Power tool battery pack with wireless communication

• US 10,408,884 B2
• Filed: 03/16/2017
• Issued: 09/10/2019
• Est. Priority Date: 03/16/2016
• Status: Active Grant

• Current Assignee: TTi (Macao Commercial Offshore) Limited (Techtronic Industries Company Limited)
• Original Assignee: TTi (Macao Commercial Offshore) Limited (Techtronic Industries Company Limited)
• Inventors: Willey, Brent M.
• Primary Examiner(s): Nguyen, Vincent Q
• Application Number:
  US15/461,067
• Publication Number:
  US 20170269167A1
• Time in Patent Office: 908 Days
• Field of Search: 324426-434, 320124, 320125
• CPC Class Codes: B25F 5/00 Details or components of portable power-driven tools not particularly related to the operations performed and not otherwise provided for
• CPC Class Codes: G01R 31/3648 comprising digital calculation means, e.g. for performing an algorithm
• CPC Class Codes: G01R 31/371 with remote indication, e.g. on external chargers
• CPC Class Codes: G01R 31/382 Arrangements for monitoring battery or accumulator variables, e.g. SoC
• CPC Class Codes: G01R 31/396 Acquisition or processing of data for testing or for monitoring individual cells or groups of cells within a battery
• CPC Class Codes: H01M 10/425 Structural combination with electronic components, e.g. electronic circuits integrated to the outside of the casing printed circuits H05K1/00
• CPC Class Codes: H01M 10/482 for several batteries or cells simultaneously or sequentially
• CPC Class Codes: H01M 10/488 Cells or batteries combined with indicating means for external visualization of the condition, e.g. by change of colour or of light density
• CPC Class Codes: H01M 2010/4271 Battery management systems including electronic circuits, e.g. control of current or voltage to keep battery in healthy state, cell balancing
• CPC Class Codes: H01M 2220/30 Batteries in portable systems, e.g. mobile phone, laptop
• CPC Class Codes: H01M 50/569 Constructional details of current conducting connections for detecting conditions inside cells or batteries, e.g. details of voltage sensing terminals battery terminal connectors with integrated measuring arrangements G01R31/364
• CPC Class Codes: H02J 7/0047 with monitoring or indicating devices or circuits
• CPC Class Codes: Y02E 60/10 Energy storage using batteries

Abstract

Trigger pull tracking, charge time estimation, and other features for a power tool battery pack with wireless communication. A battery pack system includes a power tool battery pack and a processor. The battery pack includes a plurality of cells and a voltage sensor connected to the plurality of cells. The processor is in communication with the voltage sensor that detects a voltage across the plurality of cells using the voltage sensor. The processor further converts the voltage across the plurality of cells to a state of charge; determines a charge rate of a charger charging the battery pack; and determines a conversion factor based on the charge rate. The processor then generates a time to full charge of the battery pack based on the state of charge, the charge rate, and the scalar conversion factor. The processor may further generate current traces for the battery pack.

Claims

1. A method for charge time generation for a battery pack configured to be attached to a power tool, the method comprising:

detecting, by a processor, a voltage across a plurality of cells of the battery pack using a voltage sensor;

converting, by the processor, the voltage across the plurality of cells to a state of charge;

determining, by the processor, a bulk charge rate of a charger charging the battery pack;

calculating, by the processor, a scalar conversion factor based on a ratio of the bulk charge rate of the charger and a capacity of the battery pack; and

generating, by the processor, a time to full charge of the battery pack based on the state of charge and the scalar conversion factor.

2. The method of claim 1, wherein the processor is included in the battery pack and is configured to communicate with a mobile application on a mobile device over a wireless communication network, the method further comprising:

outputting the time to full charge to the mobile application; and

displaying, on the mobile device, the time to full charge.

3. The method of claim 1, wherein determining, by the processor, the bulk charge rate of the charger comprises:

receiving, via a user interface of a mobile application, a selection of a charger type of the charger from a plurality of charger types, wherein the plurality of charger types are associated with a plurality of charge rates.

4. The method of claim 1, further comprising:

detecting, by the processor, that a trigger of the power tool is activated;

detecting, by the processor, a current output of the plurality of cells of the battery pack;

storing, in a memory of the battery pack by the processor, the current output as a current trace; and

continuing to store the current output as the current trace until the trigger is released.

