Distributed and networked power tool battery charging with user-defined settings

Abstract

Systems, devices, and methods are described for charging networked power tool battery packs. One system includes an electronic controller, having a processor and memory, obtains information associated with a first battery pack charger electrically connected to a power input and information associated with a second battery pack charger electrically connected to the power input. The electronic controller controls a charge operation of each of a plurality of battery packs, each of the plurality of battery packs connected to one of the first battery pack charger and the second battery pack charger. The electronic controller may be included in the second battery pack charger and may obtain the information associated with the first battery pack charger over a wireless connection with the second battery pack charger or a power line shared by the first battery pack charger and the second battery pack charger.

Description

DISTRIBUTED AND NETWORKED POWER TOOL BATTERY CHARGING WITH USER-DEFINED SETTINGSRELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 510,657, filed June 28, 2023, the entire content of which is hereby incorporated by reference.FIELD

[0002] Embodiments described herein generally relate to battery chargers and, more particularly, to establishing communication between battery chargers for charging more than one battery pack. Embodiments described herein also generally relate to user-defined settings for charging a battery pack.SUMMARY

[0003] Battery packs, such as battery packs used with power tools, can be recharged by plugging the battery pack into a charger receiving power from a power source (e g., an outlet or AC power line). When multiple battery packs are plugged in for charging (e g., via a single battery pack charger or via multiple battery pack chargers), the collective power draw for charging the battery packs may exceed an available power limit, which may pop (trip or open) a circuit breaker associated with power input, which causes power supply to the charger(s) to be interrupted. In this situation, a user is required to reset the circuit breaker and potentially manually control charging of the battery packs to prevent further power interruption via the circuit breaker. Accordingly, this does not provide efficient charging in terms of timing and power consumption.

[0004] Embodiments described herein provide systems and methods for charging networked power tool battery packs. One system including a first battery pack charger, a second battery pack charger, a plurality of battery packs, and an electronic controller. The first battery pack charger is electrically connected to a power input. The second battery pack charger is electrically connected to the power input and is configured to communicate with the first battery pack charger. Each of the plurality of battery packs is connected to one of the first battery packcharger and the second battery pack charger. The electronic controller has a processor and memory. The electronic controller is configured to obtain information associated with the first battery pack charger, obtain information associated with the second battery pack charger, and control a charge operation of each of the plurality of battery packs based on the information communicated via the first battery pack charger and the information associated with the second battery pack charger. In some implementations, the electronic controller is included in the second battery pack charger and the first battery pack charger communicates with the second battery pack charger to provide the information associated with the first battery pack charger. However, in other implementations, the electronic controller is included in a third battery pack charger or a dedicated networked device (e.g., a device without battery charging functionality). The first battery pack charger and the second battery pack charger communicate via at least one selected from a group consisting of a wired communication connection, a wireless communication connection, and a power line associated with the power input. The electronic controller may control the charge operation of each of the plurality of battery packs based on a user-defined setting (charging configuration), one or more environment parameters, one or more charger parameters, one or more battery parameters, or a combination thereof.

[0005] In some aspects, the information communicated via the first battery pack charger includes a remaining charging time for a first battery pack of the plurality of battery packs connected to the first battery pack charger, and the information associated with the second battery pack charger includes a remaining charging time for a second battery pack of the plurality of battery packs connected to the second battery pack charger. The electronic controller may control the charge operation of each of the plurality of battery packs by selecting one of the first battery pack charger and the second battery pack charger as the selected battery pack charger based on which of the first battery pack and the second battery pack has a least amount of remaining charging time. The electronic controller assigns an increased charging power level to the selected battery pack charger and assigns a reduced charging power level to the nonselected battery pack charger.

[0006] In some aspects, the user-defined setting includes an optimization routine from a plurality of available routines having at least one selected from a group consisting of a maximum charging current and a stop charging state of charge.

[0007] Embodiments described herein also provide a battery pack charger for receiving and storing user-defined charging configurations. The battery pack charger includes a battery pack interface, a memory, an electronic processor, and a communications interface. The communications interface is configured to receive a user-defined setting from a remote device via a wireless communication. The electronic processor is configured to store the user-defined setting or data derived therefrom in the memory. The electronic processor is configured to supply charging power to a battery pack connected to the battery pack interface based on the stored user-defined setting. The user-defined setting may include at least one selected from a group consisting of a maximum charge rate or current, a maximum battery voltage, and a state- of-charge for ending charging. In some implementations, the user-defined setting is received via a user interface of the battery pack charger as an alternative to or in addition to receiving the user-defined setting from the remote device. The electronic processor may supply charging power to the battery pack based on the stored user-defined setting, one or more environment parameters, one or more charger parameters, one or more battery parameters, or a combination thereof.

[0008] Embodiments described herein also provide a battery pack charger for receiving user- defined charging configurations. The battery pack charger includes a battery pack interface, a memory, an electronic processor, and a communications interface. The communications interface is configured to receive a user-defined setting from a remote device via a wireless communication. The electronic processor is configured to communicate the user-defined setting to a battery connected to the battery pack interface based on the stored user-defined setting. The battery stores the user-defined setting and communicates the user-defined setting to battery pack charger (or a different battery pack charger when the battery is connected to a different battery pack charger), and the battery pack charger uses the user-defined setting to supply charging power to the battery pack. The electronic processor may supply charging power to the battery pack based on the received user-defined setting, one or more environment parameters, one or more charger parameters, one or more battery parameters, or a combination thereof. The user- defined setting may include at least one selected from a group consisting of a maximum charge rate or current, a maximum battery voltage, and a state-of-charge for ending charging. In some implementations, the user-defined setting is received via a user interface of the battery packcharger as an alternative to or in addition to receiving the user-defined setting from the remote device.

[0009] Embodiments described herein also provide a system including at least one battery pack charger, a plurality of battery packs, and an electronic controller. The at least one battery pack charger is electrically connected to a power input. The plurality of battery packs includes a first battery pack and a second battery pack. The first battery pack and the second battery pack are connected to the at least one battery pack charger. The first battery pack is configured to communicate with the second battery pack. The electronic controller has a processor and memory. The electronic controller is configured to obtain information associated with the first battery pack, obtain information associated with the second battery pack, and control a charge operation of each of the plurality of battery packs based on the information associated with the first battery pack and the information associated with the second battery pack. In some implementations, the electronic controller is included in the second battery pack and the first battery pack communicates with the second battery pack to provide the information associated with the first battery pack charger. However, in other implementations, the electronic controller is included in the at least one battery pack charger, a third battery pack or a dedicated networked device (e.g., a device without battery charging functionality). The first battery pack and the second battery pack communicate via at least one selected from a group consisting of a wired communication connection, a wireless communication connection, and a power line associated with the power input. The electronic controller may control the charge operation of each of the plurality of battery packs based on a user-defined setting (charging configuration), one or more environment parameters, one or more charger parameters, one or more battery parameters, or a combination thereof.

[0010] In some aspects, the information communicated via a first battery pack includes a remaining charging time for the first battery pack of the plurality of battery packs connected to the at least one battery pack charger, and the information associated with a second battery pack includes a remaining charging time for the second battery pack of the plurality of battery packs connected to the at least one battery pack charger. The electronic controller may control the charge operation of each of the plurality of battery packs by selecting one of the first battery pack and the second battery pack as the selected battery pack based on which of the first batterypack and the second battery pack has a least amount of remaining charging time. The electronic controller assigns an increased charging power level to the selected battery pack and assigns a reduced charging power level to the non-selected battery pack.

[0011] In some aspects, the user-defined setting includes an optimization routine from a plurality of available routines including at least one selected from a group consisting of a maximum charging current and a stop charging state of charge.

[0012] Before any embodiments are explained in detail, it is to be understood that the embodiments are not limited in their application to the details of the configuration and arrangement of components set forth in the following description or illustrated in the accompanying drawings. The embodiments are capable of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof are meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings.

