Power tool system

Abstract

To provide various electric tools and electric tool systems which are operable using various AC power sources and DC power sources.SOLUTION: An electric tool system (1) includes: a first electric tool (10A1) having a first electric tool rated voltage; second electric tools (10A2, 10A3 and 10B) having second electric tool rated voltages different from the first electric tool rated voltage; and a first battery pack (20A4) which can be coupled to the first electric tool (10A1) and the second electric tools (10A2, 10A3 and 10B). The first battery pack (20A4) is switchable between a first configuration having a first battery pack rated voltage corresponding to the first electric tool rated voltage so that the first battery pack can operate the first electric tool (10A1), and a second configuration having a convertible battery pack rated voltage corresponding to the second electric tool rated voltage (10A2) so that the battery pack can operate the second electric tools (10A2, 10A3 and 10B).SELECTED DRAWING: Figure 1A

Description

[Technical Field]

[0001] Cross-references to related applications This application is a U.S. Provisional Patent Application No. 61 / 994,953 filed on 18 May 2014, titled "Power Tool System," filed on 19 May 2014, titled "Power Tool System," filed on 62 / 000,112, titled "Power Tool System," filed on 5 September 2014, titled "Convertible Battery Pack," filed on 20 February 2015, titled "Convertible Battery Pack," filed on 12 December 2014, titled "Transport for System for Convertible Battery," and other U.S. Provisional Patent Applications No. 62 / 046,546 filed on 5 September 2014, titled "Convertible Battery Pack," filed on 20 February 2015, titled "Convertible Battery Pack," filed on 20 December 2014, titled "Transport for System for Convertible Battery This application claims priority to U.S. Provisional Patent Application No. 62 / 114,645, filed on 11 February 2015, titled "Pack," U.S. Provisional Patent Application No. 62 / 000,307, filed on 19 May 2014, titled "Cycle-By-Cycle Current Limit for Power Tools Having a Brushless Motor," and U.S. Provisional Patent Application No. 62 / 093,513, filed on 18 December 2014, titled "Conduction Band Control for Brushless Motors in Power Tools," each of which is incorporated by reference.

[0002] This application relates to a power tool system including various power tools and other electrical devices that can operate using various AC and DC power sources. [Background technology]

[0003] Various types of power tools are commonly used in construction, home renovation, outdoor, and DIY projects. Power tools are generally classified into two categories: AC power tools (often also called corded power tools) that can operate using one or more AC power sources (such as AC commercial power or a generator), and DC power tools (often also called cordless power tools) that can operate using one or more DC power sources (such as a removable and rechargeable battery pack).

[0004] Corded or AC power tools are generally used in heavy-duty applications such as heavy-duty sawing, heavy-duty drilling and hammering, and heavy-duty metalworking, where higher power and / or longer operating time are required compared to applications of cordless power tools. However, as the name suggests, corded tools require the use of a cord that can be connected to an AC power source. In many applications, such as on construction sites, connecting to an AC power source is not practical, and / or AC power must be generated by a separate AC power generator, such as a gasoline-powered generator.

[0005] Cordless or DC power tools are generally used in lighter applications such as light sawing, light drilling, and fastening, where lower power and / or shorter operating times are required compared to applications with corded power tools. Because cordless tools can be more limited in terms of power and / or operating time, they are generally not industrially accepted in many heavier applications. Cordless tools are also limited in weight, because batteries with higher voltage and / or capacity tend to be heavier, which can create disadvantages from an ergonomic standpoint.

[0006] Furthermore, AC and DC power tools can operate using many different types of motors and motor control circuits. For example, corded or AC power tools can operate using AC brushed motors, universal brushed motors (capable of operating using AC or DC), or brushless motors. Motors in corded tools may have a structure optimized or rated to operate on AC voltage sources having a rated voltage approximately the same as AC commercial power (e.g., 120V in the United States and 230V in much of Europe). Motors in AC or corded tools are generally controlled using AC control circuits that may include on-off switches (e.g., for tools operating at substantially constant no-load speeds), or using variable speed control circuits such as triac control circuits (e.g., for motor tools operating at variable no-load speeds). An example of a triac control circuit can be found in Patent Document 1, which is incorporated by reference.

[0007] Furthermore, cordless or DC power tools can operate using many different types of motors and control circuits. For example, cordless or DC power tools can operate using DC brushed motors, universal brushed motors, or brushless motors. Since the batteries of cordless power tools tend to have lower rated voltages than AC commercial power supplies (e.g., 12V, 20V, 40V, etc.), the motors of cordless or DC power tools generally have a structure that is optimized or rated for use with DC power supplies having one or more of these lower voltages. Control circuits for cordless or DC power tools may include an on-off switch (e.g., for tools operating at substantially constant no-load speeds) or a variable speed control circuit (e.g., for tools operating at variable no-load speeds). A variable speed control circuit may have, for example, an analog voltage regulator or a digital pulse-width modulation (PWM) control device to control the power supply to the motor. An example of a PWM control circuit can be found in Patent Document 2, which is incorporated by reference. [Prior art documents] [Patent Documents]

[0008] [Patent Document 1] U.S. Patent No. 7,928,673 [Patent Document 2] U.S. Patent No. 7,821,217 [Overview of the project] [Means for solving the problem]

[0009] In one embodiment, the power tool system includes a first power tool having a low power tool rating voltage, a second power tool having an intermediate power tool rating voltage higher than the low power tool rating voltage, a third power tool having a high power tool rating voltage higher than the intermediate power tool rating voltage, a first battery pack having a low battery pack rating voltage corresponding to the low power tool rating voltage, and a convertible battery pack. The convertible battery pack is operable in a first configuration in which the convertible battery pack has a convertible battery pack rating voltage corresponding to the first power tool rating voltage, and in a second configuration in which the convertible battery pack has a second convertible battery pack rating voltage corresponding to the second power tool rating voltage. The first battery pack is connectable to the first power tool to enable operation of the first power tool. The convertible battery pack is connectable to the first power tool in a first configuration to enable operation of the first power tool. The convertible battery pack is connectable to the second power tool in a second configuration to enable operation of the second power tool. Multiple convertible battery packs can be coupled to the third power tool in their second configuration to enable the operation of the third power tool.

[0010] Embodiments of this configuration may include one or more of the following features: The third power tool may be coupled to an AC power supply having a rated voltage corresponding to the voltage rating of an AC commercial power supply in order to enable the operation of the third power tool using a plurality of convertible battery packs or AC power supplies. The AC commercial power supply voltage rating may be about 100 volts to 120 volts or about 220 volts to 240 volts. The high power tool rated voltage may correspond to the voltage rating of an AC commercial power supply. The system may further include a battery pack charger having a low charger rated voltage corresponding to the low battery pack rated voltage and the convertible battery pack rated voltage, in which case the battery pack charger is configured to be coupled to the first battery pack in order to charge the first battery pack, and, in the first configuration, to be coupled to the convertible battery pack in order to charge the convertible battery pack.

[0011] The rated voltage of the intermediate power tool may be an integer multiple of the rated voltage of the low power tool, and the rated voltage of the high power tool may be an integer multiple of the rated voltage of the intermediate power tool. The rated voltage of the low power tool may be approximately 17 to 20 volts, the rated voltage of the intermediate power tool may be approximately 51 to 60 volts, and the rated voltage of the high power tool may be approximately 102 to 120 volts. The first power tool may have been sold before May 18, 2014, and the second and third power tools may not have been sold before May 18, 2014. The first power tool may be a DC-only power tool, the second power tool may be a DC-only power tool, and the third power tool may be an AC / DC power tool.

[0012] The convertible battery pack may be automatically configured to a first configuration when coupled to a first power tool, and may be automatically configured to a second configuration when coupled to a second or third power tool. The system may include a third battery pack having an intermediate battery pack rated voltage. The third battery pack may be coupled to a second power tool to enable operation of the second power tool. Multiple third battery packs may be coupled to a third power tool to enable operation of the third power tool. The first battery pack may not have the capability to enable operation of a second or third power tool.

[0013] In another embodiment, the power tool system includes a first battery pack having a first battery pack rated voltage, and a convertible battery pack that is operable in a first configuration in which the convertible battery pack has the first battery pack rated voltage, and in a second configuration in which the convertible battery pack has a second convertible battery pack rated voltage higher than the first convertible battery pack rated voltage. The first power tool includes a first motor, a first motor control circuit, and a first power interface. The first power tool has a first power tool rated voltage corresponding to the first battery pack rated voltage and a first convertible battery pack rated voltage. The first power tool is operable using the first battery pack when the first power interface is coupled to the first battery pack, or using the convertible battery pack when the first power interface is coupled to the convertible battery pack so that the convertible battery pack is in a first configuration. The second power tool includes a second motor, a second motor control circuit, and a second power interface. The second power tool has a second power tool rated voltage corresponding to the second convertible battery pack rated voltage. The second power tool is capable of operating with a convertible battery pack when the second power interface is coupled to the convertible battery pack so that the convertible battery pack forms a second configuration. The third power tool comprises a third motor, a third motor control circuit, and a third power interface. The third power tool has a third rated voltage that is an integer multiple of the rated voltage of the second convertible battery pack. The third power tool is capable of operating with multiple convertible battery packs when the third power tool interface is coupled to multiple convertible battery packs so that each of the multiple convertible battery packs forms a second configuration.

[0014] Embodiments of this design may include one or more of the following features: The third power interface of the third power tool may, alternatively, be coupled to an AC power supply having a rated voltage corresponding to the voltage rating of the AC commercial power supply, in order to enable the operation of the third power tool using multiple convertible battery packs or AC power supplies. The voltage rating of the AC commercial power supply may be approximately 100 volts to 120 volts or approximately 220 volts to 240 volts. The high power tool rated voltage may correspond to the voltage rating of the AC commercial power supply.

[0015] The system may include a battery pack charger having a first charger rated voltage corresponding to the rated voltage of the first battery pack and the rated voltage of the first convertible battery pack. The battery pack charger may be configured to be coupled to the first battery pack in order to charge the first battery pack, and, in the first configuration, to be coupled to the convertible battery pack in order to charge the convertible battery pack. The rated voltage of the second power tool may be an integer multiple of the rated voltage of the first power tool. The rated voltage of the first power tool may be approximately 17 to 20 volts, the rated voltage of the second power tool may be approximately 51 to 60 volts, and the rated voltage of the third power tool may be approximately 100 to 120 volts. The first power tool may have been sold before May 18, 2014, and the second and third power tools may not have been sold before May 18, 2014.

[0016] The first power tool may be a DC-only power tool. The second power tool may be a DC-only power tool. The third power tool may be an AC / DC power tool. The convertible battery pack may be automatically configured to a first configuration when coupled to the first power tool, or automatically configured to a second configuration when coupled to the second or third power tool. The system may include a third battery pack having a third battery pack rated voltage corresponding to the second power tool's rated voltage. The third battery pack may be coupled to the second power tool to enable operation of the second power tool, and multiple third battery packs may be coupled to the third power tool to enable operation of the third power tool. The first battery pack may not have the capability to enable operation of the second or third power tool.

[0017] In another embodiment, the power tool includes a power interface, a motor, and a motor control circuit. The power interface is configured to receive AC power from an AC power source having a rated AC voltage corresponding to the rated voltage of a commercial AC power supply, and DC power from one or more removable battery packs having a total rated DC voltage, also corresponding to the rated voltage of a commercial AC power supply. The motor has rated voltages corresponding to the rated AC voltage and the rated DC voltage. The motor is capable of operating using both AC power from an AC power source and DC power from a DC power source. The motor control circuit is configured to control the operation of the motor using either AC power or DC power without reducing the magnitude of the rated AC voltage, without reducing the magnitude of the rated DC voltage, and without converting DC power to AC power.

[0018] Embodiments of this design may include one or more of the following features: The rated AC voltage may be about 100 volts to 120 volts. The DC rated voltage may be about 102 volts to 120 volts. The motor's rated voltage is about 100 volts to 120 volts. The rated AC voltage may include an RMS voltage of 120VAC, and the rated DC voltage may include a nominal voltage of 120 volts. The rated AC voltage may include an average voltage of about 108 volts, and the rated DC voltage may include a nominal voltage of about 108 volts. The AC power supply may include a commercial AC power supply.

[0019] One or more removable battery packs may include at least two removable battery packs. At least two battery packs may be connected in series with each other. Each battery pack may have a rated DC voltage that is approximately half of the rated AC voltage. The motor may be a universal motor. The control circuit may be configured to operate the universal motor at a constant no-load speed. The control circuit may be configured to operate the universal motor at a variable no-load speed based on user input. The motor may include a brushless motor.

[0020] In another aspect, the power tool system includes a DC power source and a power tool. The DC power source includes one or more battery packs that cooperatively have a rated DC voltage corresponding to the rated voltage of the AC commercial power supply. The power tool has a power interface, a motor, and a motor control circuit. The power interface is configured to receive AC power from an AC power source having the rated voltage of the AC commercial power supply and to receive DC power from the DC power source. The motor has a rated voltage corresponding to the rated voltage of the AC commercial power supply and to the rated DC voltage. The motor is operable using both AC power from the AC commercial power supply and DC power from the DC power source. The motor control circuit is configured to control the operation of the motor using one of the AC power and the DC power without reducing the magnitude of the rated AC voltage, without reducing the magnitude of the rated DC voltage, and without converting DC power to AC power.

[0021] Embodiments of this aspect may include one or more of the following features. The rated AC voltage may be about 100 volts to 120 volts. The DC rated voltage may be about 102 volts to about 120 volts. The rated voltage of the motor is about 100 volts to 120 volts. The rated AC voltage may include a 120VAC RMS voltage, and the rated DC voltage may include a nominal voltage of 120 volts. The rated AC voltage may include an average voltage of about 108 volts, and the rated DC voltage may include a nominal voltage of about 108 volts. The AC power source may include an AC commercial power supply.

[0022] One or more removable battery packs may include at least two removable battery packs. The at least two battery packs may be connected in series with each other. Each battery pack may have a rated DC voltage that is about half of the rated AC voltage. The motor may be a universal motor. The control circuit may be configured to operate the universal motor at a constant no-load speed. The control circuit is configured to operate the universal motor at a variable no-load speed based on user input. The motor may include a brushless motor.

[0023] In another aspect, the power tool includes a power interface, a motor, and a motor control circuit. The power interface is configured to receive AC power from an AC commercial power source having a rated AC voltage and to receive DC power from a DC power source having one or more battery packs that cooperate to have a rated DC voltage different from the rated AC voltage. The motor has a rated voltage corresponding to one of the rated AC voltage and the rated DC voltage. The motor is operable using both AC power from the AC power source and DC power from the DC power source. The motor control circuit is configured to enable operation of the motor using one of the AC power and the DC power such that the motor has substantially the same output speed performance when operating using the AC power and the DC power.

[0024] Embodiments of this configuration may include one or more of the following features: The rated DC voltage may be less than the rated AC voltage. The rated AC voltage may be about 100 volts to 120 volts, and the rated DC voltage may be less than 100 volts. The rated DC voltage may be about 51 volts to 60 volts. The rated AC voltage may be less than the rated DC voltage. One or more battery packs may include two battery packs connected to each other in series, in which case each battery pack has a rated voltage that is about half the rated AC voltage. The motor may be a universal motor. The control circuit may operate the universal motor at a constant no-load speed. The control circuit may operate the universal motor at a variable no-load speed based on user input. The control circuit may optimize the pulse width modulation range according to the rated voltages of the AC and DC power supplies so that the motor has substantially the same output performance when operating with AC and DC power supplies. The motor may be a brushless motor. The control circuit may use at least one of cycle-by-cycle current limiting, conduction band control, and lead angle control so that the motor has substantially the same output speed performance when operating with AC power and DC power.

[0025] In another embodiment, the power tool includes means for receiving AC power from an AC commercial power source having a rated AC voltage, and means for receiving DC power from a DC power source having one or more battery packs having a rated DC voltage different from the rated AC voltage. The power tool also has a motor having a rated voltage corresponding to the higher of the rated AC voltage and the rated DC voltage. The motor is capable of operating using both AC power from the AC power source and DC power from the DC power source. The power tool also has means for operating the motor using one of the AC power and DC power so that the motor has substantially the same output speed performance when operating using both the AC power and the DC power source.

[0026] Embodiments of this aspect may include one or more of the following features: The rated DC voltage may be less than the rated AC voltage. The rated AC voltage may be about 100 to 120 volts, and the DC voltage may be less than 100 volts. The rated DC voltage may be about 51 to 60 volts. The rated AC voltage may be less than the rated DC voltage. One or more battery packs may include two battery packs connected to each other in series, in which case each battery pack has a rated voltage that is about half the rated AC voltage. The motor may be a universal motor. The means for operating the motor may operate the universal motor at a constant no-load speed. The means for operating the motor may operate the universal motor at a variable no-load speed based on user input. The means for operating the motor may optimize the pulse width modulation range according to the rated voltages of the AC and DC power supplies so that the motor has substantially the same output speed performance when operating with AC and DC power supplies. The motor may be a brushless motor. The means for operating the motor may use at least one of cycle-by-cycle current limiting, conduction band control, and lead angle control so that the motor has substantially the same output speed performance when operating with AC power and DC power.

[0027] In another embodiment, the power tool system includes a first power tool having a first power tool rated voltage, a second power tool having a second power tool rated voltage different from the first power tool rated voltage, and a first battery pack that can be coupled to the first power tool and the second power tool. The first battery pack is switchable between a first configuration having a first battery pack rated voltage corresponding to the first power tool rated voltage so that the first battery pack can operate the first power tool, and a second configuration having a convertible battery pack rated voltage corresponding to the second power tool rated voltage so that the battery pack can operate the second power tool.

[0028] Embodiments of this aspect may include one or more of the following features: The system may include a second removable battery pack having a first battery pack rating voltage and configured to be coupled to the first power tool to enable the operation of the first power tool, but not to enable the operation of the second power tool. The second power tool rating voltage may be greater than the first power tool rating voltage. The first power tool rating voltage may be an integer multiple of the second power tool rating voltage. The first power tool rating voltage may be about 17 to 20 volts, and the second power tool rating voltage may be about 51 to 60 volts. The first power tool may have been sold before May 18, 2014, and the second power tool may not have been sold before May 18, 2014. The first power tool may be a DC-only power tool, and the second power tool may be a DC-only power tool or an AC / DC power tool. The second power tool may, alternatively, be coupled to an AC power supply having a rated voltage corresponding to the voltage rating of the AC commercial power supply, in order to enable the operation of the second power tool using a convertible battery pack or an AC power supply.

[0029] In another aspect of the present invention, a power tool is provided, the power tool comprising: a housing and an electric universal motor having a commutator engaged with a positive terminal, a negative terminal and a pair of brushes coupled to the positive and negative terminals, the motor being configured to operate within an operating voltage range of about 90V to 132V; a power interface configured to receive at least one of AC power from an AC power source having a first nominal voltage and DC power from a DC power source having a second nominal voltage, the DC power source having at least one removable battery pack coupled to the power interface, the power interface being configured to output AC power via an AC power line and DC power via a DC power line, the first and second nominal voltages being substantially within the operating voltage range of the motor; and a motor control circuit configured to supply power to the motor from one of the AC power lines or DC power lines via a common node such that the brushes are electrically coupled to one of the AC or DC power sources.

[0030] In one embodiment, the motor control circuit has an on / off switch located between the motor and a common node of the AC and DC power lines.

[0031] In one embodiment, the motor control circuit has a control unit coupled to a power switch located on a DC power line. In one embodiment, the control unit is configured to monitor fault conditions associated with the DC power supply and to turn off the power switch to interrupt the supply of power from the DC power supply to the motor.

[0032] In one embodiment, the power tool further includes a power switching unit configured to isolate AC power lines and DC power lines. In one embodiment, the power switching unit includes a relay switch located on the DC power line and activated by a coil coupled to the AC power line. In one embodiment, the power switching unit includes at least one double-pole double-throw switch located between a common node of the AC and DC power lines and the power interface. In one embodiment, the power switching unit includes at least one single-pole double-throw switch having an output terminal coupled to a common node of the AC and DC power lines.

[0033] In one embodiment, the DC power supply has a high-rated voltage battery pack.

[0034] In one embodiment, the DC power supply comprises at least two intermediate rated voltage battery packs, and the power interface is configured to connect two or more of the at least two battery packs in series.

[0035] According to another aspect of the present invention, the power tool described above is a variable-speed tool, as described herein.

[0036] In one embodiment, the power tool further includes a DC switch circuit positioned between a DC power line and a motor, an AC switch positioned between an AC power line and a motor, and a control unit configured to control the switching operation of the DC switch circuit or the AC switch in order to enable variable speed operation of the motor at a constant torque by controlling the motor speed.

[0037] In one embodiment, the DC switch circuit comprises one or more controllable semiconductor switches configured as at least one of a chopper circuit, a half-bridge circuit, or a full-bridge circuit, and the control unit is configured to control the pulse-width modulation (PWM) duty cycle of one or more semiconductor switches according to a desired motor speed.

[0038] In one embodiment, the AC switch comprises a phase-controlled switch having at least one of a triac, a thyristor, or an SCR switch, and the control unit is configured to control the phase of the AC switch according to the desired motor speed.

[0039] In one embodiment, the control unit is configured to detect the current on one of the AC power lines or DC power lines in order to set the operating mode to one of the AC operating mode or DC operating mode, and to control the switching operation of one or the other of the DC switch circuit or AC switch based on the operating mode.

[0040] In one alternative embodiment, the power tool further comprises a power switching unit having a diode bridge and a controllable semiconductor switch incorporated within the diode bridge, wherein the AC and DC power lines of a power interface are coupled together to a first node of the diode bridge, and the motor is coupled to a second node of the diode bridge, and a control unit configured to control the switching operation of the semiconductor switch in order to enable variable speed operation of the motor at a constant torque by controlling the speed of the motor.

[0041] In one embodiment, the control unit is configured to detect the current on one of the AC power lines or DC power lines in order to set the operating mode to one of the AC operating mode or DC operating mode, and to control the switching operation of the semiconductor switch according to the operating mode.

[0042] In one embodiment, in DC operating mode, the control unit is configured to set a pulse width modulation (PWM) duty cycle according to the desired motor speed and to periodically turn a semiconductor switch on and off according to the PWM duty cycle.

[0043] In one embodiment, in AC operation mode, the control unit is configured to set the conduction band according to the desired motor speed, and to turn on the semiconductor switch approximately at the beginning of the conduction band and to turn off the semiconductor switch approximately at the zero crossing of the AC power line within the half-cycle of each AC line.

[0044] In one embodiment, the power tool further includes a second semiconductor switch and a freewheeling diode arranged in series with the motor to allow a current path for the motor current during the off-cycle of the semiconductor switch in DC operating mode.

[0045] In one embodiment, the semiconductor switch includes one of the following: a field-effect transistor (FET) and an insulated-gate bipolar transistor (IGBT).

[0046] In one embodiment, the diode bridge is configured to rectify the AC power line through a semiconductor switch rather than through a motor.

[0047] In one embodiment, the semiconductor switching unit is located between the common nodes of the AC and DC power lines.

[0048] According to another aspect of the present invention, a power tool is provided, the power tool comprising a housing and a universal motor having a commutator engaged with a positive terminal, a negative terminal, and a pair of brushes coupled to the positive and negative terminals, the universal motor being configured to operate within an operating voltage range, and a power interface configured to receive at least one of AC power from an AC power source having a first nominal voltage or DC power from a DC power source having a second nominal voltage, the DC power source having at least one removable battery pack coupled to the power interface, and the power interface receiving AC power via an AC power line The motor comprises a power interface configured to output a voltage and also output DC power via a DC power line, wherein a second nominal voltage is substantially within the motor's operating voltage range, but a first nominal voltage is practically higher than the motor's operating voltage range; and a motor control circuit configured to supply power from one of the AC power lines or DC power lines to the motor via a common node so that the brushes are electrically coupled to one of the AC or DC power supply, wherein the motor control circuit is configured to reduce the power supplied to the motor from the AC power line to a level corresponding to the operating voltage of the motor's operating voltage range.

[0049] In one embodiment, the motor control circuit includes an AC switch arranged in series with an AC power line, and a control unit configured to control the phase of the AC power line via the AC switch and to set a fixed conduction band of the AC switch in order to reduce the average voltage value on the AC line to a level corresponding to the motor's operating voltage range.

[0050] In one embodiment, the motor control circuit has an on / off switch located between the motor and a common node of the AC and DC power lines.

[0051] In one embodiment, the motor control circuit has a control unit coupled to a power switch located on a DC power line. In one embodiment, the control unit is configured to monitor fault conditions associated with the DC power supply and to turn off the power switch to interrupt the supply of power from the DC power supply to the motor.

[0052] In one embodiment, the power tool further includes a power switching unit configured to isolate AC power lines and DC power lines. In one embodiment, the power switching unit includes a relay switch located on the DC power line and activated by a coil coupled to the AC power line. In one embodiment, the power switching unit includes at least one double-pole double-throw switch located between a common node of the AC and DC power lines and the power interface. In one embodiment, the power switching unit includes at least one single-pole double-throw switch having an output terminal coupled to a common node of the AC and DC power lines.

[0053] In one embodiment, the DC power supply has a high-rated voltage battery pack.

[0054] In one embodiment, the DC power supply comprises at least two intermediate rated voltage battery packs, and the power interface is configured to connect two or more of the at least two battery packs in series. In one embodiment, the motor operating voltage range is in the range of approximately 100V to 120V, encompassing a second nominal voltage, and the first nominal voltage is in the range of 220VAC to 240VAC. In one embodiment, the control unit is configured to set the fixed conduction band of the AC switch to a value in the range of 100 to 140 degrees.

[0055] In one embodiment, the motor's operating voltage range is in the range of approximately 60V to 90V, encompassing a second nominal voltage, and the first nominal voltage is in the range of 100VAC to 120VAC. In one embodiment, the control unit is configured to set the fixed conduction band of the AC switch to a value in the range of 70 to 110 degrees.

[0056] In one embodiment, the control unit is configured to operate the tool at a constant speed in a fixed conduction band.

[0057] In one embodiment, the AC switch includes a phase-controlled switch having one of a triac, a thyristor, or an SCR switch, and the controller is configured to control the phase of the AC switch according to a desired motor speed.

[0058] According to another aspect of the present invention, the power tool described above is a variable-speed power tool, as described herein.

[0059] According to one embodiment, the motor control circuit further comprises a DC switch circuit positioned between the DC power line and the motor, in which case the control unit is configured to control the switching operation of the DC switch circuit or AC switch in order to enable variable speed operation of the motor under a constant load by controlling the speed of the motor.

[0060] According to one embodiment, the DC switch circuit comprises one or more controllable semiconductor switches configured as at least one of a chopper circuit, a half-bridge circuit, or a full-bridge circuit, and the control unit is configured to control the pulse-width modulation (PWM) duty cycle of one or more semiconductor switches according to a desired motor speed.

[0061] According to one embodiment, the control unit is configured to change the conduction angle of the AC switch from zero to a fixed conduction band according to the desired motor speed.

[0062] According to one embodiment, the control unit is configured to detect the current on one of the AC power lines or DC power lines in order to set the operating mode to one of the AC operating mode or DC operating mode, and to control the switching operation of one or the other of the DC switch circuit or AC switch based on the operating mode.

[0063] According to one embodiment, the motor control circuit is a power switching unit including a diode bridge and a controllable semiconductor switch incorporated within the diode bridge, wherein the AC and DC power lines of a power interface are coupled together to a first node of the diode bridge, and the motor is coupled to a second node of the diode bridge; and a control unit configured to control the switching operation of the semiconductor switch in order to enable variable speed operation of the motor under a constant load by controlling the speed of the motor, and the control unit configured to control the phase of the AC power line via the semiconductor switch.

[0064] In one embodiment, the control unit is configured to detect the current on one of the AC power lines or DC power lines in order to set the operating mode to one of the AC operating mode or DC operating mode, and to control the switching operation of the semiconductor switch in one of the AC operating mode or DC operating mode according to the operating mode.

[0065] In one embodiment, in DC operation mode, the control unit is configured to set a pulse width modulation (PWM) duty cycle according to the desired motor speed and to periodically activate and deactivate a semiconductor switch according to the PWM duty cycle.

[0066] In one embodiment, in AC operation mode, the control unit is configured to set the maximum conduction band corresponding to the motor's operating voltage range.

[0067] In one embodiment, the control unit is configured to set the conduction band from zero to the maximum conduction band in accordance with and proportional to the desired motor speed, and to turn on the semiconductor switch approximately at the beginning of the conduction band and turn off the semiconductor switch approximately at the zero crossing of the AC power line within each AC line half-cycle.

[0068] In one embodiment, the motor's operating voltage range is within the range of 100V to 120V, which encompasses approximately the second nominal voltage, and the first nominal voltage is within the range of 220VAC to 240VAC. In one embodiment, the control unit is configured to set the maximum conduction band to a value within the range of 100 to 140 degrees.

[0069] In one embodiment, the motor's operating voltage range is within the range of 60V to 100V, which encompasses approximately a second nominal voltage, and the first nominal voltage is within the range of 100VAC to 120VAC. In one embodiment, the control unit is configured to set the maximum conduction band of the AC switch to a value within the range of 70 to 110 degrees.

[0070] In one embodiment, the diode bridge is configured to rectify the AC power line through a semiconductor switch without passing it through a motor.

[0071] In one embodiment, the motor control circuit further includes a second semiconductor switch and a freewheeling diode arranged in series with the motor to allow a current path for the motor current during the off-cycle of the semiconductor switch in DC operating mode.

[0072] In one embodiment, the semiconductor switch includes one of a field-effect transistor (FET) or an insulated-gate bipolar transistor (IGBT).

[0073] According to another aspect of the present invention, a power tool is provided, the power tool comprising: a housing; an electric universal motor having a commutator engaged with a positive terminal, a negative terminal, and a pair of brushes coupled to the positive and negative terminals; a power interface configured to receive at least one of AC power from an AC power source or DC power from a DC power source, and to output AC power via an AC power line and DC power via a DC power line; a power switching unit having a diode bridge and a controllable semiconductor switch incorporated within the diode bridge, wherein the AC and DC power lines of the power interface are coupled together to a first node of the diode bridge, and the motor is coupled to a second node of the diode bridge; and a control unit configured to control the switching operation of the semiconductor switch in order to enable variable speed operation of the motor at a constant torque by controlling the speed of the motor.

[0074] In one embodiment, the control unit is configured to detect the current on one of the AC power lines or DC power lines in order to set the operating mode to one of the AC operating mode or DC operating mode, and to control the switching operation of the semiconductor switch according to the operating mode.

[0075] In one embodiment, in DC operation mode, the control unit is configured to set a pulse width modulation (PWM) duty cycle according to the desired motor speed and to periodically activate and deactivate a semiconductor switch according to the PWM duty cycle.

[0076] In one embodiment, in AC operating mode, the control unit is configured to set the conduction band according to the desired speed of the motor, and to turn on the semiconductor switch approximately at the beginning of the conduction band and turn off the semiconductor switch approximately at the zero crossing of the AC power line within each AC line half-cycle.

[0077] In one embodiment, the power tool further includes a second semiconductor switch and a freewheeling diode arranged in series with the motor to allow a current path for the motor current during the off-cycle of the semiconductor switch in DC operating mode.

[0078] In one embodiment, the semiconductor switch includes one of a field-effect transistor (FET) or an insulated-gate bipolar transistor (IGBT).

[0079] In one embodiment, the diode bridge is configured to rectify the AC power line through a semiconductor switch without passing it through a motor.

[0080] In one embodiment, the power switching unit is located between the common nodes of the AC and DC power lines.

