch 468. The on-board charging circuit 460 is coupled to the battery pack 50 through a charging switch 472. The discharge switch 468 and the charging switch 472 are FETs that are controlled to be enabled and disabled, for example, by an electronic processor 302. When the discharge switch 468 is enabled, the discharge switch 468 allows current to flow from the battery pack 50 to the power switching network 310. When the discharge switch 468 is disabled, the discharge switch 468 blocks current from flowing from the battery pack 50 to the power switching network 310. When the charging switch 472 is enabled, the charging switch 472 allows current to flow from the on-board charging circuit 460 to the battery pack 50 to charge the battery pack 50. When the charging switch 472 is disabled, the charging switch 472 blocks current from flowing from the on-board charging circuit 460 to the battery pack 50.

[0068] In some embodiments, the electronic processor 302 may control the discharge switch 468 and the charging switch 472 such that both the discharge switch 468 and the charging switch 472 are not enabled simultaneously. Thus, the motor 36 of the gas engine replacement device 10 may be made not to operate while the battery pack 50 is being charged.

[0069] In some embodiments, the electronic processor 302 may control the discharge switch 468 and the charge switch 472 such that both the discharge switch 468 and the charge switch 472 are enabled simultaneously. Thus, the motor 36 of the gas engine replacement device 10 may be operated while the battery pack 50 is being charged. For example, the charging circuit 460 may provide a trickle charge to the battery pack 50 when the power cord 464 is coupled to an AC power source. Further, an AC / DC rectifier circuit that provides a DC output to the DC bus connecting the power switching network 310 and the battery pack 50 may be provided to the gas engine replacement device 10 (e.g., to the on-board charging circuit 460). In this way, the power switching network 310 draws DC power from the rectifier, and the AC power from the power cord 464 supplies power to the motor 36. Further, when the current drawn from the rectifier is less than a specific current limit value with respect to the wall outlet coupled to the power cord 464, the excess current (the amount of current between the currently drawn current and the current limit value) is charged to the battery pack 50. In some embodiments, the DC bus includes a capacitor that smoothes the ripple on the DC bus between the positive DC bus line and the negative DC bus line, and the charging current is drawn from the capacitor.

[0070] In some embodiments, the gas engine replacement device 10 includes a charge enabling switch that can be actuated by a user. When the charge enabling switch is actuated, the electronic processor 302 disables the discharge switch 468 and enables the charge switch 472 to start charging the battery pack 50. In some embodiments, when the electronic processor 302 determines that the charge state of the battery pack 50 has dropped below a predetermined threshold (e.g., using the voltage sensor 320 as described above or receiving an indication from the battery pack 50), the electronic processor actuates the charge enabling switch, stops the discharge switch 468, and the on-board charging circuit 460 starts charging the battery pack 50.

[0071] In one example, the gas engine replacement device 10 of FIGS. 18-19 is used for rental fleets. Equipment rental companies may prefer to lock certain functions of rental equipment for anti-theft purposes. In the case of the gas engine replacement device 10, the rental company may wish to lock the battery pack 50 to the gas engine replacement device 10 so that the battery pack 50 cannot be removed from the gas engine replacement device 10. In these situations, the on-board charging circuit 460 can be used to charge the battery pack 50 while the battery pack 50 is coupled to the gas engine replacement device 10.

[0072] FIGS. 1-18 are shown as including separate embodiments of the gas engine replacement device 10. However, it should be understood that features of any of these embodiments can be combined with features of other embodiments. For example, the gas engine replacement device 10 can include a plurality of battery receptacles 54 and a module port 162 that connects to one or more battery modules 158. Additionally, the gas engine replacement device 10 can include an on-board charging circuit 460 and a plurality of battery receptacles 54 and / or module ports 162. Further, it should be understood that one or more of the battery receptacles 54 can accept battery packs 50 of any configuration. For example, the first battery receptacle 54A can accept a battery pack 50-1 having a first configuration, and the second battery receptacle 54B can accept a battery pack 50-2 having a second configuration. Additionally, the user can replace the battery pack 50-1 having the first configuration and accepted by the battery receptacle 54 with a battery pack 50-2 having the second configuration. Thus, in some of the embodiments of the gas engine replacement device 10 described above, the gas engine replacement device 10 is configured to be coupled to different types of battery packs 50.