[0013] In addition, it should be understood that embodiments may include hardware, software, and electronic components or modules that, for purposes of discussion, may be illustrated and described as if the majority of the components were implemented solely in hardware. However, one of ordinary skill in the art, and based on a reading of this detailed description, would recognize that, in at least one embodiment, the electronic-based aspects may be implemented in software (e.g., stored on non-transitory computer-readable medium) executable by one or more processing units, such as a microprocessor and / or application specific integrated circuits (“ASICs”). As such, it should be noted that a plurality of hardware and software based devices, as well as a plurality of different structural components, may be utilized to implement the embodiments. For example, “servers,” “computing devices,” “controllers,” “processors,” etc., described in the specification can include one or more processing units, one ormore computer-readable medium modules, one or more input / output interfaces, and various connections (e.g., a system bus) connecting the components.

[0014] Relative terminology, such as, for example, “about,” “approximately,” “substantially,” etc., used in connection with a quantity or condition would be understood by those of ordinary skill to be inclusive of the stated value and has the meaning dictated by the context (e.g., the term includes at least the degree of error associated with the measurement accuracy, tolerances [e.g., manufacturing, assembly, use, etc.] associated with the particular value, etc.). Such terminology should also be considered as disclosing the range defined by the absolute values of the two endpoints. For example, the expression “from about 2 to about 4” also discloses the range “from 2 to 4”. The relative terminology may refer to plus or minus a percentage (e.g., 1%, 5%, 10%, or more) of an indicated value.

[0001] Unless the context of their usage unambiguously indicates otherwise, the articles “a,” “an,” “the,” and “said” should not be interpreted as meaning “one” or “only one.” Rather these articles should be interpreted as meaning “at least one” or “one or more” and may be used interchangeably with “a,” “an,” “the,” and “said” without implying a different meaning.

[0002] Also, it should be understood that the illustrated components, unless explicitly described to the contrary, may be combined or divided into separate software, firmware and / or hardware. For example, instead of being located within and performed by a single electronic processor, logic and processing described herein may be distributed among multiple electronic processors. Similarly, one or more memory modules and communication channels or networks may be used even if embodiments described or illustrated herein have a single such device or element. Also, regardless of how they are combined or divided, hardware and software components may be located on the same computing device or may be distributed among multiple different devices. Accordingly, in the claims, if an apparatus, method, or system is claimed, for example, as including a controller, control unit, electronic processor, computing device, logic element, module, memory module, communication channel or network, or other element configured in a certain manner, for example, to perform multiple functions, the claim or claim element should be interpreted as meaning one or more of such elements where any one of the one or more elements is configured as claimed, for example, to make any one or more of the recited multiple functions, such that the one or more elements, as a set, perform the multiplefunctions collectively. Similarly, a component described as performing particular functionality may also perform additional functionality not described herein. For example, a device or structure that is “configured” in a certain way is configured in at least that way but may also be configured in ways that are not explicitly listed.

[0015] Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings.BRIEF DESCRIPTION OF THE DRAWINGS

[0016] FIG. 1 is a perspective view of a multi-bay battery charger according to embodiments described herein.

[0017] FIG. 2 is a perspective view of a battery pack charged via the multi-bay battery charger of FIG. 1 according to embodiments described herein.

[0018] FIG. 3 is a block diagram of a control system of the charger of FIG. 1 according to embodiments described herein.

[0019] FIG. 4 is a block diagram of a communications interface of the charger of FIG. 1 according to embodiments described herein.

[0020] FIG. 5 schematically illustrates a communication system according to embodiments described herein.

[0021] FIG. 6 illustrates a method for operating the multi -bay battery charger of FIG. 1 according to embodiments described herein.

[0022] FIG. 7 is a block diagram illustrating a network of chargers according to embodiments described herein.

[0023] FIG. 8 illustrates a method for operating the network of chargers of FIG. 7 according to embodiments described herein.

[0024] FIG. 9 is a block diagram illustrating battery-to-battery communication system according to embodiments described herein.

[0025] FIG. 10 is a block diagram illustrating a network of battery packs according to embodiments described herein.DETAILED DESCRIPTION

[0026] FIG. 1 illustrates a multi -bay battery charger 10 configured to support and charge multiple battery packs 14A-F via a plurality of battery pack interfaces. In the illustrated embodiment, the battery charger 10 supports and charges up to six battery packs 14A-F. In other embodiments, the battery charger 10 is configured to support and charge fewer or more battery packs 14A-F. The battery packs 14A-F are, for example, 18-volt Li-ion power tool battery packs. In other embodiments, the battery packs 14A-F may have different voltages (e.g., 8-volt, 12-volt, 16-volt, 28-volt, 48-volt, etc.) and / or different chemistries (e.g., NiMH, NiCd, etc ). The illustrated charger 10 includes a base 18 and a housing 22. The base 18 is coupled to a bottom portion of the housing 22. The base 18 is generally larger (e.g., wider and longer) than the housing 22 to add stability to the charger 10.

[0027] The housing 22 extends outwardly from the base 18 and includes four side surfaces 46, 50 (side surfaces 54, 58 are not shown) and an upper surface 62. The side surfaces 46, 50, 54, 58 are arranged perpendicular to one another in a generally rectangular pattern. The upper surface 62 is spaced apart from the base 18 and extends generally perpendicular to the side surfaces 46, 50, 54, 58. In some embodiments, the housing 22 is composed of two clamshell halves that connect to define the surfaces 46, 50, 54, 58, 62 of the housing 22. The clamshell halves thereby enclose the interior components of the charger 10. In other embodiments, the housing 22 may be formed as a single piece connected to the base 18.

[0028] The side surfaces 46, 50, 54, 58 are generally vertically oriented when the charger 10 is supported by the base 18 on a surface. Each side surface 46, 50, 54, 58 supports at least one of the battery pack interfaces. In other embodiments, one or more of the side surfaces 46, 50, 54, 58 may support two or more battery pack interfaces. Also, in some embodiments, the charger 10 may include only a single battery pack interface for charging a single battery pack. Accordingly, embodiments described herein are not limited to multi-bay chargers.

[0029] In the illustrated embodiment, the housing 22 also includes a handle 82 extending from the upper surface 62. The handle 82 is centrally positioned on the charger 10 such that a central axis defined by the side surfaces 46, 50, 54, 58 of the housing 22 extends through the handle 82. The handle 82 defines a longitudinal axis generally parallel to the side surfaces 46, 54 and generally perpendicular to the side surfaces 50, 58. The handle 82 thereby defines an elongated grip generally parallel to and spaced apart from the upper surface 62 to facilitate lifting and carrying the charger 10.

[0030] In some embodiments, each of the battery pack interfaces of the charger 10 includes a connecting structure and electrical contacts. In some embodiments, the connecting structures include one or more guide rails configured to receive slide-on style battery packs (FIG. 2). In other embodiments, the connecting structures may be configured to receive different styles of battery packs, such as, for example, tower style battery packs.

[0031] In some embodiments, the electrical contacts of the battery pack interfaces of the charger 10 are coupled to a charging circuit. The charging circuit is positioned within the housing 22 and charges the battery packs 14A-F when the packs 14A-F are connected to the battery pack interfaces.

[0032] In the illustrated embodiment, the battery charger 10 also includes one or more indicator lights 106A-F, which may be coupled to the charging circuit. The illustrated indicator lights 106A-F are light-emitting diodes (LEDs). As shown in FIG. 1, the LEDs 106A-F extend from the upper surface 62 of the housing 22. In some embodiments, each battery pack interface of the charger 10 may be associated with one or more indicator lights and indicate an operational status of the associated battery pack interface. For example, a continuous red light may indicate the battery pack connected to the associated battery pack interface is charging, a continuous green light may indicate charging is complete for the battery pack connected to the associated battery pack interface, and flashing red and green lights may indicate an error associated with the battery pack connected to the associated battery pack interface or the battery pack interface itself. In some instances, in response to a battery pack being connected to a battery pack interface while another battery pack is already being charged via one of the other battery pack interfaces, one of the indicator lights (e.g., a red LED) may flash to indicate that charging is pending and will beginwhen the other battery pack is finished charging. As described in more detail below, in some embodiments, the upper surface 62 of the housing 22 includes a user interface for receiving user input adjusting parameter settings related to charging one or more of the battery packs 14A-F (i.e., one or more of the battery pack interfaces). The user interface may include a screen (e.g., touchscreen), one or more buttons, knobs, or other input mechanisms, or a combination thereof.