[0081] In another aspect of the present invention, a power tool is provided, the power tool comprising: a housing; an electric direct current (DC) motor having a commutator engaged with a positive terminal, a negative terminal, and pairs of brushes coupled to the positive and negative terminals, the motor configured to operate in an operating voltage range in the range of approximately 90V to 132V; a power interface configured to receive at least one of AC power from an AC power source having a first nominal voltage or DC power from a DC power source having a second nominal voltage, the DC power source having at least one removable battery pack coupled to the power interface, the power interface configured to output AC power via an AC power line and DC power via a DC power line, the first and second nominal voltages being substantially within the operating voltage range of the motor; and a motor control circuit including a rectifier circuit configured to rectify an AC signal into a rectified signal on an AC power line, the motor control circuit configured to supply power to the motor from one of the AC lines or DC lines via a common node such that the brushes are electrically coupled to one of the AC or DC power sources.

[0082] In one embodiment, the rectifier circuit includes a full-wave diode bridge rectifier.

[0083] In one embodiment, the motor control circuit has an on / off switch located between the motor and a common node of the AC and DC power lines.

[0084] In one embodiment, the motor control circuit has a control unit coupled to a power switch located on a DC power line. In one embodiment, the control unit is configured to monitor fault conditions associated with the DC power supply and to turn off the power switch in order to interrupt the supply of power from the DC power supply to the motor.

[0085] In one embodiment, the power tool further includes a power switching unit configured to isolate AC power lines and DC power lines. In one embodiment, the power switching unit has a relay switch located on the DC power line and activated by a coil coupled to the AC power line. In one embodiment, the power switching unit has at least one double-pole double-throw switch located between a common node of the AC and DC power lines and the power interface. In one embodiment, the power switching unit includes at least one single-pole double-throw switch having an output terminal coupled to a common node of the AC and DC power lines.

[0086] In one embodiment, the DC power supply has a high-rated voltage battery pack.

[0087] In one embodiment, the DC power supply comprises at least two intermediate rated voltage battery packs, and the power interface is configured to connect two or more of the at least two battery packs in series.

[0088] According to another aspect of the present invention, the power tool described above is a variable-speed tool, as described herein.

[0089] In one embodiment, the power tool further includes a switching circuit positioned between a common node of AC and DC power lines and a motor, and a control unit configured to control the switching operation of the switching circuit in order to enable variable speed operation of the motor at a constant torque by controlling the motor speed.

[0090] In one embodiment, the switching circuit comprises one or more controllable semiconductor switches configured as at least one of a chopper circuit, a half-bridge circuit, or a full-bridge circuit, and the control unit is configured to control the pulse-width modulation (PWM) duty cycle of one or more semiconductor switches according to a desired motor speed.

[0091] In one embodiment, the motor is a permanent magnet DC motor.

[0092] According to another aspect of the present invention, a power tool is provided, the power tool comprising a housing and an electric direct current (DC) motor having a commutator engaged with a positive terminal, a negative terminal, and a pair of brushes coupled to the positive and negative terminals, the motor configured to operate within an operating voltage range, and a power interface configured to receive at least one of AC power from an AC power source having a first nominal voltage or DC power from a DC power source having a second nominal voltage, wherein the DC power source has at least one removable battery pack coupled to the power interface, and the power interface is configured to output AC power via an AC power line and DC power via a DC power line. A motor control circuit comprising a power interface having a second nominal voltage which is substantially within the motor's operating voltage range, but a first nominal voltage which is substantially higher than the motor's operating voltage range, and a rectifier circuit configured to rectify an AC signal into a rectified signal on an AC power line, wherein the motor control circuit is configured to supply power to the motor from one of the AC power lines or DC power lines via a common node such that the brushes are electrically coupled to one of the AC or DC power supply, and the motor control circuit is configured to reduce the power supplied to the motor from the AC power line to a level corresponding to the motor's operating voltage range.

[0093] In one embodiment, the rectifier circuit includes a half-wave diode bridge circuit configured to reduce the average voltage value on the AC power line by about half.

[0094] In one embodiment, the motor control circuit comprises a power switch positioned between a common node of AC and DC power lines, and a control unit configured to control the pulse width modulation (PWM) of the power switch, wherein the control unit is configured to set the pulse width modulation (PWM) duty cycle of the power switch to a fixed value of less than 100% in order to reduce the average voltage value on the AC line to a level corresponding to the motor's operating voltage range. In one embodiment, the power switch has one of either a field-effect transistor (FET) or an insulated-gate bipolar transistor (IGBT).

[0095] In one embodiment, the motor control circuit includes an AC switch arranged in series with the AC power line between the power interface and the rectifier circuit, and a control unit configured to control the phase of the AC power line via the AC switch and to set a fixed conduction band of the AC switch in order to reduce the average voltage value on the AC power line to a level corresponding to the motor's operating voltage range.

[0096] In one embodiment, the AC switch includes a phase-controlled switch having one of a triac, a thyristor, or an SCR switch, and the controller is configured to control the phase of the AC switch according to a desired motor speed.

[0097] In one embodiment, the motor control circuit has an on / off switch located between the motor and a common node of the AC and DC power lines.

[0098] In one embodiment, the motor control circuit has a control unit coupled to a power switch located on a DC power line. In one embodiment, the control unit is configured to monitor fault conditions associated with the DC power supply and to turn off the power switch in order to interrupt the supply of power from the DC power supply to the motor.

[0099] In one embodiment, the power tool further includes a power switching unit configured to isolate AC power lines and DC power lines. In one embodiment, the power switching unit includes a relay switch located on the DC power line and activated by a coil coupled to the AC power line. In one embodiment, the power switching unit includes at least one double-pole double-throw switch located between a common node of the AC and DC power lines and the power interface. In one embodiment, the power switching unit includes at least one single-pole double-throw switch having an output terminal coupled to a common node of the AC and DC power lines.

[0100] In one embodiment, the DC power supply has a high-rated voltage battery pack.

[0101] In one embodiment, the DC power supply comprises at least two intermediate rated voltage battery packs, and the power interface is configured to connect two or more of the at least two battery packs in series. In another embodiment, the motor's operating voltage range is in the 100V to 120V range, encompassing approximately a second nominal voltage, and the first nominal voltage is in the 220VAC to 240VAC range. In one embodiment, the control unit is configured to set the fixed conduction band of the AC switch to a value in the 100 to 140 degree range.

[0102] In one embodiment, the motor's operating voltage range is within the range of 60V to 90V, which encompasses approximately a second nominal voltage, and the first nominal voltage is within the range of 100VAC to 120VAC. In one embodiment, the control unit is configured to set the fixed conduction band of the AC switch to a value within the range of 70 to 110 degrees.

[0103] In one embodiment, the control unit is configured to operate the tool at a constant speed in a fixed conduction band.

[0104] According to another aspect of the present invention, the power tool described above is a variable-speed tool, as described herein.

[0105] In one embodiment, the power tool further includes a switching circuit positioned between a common node of AC and DC power lines and a motor, and a control unit configured to control the pulse width modulation (PWM) switching operation of the switching circuit in order to enable variable speed operation of the motor at a constant torque by controlling the motor speed.

[0106] In one embodiment, the switching circuit comprises one or more controllable semiconductor switches configured as at least one of a chopper circuit, a half-bridge circuit, or a full-bridge circuit, and the control unit is configured to control the pulse-width modulation (PWM) duty cycle of one or more semiconductor switches according to a desired motor speed.

[0107] According to one embodiment, the control unit is configured to detect the current on one of the AC power lines or DC power lines in order to set the operating mode to one of either the AC operating mode or the DC operating mode.

[0108] In one embodiment, the controller is configured to reduce the power supply through the switching circuit to a level corresponding to the motor's operating voltage range in AC operation mode.

[0109] In one embodiment, the control unit is configured to control the switching operation of the switching circuit within a first duty cycle range in DC operation mode, and to control the switching operation of the switching circuit within a second duty cycle range in AC operation mode, in which case the second duty cycle range is smaller than the first duty cycle range.

[0110] In one embodiment, the control unit is configured to control the switching operation of the switching circuit in a duty cycle from zero to 100% in DC operating mode, and to control the switching operation of the switching circuit from zero to a threshold of less than 100% in AC operating mode.

[0111] According to another aspect of the present invention, a power tool is provided, the power tool comprising a housing and a brushless direct current (BLDC) motor including a rotor and a stator having at least three stator windings corresponding to at least three phases of the motor, wherein the rotor is movable by the stator when the stator windings are adequately energized within their corresponding phases, each phase being characterized by a corresponding voltage waveform that energizes the corresponding stator windings, and the motor is configured to operate within an operating voltage range, and a power interface configured to receive at least one of AC power from an AC power supply having a first nominal voltage or DC power from a DC power supply having a second nominal voltage. The DC power supply comprises a power interface having at least one removable battery pack coupled to the power interface, the power interface being configured to output AC power via an AC power line and DC power via a DC power line, and a motor control circuit configured to receive the AC power line and the DC power line and to supply power to the motor at a level corresponding to the motor's operating voltage range, the motor control circuit comprising a rectifier circuit configured to rectify the AC signals on the AC power line to rectified voltage signals on the DC bus line and a power switch circuit configured to regulate the supply of power from the DC bus line to the motor.

[0112] In one embodiment, the rectifier circuit has a diode bridge. In one embodiment, the rectifier circuit further has a link capacitor arranged in parallel with the diode bridge on the DC bus line. In one embodiment, the diode bridge is a full-wave bridge. In an alternative embodiment, the diode bridge is a half-wave bridge.

[0113] In one embodiment, the DC power line is directly connected to a node on the DC bus line, thereby bypassing the rectifier circuit. In an alternative embodiment, the DC power line and the AC power line are coupled together to the input node of the rectifier circuit.

[0114] In one embodiment, the power tool further includes a power switching unit configured to isolate AC power lines and DC power lines. In one embodiment, the switching unit includes a relay switch located on the DC power line and activated by a coil coupled to the AC power line. In one embodiment, the power switching unit includes at least one single-pole double-throw switch having input terminals coupled to the AC and DC power lines and an output terminal coupled to the input node of a rectifier circuit. In one embodiment, the power switching unit includes at least one double-pole double-throw switch having input terminals coupled to the AC and DC power lines, a first output terminal coupled to the input node of a rectifier circuit, and a second output terminal directly coupled to a node on the DC bus line, thereby bypassing the rectifier circuit.

[0115] In one embodiment, the motor control circuit further includes a controller configured to control the switching operation of a power switch circuit. In one embodiment, the controller is a programmable device including a microcontroller, microprocessor, computer processor, or signal processor. Alternatively, the controller is an integrated circuit configured and customized to control the switching operation of a power switch unit. In one embodiment, the control unit is further configured to monitor fault conditions associated with the power tool or DC power supply and to start and stop the power switch circuit to interrupt the power supply to the motor. In one embodiment, the control unit is configured to detect current on one of either an AC or DC power line to set the operating mode to one of either an AC or DC operating mode and to control the switching operation of the power switch circuit based on the operating mode. In an alternative embodiment, the control unit is configured to control the switching operation of the power switch circuit independently of the AC or DC operating mode.

[0116] In one embodiment, the power switch circuit has a plurality of power switches, including three pairs of high-side and low-side power switches configured as a three-phase bridge circuit coupled to the phase of the motor.

[0117] In one embodiment, the motor control circuit further comprises a gate driver circuit coupled to a controller and a power switch circuit, and configured to drive the gates of a plurality of power switches based on one or more drive signals from the controller.

[0118] In one embodiment, the motor control circuit further includes a power regulator which includes at least one voltage regulator configured to output a voltage signal in order to supply power to at least one of the gate driver circuits or controllers.

[0119] In one embodiment, the motor control circuit further includes an on / off switch that is coupled to at least one of an on / off actuator or a trigger switch and is configured to interrupt the supply of power from a power regulator and a gate driver circuit.

[0120] In one embodiment, the power tool further includes a plurality of position sensors disposed near the rotor to provide a rotor rotation position signal to a control unit. In one embodiment, the controller is configured to control the switching operation of a power switch circuit based on the position signal to appropriately supply energy to the stator windings in the corresponding phases.

[0121] According to one embodiment, in each phase of the motor, the controller is configured to activate a drive signal for one of a plurality of power switches within the conduction band corresponding to the phase of the motor.

[0122] In one embodiment, the controller is configured to set a pulse-width modulation (PWM) duty cycle according to a desired motor speed, and to control the drive signal to enable variable-speed operation of the motor under a constant load by periodically turning on and off one of a plurality of power switches in the conduction band according to the PWM duty cycle.

[0123] According to one aspect of the present invention, both the first and second nominal voltages are substantially within the motor's operating voltage range.

[0124] In one embodiment, the motor's operating voltage range is approximately within the range of 90V to 132V, encompassing a second nominal voltage, and the first nominal voltage is approximately within the range of 100VAC to 120VAC. In one embodiment, the DC power supply has a high-rated voltage battery pack. In one embodiment, the DC power supply comprises at least two intermediate-rated voltage battery packs, and the power interface is configured to connect two or more of the at least two battery packs in series.

[0125] In one embodiment, the link capacitor has a capacitance value optimized to provide an average voltage of approximately 110V or less on the DC bus line when the power tool is powered by an AC power source, in which case the first nominal voltage is approximately 120VAC. In one embodiment, the link capacitor has a capacitance value of approximately 50μF or less.

[0126] In one embodiment, the link capacitor has a capacitance value optimized to provide an average voltage of approximately 120V on the DC bus line when the power tool is powered by an AC power supply, in which case the first nominal voltage is approximately 120VAC. In one embodiment, the link capacitor has a capacitance value of approximately 200 to 600μF or less. In one embodiment, the DC power supply has a nominal voltage of approximately 120VDC.

[0127] According to one aspect of the present invention, at least one of the first and second nominal voltages does not substantially correspond to the motor's operating voltage range.

[0128] In one embodiment, the motor control circuit is configured to optimize the supply of power to the motor from at least one of the AC power line or DC power line at a level corresponding to the motor's operating voltage range.

[0129] In one embodiment, the controller is configured to set the operating mode to one of either an AC operating mode or a DC operating mode, and to control the switching operation of the power switch circuit based on the operating mode. In one embodiment, the controller is configured to detect the current on one of either an AC power line or a DC power line in order to set the operating mode. In one embodiment, the controller is configured to receive a signal indicating the operating mode from the power interface.

[0130] In one embodiment, the motor's operating voltage range includes a first nominal voltage but does not include a second nominal voltage. In one embodiment, the motor's operating voltage range is approximately within the range of 100V to 120V, which includes the first nominal voltage, and the second nominal voltage is within the range of approximately 60VDC to 100VDC. In one embodiment, the controller may be configured to increase the effective power supply to the motor in DC operating mode to correspond to the motor's operating voltage range.

[0131] In one embodiment, the motor's operating voltage range includes a second nominal voltage but does not include a first nominal voltage. In one embodiment, the motor's operating voltage range is approximately in the range of 60V to 100V, which includes the second nominal voltage, and the first nominal voltage is in the range of approximately 100VAC to 120VAC. In one embodiment, the controller may be configured to reduce the effective power supply to the motor in AC operating mode to correspond to the motor's operating voltage range.

[0132] In one embodiment, the motor's operating voltage range does not include either the first nominal voltage or the second nominal voltage. In one embodiment, the motor control circuit is configured to optimize the supply of power to the motor from both AC and DC power lines at levels corresponding to the motor's operating voltage range.

[0133] In one embodiment, the motor's operating voltage range is approximately in the range of 150V to 170V, the first nominal voltage is in the range of approximately 100VAC to 120VAC, and the second nominal voltage is in the range of approximately 90VDC to 120VDC. In one embodiment, the controller may be configured to increase the effective power supply to the motor in both AC and DC operating modes to correspond to the motor's operating voltage range.

[0134] In one embodiment, the motor's operating voltage range is approximately within the range of 150V to 170V, the first nominal voltage is approximately within the range of 220VAC to 240VAC, and the second nominal voltage is approximately within the range of 90VDC to 120VDC. In one embodiment, the controller may be configured to increase the effective power supply to the motor in DC operating mode, but to decrease the effective power supply to the motor in AC operating mode, in accordance with the motor's operating voltage.

[0135] In one embodiment, the controller is configured to control the switching operation of a power switch circuit via one or more drive signals in a fixed pulse-width modulation (PWM) duty cycle, wherein the controller sets the fixed PWM duty cycle to a first value with respect to a first nominal voltage when powered by an AC power supply, and to a second value different from the first value with respect to a second nominal voltage when powered by a DC power supply.

[0136] In one embodiment, the controller is configured to control the switching operation of a power switch circuit via one or more drive signals in AC operating mode with a fixed pulse-width modulation (PWM) duty cycle of less than 100% in order to reduce the effective power supply to the motor in AC operating mode to correspond to the motor's operating voltage range.

[0137] In one embodiment, the controller is configured to control the switching operation of a power switch circuit via one or more drive signals in a pulse-width modulation (PWM) duty cycle up to a threshold, wherein the controller sets the threshold to a first value with respect to a first nominal voltage when powered by an AC power supply, and to a second value different from the first value with respect to a second nominal voltage when powered by a DC power supply.

[0138] In one embodiment, the controller is configured to control the switching operation of the power switch circuit within a first duty cycle range in DC operation mode and within a second duty cycle range in AC operation mode, in order to reduce the effective power supply to the motor in AC operation mode so as to correspond to the motor's operating voltage range, and in this case, the second PWM duty cycle range is smaller than the first duty cycle range.

[0139] In one embodiment, the controller is configured to reduce the effective power supply to the motor in AC operating mode to correspond to the motor's operating voltage range, by controlling the switching operation of the power switch circuit in DC operating mode at a duty cycle from zero to 100%, and by controlling the switching operation of the power switch circuit in AC operating mode at a threshold of zero to less than 100%.

[0140] In one embodiment, the controller is configured to receive instantaneous current measurements on a DC bus line, and to implement current limiting on the current through a power switch circuit by comparing the instantaneous current measurements with a current limit, and by interrupting the current flowing to the electric motor by turning off a plurality of power switches for the remainder of the current time interval in response to the instantaneous current measurements exceeding the current limit, in which case the duration of each time interval is defined as a function of a given frequency at which the electric motor is controlled by the controller.

[0141] In one embodiment, the controller turns on the select power switch at the end of the current time interval, thereby restarting the flow of current to the motor.

[0142] In one embodiment, the duration of each time interval is approximately 10 × "the reciprocal of a given frequency at which the motor is controlled by the controller". In one embodiment, the duration of each time interval is approximately 100 microseconds.

[0143] In one embodiment, the duration of each time interval corresponds to the period of the pulse width modulation (PWM) cycle.

[0144] In one embodiment, the controller is configured to receive a measured value of the current on the DC bus line and to implement current limiting on the current through the power switch circuit by setting or adjusting the PWM duty cycle of one or more drive signals. In another embodiment, the controller is configured to monitor the current through the DC bus line and to adjust the PWM duty cycle if the current through the DC bus line exceeds a current limit.

[0145] In one embodiment, the controller is configured to set a current limit according to the voltage rating of one of the AC or DC power supplies.

[0146] In one embodiment, the controller is configured to set the current limit to a first threshold in AC operating mode and a second threshold in DC operating mode in order to reduce the effective power supply to the motor in AC operating mode, corresponding to the motor's operating voltage range, in which case the second threshold is higher than the first threshold.

[0147] According to one embodiment, the controller is configured to activate a drive signal for each phase of the motor within a conduction band (CB) corresponding to the motor's phase, for one of a group of power switches. According to one embodiment, the CB is set to approximately 120 degrees.

[0148] In one embodiment, the controller is configured to shift the CB by an advance angle (AA) such that the CB leads the motor's reverse electromagnetic field (EMF) current. According to one embodiment, AA is set to approximately 30 degrees.

[0149] In one embodiment, the controller is configured to set at least one of CB or AA according to the voltage rating of one or more AC or DC power sources. In one embodiment, the controller is configured to set at least one of CB or AA to a first value with respect to a first nominal voltage when powered by an AC power source, and to a second value different from the first value with respect to a second nominal voltage when powered by a DC power source.

[0150] In one embodiment, the controller is configured to set CB to a first CB value in AC operating mode and to a second CB value greater than the first CB value in DC operating mode. In one embodiment, the second CB value is determined to increase the effective power supply to the motor in DC operating mode so as to correspond to the motor's operating voltage range. In one embodiment, the first CB value is about 120 degrees and the second CB value is greater than about 130 degrees.

[0151] In one embodiment, the controller is configured to set AA to a first AA value in AC operating mode and to a second AA value greater than the first AA value in DC operating mode. In one embodiment, the second AA value is determined to increase the effective power supply to the motor in DC operating mode so as to correspond to the motor's operating voltage range. In one embodiment, the first AA value is about 30 degrees and the second AA value is greater than about 35 degrees.

[0152] In one embodiment, the controller is configured to set CB and AA to a coordinated state according to the voltage rating of the AC or DC power supply.

[0153] In one embodiment, the controller is configured to set at least one of CB or AA to a base value corresponding to the maximum speed of the motor under near no load, and to gradually increase at least one of CB or AA from the base value to a threshold with respect to torque increase, resulting in a substantially linear speed-torque curve. In one embodiment, the controller is configured to maintain a substantially constant speed on the speed-torque curve. In one embodiment, the base value and threshold correspond to a low torque range where the speed-torque curve is substantially linear. In one embodiment, the controller is configured to maintain at least one of CB or AA at torques greater than the low torque range.

[0154] According to another aspect of the present invention, a power tool is provided, the power tool comprising a housing and a brushless direct current (BLDC) motor including a rotor and a stator having at least three stator windings corresponding to at least three phases of the motor, wherein the rotor is movable by the stator when the stator windings are adequately energized within the corresponding phases, each phase being characterized by a corresponding voltage waveform that energizes the corresponding stator windings, and the motor is configured to operate within an operating voltage range; and a motor control circuit configured to receive power from a first power supply having a first nominal voltage or a second power supply having a second nominal voltage different from the first nominal voltage, and to supply power to the motor at a level corresponding to the motor's operating voltage range. In one embodiment, the first and second power supplies are, each, an AC power supply or a DC power supply.

[0155] In one embodiment, at least one of the first and second nominal voltages is either not substantially corresponding to the motor's operating voltage range, is different from the motor's operating voltage range, or is outside the motor's operating voltage range. In one embodiment, the motor control circuit is configured to optimize the power supply from at least one of the first or second power sources to the motor at a level corresponding to the motor's operating voltage range.

[0156] In one embodiment, the motor's operating voltage range includes a first nominal voltage but does not include a second nominal voltage. In one embodiment, the motor's operating voltage range is approximately within the range of 100V to 120V, which includes the first nominal voltage, and the second nominal voltage is approximately within the range of 60V to 100V. In one embodiment, the controller may be configured to increase the effective power supply to the motor to correspond to the motor's operating voltage range when powered by a second power supply.

[0157] In one embodiment, the motor's operating voltage range includes a second nominal voltage but does not include a first nominal voltage. In one embodiment, the motor's operating voltage range is approximately within the range of 60V to 100V, which includes the second nominal voltage, and the first nominal voltage is approximately within the range of 100VAC to 120VAC. In one embodiment, the controller may be configured to reduce the effective power supply to the motor to correspond to the motor's operating voltage range when powered by a first power supply.

[0158] In one embodiment, the motor's operating voltage range does not include either the first nominal voltage or the first nominal voltage. In one embodiment, the motor control circuit is configured to optimize the supply of power to the motor from both the first and second power sources at levels corresponding to the motor's operating voltage range.

[0159] In one embodiment, at least one of the first or second power supply is an AC power supply, and the motor control circuit has a rectifier circuit including a diode bridge. In one embodiment, the rectifier circuit further has a link capacitor arranged in parallel with the diode bridge on a DC bus line. In one embodiment, the diode bridge is a full-wave bridge. In an alternative embodiment, the diode bridge is a half-wave bridge.

[0160] In one embodiment, both the first and second power supplies have DC power supplies with different nominal voltage levels.

[0161] In one embodiment, the motor control circuit further includes a controller configured to control the switching operation of a power switch circuit. In one embodiment, the controller is a programmable device including a microcontroller, microprocessor, computer processor, or signal processor. Alternatively, the controller is an integrated circuit configured and customized to control the switching operation of a power switch unit.

[0162] In one embodiment, the power switch circuit has a plurality of power switches, including three pairs of high-side and low-side power switches configured as a three-phase bridge circuit coupled to the phase of the motor. In one embodiment, the motor control circuit further has a gate driver circuit coupled to the controller and the power switch circuit and configured to drive the gates of the plurality of power switches based on one or more drive signals from the controller. In one embodiment, the motor control circuit further has a power regulator including at least one voltage regulator configured to output a voltage signal to supply power to at least one of the gate driver circuit or the controller. In one embodiment, the motor control circuit further has an on / off switch coupled to at least one of the on / off actuator or trigger switch and configured to interrupt the supply of power from the power regulator and the gate driver circuit.

[0163] In one embodiment, the power tool further includes a plurality of position sensors disposed near the rotor to provide a rotor rotation position signal to a control unit. In one embodiment, the controller is configured to control the switching operation of a power switch circuit based on the position signal to appropriately supply energy to the stator windings within the corresponding phase.

[0164] According to one embodiment, within each phase of the motor, the controller is configured to activate a drive signal for a corresponding one of a plurality of power switches within the conduction band corresponding to the phase of the motor.

[0165] In one embodiment, the controller is configured to set a pulse-width modulation (PWM) duty cycle according to a desired motor speed, and to control the drive signal to enable variable-speed operation of the motor under constant load by periodically turning on and off one of a plurality of power switches in the conduction band according to the PWM duty cycle.

[0166] In one embodiment, the link capacitor has a capacitance value of approximately 50 μF or less.

[0167] In one embodiment, the controller is configured to control the switching operation of a power switch circuit via one or more drive signals in a fixed pulse-width modulation (PWM) duty cycle, wherein the controller sets the fixed PWM duty cycle to a first value with respect to a first nominal voltage when powered by a first power supply, and to a second value different from the first value with respect to a second nominal voltage when powered by a second power supply.

[0168] In one embodiment, the controller is configured to control the switching operation of a power switch circuit via one or more drive signals during pulse-width modulation (PWM) duty cycles up to a threshold, wherein the controller sets the threshold to a first value with respect to a first nominal voltage when powered by a first power supply, and to a second value different from the first value with respect to a second nominal voltage when powered by a second power supply.

[0169] In one embodiment, the controller is configured to optimize the effective power supply to the motor when powered by a first or second power supply to correspond to the motor's operating voltage range. This is achieved by controlling the switching operation of the power switch circuit within a first duty cycle range when coupled to a first power supply, and controlling the switching operation of the power switch circuit within a second duty cycle range when coupled to a second power supply. In this case, the second PWM duty cycle range is smaller than the first duty cycle range.

[0170] In one embodiment, the controller is configured to receive instantaneous current measurements on a DC bus line, and to implement current limiting on the current through a power switch circuit by comparing the instantaneous current measurements with a current limit, and by interrupting the current flowing to the electric motor by turning off a plurality of power switches for the remainder of the current time interval in response to the instantaneous current measurements exceeding the current limit, in which case the duration of each time interval is defined as a function of a given frequency at which the electric motor is controlled by the controller.

[0171] In one embodiment, the controller turns on the select power switch at the end of the current time interval, thereby restarting the flow of current to the motor.

[0172] In one embodiment, the duration of each time interval is approximately 10 × "the reciprocal of a given frequency at which the motor is controlled by the controller". In one embodiment, the duration of each time interval is approximately 10 microseconds.

[0173] In one embodiment, the duration of each time interval corresponds to the period of the pulse width modulation (PWM) cycle.

[0174] In one embodiment, the controller is configured to receive a measured value of the current on the DC bus line and to implement current limiting on the current through the power switch circuit by setting or adjusting the PWM duty cycle of one or more drive signals. In another embodiment, the controller is configured to monitor the current through the DC bus line and to adjust the PWM duty cycle if the current through the DC bus line exceeds a current limit.

[0175] In one embodiment, the controller is configured to set a current limit according to the voltage rating of one of the first or second power supplies.

[0176] In one embodiment, the controller is configured to optimize the effective power supply from the first or second power source to the motor to correspond to the motor's operating voltage range. Specifically, it sets the current limit to a first threshold when the power tool is powered by the first power source, and to a second threshold when the power tool is powered by the second power source, in which case the second threshold is higher than the first threshold.

[0177] According to one embodiment, the controller is configured to activate a drive signal for each phase of the motor within a conduction band (CB) corresponding to the motor's phase, for one of a group of power switches. According to one embodiment, the CB is set to approximately 120 degrees.

[0178] In one embodiment, the controller is configured to shift the CB by a leading angle (AA) so that the CB leads the motor's reverse electromagnetic field (EMF) current. According to one embodiment, AA is set to approximately 30 degrees.

[0179] In one embodiment, the controller is configured to set at least one of CB or AA according to the voltage rating of one or more of the first or second power supplies.

[0180] In one embodiment, the controller is configured to set CB to a first CB value when the power tool is powered by a first power source, and to a second CB value greater than the first CB value when the power tool is powered by a second power source. In one embodiment, the second CB value is determined to increase or decrease the effective power supply to the motor when powered by the first or second power source, corresponding to the motor's operating voltage range. In one embodiment, the first CB value is about 120 degrees, and the second CB value is greater than about 130 degrees.

[0181] In one embodiment, the controller is configured to set AA to a first AA value when the power tool is powered by a first power source, and to a second AA value greater than the first AA value when the power tool is powered by a second power source. In one embodiment, the second AA value is determined to increase or decrease the effective power supply to the motor when powered by the first or second power source, corresponding to the motor's operating voltage range. In one embodiment, the first AA value is about 30 degrees, and the second AA value is greater than about 35 degrees.

[0182] In one embodiment, the controller is configured to set CB and AA to a coordinated state according to the voltage rating of the first or second power supply.

[0183] In one embodiment, the controller is configured to set at least one of CB or AA to a base value corresponding to the maximum motor speed under nearly no-load conditions, and to gradually increase at least one of CB or AA from the base value to a threshold with respect to torque increase, resulting in a substantially linear speed-torque curve. In one embodiment, the controller is configured to maintain a substantially constant speed on the speed-torque curve. In one embodiment, the base value and threshold correspond to a low torque range where the speed-torque curve is substantially linear. In one embodiment, the controller is configured to maintain at least one of CB or AA at torques greater than the low torque range.

[0184] In another embodiment, the battery pack is bidirectionally convertible between a low-rated voltage / high-capacity configuration and an intermediate-rated voltage / low-capacity configuration.

[0185] In another embodiment, the power tool system includes a battery pack that is bidirectionally convertible between a low-rated voltage / high-capacity configuration and an intermediate-rated voltage / low-capacity configuration, and a power tool coupled to the battery pack that converts the battery pack from a low-rated voltage / high-capacity configuration to an intermediate-rated voltage / low-capacity configuration and operates with the battery pack in that intermediate-rated voltage / low-capacity configuration.

[0186] In another embodiment, the power tool system includes a battery pack that is bidirectionally convertible between a low-rated voltage / high-capacity configuration and an intermediate-rated voltage / low-capacity configuration; a first power tool coupled with the battery pack, converting the battery pack from a low-rated voltage / high-capacity configuration to an intermediate-rated voltage / low-capacity configuration and operating with the battery pack in the intermediate-rated voltage / low-capacity configuration; and a second power tool coupled with the battery pack and operating with the battery pack in the low-rated voltage / high-capacity configuration.