Claims

1. Housing and a first battery receptacle and a second battery receptacle provided in the housing; a first battery pack received in the first battery receptacle; a second battery pack received in the second battery receptacle; a motor within the housing; a power switching network connected to the motor, the first battery pack, and the second battery pack; a first switch configured to connect the first battery pack to the power switching network; a second switch configured to connect the second battery pack to the power switching network; a power take-off shaft protruding from a side of the housing and receiving torque from the motor; an electronic processor coupled to the first switch, the second switch and the power switching network, connecting the first battery pack to the power switching network using the first switch; determining whether a state of charge of the first battery pack is less than a predetermined threshold; if the state of charge of the first battery pack is less than the predetermined threshold; connecting the second battery pack to the power switching network using the second switch; and disconnecting the first battery pack from the power switching network using the first switch. an electronic processor; Battery powered equipment.

2. the first battery receptacle extends between a top surface of the housing and a first side surface of the housing; the second battery receptacle extends between the top surface and a second side surface of the housing; and the second side is opposite the first side; 2. The battery-powered device of claim 1.

3. 3. The battery-powered device of claim 2, wherein the first battery receptacle is configured such that the first battery pack is slid from a top of the battery-powered device and received in the first battery receptacle.

4. 3. The battery-powered device according to claim 2, wherein a portion of the first battery pack protrudes outside an intersection of the top surface and the first side surface of the housing when received in the first battery receptacle.

5. The battery-powered device of claim 4 , further comprising a support provided on an upper portion of the housing and extending to support the portion of the first battery pack.

6. a first handle and a second handle provided on the housing and extending from the first side to the second side of the housing; the first battery receptacle is between the first handle and the second handle on the first side, and the second battery receptacle is between the first handle and the second handle on the second side.

3. The battery-powered device of claim 2.

7. 2. The battery-powered device of claim 1, further comprising an elastomeric member disposed on the first battery receptacle to dampen vibrations transmitted from the motor to the first battery pack.

8. The electronic processor includes: providing a first indication of a connection status of the first battery pack, the first indication of a connection status indicating whether the first battery pack is being discharged by the battery powered device; and providing a second indication of a connection status of the second battery pack, the second indication of a connection status indicating whether the second battery pack is being discharged by the battery-powered device.

2. The battery-powered device of claim 1.

9. 2. The battery-powered device of claim 1, further comprising an on-board charging circuit configured to charge the first battery pack, the first battery pack being connected to the on-board charging circuit through a charging switch.

10. The battery-powered device of claim 9 , further comprising a power cord provided in the housing and configured to provide charging power to the on-board charging circuitry.

11. the electronic processor is connected to the first switch and the charging switch; and connecting the first battery pack to the power switching network to operate the motor; connecting the first battery pack to the on-board charging circuitry for charging the first battery pack; and further configured to:

10. The battery powered device of claim 9.

12. 10. The battery-powered device of claim 1, wherein the first battery pack has a nominal voltage of at least 80 volts.

13. 2. The battery-powered device of claim 1 further comprising a flange provided on the side of the housing, the power take-off shaft protruding from the flange.

14. 14. The battery powered device of claim 13, wherein the flange includes a first bolt pattern configured to align with a second bolt pattern of a powered device powered by the battery powered device.

15. The battery-powered device of claim 13 , wherein an intermediate mounting member is configured to be disposed between the flange and a powered device powered by the battery-powered device.