[0033] In operation, the charger 10 may charge the battery packs 14A-F in series such that one battery pack 14A-F is charged at a time. Accordingly, in such implementations, the charger 10 may be referred to as a “sequential charger.” The charging circuit in a sequential charger may cycle serially through the battery pack interfaces to determine parameters regarding the battery packs 14A-F that are connected to each interface. These parameters may include the presence of a battery pack and which, if any, of the battery packs require charging (e.g., based on a current state of charge of the battery pack). In response to detecting that more than one battery pack connected to the charger 10 requires charging, the charging circuit sequentially charges the battery packs in order from the battery pack connected to the lowest (e.g., with respect to a physical position on the charger 10) battery pack interface (e.g., a first battery pack interface) to the battery pack connected to the highest battery pack interface (e.g., a sixth battery pack interface). In response to finishing charging of a battery pack connected to a particular battery pack interface, the charging circuit starts charging the battery pack connected to the sequentially next (i.e., based on physical position) battery pack interface. The charger 10 repeats this process until no connected battery packs remain that need charging. In response to not detecting a connected battery pack at one of the battery pack interfaces, or if the battery pack and / or battery pack interface is experiencing an error, the charging circuit will skip that particular interface and move on to the next sequential battery pack interface. It should be understood that other sequences may be used to perform charging and is not limited to moving from a lowest battery pack interface to a highest battery pack interface as any particular sequence may be applied by the charger 10. Also, alternatively or in addition, in some embodiments, the charger 10 can charge one or more the battery packs 14A-F simultaneously such that one or more connected battery packs are charged at the same time.

[0034] In some embodiments, the charger 10 determines additional parameters (e.g., regarding the battery packs 14A-F, the environment, the charger 10, or a combination thereof)and may optimize charging operations accordingly (e.g., rather than performing a simple sequential charging sequence). For example, the parameters can include a charger rate / current, a state of charge to end charging (e.g., a state of charge set point of a battery that stops charging), ambient temperature, battery temperature, battery capacity, battery voltage, battery condi tion / age, battery charging characteristics, battery chemistry, maximum charging current of battery, number of batteries on one (1) charger, number of batteries on one (1) power outlet, number of batteries on multiple connected devices, maximum available AC power, or a combination thereof. The charger 10 uses the parameters to generate a charging configuration that provides the operational settings for the charger 10 and / or the battery packs 14A-F.

[0035] In some embodiments, in addition to or separate from the battery parameters, charger parameters, and environment parameters described above, the charger 10 is configured to use one or more user-defined settings to generate a charging configuration. The charger 10 may use the user-defined settings in combination with other parameters when generating a charging configuration (e.g., parameters of the battery pack interfaces, battery packs, environment, and / or the charger 10) or, alternatively, may use a user-defined setting as an override for other parameters. The user-defined settings allow a user to configure the charger 10 to meet their needs and use scenarios and manage (e.g., adjust) battery cycle life as compared to being forced to accept default charging parameters set by a manufacturer or supplier. The user-defined settings maximum charger rate / current, a state of charge to end charging, and the like. For example, setting a charge rate may allow multiple chargers to be connected to a single outlet (e.g., 120V AC outlet) and throttle charger rates to allow for simultaneous charging. Similar control may be used for a sequential charger to allow for simultaneous charging of battery packs connected to the charger. Also, setting a state of charge to end charging allows charging to be stopped in response to a battery state of charge reaching a set point, such as, for example, 70%, 75%, 80%, 85%, 90%, 95%, 98%, or the like. Thus, the user-defined settings allow a user to choose if they want to get full capacity from their battery pack or stop charging earlier to potentially extend the life of their battery pack. Similarly, a user-defined setting can include a maximum charge rate and / or current, which may be used to extend battery life; a maximum battery voltage, which may also be used to extend battery life; a preferred charging sequence for a plurality of chargers or a plurality of battery pack interfaces on a charger (e.g., charge two (2) battery packs to maximum capacity as quick as possible and charge the other connected batteriesat a slower rate, set a sequence or order for charging battery packs, charge available batteries to maximum capacity in the shortest possible time, etc.); or the like.

[0036] For example, in some embodiments, the charger 10 and / or the battery packs 14A-F store one or more user-defined settings to meet use scenarios and manage battery life cycle. As described in more detail below, the user-defined settings may be input or received by a user interface of the charger 10 or communicated to the charger 10 from a remote device, such as, for example, a mobile phone or other portable device of a user. In some embodiments, a dedicated programmer device may communicate with the charger 10, wherein the dedicated programmer device includes various input mechanisms for receiving user-defined settings. As noted above, the user-defined settings may be used to override a default charging configuration for the charger 10 or a particular battery pack. For example, rather than charging the battery packs 14A-F simultaneously or sequentially based on a physical order or position of the battery pack interfaces, the charger 10 can charge the battery packs 14A-F using a charging sequence defined by a user-defined setting. One or more user-defined settings may be stored in the charger 10 and / or one or more of the battery packs 14A-F. For example, user-defined settings received by the charger 10 may be communicated to one or more of the battery packs 14A-F, and each battery pack receiving the user-defined settings may store the settings in a memory of the battery pack. Accordingly, user-defined settings may be applied at the charger level (e.g., applied to each battery pack charged by the charger), at the battery pack level (e g., communicated to the charger from the battery pack before initiating a charging operation / sequence and applied by the charger to the particular battery pack), or a combination thereof.

[0037] FIG. 2 illustrates a battery pack 200, which is representative of the battery packs 14A- F of FIG. 1. The battery pack 200 includes a housing 205, a user interface portion 210 for providing a state-of-charge indication for the battery pack 200, and a device interface portion 215 for connecting the battery pack 200 to a device, such as for example, a power tool or the charger 110. In some embodiments, the battery pack 200 includes a plurality of battery cells within the housing 205. In other embodiments, the battery pack 200 includes a communication interface and a memory that includes default and / or user-defined parameters (e.g., battery parameters, environmental parameters) of a charging configuration. As described above, the battery pack 200 can provide the stored settings of parameters to the charger 10 for chargingaccording to the charging configuration (e.g., via the communication interface), and the stored user-defined parameters may be initially received from the charger 10 or a separate device. For example, similar to how a remote device may communicate with the charger 10 to provide user- defined settings, user-defined settings may be communicated from a remote device directly to a battery pack (e.g., using a communication interface of the battery pack). FIG. 3 schematically illustrates a control system for the charger 10. The control system includes a controller 300. The controller 300 is electrically and / or communicatively connected to a variety of modules or components of the charger 10. For example, the illustrated controller 300 is electrically connected to a battery pack interface 410, one or more sensors or sensing circuits 415, one or more indicators 416, a user interface 420, a communications controller or interface 425, and a power control module 430. The controller 300 includes combinations of hardware and software that are operable to, among other things, control the operation of the charger 10, monitor the operation of the charger 10, activate the one or more indicators 416 (e.g., an LED), etc.

[0038] The controller 300 includes a plurality of electrical and electronic components that provide power, operational control, and protection to the components and modules within the controller 300, the charger 10, and / or the battery pack 200. For example, the controller 300 includes, among other things, a processing unit 440 (e.g., a microprocessor, a microcontroller, an electronic processor, an electronic controller, or another suitable programmable device), a memory 445, input units 450, and output units 455. The processing unit 440 includes, among other things, a control unit 460, an arithmetic logic unit (ALU) 465, and a plurality of registers 470 (shown as a group of registers) and is implemented using a known computer architecture (e.g., a modified Harvard architecture, a von Neumann architecture, etc.). The processing unit 440, the memory 445, the input units 450, and the output units 455, as well as the various modules or circuits connected to the controller 300 are connected by one or more control and / or data buses (e.g., common bus 475). The control and / or data buses are shown generally in FIG. 3 for illustrative purposes. The use of one or more control and / or data buses for the interconnection between and communication among the various modules, circuits, and components would be known to a person skilled in the art in view of the invention described herein.