[0187] In another embodiment, the power tool system includes a first battery pack that is bidirectionally convertible between a low-rated voltage / high-capacity configuration and an intermediate-rated voltage / low-capacity configuration; a second battery pack that is always in a low-rated voltage / high-capacity configuration; and a power tool coupled to the first battery pack and operating together with the first battery pack in its low-rated voltage / high-capacity configuration, and coupled to the second battery pack and operating together with the second battery pack in its low-rated voltage / high-capacity configuration.

[0188] In another embodiment, the power tool system includes a first battery pack that is bidirectionally convertible between a low-rated voltage / high-capacity configuration and an intermediate-rated voltage / low-capacity configuration; a second battery pack that is always in a low-rated voltage / high-capacity configuration; a first power tool coupled to the first battery pack and operating together with the first battery pack in its low-rated voltage / high-capacity configuration, and coupled to the second battery pack and operating together with the second battery pack in its low-rated voltage / high-capacity configuration; and a second power tool coupled to the first battery pack but not to the second battery pack, and operating together with the first battery pack in its high-rated voltage / low-capacity configuration.

[0189] In another embodiment, the power tool system includes a battery pack that is bidirectionally convertible between a low-rated voltage / high-capacity configuration and an intermediate-rated voltage / low-capacity configuration; a first intermediate-rated voltage power tool coupled with the battery pack, converting the battery pack from a low-rated voltage / high-capacity configuration to an intermediate-rated voltage / low-capacity configuration and operating with the battery pack in that intermediate-rated voltage / low-capacity configuration; and a second high-rated voltage power tool coupled with a plurality of battery packs, converting each battery pack from a low-rated voltage / high-capacity configuration to an intermediate-rated voltage / low-capacity configuration and operating with the battery packs in those intermediate-rated voltage / low-capacity configurations.

[0190] In another embodiment, the power tool system includes a battery pack that is bidirectionally convertible between a low-rated voltage / high-capacity configuration and an intermediate-rated voltage / low-capacity configuration, and a high-rated voltage power tool that is coupled with a plurality of battery packs, converting each battery pack from a low-rated voltage / high-capacity configuration to an intermediate-rated voltage / low-capacity configuration, and / or coupled with a high-rated voltage AC power supply, and operating at a high-rated voltage together with the battery packs in the intermediate-rated voltage / low-capacity configuration and / or the high-rated voltage AC power supply.

[0191] In another embodiment, the first battery pack is bidirectionally convertible between a low-rated voltage / high-capacity configuration and an intermediate-rated voltage / low-capacity configuration, the second battery pack is always in a low-rated voltage / high-capacity configuration, and a battery pack charger electrically and mechanically connectable to both the first and second battery packs can charge both the first and second battery packs.

[0192] In another embodiment, the battery pack includes a housing and a battery located within the housing. The battery may include a plurality of rechargeable cells and a switching network coupled to the plurality of rechargeable cells. The switching network may have a first configuration and a second configuration. The switching network may be switchable from the first configuration to the second configuration and from the second configuration to the first configuration. The plurality of rechargeable cells may be in the first configuration when the switching network is in the first configuration, and in the second configuration when the switching network is in the second configuration. The second configuration is different from the first configuration.

[0193] The switching network of the battery pack in this embodiment may have a third configuration, in which case the plurality of rechargeable cells are in the third configuration when the switching network is in the third configuration. The switching network of the battery pack in this embodiment may be switched between the first configuration and the second configuration by an external input to the battery pack. The first configuration of the rechargeable cells of the battery pack in this embodiment may be a relatively low-voltage and high-capacity configuration, and the second configuration of the rechargeable cells of the battery pack may be a relatively high-voltage and low-capacity configuration. The battery pack in this embodiment may include a cell configuration in which the first configuration provides a first rated pack voltage and the second configuration provides a second rated pack voltage, in which case the first rated pack voltage is different from the second rated pack voltage. The third configuration of the battery pack in this embodiment may be an open-circuit configuration.

[0194] The rechargeable cells of the battery pack in the first configuration may enter the third configuration during conversion between the first and second configurations. The battery pack in this embodiment may have a terminal block coupled to a plurality of rechargeable cells and a switching network, in which case the terminal block accepts switching elements for switching the switching network from the first configuration to the second configuration.

[0195] In another embodiment, the battery pack comprises a housing and a battery located within the housing. The battery may include a set P of O rechargeable cells Q, where O is number ≥ 2. The set P of rechargeable cells Q may include N subsets R of cells Q, where N is number ≥ 2. Each subset R of cells Q may include M cells Q, where M is number ≥ 1, and M × N = O. The battery may include a switching network coupled to the rechargeable cells, in which case the switching network may have a first configuration and a second configuration, and may be switchable from the first configuration to the second configuration and from the second configuration to the first configuration. All of the subsets R of rechargeable cells Q may be connected in parallel when the switching network is in the first configuration, and may be separated when the switching network is in the second configuration. The first power terminal may be connected to the positive terminal of cell Q1, and the second power terminal may be connected to the negative terminal of QO, in which case the first and second power terminals supply power from the battery pack to the outside. Negative conversion terminals may be connected to the negative terminals of each subset R1 to RN-1, and positive conversion terminals may be connected to the positive terminals of each subset R2 to RN. The negative and positive conversion terminals of the battery pack in this embodiment are accessible from outside the battery housing.

[0196] In another embodiment, the battery pack comprises a housing and batteries located within the housing. The battery of this embodiment may include batteries located within the housing. The battery of this embodiment may include a set P of O rechargeable cells Q, where O is number ≥ 2. The set P of rechargeable cells Q may include N subsets R of cells Q, where N is number ≥ 2. Each subset R of cells Q may include M cells Q, where M is number ≥ 1 and M × N = O. The battery pack of this embodiment may include a switching network coupled to the rechargeable cells. The switching network may have a first configuration and a second configuration, and may be switchable from the first configuration to the second configuration and from the second configuration to the first configuration. All of the subsets R of rechargeable cells Q may be connected in parallel when the switching network is in the first configuration, and may be separated when the switching network is in the second configuration. The battery pack may include a first power terminal connected to the positive terminal of Q1 and a second power terminal connected to the negative terminal of QO, in which case the first and second power terminals supply power from the battery pack to the outside. The battery pack may also include a negative conversion terminal connected to the negative terminal of each subset of cells and a positive conversion terminal connected to the positive terminal of each subset of cells.

[0197] In another embodiment, the power tool includes a first power source from an AC input having a rated AC voltage, a second power source from a plurality of rechargeable battery cells having a rated DC voltage, a motor that can be coupled to the first and second power sources, and a control circuit configured to operate the motor with substantially the same output power when operated by the first and second power sources. The rated DC voltage of the power tool in this embodiment may be substantially equal to the rated AC voltage. The motor of the power tool in this embodiment is a brushed motor. The control circuit of the power tool in this embodiment may operate the brushed motor at a constant no-load speed, regardless of whether the motor is operated by the first or second power source. The control circuit of the power tool in this embodiment may operate the brushed motor at a variable no-load speed based on user input. The control circuit of the power tool in this embodiment may include an IGBT / MOSFET circuit configured to operate the motor at a variable no-load speed using the first or second power source. The motor of the power tool in this embodiment may be a brushless motor. The control circuit of the power tool in this embodiment may include a small capacitor and a cycle-by-cycle current limiter. The rated DC voltage of the power tool in this embodiment may be less than the rated AC voltage. The control circuit of the power tool in this embodiment may include a small capacitor and a cycle-by-cycle current limiter. The control circuit of the power tool in this embodiment may include at least one of a lead angle control device and a conduction band control device. The control circuit of the power tool in this embodiment may detect whether the first power supply and the second power supply are activated. The control circuit of the power tool in this embodiment may always select the first power supply when the first power supply is active. The control circuit of the power tool in this embodiment may switch to the second power supply when the first power supply is stopped. The control circuit of the power tool in this embodiment may include a boost mode in which the control circuit operates the power supply at a higher output power by using both the first and second power supplies simultaneously. The power supply of the power tool in this embodiment may be provided by a cord set.The first and second power sources of the power tool in this embodiment may simultaneously supply power to the motor, and may provide substantially greater power than the first or second power source can provide individually.

[0198] In another embodiment, the power tool includes an input that receives power from an AC power source, an input that receives power from a rechargeable DC power source, a charger that charges the rechargeable DC power source with the AC power source, and a motor configured to be powered by at least one of the AC power source and the rechargeable DC power source. The AC power source of the power tool in this embodiment may be a commercial power line. The rechargeable DC power source of the power tool in this embodiment may be a removable battery pack.

[0199] In another embodiment, the power tool has an input that receives AC power from an AC power source, the AC power source having a rated AC voltage and located outside the power tool; an input that receives DC power from a DC power source, the DC power source having a rated DC voltage and comprising a plurality of rechargeable battery cells, the rated DC voltage being approximately equal to the rated AC voltage; and a motor configured to be powered by at least one of the AC power source and the DC power source. The AC power source of the power tool in this embodiment may be a commercial power line. The rechargeable DC power source of the power tool in this embodiment may be a battery pack. The AC power source and DC power source of the power tool in this embodiment may have a rated voltage of 120 volts.

[0200] In another embodiment, the power tool includes a motor, a first power source from an AC input line, and a second power source from a rechargeable battery, which provides power substantially equivalent to that of the first power source. The first and second power sources of the power tool in this embodiment may supply power to the motor simultaneously. The first and second power sources of the power tool in this embodiment may supply power to the motor alternately.

[0201] In another embodiment, the power tool includes a motor, a first power source from an AC input line, and a second power source from a rechargeable battery, which provides power substantially equivalent to that of the first power source. The first and second power sources of the power tool in this embodiment may supply power to the motor simultaneously. The first and second power sources of the power tool in this embodiment may supply power to the motor alternately.

[0202] In another embodiment, the battery pack may include a housing, a plurality of cells, and a converter element, the converter element being movable between a first position configured such that the plurality of cells provide a first rated voltage and a second position configured such that the plurality of cells provide a second rated voltage different from the first rated voltage.

[0203] Embodiments of this aspect may include one or more of the following features: In the case of the battery pack described above, the converter element has a housing and a plurality of contacts. In the case of the battery pack described above, the housing forms an internal cavity and the plurality of cells are housed within the internal cavity. In the case of the battery pack described above, the housing forms an internal cavity and the converter element is housed within the internal cavity and is accessible from outside the housing. The battery pack described above further has a battery having a plurality of cells and a converter element and a switching network. In the case of the battery pack described above, the housing further has an external slot and a through hole at the first end of the slot, the through hole extending from the external surface of the housing to the internal cavity of the housing. In the case of the battery pack described above, the converter element further has a projection extending through the through hole and a plurality of contacts. In the case of the battery pack described above, the converter element has a jumper switch. The battery pack further comprises a battery having a plurality of cells, a plurality of conductive contact pads, and nodes between adjacent electrically connected cells, each of the plurality of conductive contact pads being coupled to a single node, and a converter element having a plurality of contacts, (a) when the converter element is in a first position, each of the plurality of converter element contacts is electrically connected to a first set of the plurality of conductive contact pads, and each of the plurality of conductive contact pads is within a single first set of the plurality of conductive contact pads, and (b) when the converter element is in a second position, each of the converter element contacts is electrically connected to a second set of the plurality of conductive contact pads, each second set of the plurality of conductive contact pads being different from all other second sets of the plurality of conductive contact pads, and each first set of the plurality of conductive contact pads being different from each second set of the plurality of conductive contact pads.The battery pack described above further comprises a battery having a plurality of cells, a plurality of conductive contact pads, and nodes between adjacent electrically connected cells, each of the plurality of conductive contact pads being coupled to a single node, wherein when the converter element is in a first position, each of the plurality of converter element contacts is a shunt between the conductive contact pads in a corresponding first set of the plurality of conductive contact pads, and when the converter element is in a second position, each of the plurality of converter element contacts is a shunt between the conductive contact pads in a corresponding second set of the plurality of conductive contact pads.

[0204] In another embodiment, the battery pack includes a housing, a plurality of cells, and a converter element, the converter element being movable between a first position in which the plurality of cells are electrically connected in a first cell configuration and a second position in which the plurality of cells are electrically connected in a second cell configuration, wherein the first cell configuration is different from the second cell configuration.

[0205] Embodiments of this aspect may include one or more of the following features: In the battery pack described above, the converter element has a housing and a plurality of contacts. In the battery pack described above, the housing forms an internal cavity and the plurality of cells are housed within the internal cavity. In the battery pack described above, the housing forms an internal cavity and the converter element is housed within the internal cavity and is accessible from outside the housing. In the battery pack described above, the battery further comprises a battery having a plurality of cells and a converter element and a switching network. In the battery pack described above, the housing further has an external slot and a through hole at the first end of the slot, the through hole extending from the external surface of the housing to the internal cavity of the housing. In the battery pack described above, the converter element further has a projection extending through the through hole and a plurality of contacts. In the battery pack described above, the converter element has a jumper switch. The battery pack described above further comprises a battery having a plurality of cells, a plurality of conductive contact pads, and nodes between adjacent electrically connected cells, wherein each of the plurality of conductive contact pads is connected to a single node, and in this case the converter element includes a plurality of contacts, (a) when the converter element is in a first position, each of the plurality of converter element contacts is electrically connected to a first subset of the plurality of conductive contact pads, and (b) when the converter element is in a second position, each of the plurality of converter element contacts is electrically connected to a second subset of the plurality of conductive contact pads, the second subset of the plurality of conductive contact pads being different from the first subset of the plurality of conductive contact pads.The battery pack further comprises a battery having a plurality of cells, a plurality of conductive contact pads, and nodes between adjacent electrically connected cells, each of the plurality of conductive contact pads being coupled to a single node, wherein when the converter element is in a first position, each of the plurality of converter element contacts is a shunt between conductive contact pads in a first subset of the plurality of conductive contact pads, and when the converter element is in a second position, each of the plurality of converter element contacts is a shunt between conductive contact pads in a second subset of the plurality of conductive contact pads.

[0206] In another embodiment, the battery pack includes a housing; a set of cells, the set having at least two cells; two subsets of the set of cells, each cell of the set of cells being in a single subset, each subset of cells being electrically connected in series and having a positive node and a negative node; a switching network having a first switch connecting the positive end of the first subset to the positive end of the second subset; a second switch connecting the negative end of the first subset to the negative end of the second subset; and a third switch connecting the negative end of the first subset to the positive end of the second subset; and a converter element operating with the switching network to open and close the first, second, and third switches to convert the set of cells between a low-rated voltage configuration and an intermediate-rated voltage configuration.

[0207] In another embodiment, the battery pack includes a housing; a set of cells, the set having at least two cells; two subsets of the set of cells, each cell of the set of cells being in a single subset, each subset of cells being electrically connected in series and having a positive node and a negative node; a switching network having a first switch connecting the positive end of the first subset to the positive end of the second subset; a second switch connecting the negative end of the first subset to the negative end of the second subset; and a third switch connecting the negative end of the first subset to the positive end of the second subset; and a converter element operating with the switching network to constitute the first, second, and third switches in a first state where the set of cells is electrically connected in a first cell configuration, and in a second state where the set of cells is electrically connected in a second cell configuration, wherein the first cell configuration is different from the second cell configuration.

[0208] Embodiments of this design may include one or more of the following features: In the battery pack described above, the converter element operates when the battery pack is coupled to an electrical device. In the battery pack described above, the converter element has a set of terminals, and the converter element operates when the battery pack is coupled to an electrical device.

[0209] In another embodiment, the combination of an electrical device and a battery pack includes a battery pack comprising (1) a housing including a battery pack interface, (2) a plurality of cells, and (3) a converter element movable between a first position in which the plurality of cells are configured to provide a first rated voltage and a second position in which the plurality of cells are configured to provide a second rated voltage different from the first rated voltage, and an electrical device comprising a housing, wherein the housing includes an electrical device interface configured to couple with a battery pack interface for mechanically coupling the electrical device to the battery pack, and the electrical device interface includes a conversion function for moving the converter element from the first position to the second position when the electrical device is mechanically coupled to the battery pack.

[0210] Embodiments of this aspect may include one or more of the following features: In the combination, the converter element has a plurality of battery terminals, and the conversion function has a plurality of electrical device terminals. In the above combination, the converter element has a housing and a plurality of contacts. In the above combination, the housing forms an internal cavity, and a plurality of cells are housed within the internal cavity. In the above combination, the housing forms an internal cavity, and the converter element is housed within the internal cavity. In the above combination, the further comprises a battery containing a plurality of cells. In the combination, the electrical device is a power tool. In the above combination, the electrical device is a charger. In the above combination, the electrical device is a battery holding tray.

[0211] In another embodiment, the battery pack includes a housing, a plurality of cells, a first set of terminals electrically coupled to the plurality of cells, the first set of terminals providing output power, and a second set of terminals electrically coupled to the set of cells, the second set of terminals configured to enable conversion of the plurality of cells between the first and second configurations.

[0212] Embodiments of this aspect may include one or more of the following features: In the battery pack described above, the housing forms a cavity in which a plurality of cells, a first set of terminals, and a second set of terminals are housed within the internal cavity. The battery pack described above further comprises a battery having a plurality of cells. In the battery pack described above, the second set of terminals includes a set of switches. In the battery pack described above, the second set of terminals is configured to accept a switching device that enables the switches to convert the plurality of cells from a first configuration to a second configuration. In the battery pack described above, the second set of terminals is configured to convert the plurality of cells from a first configuration to a second configuration upon acceptance of the switching device. In the battery pack described above, the plurality of cells are converted from a first configuration to a second configuration when the second set of terminals accepts the switching device. In the battery pack described above, the second set of terminals is configured to enable the conversion of the plurality of cells to a third configuration. In the battery pack described above, the plurality of cells enter the third configuration between switching from the first and second configurations.

[0213] In another embodiment, the battery pack and electrical device combination comprises (a) a battery pack having a housing, a plurality of cells, a first set of battery terminals electrically coupled to the plurality of cells, the first set of terminals providing output power, and a second set of battery terminals electrically coupled to the plurality of cells, the second set of terminals configured to allow the plurality of cells to be converted from a first configuration to a second configuration; and (b) an electrical device having a first set of electrical device terminals configured to be electrically coupled to the first set of battery terminals, and a converter element configured to be electrically coupled to the second set of battery terminals to enable the conversion of the plurality of cells from a first configuration to a second configuration.

[0214] Embodiments of this aspect may include one or more of the following features: The battery pack described above further comprises a battery containing a plurality of cells. The battery pack described above includes an electrical device which is a power tool having a motor, wherein a first set of power tool terminals is configured to be electrically coupled to the motor and to a first set of battery terminals, and the first set of tool terminals provides input power. The battery pack described above includes an electrical device which is a charger. The battery pack described above includes an electrical device which is a battery holder.

[0215] In another embodiment, the battery pack includes a housing, a plurality of cells, and a set of coupling terminals, the coupling terminals being movable between a first position configured to provide a first rated voltage and a second position configured to provide a second rated voltage different from the first rated voltage.

[0216] In another embodiment, the battery pack includes a housing, a plurality of cells, and a set of coupling terminals, the coupling terminals being movable between a first terminal configuration in which the plurality of cells are electrically connected in a first cell configuration and a second terminal configuration in which the plurality of cells are electrically connected in a second cell configuration, wherein the first cell configuration is different from the second cell configuration.

[0217] In another embodiment, the convertible battery pack comprises a housing, a plurality of cells, a set of battery terminals, and a conversion subsystem, the conversion subsystem having a converter element, the converter element being movable between a first position configured such that the plurality of cells provide a first rated voltage at the set of battery terminals and a second position configured such that the plurality of cells provide a second rated voltage at the set of battery terminals, the second rated voltage being different from the first rated voltage.

[0218] Embodiments of this configuration may include one or more of the following features. In this exemplary embodiment of the battery pack, the converter element has a housing and a plurality of contacts, the housing forming an internal cavity, and the plurality of cells are housed within the internal cavity. In this exemplary embodiment, the converter element is housed within the internal cavity and is accessible from outside the housing. In this exemplary embodiment, the battery pack further has a battery having a plurality of cells, and the conversion subsystem has a converter element and a switching network. In this exemplary embodiment, the battery pack further has an external slot and a through hole at the first end of the slot, the through hole extending from the external surface of the housing to the internal cavity of the housing. In this exemplary embodiment of the battery pack, the converter element further has a projection extending through the through hole and a plurality of contacts. In this exemplary embodiment of the battery pack, the switching network of the conversion subsystem includes a switch for sending power current through a second set of battery terminals. In this exemplary embodiment, the set of battery terminals of the battery pack further comprises a first set of battery terminals electrically coupled to a plurality of cells, and a second set of battery terminals electrically coupled to a plurality of cells, wherein the first set of battery terminals is configured to provide power when the battery pack is in a first rated voltage configuration and a second rated voltage configuration, and the second set of battery terminals is configured to provide power only when the battery pack is in a second rated voltage configuration.

[0219] In another embodiment, an exemplary embodiment of a convertible battery pack includes a housing, a system of multiple cells, and a conversion subsystem, the conversion subsystem having a converter element, in this case the converter element is movable between a first position in which the system of multiple cells is electrically connected in a first cell configuration and a second position in which the system of multiple cells is electrically connected in a second cell configuration, the first cell configuration being different from the second cell configuration.

[0220] Embodiments of this model may include one or more of the following features. In this exemplary embodiment of the battery pack, the converter element has a housing and a plurality of contacts, the housing forming an internal cavity, and the system of the plurality of cells is housed within the internal cavity. In this exemplary embodiment of the battery pack, the converter element is housed within the internal cavity and is accessible from outside the housing. This exemplary battery pack further includes a battery having a system of the plurality of cells and a converter element, and a switching network. In this exemplary embodiment of the battery pack, the housing further has an external slot and a through hole at the first end of the slot, the through hole extending from the external surface of the housing to the internal cavity of the housing. In this exemplary embodiment of the battery pack, the converter element further has a projection extending through the through hole and a plurality of contact pads. In this exemplary embodiment of the battery pack, the converter element has a plurality of switching contacts.

[0221] In another embodiment, an exemplary embodiment of a convertible battery pack includes a housing; a set of cells, the set of cells having two sets of cells, each set of cells having at least one cell, the cells of each set of cells being electrically connected in series, and each set of cells having a positive terminal and a negative terminal; a switching network having a first switch connecting the positive terminal of the first set of cells to the positive terminal of the second set of cells, a second switch connecting the negative terminal of the first set of cells to the negative terminal of the second set of cells, and a third switch connecting the negative terminal of the first set of cells to the positive terminal of the second set of cells; and a converter element operating with the switching network to open and close the first, second, and third switches in order to convert the set of cells between a low-rated voltage configuration and an intermediate-rated voltage configuration.

[0222] In another embodiment, an exemplary embodiment of a convertible battery pack includes a housing; a set of cells, each set of cells having two systems of cells, each system of cells having at least one cell, the cells in each system of cells being electrically connected in series, and each system of cells having a positive terminal and a negative terminal; a switching network having a first switch connecting the positive terminal of the first system of cells to the positive terminal of the second system of cells, a second switch connecting the negative terminal of the first system of cells to the negative terminal of the second system of cells, and a third switch connecting the negative terminal of the first system of cells to the positive terminal of the second system of cells; and a converter element that, when in operation, configures the first, second, and third switches to a first state in which the set of cells are electrically connected in a first cell configuration and a second state in which the set of cells are electrically connected in a second cell configuration, wherein the first cell configuration is different from the second cell configuration.

[0223] Embodiments of this aspect may include one or more of the following features: In the battery pack of this exemplary embodiment, the converter element operates when the battery pack is coupled to an electrical device and has a set of switching contacts.

[0224] In another embodiment, an exemplary embodiment of a combination of an electrical device and a convertible battery pack includes a battery pack comprising: (1) a housing including a battery pack interface; (2) a plurality of cells; and (3) a converter element, wherein the converter element is movable between a first position in which the plurality of cells are configured to provide a first rated voltage and have a first capacitance, and a second position in which the plurality of cells are configured to provide a second rated voltage and have a second capacitance, the second rated voltage and second capacitance being different from the first rated voltage and first capacitance; and an electrical device comprising a housing, wherein the housing includes an electrical device interface configured to couple with a battery pack interface for mechanically coupling the electrical device to the battery pack, the electrical device interface including a conversion function for moving the converter element from the first position to the second position when the electrical device is mechanically coupled to the battery pack.

[0225] Embodiments of this aspect may include one or more of the following features: This exemplary convertible battery pack further comprises a first set of battery pack terminals for supplying power to a load of an electrical device, and a second set of battery pack terminals for supplying power to a load of an electrical terminal.

[0226] In another embodiment, an exemplary embodiment of a convertible battery pack includes a housing, a plurality of cells, a first set of battery pack terminals electrically coupled to the plurality of cells, the first set of battery pack terminals providing output power, and a second set of battery pack terminals electrically coupled to the plurality of cells, the second set of battery pack terminals configured to enable conversion of the plurality of cells between the first and second configurations.

[0227] Embodiments of this model may include one or more of the following features: In the battery pack of this exemplary embodiment, a second set of battery pack terminals is electrically coupled to a set of switches. In the battery pack of this exemplary embodiment, when the set of switches is in a first state, the second set of battery pack terminals is configured to allow multiple cells to be converted from a first configuration to a second configuration. In the battery pack of this exemplary embodiment, when the switching device is accepted, the set of switches is positioned in a first state. In the battery pack of this exemplary embodiment, when the set of switches is in a first state, the second set of battery pack terminals is configured to transfer power current from the battery pack to the coupled electrical device. In the battery pack of this exemplary embodiment, multiple cells are converted from a first configuration to a second configuration when the battery pack accepts the conversion element.

[0228] In another embodiment, an exemplary combination of a battery pack and an electrical device includes: (a) a battery pack having a housing, a plurality of cells, a first set of battery pack terminals electrically coupled to the plurality of cells, and a second set of battery pack terminals electrically coupled to the plurality of cells, wherein the plurality of cells can be configured to provide a first rated voltage and a second rated voltage, the first set of battery pack terminals is configured to provide power when the battery pack is in a first rated voltage configuration and a second rated voltage configuration, and the second set of battery pack terminals is configured to provide power only when the battery pack is in a second rated voltage configuration; and (b) an electrical device having a first set of electrical device terminals configured to be electrically coupled to the first set of battery pack terminals and a second set of electrical device terminals configured to be electrically coupled to the second set of battery pack terminals in order to provide power to a load of the electrical device. In the exemplary combination, the electrical device includes a conversion element for converting the battery pack from a first rated voltage to a second rated voltage.

[0229] Embodiments of this aspect may include one or more of the following features: In an exemplary combination, the electrical device is a power tool having a motor, wherein a first set of power tool terminals is configured to be electrically coupled to the motor and to a first set of battery pack terminals, and the first set of tool terminals provides input power.

[0230] In another embodiment, an exemplary combination of a battery pack and an electrical device includes: (a) a battery pack having a housing, a plurality of cells, a first set of battery pack terminals electrically coupled to the plurality of cells, and a second set of battery pack terminals electrically coupled to the plurality of cells, wherein the plurality of cells can be configured to provide a first rated voltage and a second rated voltage, the first set of battery pack terminals is configured to provide power when the battery pack is in a first rated voltage configuration and a second rated voltage configuration, and the second set of battery pack terminals is configured to provide power only when the battery pack is in a second rated voltage configuration; and (b) a charger having a first set of charger terminals configured to be electrically coupled to the first set of battery pack terminals and a second set of charger terminals configured to be electrically coupled to the second set of battery pack terminals in order to provide power from the charger to the plurality of cells. In the exemplary combination, the charger includes a conversion element for converting the battery pack from a first rated voltage to a second rated voltage.