5. The method of claim 4, further comprising:

determining, by the processor, whether the current output deviates from an expected current output stored in the memory; and

generating, by the processor, an alert in response to the processor determining that the current output deviates from the expected current output.

6. The method of claim 1, further comprising:

comparing the voltage across the plurality of cells to a first predetermined voltage indicating a charge complete status of the battery pack; and

when the voltage is equal to or greater than the first predetermined voltage, sending a signal to a speaker of the battery pack to produce an audio output.

7. The method of claim 1, wherein the battery pack is configured to communicate with a mobile application on a mobile device over a wireless communication network, the method further comprising:

detecting an activation of a reverse locator button on the battery pack; and

sending a notification to the mobile application based on detecting the activation of the reverse locator button.

8. The method of claim 1, wherein the battery pack is configured to communicate with a mobile application on a mobile device over a wireless communication network, the method further comprising:

detecting, by a current sensor connected to the plurality of cells, that a current is flowing through the plurality of cells;

sending, by the processor, a first signal indicating that the battery pack is in-use to the mobile application;

displaying, on a user interface of the mobile application, a first indication that the battery pack is in-use;

detecting, by the current sensor, that no current is flowing through the plurality of cells;

sending, by the processor, a second signal indicating that the battery pack is idle to the mobile application; and

displaying, on the user interface, a second indication that the battery pack is idle.

9. A battery pack system including a battery pack configured to be attached to a power tool, the battery pack system comprising;

a plurality of cells of the battery pack;

a voltage sensor of the battery pack connected to the plurality of cells; and

a processor in communication with the voltage sensor and a memory and configured to;

detect, by the processor, a voltage across the plurality of cells using the voltage sensor;

convert the voltage across the plurality of cells to a state of charge;

determine a bulk charge rate of a charger charging the battery pack;

determine a scalar conversion factor based on the charge rate based on a ratio of the bulk charge rate of the charger and a capacity of the battery pack; and

generate a time to full charge of the battery pack based on the state of charge and the scalar conversion factor.

10. The battery pack system of claim 9, wherein the memory stores a look-up table having a mapping between a plurality of state of charge values and a plurality of voltage ranges and wherein the processor is configured to convert the voltage across the plurality of cells to the state of charge using the look-up table.

11. The battery pack system of claim 9, further comprising:

a temperature sensor; and

wherein the processor is coupled to the temperature sensor and is further configured to;

determine, based on the temperature sensor output, a temperature of the plurality of cells;

determine whether the temperature is within a predetermined temperature range; and

when the temperature is outside of the predetermined temperature range, suspend generation of the time to full charge.

12. The battery pack system of claim 9, wherein, to determine the bulk charge rate of the charger, the processor is configured to determine a charger type, which is associated with the bulk charge rate, and, to determine the charger type, the processor is configured to:

record an initial voltage of the plurality of cells;

record a second voltage of the plurality of cells at a predetermined time period after recording the initial voltage; and

determine a normalized voltage rise based on the initial voltage, the second voltage, and a normalization factor of the battery pack.

13. The battery pack system of claim 9, further comprising:

a current sensor connected to the plurality of cells; and

wherein the processor is coupled to the current sensor and is further configured to;

detect that a trigger of the power tool is activated;

detect, by the current sensor, a current output of the plurality of cells;

store, in the memory, the current output until the trigger is released to form a current trace;

determine whether the current output deviates from an expected current output stored in the memory; and

in response to the determining that the current output deviates from the expected current output, generate an alert.

14. The battery pack system of claim 9, further comprising:

a speaker included in the battery pack; and

wherein the processor is coupled to the speaker and is further configured to;

compare the voltage across the plurality of cells to a first predetermined voltage indicating a charge complete status of the battery pack; and

when the voltage is equal to or greater than the first predetermined voltage, send a signal to the speaker to produce an audio output.

15. A method for charge time generation for a battery pack configured to be attached to a power tool, the method comprising:

detecting, by a processor, a voltage across a plurality of cells of the battery pack using a voltage sensor;

converting, by the processor, the voltage across the plurality of cells to a state of charge;

determining, by the processor, a charge rate of the charger charging the battery pack, wherein determining the charge rate of the charger includes

receiving, via a user interface of a mobile application, a selection of a charger type of a charger charging the battery pack from a plurality of charger types, wherein the plurality of charger types are associated with a plurality of charge rates;

determining, by the processor, a conversion factor based on the charge rate; and

generating, by the processor, a time to full charge of the battery pack based on the state of charge and the conversion factor.