[0039] The memory 445 is a non-transitory computer readable medium and includes, for example, a program storage area and a data storage area. The program storage area and the data storage area can include combinations of different types of memory, such as a read only memory (“ROM”), a random access memory (“RAM”) (e.g., dynamic RAM [“DRAM”], synchronous DRAM [“SDRAM”], etc.), electrically-erasable programmable ROM (“EEPROM”), flash memory, a hard disk, an SD card, or other suitable magnetic, optical, physical, or electronic memory devices. The processing unit 440 is connected to the memory 445 and is configured to execute software instructions that are capable of being stored in a RAM of the memory 445 (e.g., during execution), a ROM of the memory 445 (e.g., on a generally permanent basis), or another non-transitory computer readable medium such as another memory or a disc. Software included in the implementation of the charger 10, the battery pack 200, and controller 300 can be stored in the memory 445 of the controller 300. The software includes, for example, firmware, one or more applications, program data, filters, rules, one or more program modules, and other executable instructions. The controller 300 is configured to retrieve from the memory 445 and execute, among other things, instructions related to the control processes and methods described herein. In other embodiments, the controller 300 includes additional, fewer, or different components.

[0040] The battery pack interface 410 includes a combination of mechanical components (e.g., rails, grooves, latches, etc.) and electrical components (e.g., one or more terminals) configured to and operable for interfacing (e.g., mechanically, electrically, and communicatively connecting) the charger 10 with a battery pack (e.g., the battery pack 200). For example, power provided by the charger 10 to the battery pack 200 is provided from a power input 405 through the power control module 430 to the battery pack interface 410. The power control module 430 includes combinations of active and passive components to regulate or control the power received from the power input 405 prior to power being provided to the controller 300. The battery pack interface 410 also supplies power from the power input 405 to the battery pack 200. The battery pack interface 410 also includes, for example, a communication line 495 for providing a communication line or link between the controller 300, the battery pack interface 410, and the battery pack 200.

[0041] The sensing circuits 41 include, for example, one or more voltage sensors, one or more current sensors, one or more temperature sensors, and / or one or more additional sensors used for measuring electrical and / or other characteristics of the charger 10 and / or the battery pack 200. Each of the sensing circuits 415 generates one or more output signals that are provided to the controller 300 for processing and evaluation. The indicators 416 include, for example, one or more light-emitting diodes (“LEDs”). The indicators 416 can be configured to display conditions of, or information associated with, the charger 10. For example, the indicators 416 are configured to indicate measured electrical characteristics of the charger 10, the status of the charger 10, etc. The user interface 420 is operably coupled to the controller 300 and receives user input including, for example, a selection of a mode of operation, an adjustment a charger parameter setting (i.e., one or more user-defined settings as described above), or a combination thereof. In some embodiments, the user interface 420 includes a combination of digital and analog input or output devices required to achieve a desired level of operation for the charger 10, such as one or more knobs, one or more dials, one or more switches, one or more buttons, etc. In some embodiments, the user interface 420 is integrated with a display (e.g., as a touchscreen display).

[0042] The controller 300 is configured to implement a charging configuration by determining whether a particular condition is present and generate one or more control signals related to the condition. For example, the sensing circuits 415 include one or more current sensors, one or more voltage sensors, one or more temperature sensors, etc., and the controller 300 receives data from the sensing circuits 415, which the controller 300 uses to detect whether a particular condition is present. The controller 300 calculates or includes, within memory 445, predetermined operational threshold values and limits for operation of the charger 10 and / or a battery pack connected to the charger 10, which the controller 300 may compare to data from the sensing circuits 415 (or data derived from such data) to detect or predict (e.g., using static rules, historical data, machine learning, or the like) a condition. For example, in response to detecting or predicting an out-of-range temperature (e.g., of a battery pack connected to the charger 10, etc.), the controller 300 may limit or interrupt power to the connected battery pack (through the power control module 430) until the temperature is reduced.

[0043] The communications interface 425 can communicate with a network 435 and enables the controller 300 to communicate with one or more peripheral (remote) devices also connected to the network 435, such as, for example, a smartphone, a tablet computer, a smart wearable device, other charging devices, a server, or a combination thereof. As described in more detail below, the controller 300 includes combinations of hardware and software that are configured to, among other things, control the operation of the power control module 430 and the associated power input 405, communicate over the network 435, receive input from a user via the user interface 420, provide information to a user via user interface 420 (e.g., a display), etc.

[0044] Although the controller 300 is illustrated in FIG. 3 as one controller, the controller 300 may include multiple controllers configured to work together to achieve a desired level of control for the charger 10. As such, any control functions and processes described herein with respect to the controller 300 could also be performed by two or more controllers functioning in a distributed manner, wherein the two or more controllers perform the control functions and processes described herein collectively as a set.

[0045] During operation of the charger 10, the controller 300 is configured to monitor voltage, current, and / or other signals received from the various components described above. More generally, the controller 300 is configured to monitor and / or control power flow to and from the above-described components of the charger 10 that are electrically and communicatively coupled to the controller 300.

[0046] As shown in FIG. 4, the communications interface 425 may include a processor 436, a memory 437, an antenna and a transceiver 438, and, optionally, a real-time clock (RTC) 439. The communications interface 425 enables the charger 10 to communicate with an external or remote device 510 (see, e.g., FIG. 5). The radio antenna and transceiver 438 operate together to send and receive wireless messages to and from the external device 510. For example, as described above, the external device 510 may communicate with the charger 10 to provide user- defined settings, which may be stored by the charger 10 and / or communicated to additional devices (e.g., other chargers 10, one or more battery packs connected to the charger 10, etc.). The memory 437 can store instructions to be implemented by the processor 436 and / or may store data related to communications between the charger 10, a connected battery pack, the externaldevice 510, or a combination thereof. The processor 436 of the communications interface 425 controls wireless communications between the charger 10 and the external device 510. For example, the processor 436 associated with the communications interface 425 buffers incoming and / or outgoing data, communicates with the controller 300, determines the communication protocol and / or settings to use in wireless communications, or a combination thereof. The communication via the communication interface 425 can be encrypted to protect the data exchanged between the charger 10, the battery pack 200, and the external device 510 from third parties.

[0047] In the illustrated embodiment, the communications interface 425 includes a Bluetooth® controller. The Bluetooth® controller communicates with the external device 510 employing the Bluetooth® protocol (e.g., the Bluetooth® Classic protocol or Bluetooth® Light Energy (BLE) protocol) over a Bluetooth® connection or “network.” Therefore, in the illustrated embodiment, the external device 510, the charger 10, and / or the battery pack 200 are within a communication range (i.e., in proximity) of each other while they exchange data. Alternatively or in addition, the communications interface 425 may communicate using other protocols (e.g., Wi-Fi, ZigBee, a proprietary protocol, etc.) over different types of wireless networks. For example, the communications interface 425 may be configured to communicate via Wi-Fi through a wide area network such as the Internet or a local area network, or to communicate through a piconet (e.g., using infrared or NFC communications).

[0048] In some embodiments, the network 435 includes a cellular network, such as, for example, a Global System for Mobile Communications (“GSM”) network, a General Packet Radio Service (“GPRS”) network, a Code Division Multiple Access (“CDMA”) network, an Evolution-Data Optimized (“EV-DO”) network, an Enhanced Data Rates for GSM Evolution (“EDGE”) network, a 3GSM network, a 4GSM network, a 4G LTE network, 5G New Radio, a Digital Enhanced Cordless Telecommunications (“DECT”) network, a Digital AMPS (“IS- 136 / TDMA”) network, or an Integrated Digital Enhanced Network (“iDEN”) network, etc. Alternatively or in addition, the network 435 includes a Wi-Fi network, a LoRa network, a ZigBee network, a local area network (LAN), the Internet, a proprietary protocol network, a point-to-point or mesh network, or the like.

[0049] The communications interface 425 is configured to receive information from the controller 300 and transmit the information to the external device 510 via the antenna and transceiver 438. In a similar manner, the communications interface 425 is configured to receive information (e.g., one or more user-defined settings) from the external device 510 via the antenna and transceiver 438 and transmit the information to the controller 300.

[0050] The RTC 439 increments and keeps time independently of the other power supply components. The RTC 439 receives power from the power input 405 or the battery pack 200. Having the RTC 439 as an independently powered clock enables time stamping of operational data (stored in memory 437 for later export) and a security feature whereby a lockout time or threshold is set by a user (e.g., via the external device 510) and the power supply 100 is locked- out, or disabled, when the time of the RTC 439 exceeds the set lockout time.