[0231] The advantages may include one or more of the following: The power tool system may enable a power tool system with sufficient compatibility, including low-power, medium-power, and high-power cordless power tools and high-power AC / DC power tools. Convertible battery packs may enable backward compatibility of the system with existing power tools. The system may include a power supply tool with a DC rated voltage corresponding to the rated voltage of the AC commercial power supply for high-power operation of power tools using battery pack power. These and other advantages and features will become apparent from the specification, drawings, and claims. [Brief explanation of the drawing]

[0232] [Figure 1A] This is a schematic diagram of a power tool system. [Figure 1B] This is a schematic diagram of a specific embodiment of a power tool system. [Figure 2A] This is a simplified circuit diagram illustrating the configuration of a battery cell. [Figure 2B] This is a simplified circuit diagram illustrating the configuration of a battery cell. [Figure 2C] This is a simplified circuit diagram illustrating the configuration of a battery cell. [Figure 3A] Figure 1A is a schematic diagram of one or more sets of low-rated-voltage DC power tools, one or more sets of DC battery pack power supplies, and one or more sets of battery pack chargers for the power tool system. [Figure 3B] Figure 1A is a schematic diagram of one or more sets of intermediate rated voltage DC power tools, one or more sets of DC battery pack power supplies, and one or more sets of battery pack chargers for the power tool system. [Figure 3C] Figure 1A is a schematic diagram of one or more sets of high-rated-voltage DC power tools, one or more sets of DC battery pack power supplies, and one or more sets of battery pack chargers for the power tool system. [Figure 4] Figure 1A is a schematic diagram of one or more sets of high-rated-voltage AC / DC power tools, one or more sets of DC battery pack power supplies, one or more sets of AC power supplies, and one or more sets of battery pack chargers for the power tool system. [Figure 5A] Figure 1A is a schematic diagram showing the classification of AC / DC power tools in the power tool system. [Figure 5B] Figure 1A is a schematic diagram showing the classification of AC / DC power tools in the power tool system. [Figure 6A] An exemplary system block diagram of a constant-speed AC / DC power tool having a universal motor, according to one embodiment, is shown. [Figure 6B]Figure 6A shows an exemplary system block diagram of a constant-speed AC / DC power tool, further comprising an exemplary power switching unit according to one embodiment. [Figure 6C] Figure 6A shows an exemplary system block diagram of a constant-speed AC / DC power tool, further comprising an alternative exemplary power switching unit according to one embodiment. [Figure 6D] Figure 6A shows an exemplary system block diagram of a constant-speed AC / DC power tool, further comprising another exemplary power switching unit according to one embodiment. [Figure 6E] An exemplary system block diagram of a constant-speed AC / DC power tool having a universal motor according to one embodiment is shown, in which the power supplied from the AC power source has a nominal voltage that is significantly different from the nominal voltage supplied from the DC power source. [Figure 7A] An exemplary system block diagram of a variable-speed AC / DC power tool having a universal motor, according to one embodiment, is shown. [Figure 7B] Figure 7A shows an exemplary system block diagram of a constant-speed AC / DC power tool, further equipped with a power switching unit according to one embodiment. [Figure 7C] Exemplary circuit diagrams of various embodiments of DC switch circuits are shown. [Figure 7D] Exemplary circuit diagrams of various embodiments of DC switch circuits are shown. [Figure 7E] Exemplary circuit diagrams of various embodiments of DC switch circuits are shown. [Figure 7F] An exemplary system block diagram of a variable-speed AC / DC power tool having a universal motor with an integrated AC / DC power switching circuit, according to one alternative embodiment, is shown. [Figure 7G] Exemplary circuit diagrams of various embodiments of an integrated AC / DC power switching circuit are shown. [Figure 7H] Exemplary circuit diagrams of various embodiments of an integrated AC / DC power switching circuit are shown. [Figure 8A]An exemplary system block diagram of a constant-speed AC / DC power tool having a brushed DC motor according to one embodiment is shown. [Figure 8B] Figure 8A shows an exemplary system block diagram of a constant-speed AC / DC power tool, further comprising an exemplary power switching unit according to one embodiment. [Figure 8C] An exemplary system block diagram of a constant-speed AC / DC power tool having a brushed DC motor according to one embodiment is shown, in which the power supplied from the AC power source has a nominal voltage that is significantly different from the nominal voltage supplied from the DC power source. [Figure 8D] Another exemplary system block diagram of a constant-speed AC / DC power tool having a brushed DC motor according to an alternative embodiment is shown, in which the power supplied from the AC power source has a nominal voltage that is significantly different from the nominal voltage supplied from the DC power source. [Figure 9A] An exemplary system block diagram of a variable-speed AC / DC power tool having a brushed DC motor, according to one embodiment, is shown. [Figure 9B] Figure 9A shows an exemplary system block diagram of a constant-speed AC / DC power tool, further equipped with a power switching unit according to one embodiment. [Figure 10A] An exemplary system block diagram of an AC / DC power tool having a three-phase brushless DC motor with a power switching unit and motor control circuit, according to one embodiment, is shown. [Figure 10B] Figure 10A shows an exemplary system block diagram of an AC / DC power tool having an alternative power switching unit according to one embodiment. [Figure 10C] An exemplary power switch circuit having a three-phase inverter bridge according to one embodiment is shown. [Figure 11A] An exemplary waveform diagram of a drive signal for a power switch circuit within a single conduction band of the motor phase at various pulse-width modulation (PWM) duty cycle levels for variable speed operation in brushless mode is shown according to one embodiment. [Figure 11B] An exemplary current-time waveform is shown, demonstrating an exemplary 20-ampere cycle-by-cycle current limit according to one embodiment. [Figure 11C] An illustrative flowchart for implementing cycle-by-cycle current limiting is shown. [Figure 12A] Figure 10C shows an exemplary waveform diagram of the pulse width modulation (PWM) drive sequence of the three-phase inverter bridge circuit within a full 360-degree conductive cycle according to one embodiment, in which case each phase is driven in the 120-degree conducted band (CB). [Figure 12B] An exemplary waveform diagram of the drive sequence of Figure 12A operating at the maximum speed according to one embodiment is shown. [Figure 12C] An exemplary waveform diagram corresponding to the drive sequence in Figure 12B, having a lead angle (AA) of Y = 30°, according to one embodiment, is shown. [Figure 12D] An exemplary speed-torque waveform diagram of an exemplary high-power tool is shown, illustrating the effect of increasing AA at a fixed CB of 120° on the speed / torque profile according to one embodiment. [Figure 12E] An exemplary power-torque waveform diagram of the same high-power tool is shown, illustrating the effect of increasing AA at a fixed CB of 120° on the power / torque profile according to one embodiment. [Figure 12F] An exemplary efficiency-torque waveform diagram of the same high-power tool is shown, illustrating the effect of increasing AA at a fixed CB of 120° on the efficiency / torque profile according to one embodiment. [Figure 13A] An exemplary waveform diagram of the drive sequence of a three-phase inverter bridge circuit according to one embodiment is shown, in which case each phase is driven at a 150° CB. [Figure 13B] An exemplary waveform diagram of the drive sequence of a three-phase inverter bridge circuit according to one embodiment is shown, in which case each phase is driven at CB at 150° with AA at Y=30°. [Figure 13C]An exemplary speed-torque waveform diagram of an exemplary high-power tool is shown, illustrating the effect of increased CB and AA in a coordinated state on the speed / torque profile according to one embodiment. [Figure 13D] An exemplary power-torque waveform diagram of the same high-power tool is shown, illustrating the effect of increased CB and AA in a coordinated state on the power / torque profile according to one embodiment. [Figure 13E] An exemplary efficiency-torque waveform diagram of the same high-power tool is shown, illustrating the effect of increased CB and AA in a coordinated state on the efficiency / torque profile according to one embodiment. [Figure 13F] An exemplary improved speed-torque waveform diagram of an exemplary high-power tool using a variable CB / AA according to one embodiment is shown. [Figure 13G] An alternative embodiment shows another improved speed-torque waveform diagram of the same high-power tool using variable CB / AA. [Figure 14A] An exemplary maximum power output contour plot for an exemplary power tool based on various CB and AA values ​​according to an alternative embodiment is shown. [Figure 14B] An exemplary efficiency contour plot for the same power tool based on various CB and AA values ​​according to an alternative embodiment is shown. [Figure 14C] This shows exemplary combined efficiency and maximum power output contour plots for the same power tool based on various CB and AA values ​​according to an alternative embodiment. [Figure 14D] An exemplary contour plot showing the optimal combination of efficiency and maximum power output contours at various input voltage levels according to one alternative embodiment is provided. [Figure 15A] An illustrative waveform diagram of the rectified AC waveform supplied to the motor control circuit under a load application condition, according to one embodiment, is shown. [Figure 15B] An exemplary rectified voltage waveform and corresponding current waveform diagram are shown, illustrating the use of a relatively large capacitor on a rectified AC power line (referred to here as a DC bus line) according to one embodiment. [Figure 15C] An exemplary rectified voltage waveform and corresponding current waveform diagram are shown, according to one embodiment, using a relatively medium-sized capacitor on a DC bus line. [Figure 15D] An exemplary rectified voltage waveform and corresponding current waveform diagram are shown, according to one embodiment, using a relatively small capacitor on a DC bus line. [Figure 15E] An exemplary combined figure showing power output / capacitance and average DC bus voltage / capacitance waveforms at various RMS current ratings according to one embodiment is shown. [Figure 16] This is a perspective view of an exemplary embodiment of a convertible battery pack. [Figure 17] Figure 16 is a perspective view of an exemplary embodiment of a low-rated voltage tool connected to a convertible battery pack. [Figure 18] This is a perspective view of an exemplary embodiment of an intermediate rated voltage tool connected to an exemplary embodiment of a convertible battery pack. [Figure 19a] This is an illustrative perspective view of a partial cutout in the battery outlet of a low-rated voltage power tool. [Figure 19b] This is an illustrative perspective view of a partial cutout in the battery outlet of an intermediate rated voltage power tool. [Figure 20A] This is a partial cutout perspective view of an exemplary intermediate-rated voltage power tool connected to an exemplary convertible battery pack. [Figure 20B] An alternative embodiment is shown. [Figure 20C] Another alternative embodiment is shown. [Figure 20D] Further alternative embodiments are shown. [Figure 21A] This is a simplified schematic diagram illustrating the first convertible battery in low-voltage / high-capacity cell configurations and intermediate-voltage / low-capacity cell configurations. [Figure 21B] This is a simplified schematic diagram illustrating a second convertible battery in low-voltage / high-capacity cell configurations and intermediate-voltage / low-capacity cell configurations. [Figure 21C]This is a simplified schematic diagram illustrating a third convertible battery in low-voltage / high-capacity cell configurations and intermediate-voltage / low-capacity cell configurations. [Figure 21D] This is a simplified schematic diagram illustrating a fourth convertible battery in low-voltage / high-capacity cell configurations and intermediate-rated-voltage / low-capacity cell configurations. [Figure 21E] This is a simplified, comprehensive schematic diagram illustrating a convertible battery in low-voltage / high-capacity cell configurations and intermediate-rated-voltage / high-capacity cell configurations. [Figure 22a] This is a perspective view of an exemplary convertible battery pack and an exemplary converter element. [Figure 22b] An exemplary perspective view of a convertible battery. [Figure 22c] This is an enlarged view of Figure 22b. [Figure 23a] This is a perspective view of the second terminal block and exemplary converter element of an exemplary convertible battery in the first configuration. [Figure 23b] This is a perspective view of the second terminal block and exemplary converter element of an exemplary convertible battery in the second configuration. [Figure 23c] This is a perspective view of the second terminal block and exemplary converter element of an exemplary convertible battery in the third configuration. [Figure 24a] Figure 23a shows an exemplary convertible battery pack and an exemplary intermediate, high, or very high voltage power tool partial circuit diagram / partial block diagram. [Figure 24b] Figure 23b is an exemplary convertible battery pack and an exemplary intermediate, high, or very high voltage power tool partial circuit diagram / partial block diagram. [Figure 24c] Figure 23c shows an exemplary convertible battery pack and an exemplary intermediate, high, or very high voltage power tool partial circuit diagram / partial block diagram. [Figure 25a] This is a perspective view of an exemplary convertible battery pack and an exemplary converter element. [Figure 25b] An exemplary perspective view of a convertible battery. [Figure 25c] It is an enlarged view of FIG. 25b. [Figure 26a] It is a perspective view of a second terminal block of an exemplary convertible battery and an exemplary converter element in a first configuration. [Figure 26b] It is a perspective view of a second terminal block of an exemplary convertible battery and an exemplary converter element in a second configuration. [Figure 26c] It is a perspective view of a second terminal block of an exemplary convertible battery and an exemplary converter element in a third configuration. [Figure 27a] It is a partial circuit diagram / partial block diagram of an exemplary convertible battery pack corresponding to FIG. 27a and an exemplary intermediate rated voltage or high rated voltage or very high rated voltage power tool. [Figure 27b] It is a partial circuit diagram / partial block diagram of an exemplary convertible battery pack corresponding to FIG. 26b and an exemplary intermediate rated voltage or high rated voltage or very high rated voltage power tool. [Figure 27c] It is a partial circuit diagram / partial block diagram of an exemplary convertible battery pack corresponding to FIG. 26c and an exemplary intermediate rated voltage or high rated voltage or very high rated voltage power tool. [Figure 28a] It shows a partial circuit diagram / partial block diagram of an alternative exemplary embodiment of a convertible battery pack and an exemplary intermediate rated voltage or high rated voltage or very high rated voltage power tool. [Figure 28b] It shows a partial circuit diagram / partial block diagram of an alternative exemplary embodiment of a convertible battery pack and an exemplary intermediate rated voltage or high rated voltage or very high rated voltage power tool. [Figure 28c] It shows a partial circuit diagram / partial block diagram of an alternative exemplary embodiment of a convertible battery pack and an exemplary intermediate rated voltage or high rated voltage or very high rated voltage power tool. [Figure 29a] It shows a partial circuit diagram / partial block diagram of an alternative exemplary embodiment of a convertible battery pack and an exemplary intermediate rated voltage or high rated voltage or very high rated voltage power tool. [Figure 29b]A partial circuit diagram / partial block diagram of an exemplary embodiment of a convertible battery pack and an exemplary intermediate voltage, high voltage, or very high voltage alternative for power tools is shown. [Figure 29c] A partial circuit diagram / partial block diagram of an exemplary embodiment of a convertible battery pack and an exemplary intermediate voltage, high voltage, or very high voltage alternative for power tools is shown. [Figure 30] A block diagram of an exemplary embodiment of a convertible battery pack and an exemplary intermediate voltage, high voltage, or very high voltage alternative for power tools is shown. [Figure 31] A block diagram of one exemplary embodiment of an alternative convertible battery pack is shown. [Figure 32a] Simplified schematic diagrams illustrating convertible batteries in low-voltage / high-capacity cell configurations and intermediate-voltage / low-capacity cell configurations are shown. [Figure 32b] Simplified schematic diagrams illustrating convertible batteries in low-voltage / high-capacity cell configurations and intermediate-voltage / low-capacity cell configurations are shown. [Figure 32c] A simplified, comprehensive schematic diagram illustrating a convertible battery in low-voltage / high-capacity cell configurations and intermediate-rated-voltage / high-capacity cell configurations is shown. [Figure 33] This document presents an exemplary alternative embodiment of a power tool system that utilizes a converter box to generate a high-voltage DC output. [Figure 34] This is a diagram illustrating one exemplary embodiment of a convertible battery pack. [Figure 35] This is another diagram of the exemplary embodiment shown in Figure 34. [Figure 36] Figures 36a and 36b are circuit diagrams of an exemplary embodiment of a convertible battery in a first cell configuration and a second cell configuration. [Figure 37] Figures 37a and 37b are schematic diagrams of other exemplary embodiments of a convertible battery in a first-cell configuration and a second-cell configuration. [Figure 38] Figure 34 is a detailed sub-diagram of an exemplary embodiment. [Figure 39a] This is a diagram of a part of an exemplary electrical device that can be coupled with a convertible battery pack. [Figure 39b] This is a diagram of a part of an exemplary electrical device that can be coupled with a convertible battery pack. [Figure 39c] This is a diagram of a part of an exemplary electrical device that can be coupled with a convertible battery pack. [Figure 40] This is a diagram illustrating one exemplary embodiment of a convertible battery pack with a portion of the housing removed. [Figure 41] Figures 41a and 41b are diagrams illustrating exemplary embodiments of Figure 40, showing the first and second configurations of the convertible battery pack. [Figure 42] This is a diagram of an exemplary embodiment of Figure 40 in which the converter element has been removed. [Figure 43] Figures 43a and 43b are diagrams illustrating exemplary embodiments of Figure 42, showing the first and second configurations of the battery pack. [Figure 44a] This is a side view of an exemplary embodiment of a convertible battery. [Figure 44b] This is a side view of an exemplary embodiment of a convertible battery. [Figure 45a] This is a diagram illustrating an exemplary embodiment of a converter element. [Figure 45b] This is a diagram illustrating an exemplary embodiment of a converter element. [Figure 45c] This is a diagram illustrating an exemplary embodiment of a converter element. [Figure 45d] This is a diagram illustrating an exemplary embodiment of a converter element. [Figure 46a] This is an exemplary embodiment of a terminal block, as well as the terminals, contact pad layout, and contacts of an exemplary convertible battery pack in five exemplary stages of the conversion process of an exemplary convertible battery pack. [Figure 46b] This is an exemplary embodiment of a terminal block, as well as the terminals, contact pad layout, and contacts of an exemplary convertible battery pack in five exemplary stages of the conversion process of an exemplary convertible battery pack. [Figure 46c]An exemplary embodiment of a terminal block, as well as terminals, contact pad layouts, and contacts of an exemplary convertible battery pack, in five exemplary stages of the conversion process of the exemplary convertible battery pack. [Figure 46d] An exemplary embodiment of a terminal block, as well as terminals, contact pad layouts, and contacts of an exemplary convertible battery pack, in five exemplary stages of the conversion process of the exemplary convertible battery pack. [Figure 46e] An exemplary embodiment of a terminal block, as well as terminals, contact pad layouts, and contacts of an exemplary convertible battery pack, in five exemplary stages of the conversion process of the exemplary convertible battery pack. [Figure 47] A table of an exemplary connection table for a switching network of an exemplary convertible battery pack. [Figure 48a] A diagram of an alternative exemplary embodiment of a convertible battery pack. [Figure 48b] A diagram of an alternative exemplary embodiment of a convertible battery pack. [Figure 49a] A diagram of a portion of an electrical device that can be coupled to a convertible battery pack. [Figure 49b] A diagram of a portion of an electrical device that can be coupled to a convertible battery pack. [Figure 49c] A diagram of a portion of an electrical device that can be coupled to a convertible battery pack. [Figure 49d] A diagram of a portion of an electrical device that can be coupled to a convertible battery pack. [Figure 50a] A diagram of an exemplary embodiment of a convertible battery pack with the battery pack housing removed. [Figure 50b] A diagram of an exemplary embodiment of a convertible battery pack with the battery pack housing removed. [Figure 50c] A diagram of an exemplary embodiment of a convertible battery pack with the battery pack housing removed. [Figure 51]This is a diagram illustrating the terminal block and terminals of an example of a convertible battery pack. [Figure 52a] Figure 51 shows an exemplary terminal block and terminals, as well as a portion of the terminal block and a subset of the terminals. [Figure 52b] Figure 51 shows an exemplary terminal block and terminals, as well as a portion of the terminal block and a subset of the terminals. [Figure 53a] These are exemplary terminal blocks and terminals of an electrical device that can be coupled with the terminal block of a convertible battery pack. [Figure 53b] These are exemplary terminal blocks and terminals of an electrical device that can be coupled with the terminal block of a convertible battery pack. [Figure 53c] These are exemplary terminal blocks and terminals of an electrical device that can be coupled with the terminal block of a convertible battery pack. [Figure 53d] These are exemplary terminal blocks and terminals of an electrical device that can be coupled with the terminal block of a convertible battery pack. [Figure 54a] Figure 53 shows an example of a set of terminals. [Figure 54b] Figure 53 shows an example of a set of terminals. [Figure 54c] Figure 53 shows an example of a set of terminals. [Figure 55a] This is an alternative diagram of the example terminals in Figure 54. [Figure 55b] This is an alternative diagram of the example terminals in Figure 54. [Figure 55c] This is an alternative diagram of the example terminals in Figure 54. [Figure 55d] This is an alternative diagram of the example terminals in Figure 54. [Figure 56a] This diagram shows exemplary battery terminals of a convertible battery pack and exemplary terminals of an electrical device in the first engagement position. [Figure 56b] This diagram shows exemplary battery terminals of a convertible battery pack and exemplary terminals of an electrical device in the first engagement position. [Figure 57a] Figure 56 shows exemplary battery terminals and exemplary electrical device terminals in the second engagement position. [Figure 57b]Figure 56 shows exemplary battery terminals and exemplary electrical device terminals in the second engagement position. [Figure 58a] Figure 56 shows exemplary battery terminals and exemplary electrical device terminals in the third engagement position. [Figure 58b] Figure 56 shows exemplary battery terminals and exemplary electrical device terminals in the third engagement position. [Figure 59a] This is a diagram illustrating one exemplary embodiment of a convertible battery pack replacement in a state where the battery pack housing has been removed. [Figure 59b] This is a diagram illustrating one exemplary embodiment of a convertible battery pack replacement in a state where the battery pack housing has been removed. [Figure 59c] This is a diagram illustrating one exemplary embodiment of a convertible battery pack replacement in a state where the battery pack housing has been removed. [Figure 60] This is a perspective view of an exemplary terminal block and terminals of a convertible battery pack. [Figure 61a] Figure 60 shows an exemplary terminal block and terminals, as well as a portion of the terminal block and a subset of the terminals. [Figure 61b] Figure 60 shows an exemplary terminal block and terminals, as well as a portion of the terminal block and a subset of the terminals. [Figure 62a] These are exemplary terminal blocks and terminals of an electrical device that can be coupled with the terminal block of a convertible battery pack. [Figure 62b] These are exemplary terminal blocks and terminals of an electrical device that can be coupled with the terminal block of a convertible battery pack. [Figure 62c] These are exemplary terminal blocks and terminals of an electrical device that can be coupled with the terminal block of a convertible battery pack. [Figure 62d] These are exemplary terminal blocks and terminals of an electrical device that can be coupled with the terminal block of a convertible battery pack. [Figure 63a] Figure 62 shows an example of a terminal set. [Figure 63b] Figure 62 shows an example of a terminal set. [Figure 63c]Figure 62 shows an example of a terminal set. [Figure 64a] This is an alternative diagram of the example terminals in Figure 63. [Figure 64b] This is an alternative diagram of the example terminals in Figure 63. [Figure 64c] This is an alternative diagram of the example terminals in Figure 63. [Figure 64d] This is an alternative diagram of the example terminals in Figure 63. [Figure 65] This diagram shows an exemplary set of battery terminals for a convertible battery pack and an exemplary set of terminals for an electrical device before engagement. [Figure 66] Figure 65 shows an exemplary set of battery terminals and an exemplary set of electrical device terminals in the first engagement position. [Figure 67] Figure 65 shows an exemplary set of battery terminals and an exemplary set of electrical device terminals in the second engagement position. [Figure 68] This is a diagram illustrating one exemplary embodiment of a convertible battery pack. [Figure 69a] Figure 68 shows an exemplary battery pack and an exemplary tool foot of an intermediate rated voltage power tool. [Figure 69b] Figure 68 shows an exemplary battery pack and an exemplary tool foot of an intermediate rated voltage power tool. [Figure 70] Figure 69 shows an example of a battery pack and tool foot in the connection position. [Figure 71a] Figure 70 is a cross-sectional view of an exemplary battery pack and tool foot. [Figure 71b] Figure 70 is a cross-sectional view of an exemplary battery pack and tool foot. [Figure 72] Figure 68 is an exploded view of an exemplary convertible battery pack. [Figure 73] Figure 68 is a diagram illustrating one exemplary embodiment of the battery in an exemplary convertible battery pack. [Figure 74] Figure 73 is an example of a battery exploded view. [Figure 75a] Figure 73 is an illustrative side view of a battery cell holder and a battery cell. [Figure 75b]Figure 73 is an illustrative side view of a battery cell holder and a battery cell. [Figure 76a] This is a simplified circuit diagram of an exemplary battery of the present disclosure in a low-rated voltage configuration. [Figure 76b] This is a simplified circuit diagram of an exemplary battery of the present disclosure in an intermediate rated voltage configuration. [Figure 77a] Figure 73 is a detailed diagram of the conversion mechanism of an exemplary battery in a low-rated voltage configuration. [Figure 77b] This is a detailed diagram of the conversion mechanism of an exemplary battery in an intermediate rated voltage configuration, as shown in Figure 73. [Figure 78] Figure 73 is an exploded view of an exemplary battery conversion subsystem. [Figure 79] Figures 79a, 79b, 79c, 79d, and 79e are diagrams of the converter element and the switching contacts of the converter element shown in Figure 78. [Figure 80a] Figure 78 shows the support substrate for the conversion subsystem. [Figure 80b] Figure 78 shows the support substrate for the conversion subsystem. [Figure 80c] Figure 78 shows the support substrate for the conversion subsystem. [Figure 80d] Figure 78 shows the support substrate for the conversion subsystem. [Figure 81a] Figure 78 shows the manufacturing steps for the support substrate of the conversion subsystem. [Figure 81b] Figure 78 shows the manufacturing steps for the support substrate of the conversion subsystem. [Figure 81c] Figure 78 shows the manufacturing steps for the support substrate of the conversion subsystem. [Figure 81d] Figure 78 shows the manufacturing steps for the support substrate of the conversion subsystem. [Figure 82] Figure 74 is a plan view of the support substrate of the conversion subsystem. [Figure 83] Figure 74 is an alternative plan view of the support substrate for the conversion subsystem. [Figure 84a] Figure 68 shows a simplified circuit diagram and block diagram of an exemplary battery pack. [Figure 84b] Figure 68 shows a simplified circuit diagram and block diagram of an exemplary battery pack. [Figure 84c] Figure 68 shows a simplified circuit diagram and block diagram of an exemplary battery pack. [Figure 85a] Figure 68 shows the state of the conversion mechanism of an exemplary battery pack when converting from a low-rated voltage configuration to an intermediate-rated voltage configuration. [Figure 85b] Figure 68 shows the state of the conversion mechanism of an exemplary battery pack when converting from a low-rated voltage configuration to an intermediate-rated voltage configuration. [Figure 85c] Figure 68 shows the state of the conversion mechanism of an exemplary battery pack when converting from a low-rated voltage configuration to an intermediate-rated voltage configuration. [Figure 85d] Figure 68 shows the state of the conversion mechanism of an exemplary battery pack when converting from a low-rated voltage configuration to an intermediate-rated voltage configuration. [Figure 85e] Figure 68 shows the state of the conversion mechanism of an exemplary battery pack when converting from a low-rated voltage configuration to an intermediate-rated voltage configuration. [Figure 85f] Figure 68 shows the state of the conversion mechanism of an exemplary battery pack when converting from a low-rated voltage configuration to an intermediate-rated voltage configuration. [Figure 86a] Figure 69 shows a perspective view of an exemplary terminal block of an exemplary intermediate rated voltage tool. [Figure 86b] Figure 69 shows a perspective view of an exemplary terminal block of an exemplary intermediate rated voltage tool. [Figure 87a] Figure 96 is a front view of the terminals and terminal block. [Figure 87b] Figure 96 is a front view of the terminals and terminal block. [Figure 88a] Figure 96 is a rear view of the terminals and terminal block. [Figure 88b] Figure 96 is a rear view of the terminals and terminal block. [Figure 89a] Figure 96 is a plan view of the terminals and terminal block. [Figure 89b]Figure 96 is a plan view of the terminals and terminal block. [Figure 90a] A simplified circuit diagram and block diagram of the exemplary battery of Figure 73, which has an alternative exemplary conversion subsystem. [Figure 90b] A simplified circuit diagram and block diagram of the exemplary battery of Figure 73, which has an alternative exemplary conversion subsystem. [Figure 91a] A simplified circuit diagram and block diagram of the exemplary battery of Figure 73, which has an alternative exemplary conversion subsystem. [Figure 91b] A simplified circuit diagram and block diagram of the exemplary battery of Figure 73, which has an alternative exemplary conversion subsystem. [Figure 91c] A simplified circuit diagram and block diagram of the exemplary battery of Figure 73, which has an alternative exemplary conversion subsystem. [Figure 92a] A simplified circuit diagram and block diagram of the exemplary battery of Figure 73, which has an alternative exemplary conversion subsystem. [Figure 92b] A simplified circuit diagram and block diagram of the exemplary battery of Figure 73, which has an alternative exemplary conversion subsystem. [Figure 92c] A simplified circuit diagram and block diagram of the exemplary battery of Figure 73, which has an alternative exemplary conversion subsystem. [Figure 93a] A simplified circuit diagram and block diagram of the exemplary battery of Figure 73, which has an alternative exemplary conversion subsystem. [Figure 93b] A simplified circuit diagram and block diagram of the exemplary battery of Figure 73, which has an alternative exemplary conversion subsystem. [Figure 94a] A simplified circuit diagram and block diagram of the exemplary battery of Figure 73, which has an alternative exemplary conversion subsystem. [Figure 94b] A simplified circuit diagram and block diagram of the exemplary battery of Figure 73, which has an alternative exemplary conversion subsystem. [Figure 95a]A simplified circuit diagram and block diagram of the exemplary battery of Figure 73, which has an alternative exemplary conversion subsystem. [Figure 95b] A simplified circuit diagram and block diagram of the exemplary battery of Figure 73, which has an alternative exemplary conversion subsystem. [Figure 96a] This is an example of an alternative convertible battery pack. [Figure 96b] This is an example of an alternative convertible battery pack. [Figure 97a] Figure 96 shows an exemplary conversion subsystem of the battery pack. [Figure 97b] Figure 96 shows an exemplary conversion subsystem of the battery pack. [Figure 97c] Figure 96 shows an exemplary conversion subsystem of the battery pack. [Figure 97d] Figure 96 shows an exemplary conversion subsystem of the battery pack. [Figure 97e] Figure 96 shows an exemplary conversion subsystem of the battery pack. [Figure 97f] Figure 96 shows an exemplary conversion subsystem of the battery pack. [Figure 97g] Figure 96 shows an exemplary conversion subsystem of the battery pack. [Figure 98a] Figure 30 shows an exemplary converter element of the conversion subsystem. [Figure 98b] Figure 30 shows an exemplary converter element of the conversion subsystem. [Figure 99a] An alternative exemplary conversion subsystem is shown. [Figure 99b] An alternative exemplary conversion subsystem is shown. [Figure 99c] An alternative exemplary conversion subsystem is shown. [Figure 99d] An alternative exemplary conversion subsystem is shown. [Figure 100a] An alternative exemplary conversion subsystem is shown. [Figure 100b] An alternative exemplary conversion subsystem is shown. [Figure 100c]An alternative exemplary conversion subsystem is shown. [Figure 100d] An alternative exemplary conversion subsystem is shown. [Figure 101a1] An alternative exemplary conversion subsystem is shown. [Figure 101a2] An alternative exemplary conversion subsystem is shown. [Figure 101b1] An alternative exemplary conversion subsystem is shown. [Figure 101b2] An alternative exemplary conversion subsystem is shown. [Figure 102a1] An alternative exemplary conversion subsystem is shown. [Figure 102a2] An alternative exemplary conversion subsystem is shown. [Figure 102b1] An alternative exemplary conversion subsystem is shown. [Figure 102b2] An alternative exemplary conversion subsystem is shown. [Figure 103] Figures 103a, 103b, and 103c show alternative exemplary conversion subsystems. [Figure 104a] An exemplary alternative conversion system for low-rated voltage configurations is shown. [Figure 104b] An exemplary alternative conversion system for low-rated voltage configurations is shown. [Figure 105a] An exemplary alternative conversion system to the one shown in Figure 104 in an intermediate rated voltage configuration is presented. [Figure 105b] An exemplary alternative conversion system to the one shown in Figure 104 in an intermediate rated voltage configuration is presented. [Figure 106a] This shows a system for converting convertible battery packs. [Figure 106b] This shows a system for converting convertible battery packs. [Figure 106c] This shows a system for converting convertible battery packs. [Figure 106d] This shows a system for converting convertible battery packs. [Figure 106e] This shows a system for converting convertible battery packs. [Figure 106f]This shows a system for converting convertible battery packs. [Figure 106g] This shows a system for converting convertible battery packs. [Figure 107] This shows a conventional contact punched material. [Figure 108] The contact punched material of this disclosure is shown. [Figure 109] Figure 108 shows the contact punched material in its assembled state. [Figure 110] Figure 109 shows the contact punched material within the product. [Figure 111] An exemplary embodiment of an AC / DC power tool interface for coupling an AC / DC power supply to an AC / DC power tool is shown. [Figure 112] Figure 111 shows an internal diagram of the AC / DC power tool interface. [Figure 113] Figure 111 shows an alternative internal diagram of the AC / DC power tool interface. [Figure 114] Figure 111 shows an AC / DC power tool interface coupled to an exemplary embodiment of an AC / DC power tool. [Figure 115] This document illustrates an exemplary embodiment of a power interface for coupling AC / DC power tools to an AC power supply and / or a DC battery pack power supply. [Figure 116] Figure 115 shows a power interface coupled to an exemplary embodiment of a DC battery pack power supply. [Figure 117] Figure 115 shows the power interface coupled to two exemplary embodiments of a DC battery pack power supply. [Figure 118] A partial circuit diagram of an electronic module in an exemplary embodiment of a convertible battery in a convertible battery pack is shown. [Figure 119] Figure 118 shows a partial circuit diagram of an exemplary embodiment of the monitoring circuit of the electronic module of the convertible battery. [Figure 120] Figure 118 shows a partial circuit diagram of an alternative embodiment of the monitoring circuit for the electronic module of the convertible battery. [Figure 121A] A partial circuit diagram of an electronic module in one exemplary embodiment, illustrating a replacement for a convertible battery in a convertible battery pack, is shown. [Figure 121B] A partial circuit diagram of an electronic module in one exemplary embodiment, illustrating a replacement for a convertible battery in a convertible battery pack, is shown. [Figure 121C] A partial circuit diagram of an electronic module in one exemplary embodiment, illustrating a replacement for a convertible battery in a convertible battery pack, is shown. [Figure 122] Figure 121 shows a partial circuit diagram of an exemplary embodiment of the monitoring circuit of the electronic module of the convertible battery. [Figure 123] Figure 121 shows a partial circuit diagram of an exemplary embodiment of the monitoring and control circuit of the electronic module of the convertible battery. [Figure 124A] An exemplary embodiment of a conversion subsystem for an exemplary convertible battery pack is shown. [Figure 124B] An exemplary embodiment of a conversion subsystem for an exemplary convertible battery pack is shown. [Figure 124C] An exemplary embodiment of a conversion subsystem for an exemplary convertible battery pack is shown. [Figure 125] A partial circuit diagram of an exemplary embodiment of the cell switch of the present invention is shown. [Figure 126] A partial circuit diagram of an exemplary embodiment of the cell switch alternative of the present invention is shown. [Figure 127A] This shows an exemplary embodiment of the switching network of the convertible batteries in the convertible battery pack of the present invention. [Figure 127B] This shows an exemplary embodiment of the switching network of the convertible batteries in the convertible battery pack of the present invention. [Figure 128] Show the sentence. [Figure 129] An alternative embodiment for converting a battery pack from a low-rated voltage configuration to an intermediate-rated voltage configuration is shown. [Figure 130] An alternative embodiment for converting a battery pack from a low-rated voltage configuration to an intermediate-rated voltage configuration is shown. [Figure 131]An alternative embodiment for converting a battery pack from a low-rated voltage configuration to an intermediate-rated voltage configuration is shown. [Figure 132] An alternative embodiment for converting a battery pack from a low-rated voltage configuration to an intermediate-rated voltage configuration is shown. [Figure 133A] An alternative embodiment for converting a battery pack from a low-rated voltage configuration to an intermediate-rated voltage configuration is shown. [Figure 133B] An alternative embodiment for converting a battery pack from a low-rated voltage configuration to an intermediate-rated voltage configuration is shown. [Figure 134A] An alternative embodiment for converting a battery pack from a low-rated voltage configuration to an intermediate-rated voltage configuration is shown. [Figure 134B] An alternative embodiment for converting a battery pack from a low-rated voltage configuration to an intermediate-rated voltage configuration is shown. [Figure 135] An alternative embodiment of a convertible battery pack similar to the embodiments shown in Figures 129 to 134B is shown. [Figure 136] An alternative embodiment of a convertible battery pack similar to the embodiments shown in Figures 129 to 134B is shown. [Figure 137] An alternative embodiment of a convertible battery pack similar to the embodiments shown in Figures 129 to 134B is shown. [Figure 138] An alternative embodiment of a convertible battery pack similar to the embodiments shown in Figures 129 to 134B is shown. [Figure 139A] An alternative embodiment of a convertible battery pack similar to the embodiments shown in Figures 129 to 134B is shown. [Figure 139B] An alternative embodiment of a convertible battery pack similar to the embodiments shown in Figures 129 to 134B is shown. [Figure 140A] An alternative embodiment of a convertible battery pack similar to the embodiments shown in Figures 129 to 134B is shown. [Figure 140B] An alternative embodiment of a convertible battery pack similar to the embodiments shown in Figures 129 to 134B is shown. [Figure 141] The diagram is shown. [Figure 142A] The diagram is shown. [Figure 142B] The diagram is shown. [Modes for carrying out the invention]

[0233] I. Power tool systems. Referring to Figure 1A, in one embodiment, the power tool system 1 includes a set of power tools 10 (including a DC power tool 10A and an AC / DC power tool 10B), a set of power supplies 20 (including a DC battery pack power supply 20A and an AC power supply 20B), and a set of battery pack chargers 30. Each of the power tools, power supplies, and battery pack chargers may be described as having a rated voltage. As used in this application, rated voltage may mean one or more of advertised voltage, operating voltage, nominal voltage, or maximum voltage, depending on the context. Also, rated voltage may encompass a single voltage, several individual voltages, or a range of one or more voltages. As used in this application, rated voltage may mean any of these types of voltages or a range of any of these types of voltages.