16. A method for charge time generation for a battery pack configured to be attached to a power tool, the method comprising:

detecting, by a processor, a voltage across a plurality of cells of the battery pack using a voltage sensor;

converting, by the processor, the voltage across the plurality of cells to a state of charge;

determining, by the processor, a charge rate of a charger charging the battery pack;

determining, by the processor, a conversion factor based on the charge rate;

generating, by the processor, a time to full charge of the battery pack based on the state of charge and the conversion factor;

detecting, by the processor, that a trigger of the power tool is activated;

detecting, by the processor, a current output of the plurality of cells of the battery pack;

storing, in a memory of the battery pack by the processor, the current output as a current trace; and

continuing to store the current output as the current trace until the trigger is released.

17. A method for charge time generation for a battery pack configured to be attached to a power tool, the method comprising:

detecting, by a processor, a voltage across a plurality of cells of the battery pack using a voltage sensor;

converting, by the processor, the voltage across the plurality of cells to a state of charge;

determining, by the processor, a charge rate of a charger charging the battery pack;

determining, by the processor, a conversion factor based on the charge rate;

generating, by the processor, a time to full charge of the battery pack based on the state of charge and the conversion factor, wherein the battery pack is configured to communicate with a mobile application on a mobile device over a wireless communication network;

detecting an activation of a reverse locator button on the battery pack; and

sending a notification to the mobile application based on detecting the activation of the reverse locator button.

18. A method for charge time generation for a battery pack configured to be attached to a power tool, the method comprising:

detecting, by a processor, a voltage across a plurality of cells of the battery pack using a voltage sensor;

converting, by the processor, the voltage across the plurality of cells to a state of charge;

determining, by the processor, a charge rate of a charger charging the battery pack;

determining, by the processor, a conversion factor based on the charge rate;

generating, by the processor, a time to full charge of the battery pack based on the state of charge and the conversion factor, wherein the battery pack is configured to communicate with a mobile application on a mobile device over a wireless communication network;

detecting, by a current sensor connected to the plurality of cells, that a current is flowing through the plurality of cells;

sending, by the processor, a first signal indicating that the battery pack is in-use to the mobile application;

displaying, on a user interface of the mobile application, a first indication that the battery pack is in-use;

detecting, by the current sensor, that no current is flowing through the plurality of cells;

sending, by the processor, a second signal indicating that the battery pack is idle to the mobile application; and

displaying, on the user interface, a second indication that the battery pack is idle.

19. A battery pack system including a battery pack configured to be attached to a power tool, the battery pack system comprising;

a plurality of cells of the battery pack;

a voltage sensor of the battery pack connected to the plurality of cells;

a current sensor connected to the plurality of cells; and

a processor in communication with the voltage sensor, the current sensor and a memory and configured to;

detect, by the processor, a voltage across the plurality of cells using the voltage sensor;

convert the voltage across the plurality of cells to a state of charge;

determine a charger type of a charger charging the battery pack, the charger type associated with a charge rate;

determine the charge rate by

recording an initial voltage of the plurality of cells,

recording a second voltage of the plurality of cells at a predetermined time period after recording the initial voltage, and

determining a normalized voltage rise based on the initial voltage, the second voltage, and a normalization factor of the battery pack;

determine a conversion factor based on the charge rate based on the charge rate; and

generate a time to full charge of the battery pack based on the state of charge and the conversion factor.

20. A battery pack system including a battery pack configured to be attached to a power tool, the battery pack system comprising;

a plurality of cells of the battery pack;

a voltage sensor of the battery pack connected to the plurality of cells;

a current sensor connected to the plurality of cells; and

a processor in communication with the voltage sensor and a memory and configured to;

detect, by the processor, a voltage across the plurality of cells using the voltage sensor;

convert the voltage across the plurality of cells to a state of charge;

determine a charge rate of a charger charging the battery pack;

determine a conversion factor based on the charge rate based on the charge rate;

generate a time to full charge of the battery pack based on the state of charge and the conversion factor;

detect that a trigger of the power tool is activated;

detect, by the current sensor, a current output of the plurality of cells;

store, in the memory, the current output until the trigger is released to form a current trace;

determine whether the current output deviates from an expected current output stored in the memory; and

in response to the determining that the current output deviates from the expected current output, generate an alert.