[0051] In some implementations, the communications interface 425 includes a port or interface for receiving a cable or cord for communicating with an external device over a wired communication connection. This wired communication connection may be provided in addition to or as an alternative to the wireless communication functionality described above with respect to the communications interface 425. In some embodiments, the wired communication connection can include a wired controller area network (CAN) connection, a RS485 connection, a UART connection, I2C connection, SPI connection, Ethernet connection, or the like.

[0052] FIG. 5 illustrates a communication system 500. The communication system 500 includes at least one charger 10 having at least one battery pack (e.g., the battery pack 200) and an external device 510. Each charger 10 and the external device 510 can communicate wirelessly (e.g., while they are within a communication range of each other). The charger 10 may communicate charging status, charger operation statistics, charger identification, charger sensor data, stored charger usage information, charger maintenance data, and the like. Information communicated to the remote device 510 may be displayed as part of one or more user interfaces (e.g., on a display, such as a touchscreen) to inform a user how the charger 10 and the battery pack 200 are or have been used, whether maintenance is recommended or has been performed in the past, and of any malfunctioning components or other reasons for certain performance issues. The external device 510 can also transmit data to the charger 10 and / or thebattery pack 200, such as, for example, commands (e g., operating mode selections), firmware updates, and user-defined settings for the charger 10 and / or the battery pack 200.

[0053] The external device 510 is, for example, a smart phone (as illustrated), a laptop computer, a tablet computer, a smart wearable device, a personal digital assistant (PDA), or another electronic device capable of communicating wirelessly with the charger 10 and / or the battery pack 200 and providing a user interface on a display, such as, for example, a touchscreen of the external device 510. The external device 510 provides the user interface and receives user input via the user interface (or other input mechanisms), which allows a user to access and interact with the charger 10 and / or the battery pack 200. The external device 510 can receive user inputs that include user-defined settings, enable or disable features, and the like. The user interface of the external device 510 provides an easy-to-use interface for the user to control and customize operation of the charger 10. For example, the external device 510 can connect to the charger 10 or the battery pack 200 and change and set a charging configuration (e.g., charging parameters) based on, for example, input received from the user via the user interface. The settings can be applied to (stored on) the charger 10 and / or stored on the battery pack 200. If the settings are applied to the charger 10, the charger 10 may charge all connected batteries with the applied settings. If the settings are stored on the battery pack 200, the battery pack 200 communicates charging configuration to the charger 10 before the charger 10 initiates a charging operation (e g., charging sequence). In some embodiments, in response to receiving charging configuration from one connected battery pack, the charger 10 may use a default charging configuration for other connected battery packs (i.e., battery packs not communicating a charging configuration). Alternatively, the charger 10 may select a charging configuration for other connected battery packs (i.e., battery packs not communicating a charging configuration) that is compatible with the charging configuration communicated by the one battery pack.

[0054] Alternatively or in addition, as shown in FIG. 5, the external device 510 can share data obtained from the charger 10 and / or the battery pack 200 (or data derived from such data) with a remote server 505 connected through the network 435. The remote server 505 may be used to store data obtained from the external device 510, provide additional functionality and services to the user through software and / or data provided to the external device 510, or a combination thereof. In some embodiments, storing data on the remote server 505 allows a userto access the information from a plurality of different locations (via one or more different devices). The network 435 may include various networking elements (routers 507A, hubs, switches, cellular towers 539B, wired connections, wireless connections, etc.) for connecting to, for example, the Internet, a cellular data network, a local network, or a combination thereof as previously described. In some embodiments, the charger 10 is configured to communicate directly with the remote server 505 through an additional wireless interface or with the same wireless interface that the charger 10 uses to communicate with the external device 510.

[0055] FIG. 6 illustrates a method 600 executed by the controller 300 of the charger 10 for charging one or more battery packs connected to the charger 10 and, in particular, for receiving and applying one or more user-defined settings for charging connected battery packs. As illustrated in FIG. 6, the charger 10 receives a request (STEP 605). The controller 300 may receive the request from the external device 510 via the network 435 to connect to the charger 10. The charger 10 may process the request, such as, for example, by confirming that the request was received from an authorized or valid device (e.g., based on identifying information provided in the request). The controller 300 configures a communication channel between the charger 10 and the external device 510 in response to confirming the request was received from the authorized of valid device. For example, when the charger 10 communicates with the external device 510 over a Bluetooth® connection, the request may be part of a handshake protocol for establishing a communication channel between the charger 10 and the external device 510. As noted above, in some embodiments, the charger 10 may receive a request through the user interface 420, which may include a selection of an option from a menu, data (e.g., a code or password) authorizing a user of the charger, or a combination thereof).

[0056] As part of the request or separate from the request (e.g., and assuming that the request is accepted or confirmed by the charger 10), the charger 10 receives a user input (STEP 610). The user input may be received from the external device 510 or via the user interface 420 of the controller 10. The user input may include a user-defined setting for establishing a charging configuration.

[0057] The charger 10 sets a charging parameter for a charging configuration based on the user input (i.e., based on the user-defined setting) (STEP 615). For example, the controller 300modifies a charge configuration of the charger 10 based on the user-defined setting. In this example, the charge configuration may define an operational range for the charger 10 based on the charging parameter setting (e.g., a maximum charge rate and / or current, a maximum battery pack voltage, a preferred charging sequence, a state of charge threshold for stopping charging, or the like). In some embodiments, the controller 300 stores the modified charge configuration (and / or the received settings) in the memory 445 of the charger 10. Alternatively or in addition, the controller 300 communicates the modified charge configuration (and / or the received settings) to the battery pack 200 connected to the charger 10 for storage on the battery pack 200 (i.e., a memory of the battery pack 200). In these embodiments, when the battery pack 200 is connected to the charger 10 (or a different charger 10 than the charger that initially provided the charging configuration and / or settings), the battery pack 200 provides the modified charging configuration and / or the previously-received setting to the charger 10, which uses the received information to control charging of the battery pack 200.

[0058] Returning to FIG. 6, after modifying the charge configuration, the charger 10 charges the connected battery pack 200 using the charging configuration as stored in the memory (STEP 620). For example, the controller 300 initiates charging of the battery pack 200 based on the charging configuration stored in the memory 445. As noted above, in some embodiments, a charger 10 applies the modified charge configuration to each connected battery pack. As also noted above, in some embodiments, the charger 10 may receive a charge configuration (or setting) from a connected battery pack, which the charger 10 uses to control charging of the connected battery pack. In such an implementation, the charger 10 may only apply the received charge configuration or setting to the battery pack from which the configuration or setting was received from.

[0059] As described above, a multi -bay charger 10 may perform a sequential charging of connected battery packs and / or may take into account various environmental parameters, charger parameters, battery pack parameters, user-defined settings, or a combination thereof as part of charging multiple connected battery packs. For example, as described above, a multi-bay charger 10 may analyze the state of connected battery packs and optimize the charging time of the battery packs taking into account both any user-defined settings, environmental parameters, battery pack parameters or a combination thereof.

[0060] In some implementations, a similar optimization may be performed to charge a plurality of battery packs being charged by multiple chargers (e.g., multiple multi-bay chargers, multiple single-interface chargers, or a combination thereof) wherein the chargers are configured to communicate with each other and optimize the charging of the battery packs. In some implementations, such a distributed and networked charging system is configured to optimize the charging time of the battery packs being charged and may take into account battery pack parameters, environment parameters, charger parameters, user-defined settings, or a combination thereof. In other words, each charger 10 may implement an optimization method or routine that seeks to charge battery packs based not only on just the battery packs connected to the charger 10 but also battery packs connected to other chargers, such as, for example, to charge a plurality of battery packs being charged by a plurality of chargers in a shortest possible time (e.g., while taking into account power supply constraints).

[0061] FIG. 7 is a block diagram of a distributed and networked battery pack charging system 700 implementing charger-to-charger communication according to some embodiments. As shown in FIG. 7, the system 700 includes a charger 10A, a charger 10B, a charger 10C, and a charger 10D, hereinafter referred to as “the chargers 10.” In some embodiments, each of the chargers 10 include similar components and configurations as the charger 10 of FIG. 1. For example, each of the chargers 10 may include a controller similar to the controller 300 of FIG 3. The chargers 10 included in the system 700 may include multi-bay chargers (like the charger 10 described above), single-bay chargers, or a combination thereof. Also, although four chargers 10 are illustrated in FIG. 7 as being included in the system 700, the system 700 may include any number of chargers 10 (e.g., two or more).