[0234] Published Voltage: With respect to power tools, battery packs, and chargers, published voltage generally refers to the voltage displayed by the manufacturer or distributor on labels, packaging, user manuals, instructions, advertisements, marketing materials, or other supporting documents for these products, so that users are informed of which power tools, battery packs, and chargers will operate with each other. Published voltage may include a numerical voltage value that informs the user of which power tools, battery packs, and chargers will operate with each other, or it may include another word, phrase, combination of alphanumeric characters, icon, or logo. In some embodiments, as described below, a power tool, battery pack, or charger may have a single published voltage (e.g., 20V), a range of published voltages (e.g., 20V to 60V), or multiple separate published voltages (e.g., 20V / 60V). Also, as described further below, a power tool may be advertised or labeled with a notation (e.g., AC / DC or AC / 60V) indicating that it will operate with both DC and AC power sources. Furthermore, AC power supplies are sometimes described as having a published voltage, which is a voltage that is generally known as AC commercial power voltage in a given country (for example, 120VAC in the United States and 220VAC-240VAC in Europe).

[0235] Operating Voltage: In the case of power tools, operating voltage generally refers to the voltage or voltage range of one or more AC and / or DC power sources on which the power tool, its motor, and its electronic components are designed to operate. For example, a power tool advertised as a 120VAC / DC tool may have an operating voltage range of 92V to 132V. Alternatively, the operating voltage of a power tool may refer to the combined operating voltages of multiple power sources coupled to the power tool (for example, a 120V power tool may be able to operate using two 60V battery packs connected in series). In the case of battery packs and chargers, operating voltage refers to the DC voltage or DC voltage range on which the battery pack or charger is designed to operate. For example, a battery pack or charger advertised as a 20V battery pack or charger may have an operating voltage range of 17V to 19V. In the case of AC power sources, operating voltage may refer to the root-mean-square (RMS) value of the AC waveform and / or the average voltage within each positive half-cycle of the AC waveform. For example, a 120VAC commercial power supply can be described as having an RMS operating voltage of 120V and an average positive operating voltage of 108V.

[0236] Nominal Voltage: In the case of battery packs, the nominal voltage generally refers to the average DC voltage output from the battery pack. For example, a battery pack advertised as a 20V battery pack with an operating voltage of 17V-19V may have a nominal voltage of 18V. In the case of AC power supplies, the operating voltage may refer to the mean square (RMS) of the voltage values ​​of the AC waveform and / or the average voltage within each positive half-cycle of the AC waveform. For example, a 120VAC commercial power supply may be described as having an RMS nominal voltage of 120V and an average positive nominal voltage of 108V.

[0237] Maximum Voltage: In the case of a battery pack, the maximum voltage may refer to the fully charged voltage of the battery pack. For example, a battery pack advertised as a 20V battery pack may have a fully charged maximum voltage of 20V. In the case of a charger, the maximum voltage may refer to the maximum voltage to which the battery pack can be charged by the charger. For example, a 20V charger may have a maximum charging voltage of 20V.

[0238] Furthermore, it should be noted that certain components of power tools, battery packs, and chargers may be described as having a voltage rating, each of which may mean one or more of the following: published voltage, operating voltage, nominal voltage, or maximum voltage. The voltage rating of each of these components may encompass a single voltage, several distinct voltages, or a range of one or more voltages. These voltage ratings may be the same as or different from the voltage ratings of the power tool, battery pack, and charger. For example, the motor of a power tool may be described as having its own operating voltage or voltage range on which the motor is designed to operate. The voltage rating of the motor may be the same as or different from the operating voltage or voltage range of the power tool. For example, a power tool with a voltage rating of 60V to 120V may have a motor with an operating voltage of 60V to 120V or a motor with an operating voltage of 90V to 100V.

[0239] Furthermore, power tools, power supplies, and chargers may have ratings for features other than voltage. For example, a power tool may have a rating for motor performance, such as output power (e.g., Maximum Watts Out (MWO) as described in U.S. Patent No. 7,497,275, which is incorporated by reference), or a rating for the motor speed under given load conditions. In another example, a battery pack may have a rated capacity, which means the total energy stored within the battery pack. The rated capacity of a battery pack may depend on the rated capacity of the individual cells and the way in which the cells are electrically connected.

[0240] Furthermore, this application refers to voltage (and other characteristic) ratings by using relative terms such as low, intermediate, high, and extremely high. The terms low rating, intermediate rating, high rating, and extremely high rating are relative terms used to indicate the relative relationships between various ratings of power tools, battery packs, AC power supplies, chargers, and their components, and are not intended to be limited to any specific numerical value or range. For example, it should be understood that low rating voltages are generally lower than intermediate rating voltages, intermediate rating voltages are generally lower than high rating voltages, and high rating voltages are generally lower than extremely high rating voltages. In a particular embodiment, different rating voltages may be integer multiples or divisors of each other. For example, intermediate rating voltages may be integer multiples of low rating voltages, and high rating voltages may be integer multiples of intermediate rating voltages. For example, low rating voltages may be 20V, intermediate rating voltages may be 60V (3 × 20V), and high rating voltages may be 120V (2 × 60V and 6 × 20V). In this application, the notation "XY" may often be used as a general notation for the terms low, intermediate, high, and very high.

[0241] In some cases, power tools, power supplies, or chargers may be described as having multiple voltage ratings. For example, a power tool or battery pack may have a low / intermediate voltage rating or an intermediate / high voltage rating. As will be discussed in more detail below, these multiple ratings mean a power tool, power supply, or charger configured to operate with two or more power tools, battery packs, AC power supplies, or chargers having multiple maximum, nominal, or actual voltages, or multiple published voltages, or having mutually different voltage ratings. For example, an intermediate / high voltage power tool may be labeled as having intermediate and high voltages and may be configured to operate with an intermediate voltage battery pack or a high voltage AC power supply. It should be understood that multiple voltage ratings may mean that the voltage rating spans a range across two different voltage ratings, or that the voltage rating has two distinct and different voltage ratings.

[0242] Furthermore, this application often refers to a power tool, power supply, charger, or a first component thereof as having a first rated voltage that is matched or equivalent to the second rated voltage of a power tool, power supply, charger, or a second component thereof. This comparison generally means a first rated voltage having one or more values ​​or ranges of values ​​that are substantially equal to, overlap with, or include one or more values ​​or ranges of values ​​of the second rated voltage, or that the first power tool, power supply, charger, or a first component thereof is configured to operate together with the second power tool, power supply, charger, or a second component thereof. For example, an AC / DC power tool with a nominal voltage of 120V or 90V-132V (operating) may be compatible with a pair of battery packs having a total nominal voltage of 120V (nominal and maximum), 108V (nominal), or 102V-120V (operating), and may be compatible with several AC power supplies having nominal voltages in the range of 100VAC-120VAC.

[0243] Conversely, this application often refers to power tools, power supplies, chargers, or a first of these components having a first rated voltage that is not corresponding to, different from, or equivalent to the second rated voltage of a power tool, power supply, charger, or a second of these components. These comparisons generally mean a first rated voltage having one or more values ​​or one or more value ranges that are not equal to, do not overlap with, or do not include one or more values ​​or one or more value ranges of the second rated voltage, or that a power tool, power supply, charger, or a first of these components is not configured to operate with a power tool, power supply, charger, or a second of these components. For example, AC / DC power tools with a rated voltage of 120V (nominal) or 90V-132V (operating) may not be compatible with battery packs with a total rated voltage of 60V (nominal and maximum), 54V (nominal), or 51V-60V (operating), or may not be compatible with AC power supplies with a rated voltage in the range of 220VA-240VAC.

[0244] Referring again to Figure 1A, the power tools 10 include a set of cordless only or DC power tools 10A, and a set of corded / cordless or AC / DC power tools 10B. The set of DC power tools 10A may include a set of low-rated voltage DC power tools 10A1 (less than 40V, e.g., 4V, 8V, 12V, 18V, 20V, 24V, and / or 36V), a set of intermediate-rated voltage DC power tools 102A2 (40V to 80V, e.g., 40V, 54V, 60V, 72V, and / or 80V), and a set of high-rated voltage DC power tools 10A3 (100V to 240V, e.g., 100V, 110V, 120V, 220V, 230V, and / or 240V). Furthermore, high-rated voltage DC power tools may be described as including a subset of high-rated voltage DC power tools (e.g., 100V to 120V, such as 100V, 110V, or 120V in the United States, Canada, Mexico, and Japan, etc.) and a subset of very high-rated voltage DC power tools (e.g., 220V to 240V, such as 220V, 230V, or 240V in most countries in Europe, South America, Africa, and Asia, etc.). For convenience, high-rated and very high-rated voltage DC power tools are collectively referred to as the high-rated voltage DC power tool set 10A3.

[0245] AC / DC power tools 10B generally have a rated voltage that corresponds to the rated voltage of the AC commercial power supply in the countries in which the tool operates or is sold (for example, 100V-120V in countries such as the United States, Canada, Mexico, and Japan, such as 100V, 110V, or 120V, and 220V-240V in most countries in Europe, South America, Asia, and Africa, such as 220V, 230V, and / or 240V). In some cases, these high-rated voltage AC / DC power tools 10B are also referred to as AC-rated AC / DC power tools, in which case the AC rating means that the high-voltage rating of the AC / DC power tool corresponds to the voltage rating of the AC commercial power supply in the country in which the power tool operates and / or is sold. For convenience, high-rated and extremely high-rated voltage AC / DC power tools are collectively referred to as the high-rated voltage AC / DC power tool set 10B.

[0246] A.Power supply The power supply set 20 may include a set of DC battery pack power supplies 20A and a set of AC power supplies 20B. The DC battery pack power supply set 20A may include one or more of the following: a set of low-rated voltage battery packs 20A1 (e.g., less than 40V, such as 4V, 8V, 12V, 20V, 24V, and / or 36V), a set of intermediate-rated voltage battery packs 20A2 (e.g., 40V to 80V, such as 40V, 54V, 60V, 72V, and / or 80V), a set of high-rated voltage battery packs 20A3 (e.g., 100V to 120V and 220V to 240V, such as 100V, 110V, 120V, 220V, 230V, and / or 240V), and a set of convertible voltage range battery packs 20A4 (described in more detail below). AC power supply 20B may include a power supply with a high voltage rating corresponding to the AC power voltage rating of the countries in which the tool operates and / or is sold (e.g., 100V to 120V, such as 100V, 110V, or 120V in countries such as the United States, Canada, Mexico, and Japan; and 220V to 240V, such as 220V, 230V, and / or 240V in most countries in Europe, South America, Asia, and Africa). The AC power supply may have an AC commercial power supply, or it may have an alternative power supply with a similar rated voltage, such as an AC generator or another portable AC power supply.

[0247] One or more of the DC battery pack power supplies 20A are configured to power one or more of the sets of low-rated-voltage DC power tools 10A1, intermediate-rated-voltage DC power tools 10A2, and high-rated-voltage DC power tools 10A3, as will be further described later. The AC / DC power tools 10B may be powered by one or more of the DC battery pack power supplies 20A, or by one or more of the AC power supplies 20B. Figures 111 to 114 show an exemplary embodiment of an AC / DC power tool interface 22B for providing AC power to the AC / DC power tools 10B from the AC power supplies 20B. The AC / DC power tool interface 22B includes a housing 23 and a cord 25 which, at a first end, includes two or three branch plugs (not shown), and at a second end, is coupled to the housing 23. The housing 23 includes a pair of DC power tool interfaces 27 that are substantially equivalent in shape and size to the DC power tool interface 22A of the DC battery pack power supply 20A. The housing 23 also includes three branch outlets 29 (or alternatively, two branch outlets) located between the pair of DC power tool interfaces 27. The illustrated AC / DC power tool interface 22B of the AC power supply 20B is received within an exemplary power interface 16 of the AC / DC power tool, which is illustrated in and described later in Figures 114 and 115. As shown in Figure 113, the AC / DC power tool interface 22B may include a circuit 31 for receiving a “dirty” AC signal from a specific AC power source, such as a gas-powered generator. The set of battery pack chargers 30 includes one or more battery pack chargers 30 configured to charge one or more of the DC battery pack power supplies 20A. The following is a more detailed description of the power supply 20, the battery pack chargers 30, and the power tool 10.

[0248] 1. DC battery pack power supply Referring to Figure 1, as described above, the DC battery pack power supply 20A includes a set of low-rated voltage battery packs 20A1, a set of intermediate-rated voltage battery packs 20A2, a set of high-rated voltage battery packs 20A3, and a set of convertible battery packs 20A4. Each battery pack may include a housing, a plurality of cells, and a power tool interface configured to connect the battery pack to a power tool or charger. Each cell has a rated voltage, usually expressed in volts (V), and a rated capacity, usually expressed in ampere-hours (Ah) (meaning the energy stored in the cell). As is well known to those skilled in the art, when cells in a battery pack are connected to each other in series, the cell voltages are additive. When cells are connected to each other in parallel, the cell capacities are additive. A battery pack may include several systems of cells. Within each system, cells may be connected to each other in series, and each system may be connected to the other cells in parallel. The configuration, voltage, and capacity of the cells and cell systems determine the overall rated voltage and rated capacity of the battery pack. Within each set of 20A DC battery pack power supplies, there may be multiple battery packs with the same voltage but different rated capacities, such as 1.5 amp-hours (Ah), 2Ah, 3Ah, or 4Ah.

[0249] Figures 2A and 2C show exemplary battery cell configurations of a battery 24 that is part of a set of DC battery pack power supplies 20A. These examples are not intended to limit the possible cell configurations of battery 24 within each set of DC battery pack power supplies 20A. Figure 2A shows a battery 24 having five battery cells 26 connected in series. In this example, if each cell 26 has a rated voltage of 4V and a rated capacity of 1.5Ah, then this battery 24 would have a rated voltage of 20V and a rated capacity of 1.5Ah. Figure 2B shows a battery 24 having 10 cells. The battery 24 contains five subsets 28 of cell 26, each subset 28 containing two cells 26. The cells 26 of each subset 28 are connected in parallel, and the subsets 28 are connected in series. In this example, if each of the cells 26 has a rated voltage of 4V and a rated capacity of 1.5Ah, then the battery 24 will have a rated voltage of 20V and a rated capacity of 3Ah. Figure 2C shows a battery 24 having 15 cells 120. The battery 24 contains five subsets 28 of cells 26, each subset 28 containing three cells 26. The cells 26 of each subset 28 are connected in parallel, and the subsets 28 are connected in series. In this example, if each of the cells 26 has a rated voltage of 4V and a rated capacity of 1.5Ah, then the battery 24 will have a rated voltage of 20V and a rated capacity of 4.5Ah.

[0250] a. Low-rated voltage battery pack Referring to Figures 1A and 3A, each of the low-voltage battery packs 20A1 includes a DC power tool interface 22A configured to connect to the battery pack interface 16A on the corresponding low-voltage power tool 10A1 and to the battery pack interface 16A on the corresponding low-voltage battery pack charger 30. The DC power tool interface 22A may include a DC power input / output + terminal, a DC power input / output - terminal, and a communication (COMM) terminal. The set of low-voltage battery packs 20A1 may include one or more battery packs having a first rated voltage and a first rated capacity. The first rated voltage is, relatively speaking, a low rated voltage when compared to other battery packs in the DC battery pack power supply 20A. For example, the low-voltage battery pack 20A1 may include a battery pack having a rated voltage of 17V to 20V (which may include a published voltage of 20V, an operating voltage of 17V to 19V, a nominal voltage of 18 volts, and a maximum voltage of 20V). However, the low-voltage battery pack 20A1 set is not limited to a rated voltage of 20V. The low-voltage battery pack 20A1 set may have other relatively lower rated voltages such as 4V, 8V, 12V, 18V, 24V, or 36V. Within the low-voltage battery pack 20A1 set, there may be battery packs with the same rated voltage but different rated capacities. For example, the low-voltage battery pack 20A1 set may include a 20V / 1.5Ah battery pack, a 20V / 2Ah battery pack, a 20V / 3Ah battery pack, and / or a 20V / 4Ah battery pack. When referring to the low-voltage of the low-voltage battery pack 20A1 set, it means that the rated voltage of the low-voltage battery pack 20A1 set is lower than the rated voltage of the intermediate-voltage battery pack 20A2 set and the high-voltage battery pack 20A3 set.

[0251] An example of a battery pack within the low-rated voltage battery pack 120A set may include the DEWALT 20V MAX, a set of battery packs sold by DEWALT Industrial Tool Co. of Towson, Maryland. Other examples of battery packs that may be included in the first set of battery pack 110 are described in U.S. Patent No. 8,653,787 and U.S. Patent Applications No. 13 / 079,158, 13 / 475,002, and 13 / 080,887, which are incorporated by reference.

[0252] The rated voltage of the low-voltage battery pack 20A1 set generally corresponds to the rated voltage of the low-voltage DC power tool 10A1 set, so that the low-voltage battery pack 20A1 set can supply power to the low-voltage DC power tool 10A1 and can operate together with the low-voltage DC power tool 10A1. Furthermore, as will be described in more detail later, the low-voltage battery pack 20A1 set may also supply power to one or more of the intermediate-voltage DC power tool 10A2, high-voltage DC power tool 10A3, or high-voltage AC / DC power tool 10B by, for example, connecting multiple low-voltage battery packs 20A1 in series with these tools so that the voltage of the low-voltage battery pack 20A1 becomes additive and corresponds to the rated voltage of the power tool to which the battery pack is connected. The low-voltage battery pack 20A1 may be additionally or alternatively coupled in series with one or more of the intermediate-voltage battery pack 20A2, high-voltage battery pack 20A3, or convertible battery pack 20A4 to output the desired voltage level for any of the intermediate and high-voltage DC power tools 10A2, 10A3, and / or AC / DC power tools 10B.

[0253] b. Intermediate rated voltage battery pack Referring to Figures 1A and 3B, each of the intermediate rated voltage battery packs 20A2 includes a DC power tool interface 22A configured to be coupled to a battery pack interface 16A on the corresponding intermediate rated voltage DC power tool 10A2 and to a battery pack interface 16A on the corresponding intermediate rated voltage battery pack charger 30. The DC power tool interface 22A may include DC power input / output terminals and a communication (COMM) terminal. The set of intermediate rated voltage battery packs 20A2 may include one or more battery packs having a second rated voltage and a second rated capacity. The second rated voltage is, relatively speaking, the intermediate rated voltage when compared to other battery packs in the set of DC battery pack power supplies 20A. For example, the set of intermediate rated voltage battery packs 20A2 may include battery packs having a rated voltage of 51V to 60V (which may include a published voltage of 60V, an operating voltage of 51V to 57V, a nominal voltage of 54V, and a maximum voltage of 60V). However, the intermediate rated voltage battery pack 20A2 set is not limited to a rated voltage of 60V. The intermediate rated voltage battery pack 20A2 set may have other relatively intermediate rated voltages such as 40V, 54V, 72V, or 80V. Within the intermediate rated voltage battery pack 20A2 set, there may be battery packs with the same rated voltage but different rated capacities. For example, the intermediate rated voltage battery pack 20A2 set may include a 60V / 1.5Ah battery pack, a 60V / 2Ah battery pack, a 60V / 3Ah battery pack, and / or a 60V / 4Ah battery pack. When referring to the intermediate rated voltage of the intermediate rated voltage battery pack 20A2 set, it means that the rated voltage of the intermediate rated voltage battery pack 20A2 set is higher than the rated voltage of the low rated voltage battery pack 20A1 set, but lower than the rated voltage of the high rated voltage battery pack 20A3 set.

[0254] The rated voltage of the intermediate rated voltage battery pack 20A2 set generally corresponds to the rated voltage of the intermediate rated voltage DC power tool 10A2, so that the intermediate rated voltage battery pack 20A2 set can supply power to the intermediate rated voltage DC power tool 10A2 and operate together with the intermediate rated voltage DC power tool 10A2. Furthermore, as will be described in more detail later, the intermediate rated voltage battery pack 20A2 set may also be able to supply power to a high rated voltage DC power tool 10A3 or an AC / DC power tool 10B by connecting multiple intermediate rated voltage battery packs 20A2 in series with these tools, for example, so that the voltage of the intermediate rated voltage battery pack 20A2 becomes additive and corresponds to the rated voltage of the power tool to which the battery pack is connected. The intermediate voltage rated battery pack 20A2 may be additionally or alternatively coupled in series with either the low voltage rated battery pack 20A1, the high voltage rated battery pack 20A3, or the convertible battery pack 20A4 to output a desired voltage level for either the high voltage rated DC power tool 10A or the AC / DC power tool 10B.

[0255] c. High-rated voltage battery pack Referring to Figures 1A and 3C, each of the high-rated voltage battery packs 20A3 includes a DC power tool interface 22A configured to connect to the battery pack interface 16A on the corresponding high-rated voltage DC power tool 10A3 and to the battery pack interface 16A on the corresponding intermediate-rated voltage battery charger 30. The DC power tool interface 22A may include a DC power input / output + terminal, a DC power input / output - terminal, and a communications (COMM) terminal. The set of high-rated voltage battery packs 20A3 may include one or more battery packs having a third rated voltage and a third rated capacity. The third rated voltage is a high rated voltage when expressed relatively compared to other battery packs in the set of DC battery pack power supplies 220A. For example, the set of high-rated voltage battery packs 20A3 may include a battery pack having a rated voltage of 102V to 120V (which may include a published voltage of 120V, an operating voltage of 102V to 114V, a nominal voltage of 108V, and a maximum voltage of 120V). However, the 20A3 high-voltage battery pack set is not limited to a 120V rated voltage. The 20A3 high-voltage battery pack set may have other relatively high rated voltages such as 90V, 100V, 110V, or 120V. The high rated voltage of the 20A3 high-voltage battery pack set may also be referred to as the AC rated voltage, because the high rated voltage can correspond to the rated voltage of the AC commercial power supply in the country in which the power tool operates and / or is sold. Within the 20A3 high-voltage battery pack set, there may be battery packs with the same rated voltage but different rated capacities. For example, the 20A3 high-voltage battery pack set may include a 120V / 1.5Ah battery pack, a 120V / 2Ah battery pack, a 120V / 3Ah battery pack, and / or a 120V / 4Ah battery pack. When referring to the high rated voltage of the high-rated voltage battery pack 20A3 set, it means that the rated voltage of the high-rated voltage battery pack 20A3 set is higher than the rated voltage of the low-rated voltage battery pack 20A1 set and the rated voltage of the intermediate-rated voltage battery pack 20A2 set.

[0256] The rated voltage of the high-voltage battery pack set 20A3 generally corresponds to the rated voltage of the high-voltage DC power tool 10A3 and the AC / DC power tool 10B, so that the high-voltage battery pack set 20A3 can supply power to the high-voltage DC power tool 10A3 and the AC / DC power tool 10B, and can operate together with the high-voltage DC power tool 10A3 and the AC / DC power tool 10B. Furthermore, as will be described in more detail later, the high-voltage battery pack set 20A3 may also be able to supply power to the extremely high-voltage AC / DC power tool 128 by, for example, connecting multiple high-voltage battery packs 20A3 in series to the tool so that the voltage of the high-voltage battery pack 20A3 is additive. The high-voltage rated battery pack 20A3 may be coupled in series with either the low-voltage rated battery pack 20A1, the intermediate-voltage rated battery pack 20A2, or the convertible battery pack 20A4 to output a desired voltage level for either an AC / DC power tool 10B.

[0257] d. Convertible battery pack Referring to Figure 1A, and as will be described in more detail later, the set of convertible battery packs 20A4 is a convertible battery pack in which each can be converted between (1) a first rated voltage and a first rated capacity and (2) a second rated voltage and a second rated capacity that are different from the first rated voltage and first rated capacity. For example, the configuration of the cells present in the battery pack 20A4 may be changed between a first cell configuration in which the convertible battery pack 20A4 is placed in a first battery pack configuration and a second cell configuration in which the convertible battery pack 20A4 is placed in a second battery pack configuration. In one embodiment, in the first battery pack configuration, the convertible battery pack 20A4 has a low rated voltage and a high rated capacity, and in the second battery pack configuration, the battery pack has an intermediate rated voltage and a low rated capacity. In other words, the battery packs of the set of convertible battery packs 20A4 have the capability to have at least two different rated voltages, such as a lower rated voltage and a higher rated voltage, and at least two different capacities, such as a higher rated capacity and a lower rated capacity.

[0258] As stated above, low, intermediate, and high ratings are relative terms and are not intended to limit the battery packs in the 20A4 convertible battery pack set to specific ratings. Alternatively, the convertible battery packs in the 20A4 convertible battery pack set may be compatible with both the low-rated voltage power tool 10A1 and the intermediate-rated voltage power tool 20A2, in which case the intermediate-rated voltage is greater than the low-rated voltage. In one particular embodiment, the convertible battery pack 20A4 is convertible between a low-rated voltage (e.g., 17V to 20V, which may include a published voltage of 20V, an operating voltage of 17V to 19V, a nominal voltage of 18V, and a maximum voltage of 20V) corresponding to the low-rated voltage of the low-rated voltage DC power tool 10A1, and an intermediate-rated voltage (e.g., 60V, which may include a published voltage of 60V, an operating voltage of 51V to 57V, a nominal voltage of 54V, and a maximum voltage of 60V) corresponding to the intermediate-rated voltage of the intermediate-rated voltage DC power tool 10A2. Furthermore, as will be described later, the convertible battery pack 20A4 may be capable of supplying power to the high-rated-voltage DC power tool 10A3 and the high-voltage AC / DC power tool 10B when the convertible battery pack 20A4 operates at its intermediate rated voltage and is connected to each other in series, so that its voltage is additive to correspond to the rated voltage of the high-rated-voltage DC power tool 10A3 or the AC / DC power tool 10B.

[0259] In other embodiments, the convertible battery pack may be backward compatible with a first existing set of power tools having the first rated voltage when in the first rated voltage configuration, and backward compatible with a second new set of power tools having the second rated voltage. For example, the convertible battery pack may be compatible with a first set of power tools when in the first rated voltage configuration, in which case the first set of power tools are existing power tools that were sold before May 18, 2014, and may be compatible with a second set of power tools when in the second rated voltage configuration, in which case the second set of power tools are not that which were sold before May 18, 2014. For example, in one possible embodiment, the low / intermediate rated convertible battery pack may, in a 20V rated voltage configuration, be compatible with one or more DeWALT® 20V MAX cordless power tools sold by DeWALT Industrial Tool Co., Towson, Maryland, that were on sale before May 18, 2014, and in a 60V rated voltage configuration, be compatible with one or more 60V rated power tools that were not on sale before May 18, 2014. Thus, the convertible battery pack facilitates compatibility within power tool systems having both existing and new sets of power tools.

[0260] Referring to Figures 1A and 3A-3C, each convertible battery pack 20A4 includes a plurality of cells and a DC power tool interface 22A configured to be coupled to a battery pack interface 16A on a corresponding low, intermediate, or high rated voltage DC power tool 10A1, 10A2, or 10A3. The DC power tool interface 22A is also configured to be coupled to a battery pack interface 16A on a corresponding battery pack charger 30. As will be described in more detail later, the convertible battery pack 20A4 may be coupled to one or more rated voltage battery pack chargers 30, in which case the convertible battery pack 20A4 will be in a voltage rated configuration corresponding to the battery pack charger 30 when coupled to that battery pack charger 30. For example, the DC power tool interface 22A may include a DC power input / output + terminal, a DC power input / output - terminal, and a communication (COMM) terminal. Several possible embodiments of the convertible battery pack and its interface will be described in more detail later.

[0261] B. Battery pack charger Referring to Figures 1A and 3A-3C, the battery pack charger set 30 includes one or more battery pack chargers that can be mechanically and electrically coupled to one or more battery packs from among the low-rated voltage battery pack 20A1, the intermediate-rated voltage battery pack 20A2, the high-rated voltage battery pack 20A3, and the convertible battery pack 20A4. The battery pack charger set 30 can charge any of the battery packs 20A1, 20A2, 20A3, and 20A4. The battery pack charger 30 may have different rated voltages. For example, the battery pack charger 30 may have one or more rated voltages, such as a low-rated voltage, an intermediate-rated voltage, and / or a high-rated voltage, to match the rated voltages of the set of battery packs in the system. Alternatively, the battery pack charger 30 may have multiple rated voltages or a range of rated voltages (e.g., low-to-intermediate rated voltages) so that the battery pack charger 30 can charge battery packs with different rated voltages. The battery pack charger 30 may also have a battery pack interface 16A configured to connect to a DC power tool interface 22A on the battery pack. The battery pack interface 16A may include a DC power input / output + terminal, a DC power input / output - terminal, and a communication (COMM) terminal. In certain embodiments, the battery pack interface 16A may include a converter configured to place one of the convertible battery packs into a desired rated voltage configuration in order to charge the battery pack, as will be described in more detail later.