16. Housing and a battery receptacle and a module port provided in the housing; a first battery pack configured to be received in the battery receptacle; a battery module connected to the module port, wherein a second battery pack is configured to be received by the battery module; a motor within the housing; a power switching network connected to the motor, the first battery pack, and the module port; a first switch configured to connect the first battery pack to the power switching network; a second switch configured to connect the module port to the power switching network; a power take-off shaft protruding from a side of the housing and receiving torque from the motor; an electronic processor coupled to the first switch, the second switch and the power switching network, connecting the first battery pack to the power switching network using the first switch; determining whether a state of charge of the first battery pack is less than a predetermined threshold; if the state of charge of the first battery pack is less than the predetermined threshold; connecting the module port to the power switching network using the second switch; and disconnecting the first battery pack from the power switching network using the first switch. an electronic processor; Battery powered equipment.

17. The electronic processor includes: providing a first indication of a connection status of the first battery pack, the first indication of a connection status indicating whether the first battery pack is being discharged by the battery powered device; providing a second indication of a connection status of the second battery pack, the second indication of connection status indicating whether the second battery pack is being discharged by the battery powered device; and further configured to:

17. A battery powered device as claimed in claim 16.

18. 17. The battery-powered device of claim 16, further comprising an elastomeric member disposed on the battery receptacle to dampen vibrations transmitted from the motor to the first battery pack.

19. 17. The battery-powered device of claim 16, wherein the battery module further comprises a module housing including a module battery receptacle, the second battery pack configured to be received in the module battery receptacle.

20. the module housing includes an input connector port and an output connector port; and a cord is used to couple the output connector port to the module port to provide an operating current from the second battery pack received in the battery module; 20. The battery powered device of claim 19.

21. the battery module is a first battery module, a second battery module connected to the input connector port of the first battery module; the second battery module is configured to receive a third battery pack; and the first battery module passes the operating current from the second battery module to the battery-powered device together with the operating current from the first battery module; 21. The battery powered device of claim 20.

22. the battery module is a first battery module, the module port is configured to be connected to the first battery module and the second battery module; and the second battery module is configured to receive a third battery pack.

17. A battery powered device as claimed in claim 16.

23. a third switch configured to connect the second battery pack to the module port; and a fourth switch configured to connect the third battery pack to the module port; and Further comprising: the electronic processor is further configured to control the third switch and the fourth switch to selectively connect and disconnect the second battery pack and the third battery pack to the module port.

23. A battery powered device as claimed in claim 22.

24. 23. The battery-powered device of claim 22, further comprising a multi-pole switch provided in the module port and configured to connect at least one of the second battery pack and the third battery pack to the second switch.

25. The electronic processor includes: connecting the first battery pack to the power switching network; determining whether the state of charge of the first battery pack is less than the predetermined threshold; if the state of charge of the first battery pack is less than the predetermined threshold; selecting one between the second battery pack and the third battery pack based on a state of charge, and connecting the selected one of the second battery pack and the third battery pack to the power switching network; disconnecting the first battery pack from the power switching network; configured to:

23. A battery powered device as claimed in claim 22.

26. 26. The battery-powered device of claim 25, wherein the electronic processor is configured to select the second battery pack if the state of charge of the second battery pack is higher than the state of charge of the third battery pack.

27. 17. The battery-powered device of claim 16, further comprising an on-board charging circuit configured to charge the first battery pack, the first battery pack being connected to the on-board charging circuit through a charging switch.

28. 30. The battery-powered device of claim 27, further comprising a power cord provided in the housing and configured to provide charging power to the on-board charging circuitry.

29. the electronic processor is connected to the charging switch; and connecting the first battery pack to the power switching network to operate the motor; connecting the first battery pack to the on-board charging circuitry for charging the first battery pack; and further configured to:

28. A battery powered device according to claim 27.

30. 17. The battery-powered device of claim 16, wherein the first battery pack has a nominal voltage of at least 80 volts.

31. 17. The battery powered device of claim 16, further comprising a flange provided on the side of the housing, the power take-off shaft protruding from the flange.

32. 32. The battery powered device of claim 31, wherein the flange includes a first bolt pattern configured to align with a second bolt pattern of a powered device powered by the battery powered device.

33. 32. The battery powered device of claim 31, wherein an intermediate mounting member is configured to be disposed between the flange and a powered device powered by the battery powered device.

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