Modular Gas Engine Replacement Electronics for Expandable Power Tools

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Solution Overview

Problem

Existing power equipment using gas engines requires refueling and produces emissions, and lacks configurability for various applications and user preferences.

Innovation Solution

A gas engine replacement device using a lithium-ion battery pack and electric brushless motor, which allows for expandable functionality through external electronics modules that can be interfaced with the device.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If gas engines are used to drive power equipment, then power and productivity are maintained, but emissions are produced and refueling is required

Engineering Contradiction:

ImproveemissionsVSAvoidpower output

Core Design Contradiction:

Object-affected harmful factorsVSProductivity

Solution Approach 1:

The patent replaces the gas engine (mechanical combustion system) with an electric motor driven by a battery pack. This substitution eliminates emissions and refueling requirements while maintaining the power output needed to drive power equipment, directly resolving the contradiction between harmful factors and productivity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Adaptability or versatility

If gas engines are used, then power output is maintained, but configurability for various applications is limited

Engineering Contradiction:

ImproveconfigurabilityVSAvoidpower output

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The patent segments the power system into modular components: a battery pack, an electric motor, and interchangeable external electronics modules. This segmentation allows different module configurations to be attached to the base power unit, enabling adaptability across various applications while maintaining consistent power output from the motor.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent creates a universal power platform where the battery-motor combination can perform multiple functions by interfacing with different external electronics modules. The module interface allows a single power unit to be configured for various applications (e.g., different attachments for cutting, grinding, drilling) without sacrificing power output.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If external electronics modules are added for feature expansion, then adaptability and functionality are improved, but device complexity increases

Engineering Contradiction:

Improveexpandable functionalityVSAvoidsystem complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent divides the electronic control system into a central controller and separate, interchangeable external electronics modules. Each module performs a specific function (e.g., motor control, battery management, user interface), allowing functionality to be expanded by adding modules without redesigning the entire system. This modular approach increases adaptability while managing complexity through standardized interfaces.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces a standardized module interface as an intermediary between the core power system and various external electronics modules. This interface layer simplifies connections and communications, allowing different modules to be added or removed without increasing the complexity of the core system. The interface acts as a mediator that handles the complexity of module integration transparently.

Inventive Principle:

Principle #24Intermediary (Mediator)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Eliminates the need for refueling and emissions, while providing configurability and expandable features to meet diverse application needs.

Implementation Method 1

lithium-ion battery packs

Methodology Applied

Scientific EffectBattery (electricity): Battery (electricity)

Implementation Method 2

electric brushless motors

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS20250293572A1Gas engine replacement electronics modularity for feature expansion

Publication Date: 2025.09.18 MILWAUKEE ELECTRIC TOOL CORP

AI summary

A method for expanding features of a gas engine replacement device that drives power equipment including controlling, by an electronic processor of the gas engine replacement device, a power switching network to selectively provide power from a battery pack to rotate a motor of the gas engine replacement device. A module interface of the gas engine replacement device receives an external electronics module. A type of the external electronics module received by the module interface is detected by the electronic processor of the gas engine replacement device. The gas engine replacement device is configured by the electronic processor based on the type of the received external electronics module. The electronic processor communicates with the external electronics module via the module interface.