[0262] C.Power tools 1. Low-rated voltage DC power tools Referring to Figures 1A and 3A, the low-voltage power tool set 10A1 includes one or more different types of cordless or DC-only power tools that utilize DC power supplied from one or more DC battery pack power supplies 20A (such as removable and rechargeable battery packs) having a low voltage rating. The voltage rating of the low-voltage DC power tool 10A1 may generally correspond to the voltage rating of the low-voltage battery pack 20A1, or to the voltage rating of the convertible battery pack 20A4 when placed in a low-voltage configuration. For example, a low-voltage DC power tool 10A1 having a voltage rating of 20V may be powered by using one or more 20V battery packs 20A1, or by a 20V / 60V convertible battery pack 20A4 in a 20V configuration. The 20V power tool rating may itself be an abbreviation of a broader rated voltage range of 17-20V, which may encompass the rated voltage range of a low-rated voltage battery pack, for example, an operating voltage range of 17V-20V.

[0263] Each low-voltage DC power tool 10A1 includes a motor 12A that can be powered by a DC-only power source. The motor 12A may be any brushed or brushless DC electric motor, including, but not limited to, permanent magnet brushless DC motors (BLDC), permanent magnet brushed motors, and universal motors. The low-voltage DC power tool 10A1 may also include a motor control circuit 14A configured to receive DC power from a battery pack interface 16A via DC line input DC+ / - and to control the power supply from the DC power source to the motor 12A. In one exemplary embodiment, the motor control circuit 14A may include a power unit 18A having one or more power switches (not shown) disposed between the power source and the motor 12A. The power switches may be electromechanical on / off switches, power semiconductor devices (e.g., diodes, FETs, BJTs, IGBTs, etc.), or a combination thereof. In one exemplary embodiment, the motor control circuit 14A may further include a control unit 11. The control unit 11 may be configured to control the switching operation of the power switch in the power unit 18A. In an exemplary embodiment, the control unit 11 may include a microcontroller or similar programmable module configured to control the gate of the power switch. Additionally or alternatively, the control unit 11 may be configured to monitor and manage the operation of the DC battery pack power supply 20A. Additionally or alternatively, the control unit 11 may be configured to monitor and manage the operation and status of various tools, such as temperature control, overspeed control, and braking control.

[0264] In one exemplary embodiment, as will be described in more detail later, the low-rated-voltage DC power tool 10A1 may be a constant-speed tool (e.g., a portable light, saw, grinder, etc.). In such a power tool, the power unit 18A may simply include an electromechanical on / off switch that can be engaged by the user of the tool. Alternatively, the power unit 18A may include one or more semiconductor devices controlled by the control unit 11 at a fixed no-load speed to operate or stop the motor 12A of the tool.

[0265] In another embodiment, as will be described in more detail later, the low-rated-voltage DC power tool 10A1 may be a variable-speed tool (e.g., a portable drill, impact driver, reciprocating saw, etc.). In such a power tool, the power switch of the power unit 18A may include one or more semiconductor devices (e.g., FETs and diodes, H-bridges, etc.) configured in various ways, and the control unit 11 may control the pulse width modulation of the power switch to control the speed of the motor 12A.

[0266] Low-voltage DC power tools 10A1 may include, among other things, portable cordless tools such as drills, circular saws, screwdrivers, reciprocating saws, vibratory tools, impact drivers, and flashlights. Low-voltage power tools may also include existing cordless power tools that were sold before May 18, 2014. Examples of such low-voltage DC power tools 10A1 may include one or more of the DeWALT® 20V MAX set of cordless power tools sold by DeWALT Industrial Tool Co. of Towson, Maryland. Alternatively, low-voltage DC power tools 10A1 may also include cordless power tools that were not sold before May 18, 2014. In other examples, U.S. Patents 8,381,830, 8,317,350, 8,267,192, D646,947, and D644,494 disclose tools having or similar to the low-rated-voltage cordless power tool 10A1, and these documents are incorporated by reference.

[0267] 2. Intermediate rated voltage DC power tools Referring to Figures 1A and 3B, the set of intermediate voltage DC power tools 10A2 may include one or more different types of cordless or DC-only power tools that utilize DC power supplied from one or more DC battery pack power sources 20A having intermediate voltages individually or in combination (such as removable and rechargeable battery packs). The rated voltage of the intermediate voltage DC power tool 10A2 will generally correspond to the rated voltage of the intermediate voltage battery pack 20A2, or to the rated voltage of the convertible battery pack 20A4 when placed in an intermediate voltage configuration. For example, the intermediate voltage DC power tool 10A2 may have a rated voltage of 60V and may be powered by a 60V intermediate voltage battery pack 20A2, or by a 20V / 60V convertible battery pack 20A4 in a 60V configuration. The 60V power tool rating may also be a shortened expression of a broader rating voltage of 17-20V, which may encompass an operating range of, for example, 51V-60V, including the rating voltage of an intermediate voltage battery pack. In an exemplary embodiment, the intermediate voltage DC power tool 10A2 may include a plurality of battery interfaces configured to accept two or more low voltage battery packs 20A1. In an exemplary embodiment, the intermediate voltage DC power tool 10A2 may also include a circuit for coupling a DC battery pack power supply 20A in series to generate a desired intermediate voltage corresponding to the rating voltage of the intermediate voltage DC power tool 10A2.

[0268] Similar to the low-rated-voltage DC power tool 10A1 described above, the intermediate-rated-voltage DC power tool 10A2 each includes a motor 12A which can be powered by a DC battery pack power supply 20A. The motor 12A may be any brushed or brushless DC electric motor, including, but not limited to, permanent magnet brushless DC motors (BLDC), permanent magnet brushed motors, universal motors, etc. The intermediate-rated-voltage DC power tool 10A2 also includes a motor control circuit 14A configured to receive DC power from a battery pack interface 16A via DC line input DC+ / - and to control the power supply from the DC power supply to the motor 12A. In one exemplary embodiment, the motor control circuit 14A may include a power unit 18A having one or more power switches (not shown) disposed between the power supply and the motor 12A. The power switches may be electromechanical on / off switches, power semiconductor devices (e.g., diodes, FETs, BJTs, IGBTs, etc.), or a combination thereof. In an exemplary embodiment, the motor control circuit 14A may further include a control unit 11. The control unit 11 may be configured to control the switching operation of a power switch in the power unit 18A. Similar to the motor control circuit 14A described above for the low-rated-voltage DC power tool 10A1, the motor control circuit 14A may control the motor 12A at a fixed or variable speed. In an exemplary embodiment, the control unit 11 may include a microcontroller or similar programmable module configured to control the gate of the power switch. Additionally or alternatively, the control unit 11 may be configured to monitor and manage the operation of the DC battery pack power supply 20A. Additionally or alternatively, the control unit 11 may be configured to monitor and manage various tool operations and conditions, such as temperature control, overspeed control, and braking control.

[0269] Intermediate voltage DC power tools 10A2 may include types of tools similar to low voltage DC power tools 10A1 that have relatively high power output requirements, such as drills, circular saws, screwdrivers, reciprocating saws, vibratory tools, impact drivers, and flashlights. Additionally, intermediate voltage DC power tools 10A2 may include other types of tools that require greater power or capacity than low voltage DC power tools 10A1, such as chainsaws, string trimmers, hedge trimmers, lawnmowers, nail guns, and / or rotary hammers.

[0270] In yet another and / or further embodiments, as will be described in more detail later, the motor control circuit 14A of the intermediate voltage DC power tool 10A2 enables power supply to the motor 12A using multiple DC battery pack power supplies 20A having different and lower voltage ratings than the intermediate voltage. In other words, the intermediate voltage DC power tool 10A2 may be configured to operate at multiple voltage ratings (for example, at low voltage ratings or intermediate voltage ratings). Such an intermediate voltage DC power tool 10A2 can be described as having multiple voltage ratings corresponding to the voltage ratings of multiple DC power supplies capable of powering the tool. For example, the intermediate voltage DC power tool 10A2 in Figure 3B may have low / intermediate voltages (e.g., 20V / 60V rated voltage, 40V / 60V rated voltage) capable of being selectively powered by one of the low voltage battery packs 20A1 (e.g., a 20V battery pack), one of the intermediate voltage battery packs 20A2 (e.g., a 60V battery pack), or a convertible battery pack 20A4 in a low voltage or intermediate voltage configuration. In one alternative embodiment, the intermediate voltage DC power tool 10A2 may be operated by using a pair of low voltage battery packs 20A1 connected in series to operate at yet another low or intermediate voltage different from the intermediate voltage of the motor 12A in the intermediate voltage DC power tool 10A2 (e.g., two low voltage 18V battery packs 20A1 connected in series to produce a combined low voltage of 36V).

[0271] The operation of the power tool motor 12A at significantly different voltage levels results in large differences in the performance of the power tool, particularly in the motor's rotational speed, which can be noticeable and, in some cases, unsatisfactory for the user. Therefore, in one embodiment of the present invention described herein, the motor control circuit 14A is configured to optimize the performance of motor 12A based on the rated voltage of the power supply, i.e., based on whether the intermediate rated voltage DC power tool 10A2 is coupled to a low rated voltage DC power supply (e.g., a low rated voltage battery pack 20A1) or an intermediate rated voltage power supply (e.g., an intermediate rated voltage battery pack 20A2 in which motor 212A in the intermediate rated voltage DC power tool 10A2 is optimized or rated). By doing so, differences in the output performance of the tool are minimized or at least reduced to a level satisfactory to the end user.

[0272] In this embodiment, the motor control circuit 14A is configured to increase or decrease the effective motor performance from the power supply to a level corresponding to the operating voltage range (or voltage rating) of the intermediate rated voltage DC power tool 10A2. Specifically, when used with the intermediate rated voltage battery pack 20A2, the motor control circuit 14A may reduce the power output of the tool 10A to match (or reasonably close to) the output level of the tool 10A when used with the low rated voltage battery pack 20A1 in a manner satisfactory to the end user. Alternatively, or additionally, when used with the low rated voltage battery pack 20A1, the motor control circuit 14A may increase the power output of the intermediate rated voltage DC power tool 10A2 to match (or reasonably close to) the output level of the intermediate rated voltage DC power tool 10A2 when used with the intermediate rated voltage battery pack 20A2 in a manner satisfactory to the end user. In one embodiment, the low / intermediate rated voltage DC power tool 10A2 may be configured to identify the rated voltage of the power supply, for example, via a battery ID, and to optimize motor performance accordingly. These methods for optimizing (i.e., increasing or decreasing) effective motor performance are described in detail in this disclosure.

[0273] 3. High-rated voltage DC power tools Referring to Figures 1A and 3C, the high-rated-voltage DC power tool set 10A3 may include cordless (DC only) high-rated (or AC-rated) voltage power tools having motors configured to operate at high rated voltages and high power outputs (e.g., about 1000-1500 watts). Similar to the low and intermediate-rated-voltage DC power tools 10A1 and 10A2, the high-rated-voltage DC power tool set 10A3 may also include a variety of cordless tools for high-power output applications (i.e., power tools, outdoor tools, etc.). The high-rated-voltage DC power tool set 10A3 may include tools of a similar type to those in the low-rated-voltage and intermediate-rated-voltage DC power tools, such as drills, circular saws, screwdrivers, reciprocating saws, vibratory tools, impact drivers, flashlights, string trimmers, hedge trimmers, lawnmowers, nail guns, and / or rotary hammers. High-rated-voltage DC power tools may additionally or alternatively include other types of tools that require higher power or capacity, such as miter saws, chainsaws, hammer drills, grinders, and compressors.

[0274] Similar to the low and intermediate rated voltage DC power tools 10A1 and 10A2, the high rated voltage DC power tool 10A3 includes a motor 12A, a motor control circuit 14A, and a battery pack interface 16A, each configured to enable operation from one or more DC battery pack power sources 20A, which together have a high rated voltage corresponding to the rated voltage of the power tool 10A. Similar to the motor 12A described above with reference to Figure 3A, the motor 12A may be any brushed or brushless DC electric motor, including, but not limited to, permanent magnet brushless DC motors (BLDC), permanent magnet brushed DC motors (PMDC), universal motors, etc. Similarly, the motor control circuit 14A may include a power unit 18A having one or more power switches (not shown) disposed between the power source and the motor 12A. The power switches may be electromechanical on / off switches, power semiconductor devices (e.g., diodes, FETs, BJTs, IGBTs, etc.), or a combination thereof. In one embodiment, the motor control circuit 14A may further include a control unit 11. The control unit 11 may be configured to control the switching operation of the power switch in the power unit 18A. The motor control circuit 14A may control the motor 12A at a fixed or variable speed. In one embodiment, the control unit 11 may include a microcontroller or similar programmable module configured to control the gate of the power switch. Additionally or alternatively, the control unit 11 may be configured to monitor and manage the operation of the DC battery pack power supply 20A. Additionally or alternatively, the control unit 11 may be configured to monitor and manage the operation and status of various tools.

[0275] Referring to Figure 3C, the high-rated-voltage DC power tool 10A3 may be powered by a single DC battery pack power supply 20A accepted within the battery pack interface (or battery outlet) 16A. In one embodiment, the DC battery pack power supply 20A may be a high-rated-voltage battery pack 20A3 having a high rated voltage (e.g., 120V) corresponding to the rated voltage of the high-rated-voltage DC power tool 10A3.

[0276] Referring to Figure 3C, in one alternative embodiment, the battery pack interface 16A of the high-voltage DC power tool 10A3 may include two or more battery outlets 16A1, 16A2 that accept two or more DC battery pack power supplies 20A at a given time. In one embodiment, the high-voltage DC power tool 10A3 may be powered by a pair of DC battery pack power supplies 20A accepted together in the battery outlets 216A1, 216A2. In this embodiment, the battery pack interface 16A may also include a switching unit (not shown) configured to connect two DC battery pack power supplies 20A in series. The switching unit may include, for example, a circuit provided within the battery pack interface 16A or within the motor control circuit 14A. Alternatively, the DC battery pack power supply 20A may be an intermediate voltage rated battery pack 20A2 connected in series via a switching unit 120-10 to similarly output a high rated voltage (for example, two 60V battery packs connected in series for a combined rated voltage of 120V). In yet another embodiment, a single high voltage rated battery pack 20A3 may be coupled to one of the battery outlets to provide a rated voltage of 120V. For example, a high voltage rated DC power tool 10A2 may have a rated voltage of 60V and may be powered by two 60V intermediate voltage rated battery packs 20A2, or by two 20V / 60V convertible battery packs 20A4 in its 60V configuration. The 120V power tool rating may itself be an abbreviation of a broader rated voltage range of 102V to 120V, which may encompass the operating range of two intermediate rated voltage battery packs, for example, the 102V to 120V operating range.

[0277] In one embodiment, the total rated voltage of the battery packs accepted in one or more cordless power tool battery outlets 16A may correspond to the rated voltage of the cordless DC power tool 10A itself. However, in other embodiments, the high-rated-voltage cordless DC power tool 10A3 may also be able to operate using one or more DC battery pack power supplies 20A that jointly have a rated voltage lower than the rated voltage of the motor 12A and motor control circuit 14A within the high-rated-voltage cordless DC power tool 10A3. In this latter case, the cordless DC power tool 10A may be described as having multiple rated voltages corresponding to the rated voltages of the DC battery pack power supplies 20A that the high-rated-voltage DC power tool 10A3 will accept. For example, a high-voltage DC power tool 10A3 may be an intermediate / high-voltage DC power tool (e.g., 60V / 120V, 60-120V power tool, 80V / 120V, or 80-120V power tool) if it is capable of operating with a high-voltage battery pack 20A3 or an intermediate-voltage battery pack 20A2 that has the ability to be selectively powered by a multiple low-voltage battery pack 20A1 (e.g., a 20V battery pack), one or more intermediate-voltage battery packs 20A2 (e.g., a 60V battery pack), one high-voltage battery pack 20A3, or one or more convertible battery packs 20A4. Users may mix and match any of the DC battery pack power supplies 20A for use with the high-voltage DC power tool 10A3.

[0278] To ensure that the motor in the high-voltage power tool 10A3 (which may be optimized to operate at high power and high voltage ratings as described) functions acceptable with a DC power supply having a total voltage rating less than the motor's voltage rating, the motor control circuit 14A may be configured to optimize motor performance based on the rated voltage of the low-voltage DC battery pack 20A1. As briefly stated above and as will be described in detail later in this disclosure, this can be done by optimizing (i.e., increasing or decreasing) the effective motor performance from the power supply to a level corresponding to the operating voltage range (or voltage rating) of the high-voltage DC power tool 10A3.

[0279] In an alternative or additional embodiment (not shown), an AC / DC adapter may be provided that connects an AC power source to a battery pack interface 16 and converts AC power from the AC power source to a DC signal of equivalent rated voltage in order to supply a high-rated voltage DC power source to a high-rated voltage DC power tool 10A3 via the battery pack interface 16A.

[0280] 4. High (AC) rated voltage AC / DC power tools Referring to Figures 1A and 4, the corded / cordless (AC / DC) power tool 10B has an AC / DC power interface 16 having DC line input DC+ / -(16A), AC line input ACH, ACL(16B), and a communication line (COMM), respectively, coupled to the motor control circuit 14B. The AC / DC power interface 16 is configured to be coupled to the tool interface of one or more of the DC battery pack power supply 20A and the AC power supply 20B. The DC battery pack power supply 20A may have a DC power input / output + terminal, a DC power input / output - terminal, and a communication (COMM) terminal that can be coupled to the DC+ / - line input and communication line (COMM) in the AC / DC power interface 16 within the AC / DC power tool 10B. Furthermore, the DC power input / output + terminal, DC power input / output - terminal, and communication (COMM) terminal of the DC battery pack power supply 20A may be able to couple the DC battery pack power supply 20A to the battery pack interface 16A of the battery pack charger 30, as described above. The AC power supply 20B may be coupled to the ACH, ACL, and / or COMM terminals of the power interface 16B in the AC / DC power tool 10B by AC power H and AC power L terminals or lines, and by a COMM terminal or line. In each AC / DC power tool 10B, the motor control circuit 14B and the motor 12B are designed to optimize the motor's performance for a given rated voltage of the power tool and power supply.

[0281] As will be described later, the motor 12B may be a brushed motor or brushless motor such as a permanent magnet brushless DC motor (BLDC), a permanent magnet brushed DC motor (PMDC), or a universal motor. The motor control circuit 14B may enable constant speed operation or variable speed operation, as will be described in more detail later, and may include different power switching and control circuits depending on the type of motor and speed control.

[0282] In an exemplary embodiment, the AC / DC power interface 16 may be configured to include a single battery pack interface (e.g., a battery pack outlet) 16A and an AC power interface 16B (e.g., an AC power cable received within the tool housing). In this embodiment, the motor control circuit 14B may be configured to selectively switch between the AC power supply 20B and the DC battery pack power supply 20A. In this embodiment, the DC battery pack power supply 20A may be a high-voltage rated battery pack 20A3 having a high rated voltage (e.g., 120V) corresponding to the rated voltage of the AC / DC power tool 10B and / or the rated voltage of the AC power supply 20B. The motor control unit 14B may be configured, for example, to supply AC power from the AC power supply 20B in a standard setting when it detects current from the AC power supply 20B, and otherwise to supply power from the DC battery pack power supply 20A.

[0283] Referring to Figures 114 to 117, in another exemplary embodiment, the AC / DC power interface 16 may be configured to include a pair of battery interfaces 16A, such as two battery outlets 16A1 and 16A2, in addition to the AC power interface 16B. This configuration allows the AC / DC power tool 10B to be powered by multiple DC battery pack power supplies 20A that, when connected in series, cooperate to have a high rated voltage corresponding to the AC rated voltage of the commercial power supply. In this embodiment, the AC / DC power tool 10B may be powered by a pair of DC battery pack power supplies 20A accepted in the battery outlets 16A1 and 16A2. In one embodiment, a switching unit may be provided and configured to connect the two DC battery pack power supplies 20A in series. Such a switching unit may include, for example, a simple wire connection provided within the AC / DC power interface 16 connecting the battery outlets 16A1 and 16A2. Alternatively, such a switching unit may be provided as a pair of motor control circuits 14B.

[0284] In this embodiment, the DC battery pack power supply 20A may be two of the intermediate voltage rated battery packs 20A2 connected in series via a switching unit to output a high rated voltage (for example, two 60V battery packs connected in series for a combined rated voltage of 120V). Referring to Figure 116, in yet another exemplary embodiment, a single high voltage rated pack 20A3 may be coupled to one of the battery outlets 16A2 to provide a rated voltage of 120V, while the other battery outlet 16A1 may be left unused. In this embodiment, the motor control circuit 14B may be configured to select either the AC power supply 20B or the combined DC battery pack power supply 20A to power the motor 12B.

[0285] In these embodiments, the total rated voltage of the DC battery pack power supplies 20A accepted within one or more AC / DC power tool battery pack outlets 16A may correspond to the rated voltage level of the AC / DC power tool 10B, which generally corresponds to the rated voltage of the AC commercial power supply 20B. As described above, the power supply 20 used for the high-rated voltage DC power tool 10A3 or AC / DC power tool 10B is a high-rated voltage commercial AC power supply 20B. For example, the AC / DC power tool 10A2 may have a rated voltage of 120V and may be powered by a 120VAC AC commercial power supply or by two 20V / 60V convertible battery packs 20A4 connected in series in a 60V configuration. The 120V power tool rated voltage may be an abbreviated expression of a broader rated voltage, such as 100V~120V, encompassing the operating range of the power tool and the operating range of the two intermediate rated voltage battery packs. In one embodiment, the 120V power tool rated voltage may be an abbreviated representation of all AC power supplies available in North America and Japan (e.g., 100VAC, 110VAC, 120VAC), with a broader operating range of 90V to 132V encompassing the entire operating range of two intermediate rated voltage battery packs (e.g., 102VDC to 120VDC) and a ±10% error factor to account for voltage fluctuations in AC commercial power supplies.

[0286] In other embodiments, the AC / DC power tool 10B may also be able to operate using one or more DC battery pack power supplies 20A that jointly have rated voltages that are less than the AC rated voltage of the AC commercial power supply and less than the voltage ratings of the motor 12A and the motor control circuit 14A. In this embodiment, the AC / DC power tool 10B may be described as having multiple rated voltages corresponding to the rated voltages of the DC battery pack power supplies 20A and AC power supplies 20B that the AC / DC power tool 10B will accept. For example, the AC / DC power tool 10B is an intermediate / high rated power tool if it can operate using an intermediate rated voltage battery pack 20A2 or a high rated voltage AC power supply 20B (e.g., 60V / 120V or 60~120V or 60VDC / 120VDC). According to this embodiment, the user may be given the ability to mix and match any of the DC battery pack power supplies 20A for use with the AC / DC power tool 10B. For example, the AC / DC power tool 10B may be used with two low-voltage packs 20A1 (e.g., 20V, 30V, or 40V packs) connected in series via a switching unit to output a rated voltage of 40V to 80V. In another example, the AC / DC power tool 10B may be used with a low-voltage battery pack 20A1 and an intermediate-voltage battery pack 20A2 for a total rated voltage of 80V to 100V.

[0287] In order for the motor 12B in the AC / DC power tool 10B (which, as described above, is optimized to operate at high power output and high voltage ratings) to function acceptable with a DC battery pack power supply having a total voltage rating less than the high voltage rating of the tool (for example, in the range of 40V to 100V, as described above), the motor control circuit 14B may be configured to optimize the motor performance based on the rated voltage of the DC battery pack power supply 20A. As briefly described above and as will be described in detail later in this disclosure, this can be done by optimizing (i.e., increasing or decreasing) the effective motor performance from the power supply to a level corresponding to the operating voltage range (or voltage rating) of the high-rated voltage DC power tool 10A3.

[0288] II. AC / DC Power Tools and Motor Control Referring to Figures 1A and 5A, the high-voltage AC / DC power tools 10B can be classified based on the motor type, namely, high-voltage AC / DC power tools 122 with brushed motors and high-voltage AC / DC power tools 128 with brushless motors. Furthermore, referring to Figure 5B, the AC-rated voltage AC / DC power tools 122 with brushed motors can be further classified into four subsets based on speed control and motor type: constant-speed AC / DC power tools 123 with universal motors, variable-speed AC / DC power tools 124 with universal motors, constant-speed AC / DC power tools 125 with DC brushed motors, and variable-speed AC / DC power tools 126 with universal motors. These various sets and subsets of high-voltage AC / DC power tools will be described in more detail later.

[0289] In the following Figures 5A to 15E, power tools 123, 124, 125, 126, and 128 can correspond to power tool 10B shown in Figure 4, respectively. Similarly, in the following Figures 5A to 15E, motors 123-2, 124-2, 125-2, 126-2, and 202 may correspond to motor 12B in Figure 4, motor control circuits 123-4, 124-4, 125-4, 126-4, and 204 may correspond to motor control circuit 14B in Figure 4, power units 123-6, 124-6, 125-6, 126-6, and 206 may correspond to power unit 18B in Figure 4, control units 123-8, 124-8, 125-8, 126-8, and 208 may correspond to control unit 11B in Figure 4, and power interfaces 123-5, 124-5, 125-5, 126-5, and 128-5 may correspond to power interface 16B in Figure 4.

[0290] A. Constant-speed AC / DC power tools with universal motors Referring next to Figures 6A to 6D, the first subset of AC / DC power tools 122 having brushed motors includes constant-speed AC / DC power tools 123 having universal motors (hereinafter referred to as constant-speed universal motor tools 123). These include corded / cordless (AC / DC) power tools that operate at a constant speed under no load (or constant load), and include brushed universal motors 123-2 configured to operate at high rated voltages (e.g., 100V to 120V, or even more broadly 90V to 132V) and high powers (e.g., 1500 to 2500 watts). The universal motor is a series-wound motor having a stator field coil and a commutator connected to the field coil in series. The universal motor in this configuration can operate with AC power as well as DC power. In one embodiment, the constant-speed universal motor tool 123 may include high-power tools for high-power applications such as concrete hammers, miter saws, table saws, vacuum cleaners, blowers, and lawnmowers.

[0291] In one embodiment, a constant-speed universal motor tool 123 includes a motor control circuit 123-4 that operates a universal motor 123-2 at a constant speed under no-load conditions. The power tool 123 further includes a power interface 123-5 configured to receive power from one or more of the DC and / or AC power sources described above. The power interface 123-5 is electrically coupled to the motor control circuit 123-4 by DC power lines DC+ and DC- (for supplying power from the DC power source) and by AC power lines ACH and ACL (for supplying power from the AC power source).

[0292] In one embodiment, the motor control circuit 123-4 may include a power unit 123-6. In one embodiment, the power unit 123-6 includes an electromechanical on / off switch 123-12. In one embodiment, the tool 123 includes an on / off trigger or actuator (not shown) coupled to the on / off switch 123-12, which allows the user to operate or stop the motor 123-2. The on / off switch 123-12 is provided in series with the power supply to electrically connect or disconnect the supply of power from the power interface 123-5 to the motor 123-2.

[0293] Referring to Figure 6A, a constant-speed universal motor tool 123 is shown according to one embodiment, in which the ACH and DC+ power lines are coupled together at a common positive node 123-11a, and the ACL and DC- power lines are coupled together at a common negative node 123-11b. In this embodiment, an on / off switch 123-12 is located between the positive common node 123-11a and the motor 123-2. In one embodiment, a mechanical lockout device may be used to ensure that only one of the AC or DC power sources is available at any given time. In an exemplary embodiment, the mechanical lockout device may physically block access to one of the AC or DC power sources at any given time.

[0294] In addition, as shown in Figure 6A, the constant-speed universal motor tool 123 may be further provided with a control unit 123-8. In one embodiment, the control unit 123-8 may be coupled to a power switch 123-13 located within the power unit 123-6 between the DC+ power line of the power interface 123-5 and the on / off switch 123-12. In one embodiment, the control unit 123-8 may be provided to monitor the state of the power tool 123 and / or the battery. In one embodiment, the control unit 123-8 may be coupled to an element of the tool 123, such as a thermistor in the tool. Also in one embodiment, the control unit 123-8 may be coupled to one or more battery packs via a communication signal line COMM provided from the power interface 123-5. The COMM signal line can provide the control unit 123-8 with control or information signals relating to the operation or state of one or more battery packs. In one embodiment, the control unit 123-8 may be configured to use the power switch 123-13 to interrupt power from the DC+ power line from the power interface 123-5 when a tool failure condition (e.g., tool overtemperature, tool overcurrent, etc.) or a battery failure condition (e.g., battery overtemperature, battery overcurrent, battery overvoltage, battery undervoltage, etc.) is detected. In one embodiment, the power switch 123-13 may include an FET or other controllable switch controlled by the control unit 123-8.

[0295] Figures 6B to 6D show a constant-speed universal motor tool 123 according to an alternative embodiment, in which the DC power line DC+ / DC- and AC power line ACH / ACL are isolated via a power switching unit 123-15 to ensure that power cannot be supplied simultaneously from both the AC and DC power sources (even when the power interface 123-5 is coupled to both AC and DC power sources).

[0296] In one embodiment, as shown in Figure 6B, the power switching unit 123-15 may include a normally closed single-pole single-throw relay positioned between the DC power line DC+ and the on / off switch 123-12, with its coil coupled to the AC power lines ACH and ACL. The output of the power switching unit 123-15 and the ACH power line are coupled together to the power switch 123-13. When AC power is not supplied, the relay is deactivated, and the DC power line DC+ is coupled to the power switch 123-13. When AC power is supplied, the coil is energized, the relay is activated, and therefore the DC power line DC+ is disconnected from the power switch 123-13.

[0297] In one alternative or additional embodiment, as shown in Figure 6C, the power switching unit 123-15 may include a double-pole double-throw switch 123-16 having an input terminal coupled to the DC+ and ACH power lines of the power interface 123-5 and an output terminal coupled together with the power switch 123-13. In one embodiment, a second double-pole double-throw switch 123-17 is provided, having an input terminal coupled to the negative DC- and ACL power lines of the power interface 123-5 and an output terminal coupled together with the negative terminal of the motor 123-2. In one embodiment, switches 123-16 and 123-17 may be controlled via a relay coil, similar to Figure 6B. Alternatively, switches 123-16 and 123-17 may be controlled via a mechanical switching mechanism (e.g., a movable contact provided on the battery outlet that closes the switch when the battery pack is inserted into the battery outlet).

[0298] In another embodiment, as shown in Figure 6D, the power switching unit 123-15 may include a single-pole double-throw switch 123-18 having an input terminal coupled to the DC+ and ACH power lines of the power interface 123-5 and an output terminal coupled to the power switch 123-13. In one embodiment, a second single-pole double-throw switch 123-19 is provided, having an input terminal coupled to the negative DC- and ACL power lines of the power interface 123-5 and an output terminal coupled to the negative terminal of the motor 123-2. In one embodiment, switches 123-18 and 123-19 may be controlled via a relay coil, as in Figure 6B. Alternatively, switches 123-18 and 123-19 may be controlled via a mechanical switching mechanism (e.g., a movable contact provided on the battery outlet that closes the switch when the battery pack is inserted into the battery outlet).

[0299] While the tool 123 in Figures 6A to 6D is provided with a control unit 123-8 and a power switch 123-13 to interrupt the power supply in the event of a tool or battery failure, it should be understood that the tool 123 may be provided without the control unit 123-8 and the power switch 123-13. For example, one or more battery packs may be provided with their own controllers to monitor their failure conditions and manage their operation.

[0300] 1. A constant-speed universal motor tool with a power supply having an equivalent voltage rating. In Figures 6A to 6D above, the power tool 123 is designed to operate, for example, in a high rated voltage range of 100V to 120V (corresponding to the 100VAC to 120VAC AC power voltage range in North America and Japan), or more broadly, in a range of 90V to 132V (±10% of the 100V to 120V AC power voltage range), and at high power (e.g., 1500 to 2500 watts). Specifically, the components of the motor 123-2 and power unit 123-6 of the power tool 123 are designed and optimized to handle high rated voltages of 100V to 120V, or more broadly, 90V to 132V. This can be achieved by selecting voltage-compatible power supplies and designing motors with appropriate size and winding configurations to handle high rated voltage ranges. Furthermore, the motor 123-2 has an operating voltage or operating voltage range that may be equivalent to, included in, or corresponding to the operating voltage or operating voltage range of the tool 123.