[0062] The chargers 10 included in the system 700 receive power from a power source via circuit breaker 705, which provides power to a first outlet 710A and a second outlet 710B. Although only two outlets are illustrated in FIG. 7, any number outlets may provide power to the chargers 10 of the system 700 (or a subset thereof). As illustrated in FIG. 7, the charger 10A and the charger 10B are connected to the first outlet 710A and the charger 10C and the charger 10D are connected to the second outlet 710B. As also illustrated in FIG. 7, the charger 10A is connected to (and communicates with and charges) a battery pack 200A, the charger 10B is connected to (and communicates with and charges) a battery pack 200B, the charger 10C isconnected to (and communicates with and charges) a battery pack 200C, and the charger 10D is connected to (and communicates with and charges) a battery pack 200D. Again, in some embodiments, one or more of the chargers 10 may include multi -bay chargers and, thus, may be connected to multiple battery packs. In some embodiments, the battery packs 200A, 200B, 200C, 200D, or a subset thereof are battery packs for powering a power tool.

[0063] The charger 10A, the charger 10B, the charger 10C, and the charger 10B are configured to communicate with each other, such as, for example, using the communications interface 425 included in each of the chargers 10. For example, as described above, this interface 425 may include a wired interface or connection, such as a universal asynchronous receiver / transmitter (“UART”) connection, a controller area network (“CAN”) connection, inter-integrated circuit (“I2C”) connection, a serial peripheral interface (“SPI”) connection, an Ethernet connection, a RS485 connection, etc. Alternatively or in addition, the interface 425 may include a wireless interface or connection for communicating wirelessly, such as, for example, via Bluetooth low energy (“BLE”) connection, a Wi-Fi connection, a long range (“LoRa”) connection, a point-to-point or mesh network connection, etc. Alternatively or in addition, a charger included in the system 700 may be configured to communicate with another charger included in the system 700 over the AC power lines associated with an outlet (i.e., a power line shared by the chargers 10).

[0064] The chargers 10 included in the system 700 (e.g., on the same circuit breaker) may be determined by each charger 10, such as, for example, based on latency between nodes, automated network configuration via power lines, a ping signal over AC, or the like. In some implementations, branch circuit load detection helps to determine or predict what loads are connected with a charger 10 (e.g., conducted emissions monitoring). Alternatively or in addition, a user may configure the system 700 (i.e., define the chargers 10 included in the system) through one or more user interfaces or inputs provided on a charger, an external device, etc. This user configuration may also include setting other charging parameters (e.g., user- defined settings as described above), such as, for example, scheduling power vs time demands wherein charging may be start when other loads are not attached and / or in response a drop in electrical rate representing, for example, a price (e.g., satisfying a threshold, which may also be user configured).

[0065] One of the chargers 10 (i.e., a controller included in one of the chargers 10) may be designated as a master charger for the system 700. The master may be decided by the group of chargers 10 based on exchanged communications (e.g., based on timing of exchanged communications, functions or features of each charger, etc.) or may be specified (e.g., as part of a user configuring the system 700). Alternatively, a dedicated device (e.g., that doesn’t provide charging functionality) may be used as the master device for the system 700.

[0066] During operation, the chargers 10 (or the master charger) included in the system 700 determines a state of the battery packs connected to the chargers 10 that are communicating with each other and optimizes charging of the battery packs by applying one or more optimization routines taking into account any user-defined settings, environmental parameters, and the parameters and status of the battery packs. For example, the optimization routines may seek to concurrently charge the battery packs in the shortest possible time over multiple chargers, for one charger, or a subset of the networked chargers. For example, the optimization routine may set a charge rate parameter to throttle charger rates of the charger 10A and the charger 10B to the first outlet 710A to allow for simultaneous charging of the battery pack 200A and the battery pack 200B. In this example, the optimization routine may apply any applicable user-defined settings (or other default configurations), such as, for example, using a user-defined state of charge setting to stop charging the battery pack 200A and the battery pack 200B in response to the state of charge of each battery pack 200A and 200B reaching a user-defined set point (e g., 80%).

[0067] In some embodiments, the chargers 10 communicate (via a wired or wireless communication connection) to negotiate a charging sequence (e.g., optimization routine or algorithm) between the chargers 10, which may take into account one or more user-defined settings (e.g., maximum battery voltage, maximum charge rate and / or current, state of charge for ending charging, preferred charging sequence, etc.). In some embodiments, the optimization routines that may be applied via the system 700 may include a largest charge in the least amount of time routine, a largest amount of fully-charged battery packs in the least amount of time routine, a battery cycle or life routine, an optimized routine, a cold charging routine, battery reconditioning routine, a capacity-based charging routine, or a combination thereof. In the largest charge in the least amount of time routine, the chargers 10 may complete constant current(“CC”) charging before moving to constant voltage (“CV”) charging of the battery packs, wherein priority is given to battery packs that need the least amount of time to get to a predetermined state of charge (e.g., time left in bulk charge). In the battery cycle or life routine, the chargers 10 may charge the battery packs to a predetermined (e.g., 80%) state of charge (“SoC”) at a charge rate that is less than the maximum charge rate of the chargers 10. In the optimized routine, the chargers may charge the battery packs based on a balance between state of charge of the battery packs and a charge rate of the charges 10. In the cold charging routine, the chargers 10 may charge the battery packs using charging profiles based on temperature, in which the chargers 10 may discharge a battery pack to reach a defined temperature before charging. In the battery reconditioning routine, the chargers 10 may charge the battery packs using a different or special sequence of current pulses. In the capacity -based charging sequence, the chargers 10 may charge the battery packs based on the measured capacity (e.g., health), in which the chargers 10 may charge the battery packs with high measured capacity first.

[0068] FIG. 8 illustrates a method 800 executed by one or more chargers 10 (e.g., one or more controllers included in such chargers 10) included in the system 700. The method 800 is described herein as being performed by the controller 300 of the master charger included in the system 700. However, portions of the method 800 may be performed by each charger included in the system, a dedicated device included in the system 700 (e.g., a device that does not also provide charging functionality), or a combination thereof. Also, some portions of the method 800 may be performed by a user or administrator of the system 700 (e.g., as part of configuring the system 700). The method 800 illustrates a largest charge in least amount of time optimization routine implemented for the system 700. However, as noted above, in some embodiments, other optimization routines may be applied by the system 700 and the selection of a particular optimization routine to apply may be selected automatically based on detected conditions of the system 700, manually selected by a user, or a combination thereof.

[0069] As illustrated in FIG. 8, the method 800 includes configuring the network of chargers 10 and establishing various settings (STEP 805). This step may include defining chargers 10 included in the system 700, communication channels, communication speeds / protocols for the communication channels, and allocating addresses for each of the chargers 10 (e.g., the chargers 10 as shown in FIG. 7) based on charger type and charger status (e.g., active or not active)received from the chargers 10. In some embodiments, each charger 10 may broadcast or advertise information, which may specify charger type, charger serial number, charger status (active / not active), which can be used to configure the network of chargers. As noted above, a user may also define configuration settings for the system 700 (e.g., via one or more user interfaces or communication channels with the master charger).

[0070] For example, at one or more times within the method 800 (or on a continuously or periodic basis), data may be exchanged between chargers 10 (or at least with the master charger) and / or other devices included in or associated with the system 700. For example, data exchanged regarding the circuit breaker 705 may include how much power is available or remaining for charging, a total power rating, how much power is being allocated to other loads (e g., other tools), how much power is currently being allocated to charging, or the like. In this example, the circuit breaker 705 can include processing ability, software, and other technologies that enable the circuit breaker 705 to connect and exchange data with other devices and systems over the Internet or other communications networks. In other examples, the data may be deduced from one or more measurements (e g., sensor readings) made one or more of the chargers. Data may also be exchanged between the chargers 10 to determine (negotiate) which charger 10 is designated as the master, provide proof of agreement to proceed with charging per the network-optimized charging sequence or operation, or the like. Data exchanged regarding a charger 10 may include how much current can be provided to a connected battery pack, a maximum constant current rating (per charger 10), a present capability of the charger 10 (current and voltage), a number of bays and a capability of each bay (e.g., current and voltage), how much power is the charger 10 currently using, number of attached battery packs and, for each battery pack, how much time is left in bulk charge, a present state of charge, a maximum capacity of the battery pack, a temperature, or the like. As described above, this data may be exchanged over a wired connection, a wireless connection, a power line (representing a particular type of wired connection), or a combination thereof and may be exchanged between all chargers 10 or other devices in the system 700 or may be communicated to a master charger or device.