[0301] In one embodiment, the power interface 123-5 is configured to provide an AC power line with a nominal voltage in the range of 100 to 120V from an AC power source (e.g., 120VAC at 50 to 60Hz in the United States or 100VAC in Japan), or to provide a DC power line with a nominal voltage in the range of 100 to 120V from a DC power source (e.g., 108VDC). In other words, the DC and AC nominal voltages provided through the power interface 123-5 both correspond to (e.g., matched, overlapping, or included) the operating voltage range of the motor 123-2 (i.e., high-rated voltage 100V to 120V, or more broadly, about 90V to 132V). Note that the 120VAC nominal voltage corresponds to an average voltage of about 108V measured in the positive half-cycle of an AC sinusoidal waveform, which provides speed performance equivalent to 108VAC power.

[0302] 2. Constant-speed universal motor tool with power supplies having different voltage ratings. Figure 6E shows a power tool 123 according to another embodiment of the present invention, in which the power supply provided by the AC power source has a nominal voltage that is significantly different from the nominal voltage provided by the DC power source. For example, the AC power line of the power interface 123-5 may provide a nominal voltage in the range of 100 to 120V, and the DC power line may provide a nominal voltage in the range of 60 to 100V (e.g., 72VDC or 90VDC). In another example, the AC power line may provide a nominal voltage in the range of 220 to 240V (e.g., 230V in many European countries, or 220V in many African countries), and the DC power line may provide a nominal voltage in the range of 100 to 120V (e.g., 108VDC).

[0303] The operation of the power tool motor 123-2 at significantly different voltage levels can result in large differences in the performance of the power tool, particularly in the rotational speed of the motor, which can be noticeable and, in some cases, unsatisfactory for the user. Furthermore, supplying voltage levels outside the operating voltage range of the motor 123-2 can damage the motor and associated switching components. Therefore, in one embodiment of the present invention described herein, the motor control circuit 123-4 is configured to optimize the power supply to the motor 123-2 (and thus the motor performance) in accordance with the nominal voltage of the AC or DC power line, so that the motor 123-2 provides substantially uniform speed and power performance in a manner satisfactory to the end user, regardless of the nominal voltage provided on the AC or DC power line.

[0304] In this embodiment, the motor 123-2 may be designed and configured to operate in a voltage range encompassing the nominal voltage of the DC power line. In an exemplary embodiment, the power tool 123 may be designed to operate in a voltage range of 60V to 90V (or more broadly, ±10% of this, 54V to 99V), which encompasses the nominal voltage of the DC power line of the power interface 123-5 (e.g., 72VDC or 90VDC) but is less than the nominal voltage of the AC power line (e.g., 220V to 240V). In another exemplary embodiment, the motor 123-2 may be designed to operate in a voltage range of 100V to 120V (or more broadly, ±10% of this, 90V to 132V), which encompasses the nominal voltage of the DC power line of the power interface 123-5 (e.g., 108VDC) but is less than the nominal voltage range of the AC power line of 220V to 240V.

[0305] In one embodiment, the tool 123 is further provided with a phase-controlled AC switch 123-16 so that the tool 123 operates by the nominal voltage of a higher AC power line. In one embodiment, the AC switch 123-16 may include a triac or SRC switch controlled by a control unit 123-8. In one embodiment, the control unit 123-8 may be configured to set a fixed conduction band (or firing angle) of the AC switch 123-16 corresponding to the operating voltage of the tool 123.

[0306] For example, if tool 123 has a motor 123-2 with an operating voltage range of 60V to 100V, but receives AC power with a nominal voltage of 100V to 120V, the conduction band of AC switch 123-16 may be set to a value within the range of 100 to 140 degrees, such as approximately 120 degrees. In this example, the firing angle of AC switch 123-16 may be set to 60 degrees. By setting the firing angle to approximately 60 degrees, the AC voltage supplied to the motor will be in the range of approximately 70 to 90V, which corresponds to the operating voltage of tool 123. In this way, control unit 123-8 optimizes the power supply to motor 123-2.

[0307] In another example, a motor 123-2 has an operating voltage range of 100-120V, but a tool 123 receives AC power with a nominal voltage of 220-240V. In this case, the conduction band of the AC switch 123-16 may be set to a value within the range of 70-110 degrees, such as approximately 90 degrees. In this example, the firing angle of the AC switch 123-16 may be set to 90 degrees. By setting the firing angle to 90 degrees, the AC voltage supplied to the motor is approximately in the range of 100-120V, which corresponds to the operating voltage of the tool 123.

[0308] In this way, the motor control circuit 123-4 optimizes the power supply to the motor 123-2 in accordance with the nominal voltage of the AC or DC power line, so that the motor 123-2 provides substantially uniform speed and power performance in a manner that satisfies the end user, regardless of the nominal voltage provided on the AC or DC power line.

[0309] B. Variable speed AC / DC power tools with universal motors Referring next to Figures 7A to 7H, a second subset of AC / DC power tools having a brushed motor 122 includes variable-speed AC / DC power tools 124 having a universal motor (also referred to here as variable-speed universal motor tools 124). These include corded / cordless (AC / DC) power tools that operate at a variable speed under no-load conditions, and include brushed universal motors 124-2 configured to operate at high rated voltages (e.g., 100V to 120V, and more broadly, 90V to 132V) and high powers (e.g., 1500 to 2500 watts). As described above, a universal motor is a series-wound motor having a stator field coil and a commutator connected in series with the field coil. A universal motor in this configuration can operate with both DC and AC power supplies. In one embodiment, the variable-speed universal motor tool 124 may include high-power tools with variable-speed control, such as concrete drills, hammers, grinders, and saws.

[0310] In one embodiment, the variable-speed universal motor tool 124 is provided with a variable-speed actuator (not shown), such as a trigger switch, a contact-sensing switch, a capacitive switch, a gyroscope, or other variable-speed input mechanism (not shown) that can be engaged by the user. In one embodiment, the variable-speed actuator is coupled to or includes a potentiometer or other circuit for generating a variable-speed signal (e.g., a variable voltage signal, a variable current signal, etc.) indicating the desired speed of the motor 124-2. In one embodiment, the variable-speed universal motor tool 124 may also be provided with an on / off trigger or actuator (not shown) that allows the user to start the motor 124-2. Alternatively, the on / off trigger function may be integrated into the variable-speed actuator such that the initial activation of the variable-speed trigger by the user functions to start the motor 124-2 (i.e., there is no separate on / off actuator).

[0311] In one embodiment, the variable-speed universal motor tool 124 includes a motor control circuit 124-4 that operates the universal motor 124-2 at a variable speed under no-load or constant-load conditions. The power tool 124 further includes a power interface 124-5 configured to receive power from one or more of the DC and / or AC power sources described above. The power interface 124-5 is electrically coupled to the motor control circuit 124-4 by DC power lines DC+ and DC- (for supplying power from the DC power source) and by AC power lines ACH and ACL (for supplying power from the AC power source).

[0312] In one embodiment, the motor control circuit 124-4 may include a power unit 124-6. In one embodiment, the power unit 124-6 may include a DC switch circuit 124-14 positioned between the DC power line DC+ / DC- and the motor 124-2, and an AC switch 124-16 positioned between the AC power line ACH / ACL and the motor 124-2. In one embodiment, the DC switch circuit 124-14 may include a combination of one or more power semiconductor devices (e.g., diodes, FETs, BJTs, IGBTs, etc.) configured to provide power from the DC power line DC+ / DC- to the motor 124-2 in a switchable manner. In one embodiment, the AC switch 124-16 may include a phase-controlled AC switch (e.g., triacs, SCRs, thyristors, etc.) configured to provide power from the AC power line ACH / ACL to the motor 124-2 in a switchable manner.

[0313] In one embodiment, the motor control circuit 124-4 may further include a control unit 124-8. The control unit 124-8 may be configured to control the switching operation of the DC switch circuit 124-14 and the AC switch 124-16. In one embodiment, the control unit 124-8 may include a microcontroller or similar programmable module configured to control the gates of the power switches. In one embodiment, to control the speed of the motor 124-2 based on speed signals from a variable speed actuator when power is supplied from one or more battery packs via DC power lines DC+ / DC-, the control unit 124-8 is configured to control the PWM duty cycle of one or more semiconductor switches in the DC switch circuit 124-14. Similarly, the control unit 124-8 is configured to control the firing angle (or conduction angle) of the AC switch 124-16 to control the speed of the motor 124-2 based on speed signals from a variable speed actuator when power is supplied from an AC power source via AC power lines ACH / ACL.

[0314] In one embodiment, the control unit 124-8 may be coupled to one or more battery packs via a communication signal line COMM provided from the power interface 124-5. The COMM signal line may provide the control unit 124-8 with control or informational signals relating to the operation or state of one or more battery packs. In one embodiment, the control unit 124-8 may be configured to interrupt power from the DC output line of the power interface 124-5 using a DC switch circuit 124-14 when a battery failure (e.g., battery overtemperature, battery overcurrent, battery overvoltage, battery undervoltage, etc.) is detected. The control unit 124-8 may further be configured to interrupt power from the AC or DC output line of the power interface 124-5 using the DC switch circuit 124-14 and / or AC switch 124-16 when a tool failure condition (e.g., tool overtemperature, tool overcurrent, etc.) is detected.

[0315] In one embodiment, the power unit 124-6 may further be provided with an electromechanical on / off switch 124-12 coupled to the on / off trigger or actuator described above. The on / off switch simply connects or disconnects the supply of power from the power interface 124-5 to the motor 124-2. Alternatively, the control unit 124-8 may be configured to disable the DC switch circuit 124-14 and the AC switch 124-16 until it detects user operation of the on / off trigger or actuator (or, if the on / off trigger function is built into the variable speed actuator, the initial operation of the variable speed actuator). The control unit 124-8 may then activate the motor 124-2 via the DC switch circuit 124-14 or the AC switch 124-16. In this way, the power unit 124-6 may be operable without the electromechanical on / off switch 124-12.

[0316] Referring to Figure 7A, a variable-speed universal motor tool 124 is shown according to one embodiment, in which the ACH and DC+ power lines are coupled together at a common positive node 124-11a, and the ACL and DC- power lines are coupled together at a common negative node 124-11b. In this embodiment, an on / off switch 124-12 is located between the positive common node 124-11a and the motor 124-2. To ensure that only one of the AC or DC power sources is available at any given time, in one embodiment, the control unit 124-8 may be configured to activate only one of the DC switch circuit 124-14 and the AC switch 124-16 at any given time.

[0317] In a further embodiment, a mechanical lockout device may be used as a redundancy measure and to minimize electrical leakage. In an exemplary embodiment, the mechanical lockout device may physically block access to the AC or DC power supply at any given time.

[0318] Figure 7B shows a variable-speed universal motor tool 124 according to an alternative embodiment, in which the DC power line DC+ / DC- and AC power line ACH / ACL are isolated via a power switching unit 124-15 to ensure that power cannot be supplied simultaneously from both AC and DC power sources (even when the power interface 124-5 is coupled to both AC and DC power sources). The switching unit 124-15 may be configured to include a relay, a single-pole double-throw switch, a double-pole double-throw switch, or a combination thereof, as illustrated and described with reference to Figures 6B to 6D. In Figure 7B, the power switching unit 124-15 is shown between one power interface 124-5 and the other DC switch circuit 124-14 and AC switch 124-16. However, it should be understood that the power switching unit 124-15 may alternatively be provided between the one DC switch circuit 124-14 and AC switch 124-16 and the other motor 124-2, depending on the switching configuration used within the power switching unit 124-15.

[0319] As described above, the DC switch circuit 124-14 may include a combination of one or more semiconductor devices. Figures 7C to 7E show various configurations and embodiments of the DC switch circuit 124-14. In one embodiment shown in Figure 7C, a combination of FETs and diodes is used in what is known as a chopper circuit, and a control unit 124-8 drives the gates of the FETs (via a gate driver not shown) to control the PWM duty cycle of the motor 124-2. In another embodiment shown in Figure 7D, a combination of two FETs is used in series (i.e., a half-bridge). In this case, the control unit 124-8 can drive the gates of one or both FETs (i.e., single-switch PWM control or PWM control with synchronous rectification). In yet another embodiment shown in Figure 7E, a combination of four FETs is used as an H-bridge (full-bridge). The control unit 124-8 may, in this case, drive the gates of two or four FETs to a 0% to 100% PWM duty cycle associated with a desired motor speed from zero to maximum speed (i.e., with or without synchronous rectification). Note that any type of controllable semiconductor device, such as BJTs or IGBTs, may be used instead of the FETs shown in these figures. For a detailed description of these circuits and associated PWM control mechanisms, see U.S. Patent No. 8,446,120, entitled "Electronic Switch Module for a Power Tool." The contents of this patent document are entirely incorporated herein by reference.

[0320] Referring again to Figures 7A and 7B, the AC switch 124-16 may include a phase-controlled AC power switch such as a triac, SCR, or thyristor, configured in series on the AC power line ACH and / or AC power line ACL. In one embodiment, the control unit 124-8 controls the motor speed by switching the motor current on and off at periodic intervals with respect to the zero crossing of the AC current or voltage waveform. The control unit 124-8 may fire the AC switch 124-16 at conduction angles of 0 to 180 degrees within each AC half-cycle related to a desired motor speed from zero to maximum speed. For example, if the desired motor speed is 50% of the maximum speed, the control unit 124-8 may fire the AC switch 124-16 at 90 degrees, which is the midpoint of the half-cycle. Preferably, such periodic intervals are generated to occur in synchronization with the original AC waveform. The conduction angle determines the point in the AC waveform where AC switch 124-16 is fired, i.e., turned on, thereby supplying electrical energy to motor 124-2. AC switch 124-16 is turned off at the end of the selected period, i.e., at the zero crossing of the AC waveform. Thus, the conduction angle is measured from the point of firing of AC switch 124-16 to the zero crossing. For a detailed description of the phase control of a triac or other phase-controlled AC switch in a power tool, see U.S. Patent No. 8,657,031, entitled "Universal Control Module", U.S. Patent No. 7,834,566, entitled "Generic Motor Control", and U.S. Patent No. 5,986,417, entitled "Sensorless Universal Motor Speed ​​Controller". Each of these patents is incorporated herein by reference.

[0321] As described above, the control unit 124-8 controls the switching operation of both the DC switch circuit 124-14 and the AC switch 124-16. When the tool 124 is connected to an AC power supply, the control unit 124-8 may detect the current through the AC power line ACH / ACL and set its operating mode in order to control the AC switch 124-16. In one embodiment, when the tool 124 is connected to a DC power supply, the control unit 124-8 may detect the absence of a zero crossing on the AC power line ACH / ACL and change its operating mode in order to control the DC switch circuit 124-14. Note that the control unit 124-8 may set its operating mode by various methods, such as detecting a signal from the COMM signal line or detecting voltages on the DC power line DC+ / DC-.

[0322] 1. Integrated power switch / diode bridge Next, referring to Figures 7F to 7H, a variable-speed universal motor tool 124 is shown according to an alternative embodiment in which the AC and DC power lines of the power interface 124-5 are coupled to an integrated AC / DC power switching circuit 124-18.

[0323] As shown in Figures 7G and 7H, the integrated AC / DC power switching circuit 124-18 includes a semiconductor switch Q1 incorporated within a diode bridge composed of diodes D1-D4. The semiconductor switch Q1 may be a field-effect transistor (FET), as shown in Figure 7H, or an insulated-gate bipolar transistor (IGBT), as shown in Figure 7G. The semiconductor switch Q1 is located at one end between D1 and D3, and at the other end between D2 and D4. The line inputs DC+ and ACH are coupled together at the node of the diode bridge between D1 and D4. The positive motor terminal M+ is coupled at the node of the diode bridge between D2 and D3.

[0324] When the tool 124 is connected to a DC power supply, in one embodiment, the control unit 124-8 sets its operating mode to DC mode, as described above. In this mode, the control unit 124-8 controls the motor speed by providing pulse voltages through the PWM technique, i.e., by turning the switch Q1 on and off. The PWM duty cycle, or the ratio of on and off periods in the PWM signal, is selected according to the desired motor speed.

[0325] In one embodiment, when the tool 124 is connected to an AC power supply, the control unit 124-8 sets its operating mode to AC, as described above. In this mode, the control unit 124-8 controls the semiconductor switch Q1 in a manner similar to the switching operation of a phase-controlled switch such as a triac. Specifically, the switch Q1 is turned on by the control unit 124-8 to correspond to the point in the AC half-cycle when the triac is properly lit. The control unit 124-8 continuously maintains the switch Q1 in the ON state until it reaches the zero crossing point, which indicates the end of the AC half-cycle. At that point, the control unit 124-8 turns off the switch Q1 to correspond to the point of the current zero crossing. In this way, the control unit 124-8 controls the motor speed by operating the switch Q1 within each half-cycle in order to control the conduction angle of each AC half-cycle according to the desired motor speed.

[0326] When power is supplied via the DC power line DC+ / DC-, current flows through D1-Q1-D2 into the motor 124-2. As described above, the control unit 124-8 controls the motor speed by controlling the PWM duty cycle of switch Q1. When power is supplied via the AC power line ACH / ACL, current flows through D1-Q1-D2 for all positive half-cycles and through D3-Q1-D4 for all negative half-cycles. Therefore, the diode bridge D1-D4 functions to rectify the AC power passing through switch Q1, but does not rectify the AC power passing through the motor terminals M+ / M-. As described above, the control unit 124-8 controls the motor speed by controlling the conduction band for each half-cycle via switch Q1.

[0327] In one embodiment, it should be noted that the control unit 124-8 can perform PWM control on switch Q1 in both AC and DC operating modes. Specifically, instead of controlling the conducted band of the AC line within each half-cycle, the control unit 124-8 may select a PWM duty cycle by using the PWM technique described above to control the motor speed.

[0328] Depending on the size and characteristics of motor 124-2, motor 124-2 may have an induced current that is slightly delayed with respect to the AC line current. In AC operating mode, this current is allowed to decay to zero at the end of each AC half-cycle, i.e., after all voltage zero crossovers. However, in DC operating mode, it is desirable to provide a current path for the induced current of motor 124-2. Accordingly, according to one embodiment, a freewheel switch Q2 and a freewheel diode D5 are further provided in parallel with motor 124-2 to provide a path for the induced current flowing through motor 124-2 when Q1 is turned off. In one embodiment, in AC operating mode, control unit 124-8 is configured to keep Q2 always in the off state. However, in DC operating mode, control unit 124-8 is configured to keep the freewheel switch Q2 in the on state.

[0329] In a further embodiment, the control unit 124-8 is configured to activate Q2 when switch Q1 is stopped, and to activate Q1 when switch Q2 is stopped. In other words, when Q1 is pulse-width modulated, the on and off periods of switch Q1 coincide synchronously with the off and on periods of switch Q2. This ensures that the freewheeling current path of Q2 / D5 does not short-circuit the motor 124-8 in any Q1 on-cycle.

[0330] With this configuration, the speed of the motor 124-2 can be controlled regardless of whether the power tool 124 is connected to an AC power source or a DC power source.

[0331] 2. Variable speed universal motor tool with a power supply having an equivalent voltage rating. In Figures 7A, 7B, and 7F above, the power tool 124 is designed to operate in a high rated voltage range, for example, 100V to 120V (corresponding to the AC power voltage range of 100V to 120VAC), or more broadly, 90V to 132V (corresponding to ±10% of the AC power voltage range of 100V to 120VAC), and at high power (e.g., 1500 to 2500 watts). The motor 124-2 has an operating voltage or operating voltage range that may be equivalent to, included in, or corresponding to the operating voltage or operating voltage range of the tool 124.

[0332] In one embodiment, the power interface 124-5 is configured to provide an AC voltage having a nominal voltage significantly different from the nominal voltage provided by the DC power supply. For example, the AC power line of the power interface 124-5 may provide a nominal voltage in the range of 100 to 120V, and the DC power line may provide a nominal voltage in the range of 60 to 100V (e.g., 72VDC or 90VDC). In another example, the AC power line may provide a nominal voltage in the range of 220 to 240V (e.g., 230V in many European countries or 220V in many African countries), and the DC power line may provide a nominal voltage in the range of 100 to 120V (e.g., 108VDC).

[0333] 3. Variable speed universal motor tool with power supply having different voltage ratings According to one alternative embodiment of the present invention, the voltage provided by the AC power supply has a nominal voltage that is significantly different from the nominal voltage provided by the DC power supply. For example, the AC power line of the power interface 124-5 may provide a nominal voltage in the range of 100 to 120V, and the DC power line may provide a nominal voltage in the range of 60 to 100V (e.g., 72VDC or 90VDC). In another example, the AC power line may provide a nominal voltage in the range of 220 to 240V (e.g., 230V in many European countries or 220V in many African countries), and the DC power line may provide a nominal voltage in the range of 100 to 120V (e.g., 108VDC).

[0334] The operation of the power tool motor 124-2 at significantly different voltage levels can result in large differences in the performance of the power tool, particularly in the rotational speed of the motor, which can be noticeable and, in some cases, unsatisfactory for the user. Furthermore, supplying voltage levels outside the operating voltage range of the motor 124-2 can damage the motor and associated switching components. Therefore, in one embodiment of the present invention described herein, the motor control circuit 124-4 is configured to optimize the power supply to the motor 124-2 (and thus the motor performance) in accordance with the nominal voltage of the AC or DC power line, so that the motor 124-2 provides substantially uniform speed and power performance in a manner satisfactory to the end user, regardless of the nominal voltage provided on the AC or DC power line.

[0335] In this embodiment, the motor 124-2 may be designed and configured to operate in a voltage range encompassing the nominal voltage of the DC power line. In an exemplary embodiment, the motor 124-2 may be designed to operate in a voltage range that encompasses the nominal voltage of the DC power line of the power interface 124-5 (e.g., 72VDC or 90VDC) but is below the nominal voltage of the AC power line (e.g., 220V to 240V), for example, 60V to 90V (or more broadly, ±10% of this, 54V to 99V). In another exemplary embodiment, the motor 124-2 may be designed to operate in a voltage range that encompasses the nominal voltage of the DC power line of the power interface 124-5 (e.g., 108VDC) but is below the nominal voltage range of the AC power line (220V to 240V), for example, 100V to 120V (or more broadly, ±10% of this, 90V to 132V).

[0336] In one embodiment, so that the motor 124-2 operates at a higher AC power line nominal voltage, the control unit 124-8 may be configured to set a fixed maximum conduction band for a phase-controlled AC switch 124-16 corresponding to the operating voltage of the tool 124. Specifically, the control unit 124-8 may be configured to set a fixed firing angle corresponding to the maximum speed of the tool (e.g., at 100% trigger displacement), thereby resulting in a conduction band of less than 180 degrees within each AC half-cycle at the maximum no-load speed. This allows the control unit 124-8 to optimize the power supply to the motor by effectively reducing the total voltage supplied to the motor 124-2 from the AC power source.

[0337] For example, in the case of motor 124-2 which has an operating voltage range of 60-100V but receives AC power with a nominal voltage of 100-120V, the conduction band of AC switch 124-16 may be set to a maximum value of approximately 120 degrees. In other words, the firing angle of AC switch 124-16 may be varied from 60 degrees at the desired maximum speed (corresponding to a conduction angle of 120 degrees) to 180 degrees at no speed (corresponding to a conduction angle of 0 degrees). By setting the maximum firing angle to approximately 60 degrees, the AC voltage supplied to the motor at the desired maximum speed will be in the range of approximately 70-90V, which corresponds to the operating voltage of tool 124.

[0338] In this way, the motor control circuit 124-4 optimizes the power supply to the motor 124-2 in accordance with the nominal voltage of the AC or DC power line, so that the motor 124-2 provides substantially uniform speed and power performance in a manner satisfactory to the end user, regardless of the nominal voltage provided on the AC or DC power line.

[0339] C. Constant-speed AC / DC power tools with brushed PMDC motors Referring next to Figures 8A and 8B, a third subset of AC / DC power tools having brushed motors 122 includes constant-speed AC / DC power tools 125 (hereinafter referred to as constant-speed PMDC tools 125) having permanent magnet DC (PMDC) brushed motors, which tend to have better efficiency than universal motors. These include corded / cordless (AC / DC) power tools that operate at a constant speed under no-load (or constant-load) conditions and include PMDC brushed motors 125-2 configured to operate at high rated voltages (e.g., 100V to 120V) and high powers (e.g., 1500 to 2500 watts). A PMDC brushed motor generally includes a wound rotor coupled to a commutator and a stator having permanent magnets fixed inside. As its name suggests, a PMDC motor operates solely on DC power. The reason for this is that the permanent magnets on the stator do not change polarity, and as the AC power changes from a positive half-cycle to a negative half-cycle, the change in polarity within the brushes causes the motor to stop. For this reason, in one embodiment, as shown in Figures 8A and 8B, power from the AC power source is passed through a rectifier circuit 125-20 to convert or remove the negative half-cycle of the AC power. In one embodiment, the rectifier circuit 125-20 may be a full-wave rectifier configured to rectify the AC voltage waveform by converting the negative half-cycle of the AC power to a positive half-cycle. Alternatively, in one embodiment, the rectifier circuit 125-20 may be a half-wave rectifier circuit to remove the half-cycle of the AC power. In one embodiment, the rectifier circuit 125-20 may further be provided with a link capacitor or a smoothing capacitor (not shown). In one embodiment, the constant-speed PMDC motor tool 125 may include high-power tools for high-power applications such as concrete hammers, miter saws, table saws, vacuum cleaners, blowers, and lawnmowers.

[0340] Many aspects of the constant-speed PMDC motor tool 125 are similar to those of the constant-speed universal motor tool 123 described above with reference to Figures 6A to 6E. In one embodiment, the constant-speed PMDC motor tool 125 includes a motor control circuit 125-4 that operates the PMDC motor 125-2 at a constant speed under no-load conditions. The power tool 125 further includes a power interface 125-5 configured to receive power from one or more of the DC and / or AC power sources described above. The power interface 125-5 is electrically coupled to the motor control circuit 125-4 by DC power lines DC+ and DC- (for supplying power from the DC power source) and by AC power lines ACH and ACL (for supplying power from the AC power source).

[0341] In one embodiment, the motor control circuit 125-4 includes a power unit 125-6. The power unit 125-6 is provided in series with the motor 125-2 and may include an electromechanical on / off switch 125-12 coupled to an on / off trigger or actuator (not shown). Additionally, and / or alternatively, the power unit 125 may include a power switch 125-13 coupled to DC power lines DC+ / DC- and a control unit 125-8. In one embodiment, the control unit 125-8 may be provided to monitor the state of the power tool 125 and / or the battery. In one embodiment, the control unit 125-8 may be coupled to an element of the tool 125, such as a thermistor inside the tool. Also in one embodiment, the control unit 125-8 may be coupled to one or more battery packs via a communication signal line COMM provided from the power interface 125-5. The COMM signal line may provide control or informational signals to the control unit 125-8 relating to the operation or state of one or more battery packs. In one embodiment, the control unit 125-8 may be configured to use the power switch 125-13 to interrupt power from the DC+ output line of the power interface 125-5 when a tool failure condition (e.g., tool overtemperature, tool overcurrent, etc.) or a battery failure condition (e.g., battery overtemperature, battery overcurrent, battery overvoltage, battery undervoltage, etc.) is detected. In one embodiment, the power switch 125-13 may include an FET or other controllable switch controlled by the control unit 125-8. Note that in one alternative embodiment, the power switch 125-13 may be provided between both the AC power line ACH / ACL and the DC power line DC+ / DC- on one side and the motor 125-2 on the other side, so that the control unit 125-8 may allow the interruption of power from the AC or DC power supply in the event of a tool failure condition.In another embodiment, the constant-speed PMCM motor tool 125 may be provided without an on / off switch 125-12, and the control unit 125-8 may be configured to initiate activation of the power switch 125-13 when an on / off trigger or actuator is activated by the user. In other words, the power switch 125-13 may be used for on / off and fault condition control. Note that in this embodiment, the power switch 125-13 is not used to control variable speed control (e.g., PWM control) of the motor 125-2.

[0342] Referring to Figure 8A, a constant-speed PMDC motor tool 125 is shown according to one embodiment, in which the DC+ power line and the V+ output of the rectifier circuit 125-20 (carrying the rectified ACH power line) are coupled together at a common positive node 125-11a, and the DC- power line and the Gnd output from the rectifier circuit 125-20 (corresponding to the ACL power line) are coupled together at a common negative node 125-11b. In this embodiment, an on / off switch 125-12 is located between the positive common node 125-11a and the motor 125-2. In one embodiment, a mechanical lockout device may be used to ensure that only one of the AC or DC power sources is available at any given time. In an exemplary embodiment, the mechanical lockout device may physically block access to one of the AC or DC power sources at any given time.

[0343] In Figure 8B, a constant-speed PMDC motor tool 125 is shown according to one alternative embodiment, in which the DC power line DC+ / DC- and the AC power line ACH / ACL are isolated via a power switching unit 125-15 to ensure that power cannot be supplied simultaneously from both the AC and DC power sources (even when the power interface 125-5 is coupled to both AC and DC power sources). The power switching unit 125-15 may be configured similarly to any of the configurations of the power switching units 123-15 in Figures 6B to 6D. Note that in one alternative embodiment, the power switching unit 125-15 may be located between the AC power line ACH / ACL and the rectifier circuit 125-20. In yet another embodiment, the power switching unit 125-15 may be located between the power switch 125-13 and the on / off switch 125-12.

[0344] While the tool 125 in Figures 8A and 8B is provided with a control unit 125-8 and a power switch 125-13 to interrupt the power supply in the event of a tool or battery failure, it should be understood that the tool 125 may be provided without the control unit 125-8 and the power switch 125-13. For example, one or more batteries may be provided with their own controller to monitor their failure status and manage their operation.

[0345] 1. Constant-speed PMDC tool with a power supply having equivalent voltage rating In Figures 8A and 8B above, the power tool 125 is designed to operate in high rated voltage ranges such as 100V to 120V (corresponding to the AC power voltage range of 100V to 120VAC), and more broadly, 90V to 132V (corresponding to ±10% of the AC power voltage range of 100V to 120VAC), and at high power (e.g., 1500 to 2500 watts). The motor 125-2 has an operating voltage or operating voltage range that may be equivalent to, included in, or corresponding to the operating voltage or operating voltage range of the tool 125.

[0346] In one embodiment, the power interface 125-5 is configured to provide an AC power line with a nominal voltage in the range of 100-120V from an AC power source (e.g., 120VAC at 50-60Hz in the United States, or 100VAC in Japan), or a DC power line with a nominal voltage in the range of 100-120V from a DC power source (e.g., 108VDC). In other words, the DC and AC nominal voltages provided through the power interface 125-5 both correspond to (e.g., matched, overlapping, or included in) the operating voltage range of the power tool 125 (i.e., high-rated voltage 100V-120V, or more broadly, about 90V-132V). Note that the 120VAC nominal voltage corresponds to an average voltage of about 108V measured in the positive half-cycle of an AC sinusoidal waveform, which provides speed performance equivalent to 108VDC power.

[0347] 2. Constant-speed PMDC tools with power supplies having different voltage ranges. According to another embodiment of the present invention, the voltage provided by the AC power supply has a nominal voltage that is significantly different from the nominal voltage provided by the DC power supply. For example, the AC power line of the power interface 125-5 may provide a nominal voltage in the range of 100 to 120V, and the DC power line may provide a nominal voltage in the range of 60 to 100V (e.g., 72VDC or 90VDC). In another example, the AC power line may provide a nominal voltage in the range of 220 to 240V, and the DC power line may provide a nominal voltage in the range of 100 to 120V (e.g., 108VDC).

[0348] The operation of the power tool motor 125-2 at significantly different voltage levels can result in large differences in the performance of the power tool, particularly in the rotational speed of the motor, which can be noticeable and, in some cases, unsatisfactory for the user. Furthermore, supplying voltage levels outside the operating voltage range of the motor 125-2 can damage the motor and associated switching components. Therefore, in one embodiment of the present invention described herein, the motor control circuit 125-4 is configured to optimize the power supply to the motor 125-2 (and thus the motor performance) in accordance with the nominal voltage of the AC or DC power line, so that the motor 125-2 provides substantially uniform speed and power performance in a manner satisfactory to the end user, regardless of the nominal voltage provided on the AC or DC power line.

[0349] In this embodiment, the power tool motor 125-2 may be designed and configured to operate in a voltage range encompassing the nominal voltage of the DC power line. In an exemplary embodiment, the motor 125-2 may be designed to operate in a voltage range that encompasses the nominal voltage of the DC power line of the power interface 125-5 (e.g., 72VDC or 90VDC) but is below the nominal voltage of the AC power line (e.g., 220V to 240V), for example, 60V to 90V (or more broadly, ±10% of this, 54V to 99V). In another exemplary embodiment, the motor 125-2 may be designed to operate in a voltage range that encompasses the nominal voltage of the DC power line of the power interface 125-5 (e.g., 108VDC) but is below the nominal voltage of the AC power line (e.g., 220V to 240V), for example, 100V to 120V (or more broadly, ±10% of this, 90V to 132V).

[0350] In one embodiment, the motor control circuit 125-4 may be designed to optimize the power supply to the motor 125-2 in accordance with the various embodiments described herein, so that the motor 125-2 operates at a higher nominal voltage of the AC power line.

[0351] In one embodiment, the rectifier circuit 125-20 may be provided as a half-wave diode bridge rectifier. As those skilled in the art will recognize, the half-wave rectified waveform will have about half the average nominal voltage of the input AC waveform. Therefore, in a scenario where the nominal voltage of the AC power line is in the range of 220-240V and the motor 125-2 is designed to operate in the voltage range of 100V-120V, the rectifier circuit 125-20 may be configured as a half-wave rectifier to provide the motor 125-2 with an average nominal AC voltage of 110V-120V, which is within the operating voltage range of the power tool 125.

[0352] In another embodiment, as shown in Figure 8C, the V+ output of the rectifier circuit 125-20 may be provided as an input to the power switch 125-13, and the control unit 125-8 may be configured to pulse-width modulate (PWM) the V+ signal in a fixed duty cycle corresponding to the operating voltage of the tool 125. For example, in the case of a tool 125 having an operating voltage range of 60-100V but receiving AC power with a nominal voltage of 100-120V, when the control unit 125-8 detects an AC current on the AC power line of the power interface 125-5, the control unit 125-8 controls the PWM switching operation of the power switch 125-13 in a fixed duty cycle in the range of 60%-80% (e.g., 70%). As a result, when operating with an AC power supply, a voltage level of approximately 70-90V corresponding to the operating voltage of the tool 125 is supplied to the motor 125-2.

[0353] In yet another embodiment, as shown in Figure 8D, the tool 125 may further be provided with a phase-controlled AC switch 125-16. In one embodiment, the AC switch 125-16 is positioned in series with the V+ output of the rectifier circuit 125-20. In one embodiment, the AC switch 125-16 may include a triac or SRC switch controlled by a control unit 125-8. In one embodiment, the control unit 125-8 may be configured to set a fixed conduction band (or firing angle) of the AC switch 125-16 corresponding to the operating voltage of the tool 125. For example, in the case of a motor 125-2 having an operating voltage range of 60V to 100V but receiving AC power with a nominal voltage of 100V to 120V, the conduction band of the AC switch 125-16 may be fixed at approximately 120 degrees. In other words, the firing angle of the AC switch 125-16 may be set to 60 degrees. By setting the firing angle to approximately 60 degrees, the AC voltage supplied to motor 125-2 will be within the range of 70-90V, which corresponds to the operating voltage of motor 125-2. In another example, for motor 125-2 which has an operating voltage range of 100-120V but receives AC power with a nominal voltage of 220-240V, the conduction band of AC switch 125-16 may be fixed at approximately 90 degrees. In other words, the firing angle of AC switch 125-16 may be set to 90 degrees. By setting the firing angle to 90 degrees, the AC voltage supplied to motor 125-2 will be within the range of 100-120V, which corresponds to the operating voltage of motor 125-2. In this way, control unit 125-8 optimizes the power supply to motor 125-2.

[0354] In this way, the motor control circuit 125-4 optimizes the power supply to the motor 125-2 in accordance with the nominal voltage of the AC or DC power line, so that the motor 125-2 provides substantially uniform speed and power performance in a manner satisfactory to the end user, regardless of the nominal voltage provided on the AC or DC power line.

[0355] D. Variable speed AC / DC power tools with brushed DC motors Referring next to Figures 9A and 9B, a fourth subset of AC / DC power tools having a brushed motor 122 includes variable-speed AC / DC power tools 126 having a PMDC motor (also referred to herein as variable-speed PMDC motor tools 126). These include corded / cordless (AC / DC) power tools that operate at variable speeds under no-load conditions and include brushed permanent magnet DC (PMDC) motors 126-2 configured to operate at high rated voltages (e.g., 100-120V) and high powers (e.g., 1500-2500 watts). As described above, a PMDC brushed motor generally includes a wound rotor coupled to a commutator and a stator having permanent magnets fixed inside. As its name suggests, a PMDC motor operates solely on DC power. The reason is that the permanent magnets on the stator do not change polarity, and the change in polarity within the brushes as the AC power changes from a positive half-cycle to a negative half-cycle causes the motor to stop. For this reason, in one embodiment, as shown in Figures 9A and 9B, the power from the AC power source is passed through a rectifier circuit 126-20 to convert or remove the negative half-cycle of the AC power. In one embodiment, the rectifier circuit 126-20 may be a full-wave rectifier to convert the negative half-cycle of the AC power to a positive half-cycle. Alternatively, in one embodiment, the rectifier circuit 126-20 may be a half-wave rectifier circuit to remove the half-cycle of the AC power. In one embodiment, the variable-speed PMDC motor tool 126 may include high-power tools with variable-speed control, such as concrete drills, hammers, grinders, and saws.

[0356] Many aspects of the variable-speed PMDC motor tool 126 are similar to those of the variable-speed universal motor tool 124 described above with reference to Figures 7A to 7E. In one embodiment, the variable-speed PMDC motor tool 126 is provided with a variable-speed actuator (not shown, e.g., a trigger switch, a contact-sensing switch, a capacitive switch, a gyroscope, or other variable-speed input mechanism) that can be engaged by the user. In one embodiment, the variable-speed actuator is coupled to or includes a potentiometer or other circuit for generating a variable-speed signal (e.g., a variable voltage signal, a variable current signal, etc.) indicating the desired speed of the motor 126-2. In one embodiment, the variable-speed PMDC motor tool 126 may further be provided with an on / off trigger or actuator (not shown) that allows the user to start the motor 126-2. Alternatively, the on / off trigger function may be integrated into the variable-speed actuator so that the initial activation of the variable-speed trigger by the user functions to start the motor 126-2 (i.e., there is no separate on / off actuator).

[0357] In one embodiment, the variable-speed PMDC motor tool 126 includes a motor control circuit 126-4 that operates the PMDC motor 126-2 at a variable speed under no-load or constant-load conditions. The power tool 126 further includes a power interface 126-5 configured to receive power from one or more of the DC power supply and / or AC power sources described above. The power interface 126-5 is electrically coupled to the motor control circuit 126-4 by DC power lines DC+ and DC- (for supplying power from the DC power supply) and by AC power lines ACH and ACL (for supplying power from the AC power supply). The AC power lines ACH and ACL are input to a rectifier circuit 126-20.

[0358] Since the AC line passes through the rectifier circuit 126-20, it no longer contains a negative component and therefore, in one embodiment, does not operate with the phase-controlled switch for variable speed control. Accordingly, in one embodiment, instead of the separate DC and AC switch circuits shown in Figures 7A and 7B, the motor control circuit 126-4 is provided with a PWM switching circuit 126-14. The PWM switching circuit may include a combination of one or more power semiconductor devices (e.g., diodes, FETs, BJTs, IGBTs, etc.) configured as a chopper circuit, half-bridge, or H-bridge, for example, as shown in Figures 7C to 7E.

[0359] In one embodiment, the motor control circuit 126-4 further includes a control unit 126-8. The control unit 126-8 may be configured to control the switching operation of the PWM switching circuit 126-14. In one embodiment, the control unit 126-8 may include a microcontroller or similar programmable module configured to control the gates of the power switches. In one embodiment, the control unit 126-8 is configured to control the PWM duty cycle of one or more semiconductor switches in the PWM switching circuit 126-14 to control the speed of the motor 126-2. In addition, the control unit 126-8 may be configured to monitor and manage the operation of the power tool or battery pack coupled to the power interface 126-5, and to interrupt power to the motor 126-2 in the event of a fault condition of the tool or battery (such as battery overtemperature, tool overtemperature, battery overcurrent, tool overcurrent, battery overvoltage, or battery undervoltage). In one embodiment, the control unit 126-8 may be coupled to one or more battery packs via a communication signal line COMM provided from the power interface 126-5. The COMM signal line may provide the control unit 126-6 with control or informational signals relating to the operation or state of one or more battery packs. In one embodiment, the control unit 126-6 may be configured to interrupt power from the DC output line of the power interface 126-5 if the COMM line indicates a battery fault or failure condition.

[0360] Similar to the variable-speed universal motor tool 124 described above with reference to Figures 7A to 7E, the variable-speed PMDC motor tool 126 may further be provided with an electromechanical on / off switch 126-12 coupled to the on / off trigger or actuator described above. The on / off switch 126-12 simply connects or disconnects the supply of power from the power source to the motor 126-2. Alternatively, the tool 126 may be provided without the on / off switch 126-12. In this case, the control unit 126-8 may be configured to disable the PWM switching circuit 126-14 until it detects user activation of the on / off trigger or actuator (or, if the on / off trigger function is built into the variable-speed actuator, the initial activation of the variable-speed actuator). The control circuit 126-8 may then activate the motor 126-2 by activating one or more switches in the PWM switching circuit 126-14.

[0361] Referring to Figure 9A, tool 126 is shown according to one embodiment, in which the ACH and DC+ power lines are coupled together at a common positive node 126-11a, and the ACL and DC- power lines are coupled together at a common negative node 126-11b. In this embodiment, the on / off switch 126-12 and the PWM switching circuit 126-14 are located between the positive common node 126-11a and the motor 126-2. In one embodiment, a mechanical lockout device (its embodiment is described in further detail below) may be used to ensure that only one of the AC or DC power sources is available at any given time and to minimize leakage. In an exemplary embodiment, the mechanical lockout device can physically block access to the AC or DC power source at any given time.

[0362] In Figure 9B, a variable-speed PMDC motor tool 126 is shown according to an alternative embodiment in which the DC power lines DC+ / DC- and AC power lines ACH / ACL are isolated from each other via a power switching unit 126-15 to ensure that power cannot be supplied simultaneously from both the AC power source and one or more battery packs (even when the power interface is coupled to both AC and DC power sources). The power switching unit 126-15 may be configured as any of the configurations of the power switching units 123-15 in Figures 6B to 6D, i.e., as a relay, a single-pole double-throw switch, a double-pole double-throw switch, or a combination thereof. In Figure 9B, the power switching unit 126-15 is shown between the rectifier circuit 126-20 and the PWM switching circuit 126-14, but it should be understood that the power switching unit 126-15 may alternatively be provided directly on the AC and DC line outputs of the power interface 126-5.

[0363] 1. DC power tools with variable speed brushes that have a power supply with equivalent voltage rating. In Figures 9A and 9B above, the power tool 126 is designed to operate in a high rated voltage range of, for example, 100V to 120V (corresponding to the AC power voltage range of 100V to 120VAC), and more broadly, 90V to 132V (corresponding to ±10% of the AC power voltage range of 100V to 120VAC), and at high power (e.g., 1500 to 2500 watts). Specifically, the components of the motor 126-2 and power unit 126-6 of the power tool 126 are designed and optimized to handle a high rated voltage of 100V to 120V, preferably 90V to 132V. The motor 126-2 ...

Claims

1. It is a power tool system, A battery pack having multiple voltages, which is used with a first power tool, the first power tool having a first battery pack interface and configured to operate at a first operating voltage, and the battery pack having multiple voltages, A second power tool configured to be used with the aforementioned battery pack having multiple voltages, The power tool system includes both the battery pack having multiple voltages and the second power tool, The second power tool has a second battery pack interface and is configured to operate at a second operating voltage higher than the first operating voltage. The aforementioned second power tool and It has, The battery pack having multiple voltages, Housing and A first battery cell array arranged electrically in series and located within the housing, having a first positive voltage terminal and a first negative voltage terminal, A second battery cell array, electrically arranged in series and located within the housing, having a second positive voltage terminal and a second negative voltage terminal, Power tool interface and It has, The power tool interface and the second battery pack interface are formed and configured to be mechanically and electrically coupled to each other. When the second battery pack interface is coupled to the power tool interface, the first positive voltage terminal is electrically connected to the second negative voltage terminal, and the first and second battery cell rows are electrically connected in series with each other, thereby supplying the second operating voltage to the second power tool. The power tool interface is further configured to be coupled with the first battery pack interface, the first battery pack interface is formed and configured to mate with a second power tool interface of a single-voltage battery pack, the single-voltage battery pack is configured to supply the first operating voltage but not the second operating voltage. The power tool interface is formed and configured to be mechanically and electrically coupled to the first battery pack interface. When the first battery pack interface is coupled to the power tool interface, the first and second positive voltage terminals are electrically connected to each other, and the first and second negative voltage terminals are electrically connected to each other, thereby electrically connecting the first and second battery cell rows in a parallel configuration, and supplying the first operating voltage to the first power tool. The aforementioned power tool interface and the second power tool interface are interchangeable and can be coupled to the first battery pack interface, thereby enabling the first power tool to operate with either the battery pack having multiple voltages or the battery pack having a single voltage. Power tool system.

2. In the power tool system according to claim 1, The second power tool interface of the single-voltage battery pack is configured to be mechanically incompatible with the second battery pack interface of the second power tool. The second power tool interface of the single-voltage battery pack is configured to be electrically incompatible with the second battery pack interface of the second power tool. The power tool interface has a slot in the housing, The second battery pack interface of the second power tool has a downward-extending projection that is formed and configured to fit into a slot in the housing of the battery pack having multiple voltages when coupled with the power tool interface, The second battery pack interface has a plurality of rail sections and a plurality of groove sections, The power tool interface of the battery pack having multiple voltages is formed and configured to be selectively and mechanically coupled with (1) a plurality of rail portions and a plurality of groove portions formed in a complementary shape on the first battery pack interface, and (2) the plurality of rail portions and a plurality of groove portions on the second battery pack interface of the second power tool. The power tool interface of the battery pack having multiple voltages has a latch portion formed and configured to maintain the mechanical and electrical connection between the power tool interface and the first or second battery pack interface. The second power tool interface of the single-voltage battery pack has a plurality of rail portions and a plurality of groove portions formed and configured to connect with the plurality of rail portions and a plurality of groove portions formed in a complementary shape on the first battery pack interface, The first battery cell row has five battery cells arranged in the first row within the housing, The second battery cell row has five battery cells arranged in the second row within the housing. The second column is located above the first column, The first and second rows of battery cells are arranged in a 2x5 matrix within the housing. The first and second rows of battery cells each define longitudinal axes parallel to each other. The battery pack having multiple voltages has first and second opposing sides, Each of the battery cells in the first and second battery cell rows has a positive voltage terminal and a negative voltage terminal. The positive voltage terminals of three of the five battery cells in the first battery cell row are located on the first side surface of the battery pack having multiple voltages. The positive voltage terminals of three of the five battery cells in the second battery cell row are located on the first side surface of the battery pack having multiple voltages. The negative voltage terminals of two of the five battery cells in the first battery cell row are located on the first side surface of the battery pack having multiple voltages. The negative voltage terminals of two of the five battery cells in the second battery cell row are located on the first side surface of the battery pack having multiple voltages. The negative voltage terminals of the battery cells in the first battery cell row on the first side surface are aligned perpendicularly to the corresponding negative voltage terminals of the battery cells in the second battery cell row on the first side surface. The positive voltage terminals of the battery cells in the first battery cell row on the first side surface are aligned perpendicularly to the corresponding positive voltage terminals of the battery cells in the second battery cell row on the first side surface. The second power tool has a conductive jumper having first and second contacts that are electrically interconnected. The second battery pack interface of the second power tool includes the electrically interconnected first and second contacts of the conductive jumper, so that when the power tool interface is coupled to the second battery pack interface, the first and second contacts of the conductive jumper electrically contact the first positive voltage terminal and the second negative voltage terminal, respectively, and the first and second battery cell rows are electrically connected in series to each other via the conductive jumper of the second power tool. The first operating voltage is approximately 17 to 20 volts, and the second operating voltage is approximately 34 to 40 volts. The preceding second power tool has a power tool housing, The second battery pack interface is located on the power tool housing, The battery pack having multiple voltages has an open-circuit configuration in which the first and second battery cell rows are not electrically connected in parallel or in series with respect to each other. The power tool interface has a first row of electrical terminals formed and configured to physically and electrically contact the corresponding electrical contacts of the second power tool when mechanically and electrically coupled to the second battery pack interface. The power tool interface has a second row of electrical terminals formed and configured to physically and electrically contact the corresponding electrical contacts of the second power tool when mechanically and electrically coupled to the second battery pack interface. The first column is offset perpendicularly from the second column, Multiple electrical terminals in the first row of the aforementioned electrical terminals constitute signal terminals. Multiple electrical terminals in the second row of the aforementioned electrical terminals constitute the first and second terminals. The first terminal of the second row of electrical terminals is electrically connected to the first positive voltage terminal of the first battery cell row. The second terminal of the second row of electrical terminals is electrically connected to the second negative voltage terminal of the second row of battery cells. The first row of electrical terminals is arranged spaced apart horizontally. The second row of electrical terminals is arranged spaced apart horizontally. Power tool system.

3. The power tool system according to claim 1, wherein the second power tool interface of the single-voltage battery pack is configured to be mechanically incompatible with the second battery pack interface of the second power tool.

4. The power tool system according to claim 3, wherein the second power tool interface of the single-voltage battery pack is configured to be electrically incompatible with the second battery pack interface of the second power tool.

5. In the power tool system according to claim 4, The power tool interface has a slot in the housing, The second battery pack interface of the second power tool has a downward-extending projection that is formed and configured to fit into a slot in the housing of the battery pack having multiple voltages when coupled with the power tool interface. Power tool system.

6. The power tool system according to claim 5, wherein the first battery pack interface of the first power tool does not have any protrusions formed and configured to fit into a slot in the housing when mechanically and electrically coupled with the power tool interface.

7. The power tool system according to claim 5, wherein the second power tool interface has a physical structure that occupies a space corresponding to the position of the slot of the power tool interface.

8. In the power tool system according to claim 1, The second battery pack interface has a plurality of rail sections and a plurality of groove sections, The power tool interface of the battery pack having multiple voltages has (1) a plurality of rail portions and a plurality of groove portions formed in a complementary shape on the first battery pack interface, and (2) a plurality of rail portions and a plurality of groove portions formed and configured to be selectively and mechanically coupled with the plurality of rail portions and a plurality of groove portions on the second battery pack interface, The power tool interface of the battery pack having multiple voltages has a latch portion formed and configured to maintain mechanical and electrical connections between the power tool interface and the first or second battery pack interface. Power tool system.

9. The power tool system according to claim 8, wherein the second power tool interface of the single-voltage battery pack has a plurality of rail portions and a plurality of groove portions formed and configured to connect with the plurality of rail portions and the plurality of groove portions formed in a complementary shape on the first battery pack interface.

10. In the power tool system according to claim 1, The first battery cell row has n battery cells arranged in the first row within the housing, The aforementioned second battery cell row has n battery cells arranged in the second row within the housing, The second column is located above the first column, n is an integer greater than or equal to 3. Power tool system.

11. The power tool system according to claim 10, wherein the first battery cell array and the second battery cell array are arranged in a 2xn matrix within the housing.

12. In the power tool system according to claim 1, The first battery cell array has five battery cells, The second battery cell array has five battery cells. Power tool system.

13. In the power tool system according to claim 12, The first and second rows of battery cells each define longitudinal axes parallel to each other. The battery pack having multiple voltages has first and second opposing sides, Each of the battery cells in the first and second battery cell rows has a positive voltage terminal and a negative voltage terminal. The positive voltage terminals of three of the five battery cells in the first battery cell row are located on the first side surface of the battery pack having multiple voltages. The positive voltage terminals of three of the five battery cells in the second battery cell row are located on the first side surface of the battery pack having multiple voltages. The negative voltage terminals of two of the five battery cells in the first battery cell row are located on the first side surface of the battery pack having multiple voltages. The negative voltage terminals of two of the five battery cells in the second battery cell row are located on the first side surface of the battery pack having multiple voltages. The negative voltage terminals of the battery cells in the first battery cell row on the first side surface are aligned perpendicularly to the corresponding negative voltage terminals of the battery cells in the second battery cell row on the first side surface. The positive voltage terminals of the battery cells in the first battery cell row on the first side surface are aligned perpendicularly to the corresponding positive voltage terminals of the battery cells in the second battery cell row on the first side surface. Power tool system.

14. In the power tool system according to claim 1, The second power tool has a conductive jumper having first and second contacts that are electrically interconnected. The second battery pack interface of the second power tool includes the electrically interconnected first and second contacts of the conductive jumper, so that when the power tool interface is coupled to the second battery pack interface, the first and second contacts of the conductive jumper electrically contact the first positive voltage terminal and the second negative voltage terminal, respectively, and the first and second battery cell rows are electrically connected in series to each other via the conductive jumper of the second power tool. Power tool system.

15. The power tool system according to claim 1, wherein the first operating voltage is approximately 17 to approximately 20 volts, and the second operating voltage is approximately 34 to approximately 40 volts.

16. In the power tool system according to claim 1, The preceding second power tool has a power tool housing, A power tool system wherein the second battery pack interface is located on the power tool housing.

17. The power tool system according to claim 1, wherein the battery pack having a plurality of voltages has an open-circuit configuration in which the first and second battery cell rows are not electrically connected in parallel or in series with respect to each other.

18. The power tool system according to claim 17, wherein the power tool interface and the second battery pack interface are formed and configured such that when the power tool interface is disconnected from the second battery pack interface, the battery packs having multiple voltages are changed from a series connection configuration to an open circuit configuration.

19. The power tool system according to claim 18, wherein the power tool interface is formed and configured such that when it is disconnected from the second battery pack interface, the battery packs having multiple voltages are sequentially changed from (1) the series connection configuration to (2) the open circuit configuration and (3) the parallel connection configuration.

20. In the power tool system according to claim 1, The power tool interface has a first row of electrical terminals formed and configured to physically and electrically contact the corresponding electrical contacts of the second power tool when mechanically and electrically coupled to the second battery pack interface. The power tool interface has a second row of electrical terminals formed and configured to physically and electrically contact the corresponding electrical contacts of the second power tool when mechanically and electrically coupled to the second battery pack interface. The top of the first column is offset vertically from the top of the second column. Power tool system.

21. In the power tool system according to claim 20, Multiple electrical terminals in the first row of the aforementioned electrical terminals constitute signal terminals. Multiple electrical terminals in the second row of the aforementioned electrical terminals constitute the first and second terminals. The first terminal of the second row of electrical terminals is electrically connected to the first positive voltage terminal of the first battery cell row. The second terminal of the second row of electrical terminals is electrically connected to the second negative voltage terminal of the second row of battery cells. Power tool system.

22. In the power tool system according to claim 20, The housing has a first row of slots, Multiple electrical terminals in the first row of the electrical terminals are arranged in each slot of the first row of the slots, The housing has a second row of slots, Multiple electrical terminals in the second row of the aforementioned electrical terminals are arranged in each slot of the second row of the aforementioned slots. The upper part of the first column of the slot is offset vertically from the upper part of the second column of the slot. Power tool system.

23. In the power tool system according to claim 1, The power tool interface has a first row of electrical contacts that, when mechanically and electrically coupled with the second battery pack interface, are formed and configured to physically and electrically contact the corresponding electrical contacts of the second power tool. The power tool interface has a second row of electrical contacts formed and configured to physically and electrically contact the corresponding electrical contacts of the second power tool when mechanically and electrically coupled to the second battery pack interface. The first column is offset perpendicularly from the second column. Power tool system.

24. It is a power tool system, A battery pack with multiple voltages, A first power tool having multiple grooves, multiple rail sections, and multiple electrical terminals, A second power tool having multiple grooves, multiple rail sections, and multiple electrical terminals. It has, The battery pack having multiple voltages, A housing having a bottom wall, a pair of side walls, a pair of end walls, and a top wall, wherein a receiving portion is defined by the bottom wall, the pair of side walls, the pair of end walls, and the top wall, and the housing and An electromechanical interface coupled to the upper wall portion, A terminal block having multiple slots for accommodating multiple electrical terminals, a pair of longitudinal rail sections extending along the terminal block, wherein a pair of longitudinal grooves are defined between the rail sections and the upper wall section, and a latch section is provided. The electromechanical interface is configured to be coupled to the first power tool by the pair of longitudinal rails and the pair of longitudinal grooves sliding to the corresponding grooves and rails of the first power tool which operates at a first operating voltage, thereby allowing a plurality of electrical terminals of the first power tool to be received in the slots of the electromechanical interface and engage with the plurality of electrical terminals of the battery pack, and further allowing the latch to engage with the first power tool, thereby maintaining the coupling between the electromechanical interface and the first power tool. The electromechanical interface is configured to be coupled to the second power tool by the pair of longitudinal rails and the pair of longitudinal grooves sliding along the plurality of grooves and rails of the second power tool, which operates at a second operating voltage different from the first operating voltage. This arrangement allows the plurality of electrical terminals of the second power tool to be received into the slots of the electromechanical interface and engage with the plurality of electrical terminals of the battery pack, and further, the latch engages with the second power tool, thereby maintaining the coupling between the electromechanical interface and the second power tool. The electromechanical interface and, A plurality of battery cells arranged in the receiving portion of the housing, wherein the battery cells are configured such that (1) when the electromechanical interface is coupled to the first power tool, they are connected in parallel to each other and supply power to the plurality of electrical terminals at a first operating voltage, and (2) when the electromechanical interface is coupled to the second power tool, they are connected in series to each other and supply power to the plurality of electrical terminals at a second operating voltage. It has, The terminal block, the plurality of slots of the electromechanical interface, the plurality of electrical terminals of the battery pack, the longitudinal rail portion, the longitudinal groove portion, and the latch portion have substantially the same configuration as the terminal block, the plurality of slots of the electromechanical interface, the plurality of electrical terminals of the battery pack, the longitudinal rail portion, the longitudinal groove portion, and the latch portion of the single-voltage battery pack, and the single-voltage battery pack is operable only at the first operating voltage and is coupled to the first power tool to supply power to the first power tool at the first operating voltage. Power tool system.

25. In the power tool system according to claim 24, The electromechanical interface of the single-voltage battery pack is configured to be mechanically or electrically incompatible with the second power tool. The electromechanical interface of the battery pack having multiple voltages has a slot in the housing, The second power tool has a downward-extending projection that is formed and configured to fit into a slot in the housing of the battery pack having multiple voltages when coupled to the electromechanical interface of the battery pack having multiple voltages. Power tool system.

26. In the power tool system according to claim 24, The plurality of battery cells of the battery pack having the plurality of voltages are, A first battery cell array consisting of five battery cells arranged in series with respect to each other, A second battery cell array consisting of five battery cells arranged in series with each other It has, The first row of battery cells is arranged in the first row within the housing, The aforementioned second row of battery cells is arranged in the second row within the housing, The second column is located above the first column, The first and second rows of battery cells are arranged in a 2x5 matrix within the housing. The first and second rows of battery cells each define longitudinal axes parallel to each other. The battery pack having multiple voltages has first and second opposing sides, Each of the battery cells in the first and second battery cell rows has a positive voltage terminal and a negative voltage terminal. The positive voltage terminals of three of the five battery cells in the first battery cell row are located on the first side surface of the battery pack having multiple voltages. The positive voltage terminals of three of the five battery cells in the second battery cell row are located on the first side surface of the battery pack having multiple voltages. The negative voltage terminals of two of the five battery cells in the first battery cell row are located on the first side surface of the battery pack having multiple voltages. The negative voltage terminals of two of the five battery cells in the second battery cell row are located on the first side surface of the battery pack having multiple voltages. The negative voltage terminals of the battery cells in the first battery cell row on the first side surface are aligned perpendicularly to the corresponding negative voltage terminals of the battery cells in the second battery cell row on the first side surface. The positive voltage terminals of the battery cells in the first battery cell row on the first side surface are aligned perpendicularly to the corresponding positive voltage terminals of the battery cells in the second battery cell row on the first side surface. Power tool system.

27. In the power tool system according to claim 24, The plurality of battery cells of the battery pack having the plurality of voltages are, A first row of battery cells arranged in series with respect to each other, A second row of battery cells arranged in series with each other It has, The plurality of electrical terminals in the electromechanical interface of the battery pack having a plurality of voltages have a first electrical contact and a second electrical contact, The first electrical contact is electrically connected to the first positive voltage terminal of the first battery cell array. The second electrical contact is electrically connected to the second negative voltage terminal of the second battery cell array. The first and second electrical contacts are configured to be electrically connected to each other via a conductive jumper of the second power tool when the electromechanical interface of the battery pack having multiple voltages is coupled to the second power tool, thereby electrically connecting the first and second battery cell rows in series via the conductive jumper when the electromechanical interface of the battery pack having multiple voltages is coupled to the second power tool. Power tool system.

28. In the power tool system according to claim 24, The plurality of battery cells of the battery pack having the plurality of voltages are, A first row of battery cells arranged in series with respect to each other, A second row of battery cells arranged in series with each other It has, The battery pack having multiple voltages has an open-circuit configuration in which the first and second battery cell rows are not electrically connected in parallel or in series with respect to each other. Power tool system.

29. In the power tool system according to claim 24, The plurality of battery cells of the battery pack having the plurality of voltages are, A first battery cell array arranged in series with a first positive voltage terminal and a first negative voltage terminal, A second battery cell array arranged in series with a second positive voltage terminal and a second negative voltage terminal, It has, The plurality of electrical terminals of the battery pack having a plurality of voltages have a first row of electrical terminals and a second row of electrical terminals, The first column is offset perpendicularly from the second column, Multiple electrical terminals in the first row of the aforementioned electrical terminals constitute signal terminals. Multiple electrical terminals in the second row of the aforementioned electrical terminals constitute the first and second terminals. The first terminal of the second row of electrical terminals is electrically connected to the first positive voltage terminal of the first battery cell row. The second terminal of the second row of electrical terminals is electrically connected to the second negative voltage terminal of the second row of battery cells. The first row of electrical terminals is arranged spaced apart horizontally. The second row of electrical terminals is arranged spaced apart horizontally. Power tool system.

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