[0071] The method 800 also includes determining the chargers 10 in a group (STEP 810), which may be the chargers 10 in the system 700, the chargers 10 connected to a particular outlet,the chargers 10 connected to a particular circuit breaker, or a combination thereof. For example, the controller 300 may determine whether each of the chargers 10 in the system 700 is connected to the first outlet 710A (e.g., first group) or the second outlet 710B (e.g., second group) of the circuit breaker 705. In some instances, the controller 300 uses the network configuration settings and / or data exchanged within the system 700 to determine a group associated with each of the chargers 10. In other instances, the controller 300 utilizes latency information between nodes to determine groups. In yet other instances, the controller 300 utilizes a ping rate threshold and a ping rate for each of the chargers 10 to determine one or more groups of chargers 10.

[0072] The controller 300 also receives charging information from the chargers 10 (STEP 815). As noted above, the charger information may include status information of the circuit breaker 705, the battery packs, and the chargers included in the system 700, which may include, for example, the number / type of battery packs connected to each of the chargers 10, number of battery packs per outlet, battery pack voltages, battery pack temperatures, condition / age of battery packs, charge capacity of battery packs, ambient temperature, maximum available AC power, time left in bulk charge of a charger (e.g., time is based on the remaining power needed for a battery pack), and / or current charger settings (e.g., charger configurations). In some embodiments, the controller 300 may initiate charging by enabling the battery pack interfaces 410 of each of the chargers 10 to provide power from the circuit breaker 705 to connected battery packs based on the current charger settings (e.g., provided to the chargers 10 from the battery packs) of each of the chargers 10 or default settings and may use exchanged data thereafter to optimize charging. Similarly, as battery packs are connected and disconnected (or complete charging), the controller 300 may reassess the charging situation to re-optimize charging.

[0073] As illustrated in FIG. 8, the controller 300 determines whether a total charging power is less than a maximum configured charging power (STEP 820). For example, the controller 300 receives charge time left for each of the chargers 10 based on the current charger settings of the chargers 10. The controller 300 also receives a currently used current for each of the chargers 10 and a state of charge of the battery packs. The controller 300 determines a total maximum configured power of the chargers 10 using the charge time left and the currently used current for each of the chargers 10 and state of charge of the battery packs connected to the chargers 10.

[0074] In this example, the controller 300 compares the total charging power available from the circuit breaker 705 to the total maximum configured power of the chargers 10 and, in some embodiments, in response to the total charging power being greater than or equal to the total maximum configured power (STEP 820, “NO” Branch), the controller 300 may not take any action (i.e., not modify any ongoing charging within the system 700). In response to the total charging power available being less than the total maximum configured power, the controller 300 continues to STEP 825 (STEP 820, “YES” Branch).

[0075] At STEP 825, the controller 300 selects a charger 10 with the least amount of bulk charge remaining. For example, the controller 300 selects a charger 10 included in the system 700 based on an optimization routine, such as, for example, the largest power in the least amount of time routine. In this routine, the controller 300 identifies and prioritizes charging of a battery pack that require the least amount of time to charge to a predetermined (e.g., 80%) state of charge. In some embodiments, the predetermined state of charge may be a user-defined setting.

[0076] The controller 300 modifies the power level of the selected charger (STEP 830). For example, the controller 300 assigns a power level to the selected charger 10. The controller 300 enables the battery pack interface 410 to provide power from the circuit breaker 705 at the assigned power level.

[0077] The controller 300 reduces the power available to the rest of the group (STEP 835). For example, the controller 300 assigns a power level to the chargers 10 that are not selected that reduces the current draw and input voltage of the chargers 10 that are not selected. In some embodiments, the controller 300 reduces the power level to the chargers 10 that are not selected proportional to the increase in the power level to the charger 10 that is selected. In other embodiments, the controller 300 may repeat STEP 815, STEP 820, STEP 825, STEP 830, and / or STEP 835 until the battery packs are charged or an allotted power for the networked group of chargers is depleted.

[0078] In some embodiments, one or more of the battery packs 200A, 200B, 200C, 200D may perform some or all of the functionality performed by the chargers 10 in the system 700. For example, in some embodiments, one or more of the battery packs 200 may communicate with another battery pack 200 and a controller included in the battery pack 200 may performsimilar charging optimization as described with respect to the charger-based communication system 700 in FIG. 7 and the method 800 in FIG. 8.

[0079] For example, FIG. 9 is a block diagram of a battery -to-battery communication system 900 according to some embodiments. As shown in FIG. 9, the system 900 includes a plurality of battery packs 200, such as, the battery packs 200A, 200B, 200C, 200D. Each battery pack 200 includes a battery controller 220 and a communications interface 225. For example, the battery pack 200A includes a battery controller 220A and a communications interface 225A, the battery pack 200B includes a battery controller 220B and a communications interface 225B, the battery pack 200C includes a battery controller 220C and a communications interface 225C, and the battery pack 200D includes a battery controller 220D and a communications interface 225D. It should be understood that each battery pack 200 includes additional components, such as the components described above with respect to FIG. 2, which are not illustrated in FIG. 9 for sake of brevity. Also, although four battery packs 200 are illustrated in FIG. 9, the system 900 may include any number of battery packs. The battery packs 200 may be associated with (i.e., capable of being charged by) the same charger or separate charges. For example, in some embodiments, each battery pack 200 may be associated with a separate charger. However, in other embodiments, two or more of the battery packs 200 may be associated with the same charger, such as when a charger is a multi-bay charger as described herein.

[0080] In this configuration, a battery pack 200 is configured to communicate with another battery pack 200, such as, for example, using the communications interfaces 225A, 225B, 225C, 225D included in each of the battery packs 200 and use the communicated information to optimize charging of the packs 200. In some embodiments, the communications interfaces 225A, 225B, 225C, 225D include similar components, configurations, and performs similar functions as the communications interface 425 of FIG. 4 described above with respect to a charger 10. For example, the communications interfaces 225A, 225B, 225C, 225D may include a wireless interface or connection for communicating wirelessly, such as, for example, via Bluetooth low energy (“BLE”) connection, a Wi-Fi connection, a long range (“LoRa”) connection, a point-to-point or mesh network connection, etc. Alternatively or in addition, the battery packs 200 of the system 900 may be configured to communicate with each other over AC power lines associated with an outlet (see, e g., FIG. 10).

[0081] During operation, the battery packs 200 included in the system 900 communicate with each other and coordinate and optimize charging of the battery packs 200 by applying one or more optimization routines taking into account any user-defined settings, environmental parameters, and the parameters and status of the battery packs 200, such that charging of the battery packs 200 draws a current from the circuit breaker 705 that will not cause the circuit breaker 705 trip. In particular, the back packs 200 (or one of the packs designated as a master device) may perform all or a portion of the functionality described herein as being performed by a charger 10.

[0082] For example, to identify other battery packs to be considered as part of the charging optimization and control, the battery packs 200 included in the system 900 may transmit communications within a communication range and identify other battery packs 200 in proximity and / or connected to a common circuit breaker and / or outlet based on responses to such communications. For example, in some embodiments, a battery pack 200 may be configured to transmit a Bluetooth® advertisement via the communications interfaces to detect another battery pack 200 within a defined distance, such as within a communication range of the communication interface. In another example, a battery pack 200 may transmit a ping signal over an AC line. In some embodiments, a battery pack 200 included in the system 900 (e.g., on the same circuit breaker and / or outlet) may be detected by another battery pack 200, such as, for example, based on latency between nodes, a received signal strength indication (RSSI) based on a received signal from another battery pack 200, channel sounding, or the like. For example, a battery pack 200 may utilize latency between nodes, RSSI, channel sounding, or a combination thereof to estimate a distance between itself and another battery pack 200. In this example, a battery pack 200 can determine whether another battery pack 200 is connected to the same outlet and / or the same circuit breaker based on the estimated distance and a threshold distance, which may be defined according to a standard or known distances between outlets, circuit breakers, rooms, etc.

[0083] In response to identifying a group of battery packs (e.g., battery packs located in the same room and / or connected to the same circuit breaker), the battery packs 200 exchange data to optimize charging of the battery packs 200. For example, the battery controllers 220A, 220B, 220C, 220D may include similar components, configurations, and are configured to perform similar functionality as the controller 300 of the charger 10 described with respect to FIG. 3.Accordingly, the battery packs 200 included in the system 900 communicate (as described above) to exchange data and one or more of the battery controllers 220A, 220B, 220C, and 220D and apply one or more optimization routines to coordinate charging of the battery packs 200. For example, one of the battery packs 200 may be defined as the master and may, via the associated battery controller 220, control charging of the group of battery packs (e.g., control completion of constant current (“CC”) charging and constant voltage (“CV”) charging of the battery packs 200, such as, within a defined period of time (e.g., overnight)). Accordingly, in some embodiments, the battery packs 200 included in the system 900 can perform some or all of the functionality described in the method 600 executed by the controller 300 of the charger 10 for charging one or more battery packs connected to the charger 10 and / or some or all of the method 800 executed by one or more chargers 10 included in the system 700. In other words, functionality described as part of these methods 600 and 800 as being performed by a controller 300 of a charger 10 may be performed by a controller 220 of a battery pack 200, wherein the battery pack 200 communicates with an associated charger (or a separate charger directly or through a battery pack associated with the separate charger) to control charging of a plurality of battery packs 200.

[0084] Also, in some embodiments, the system 900 may be combined with the system 700 such that battery -to-battery communication, charger-to-charger communication, or a combination thereof (i.e., battery -to-charger communication) is implemented to optimize charging for a plurality of battery packs 200 as described herein. For example, in some embodiments, depending on the charger used with a particular battery pack 200 (e.g., when a charger is not configured to communicate with other chargers), the battery pack 200 may communicate with another charger 10, another battery pack 200, or a combination thereof, to optimize charging through the system 900. Thus, the disclosure provides, among other things, a distributed and networked battery charging system. Various features and advantages of the disclosure are set forth in the following claims.

Claims

CLAIMSWhat is claimed is:

1. A system for charging networked power tool battery packs, the system including: a first battery pack charger electrically connected to a power input; a second battery pack charger electrically connected to the power input, the second battery pack charger configured to communicate with the first battery pack charger; a plurality of battery packs, each of the plurality of battery packs connected to one of the first battery pack charger and the second battery pack charger; and an electronic controller having a processor and memory, wherein the electronic controller is configured to: obtain information associated with the first battery pack charger, obtain information associated with the second battery pack charger, and control a charge operation of each of the plurality of battery packs based on the information associated with the first battery pack charger and the information associated with the second battery pack charger.

2. The system of claim 1, wherein the information associated with the first battery pack charger includes a remaining charging time for a first battery pack connected to the first battery pack charger and the information associated with the second battery pack charger includes a remaining charging time for a second battery pack, and wherein the electronic processor is configured to control the charge operation by: selecting one of the first battery pack charger and the second battery pack charger as the selected battery pack charger based on whether the first battery pack or the second battery pack has a least amount of remaining charging time, andassigning an increased charging power level to the selected battery pack charger and assigning a reduced charging power level to a non-selected battery pack charger.

3. The system of claim 1, wherein the electronic controller is configured to obtain the information associated with the first battery pack charger from the first battery pack charger over at least one selected from a group consisting of a wired communication connection, a wireless communication connection, and a power line.

4. The system of claim 1, wherein the electronic processor is configured to control the charge operation based on a user-defined setting.

5. The system of claim 4, wherein the user-defined setting is an optimization routine from a plurality of available routines.

6. The system of claim 4, wherein the user-defined setting is a maximum charging current.

7. The system of claim 4, wherein the user-defined setting is a stop charging state of charge.

8. The system of claim 1, wherein the electronic processor is included in the second battery pack charger.

9. A battery pack charger comprising: a battery pack interface; a memory; an electronic processor; and a communications interface configured to receive a user-defined setting from a remote device over a wireless communication connection; wherein the electronic processor is configured to: store the user-defined setting or data derived therefrom in the memory; and supply charging power to a battery pack connected to a battery pack interface based on the stored user-defined setting.

10. The battery pack charger of claim 9, wherein the user-defined setting includes at least one selected from the group consisting of a maximum charging current and a stop charging state of charge.

11. A battery pack charger comprising: a battery pack interface; a memory; an electronic processor; and a communications interface configured to receive a user-defined setting from a remote device over a wireless communication connection; wherein the electronic processor is configured to communicate the user-defined setting or data derived therefrom to a battery connected to the battery pack interface.

12. The battery pack charger of claim 11, wherein the user-defined setting includes at least one selected from the group consisting of a maximum charging current and a stop charging state of charge.

13. A system for charging networked power tool battery packs, the system including: at least one battery pack charger electrically connected to a power input; a plurality of battery packs, each of the plurality of battery packs connected to the at least one battery pack charger, a first battery pack of the plurality of battery packs configured to communicate with a second battery pack of the plurality of battery packs; and an electronic controller having a processor and memory, wherein the electronic controller is configured to: obtain information associated with the first battery pack, obtain information associated with the second battery pack, and control a charge operation of each of the plurality of battery packs based on the information associated with the first battery pack and the information associated with the second battery pack.

14. The system of claim 13, wherein the information associated with the first battery pack includes a remaining charging time for the first battery pack connected to the at least one battery pack charger and the information associated with the second battery pack includes a remaining charging time for the second battery pack, and wherein the electronic processor is configured to control the charge operation by: selecting one of the first battery pack and the second battery pack as the selected battery pack based on whether the first battery pack or the second battery pack has a least amount of remaining charging time, and assigning an increased charging power level to the selected battery pack and assigning a reduced charging power level to a non-selected battery pack.

15. The system of claim 13, wherein the electronic controller is configured to obtain the information associated with the first battery pack of the plurality of battery packs from the firstbattery pack over at least one selected from a group consisting of a wired communication connection, a wireless communication connection, and a power line.

16. The system of claim 13, wherein the electronic processor is configured to control the charge operation based on a user-defined setting.

17. The system of claim 16, wherein the user-defined setting is an optimization routine from a plurality of available routines.

18. The system of claim 16, wherein the user-defined setting is a maximum charging current.

19. The system of claim 16, wherein the user-defined setting is a stop charging state of charge.

20. The system of claim 13, wherein the electronic processor is included in the at least one battery pack charger.

21. The system of claim 13, wherein the electronic processor is included in at least one of the first battery pack and the second battery pack.

22. The system of claim 16, wherein each of the plurality of battery packs includes a communications interface configured to receive the user-defined setting from a remote device over a wireless communication.

23. The system of claim 16, wherein the at least one battery pack charger includes a communications interface configured to receive the user-defined setting from a remote device over a wireless communication.

24. The system of claim 13, wherein the electronic processor is configured to determine that the first battery pack and the second battery pack are connected to a common circuit breaker or a common outlet based on the information associated with the first battery pack and the information associated with the second battery pack.

25. The system of claim 13, wherein the first battery pack and the second battery pack communicate the information associated with the first battery pack and the information associated with the second battery pack over at least one selected from a group consisting of a wired communication connection, a wireless communication connection, and a power line, wherein the information associated with the first battery pack includes a remaining charging time for the first battery pack and the information associated with the second battery pack charger includes a remaining charging time for the second battery pack.

26. A battery pack charger comprising: a battery pack interface; a memory; an electronic processor; and a communications interface configured to receive a user-defined setting from a battery pack connected to the battery pack interface; wherein the electronic processor is configured to: store the user-defined setting or data derived therefrom in the memory; and supply charging power to the battery pack connected to the battery pack interface based on the stored user-defined setting.

27. The battery pack charger of claim 26, wherein the user-defined setting includes at least one selected from the group consisting of a maximum charging current and a stop charging state of charge.

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