Cordless electric lawn mower having energy management control system

• US 5,937,622 A
• Filed: 07/25/1996
• Issued: 08/17/1999
• Est. Priority Date: 07/26/1995
• Status: Expired due to Fees

• Current Assignee: Black & Decker Incorporated (Stanley Black & Decker, Inc.)
• Original Assignee: Black & Decker Incorporated (Stanley Black & Decker, Inc.)
• Inventors: Carrier, David A., Dyke, Colin M., Gifford, Carl W., Woods, Samuel G., Strong, David S.
• Primary Examiner(s): MELIUS, TERRY L
• Application Number:
  US08/686,743
• Time in Patent Office: 1,118 Days
• Field of Search: 56/11.9, 56/102 G, 56/10.2 R, 56/DIG. 15, 56/10.8, 56/16.7, 56/17.5, 56/DIG. 2
• US Class Current: 56/11.9
• CPC Class Codes: A01D 34/006 Control or measuring arrangements
• CPC Class Codes: A01D 34/78 electric
• CPC Class Codes: B60L 2200/40 Working vehicles
• CPC Class Codes: B60L 50/52 characterised by DC-motors
• CPC Class Codes: H02H 7/093 against increase beyond, or decrease below, a predetermined level of rotational speed centrifugal switches H01H35/10
• CPC Class Codes: Y02P 90/60 Electric or hybrid propulsion means for production processes
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y10S 56/15 Condition responsive

Abstract

A cordless electric mower having an energy management system that allows a user to operate the cutting blade motor of the mower at a wide range of user selected speeds. The mower is provided with a user adjustable throttle control which, when in the wide-open position allows the cutting blade motor to be rotated at a maximum, predetermined speed. When the throttle is set to some lesser speed, the system automatically implements a speed foldback routine whenever the mower encounters heavy loading which would result in an undesirably high current draw on the battery. When the speed foldback routine is implemented, the system limits the maximum amount of current that can be drawn by the motor until the excessive loading condition has been removed. Once the excessive loading condition has been removed, the speed foldback routine automatically increases the speed of the blade motor back up to almost the originally selected speed. This greatly improves the operating efficiency of the mower and thereby significantly extends the available operating time of the mower on a single charge. The state-of-charge of the battery is also monitored continuously during operation. An LED display provides the user with an indication of the approximate battery charge remaining.

Claims

1. An energy management system for use with a cordless, battery powered electric vegetation cutter having a cutting implement driven by an electric motor, the system comprising:

a user adjustable throttle control for setting the speed of said electric motor to a user selected reference speed;

a controller responsive to said throttle control for monitoring battery current being drawn by said electric motor and for generating a drive signal in accordance with said user selected reference speed;

said drive signal being incrementally reduced by said controller in the event said vegetation cutter experiences an excessive load, causing battery current drawn by said motor to exceed a threshold value, to thereby incrementally reduce the speed of said electric motor while the magnitude of said battery current drawn by said motor remains above said threshold, said drive signal being incrementally increased when said excessive load is removed such that said drive signal is increased at least close to the magnitude it was at prior to said cutting implement encountering said excessive load; and

a switching circuit responsive to said drive signal for applying power to said electric motor from said battery.

2. The system of claim 1, further comprising a visual display responsive to said controller for providing a user with an indication of the approximate state of charge of a battery of said vegetation cutter.

3. The system of claim 2, wherein said display comprises a plurality of light emitting diodes.

4. The system of claim 1, wherein said switching circuit comprises a plurality of field effect transistors for controllably applying current from said battery to said electric motor.

5. The system of claim 1, wherein said controller operates to reduce said speed of said electric motor by an amount in relation to the amount by which said battery current drawn exceeds said threshold value.

6. An energy management system for use with a cordless, battery powered electric vegetation cutter having a cutting implement driven by an electric motor and a battery for supplying power to said electric motor, said system comprising:

a user adjustable throttle control for setting the speed of said electric motor to a user selected reference speed;

a controller responsive to said throttle control for monitoring battery current being drawn by said electric motor and for generating a drive signal in accordance with said user selected reference speed;

said drive signal generated by said controller being reduced by said controller incrementally, while said battery current remains above a predetermined threshold value, to thereby reduce the speed of said electric motor in relation to the degree by which said battery current drawn by said motor exceeds said threshold value, when said vegetation cutter experiences an excessive load, to thereby cause the speed of said electric motor to be reduced by a value in relation to the amount by which current drawn by said motor exceeds said threshold value; and

a switching circuit responsive to said drive signal for applying power to said electric motor from said battery.

7. The system of claim 6, wherein said drive signal comprises a pulse-with-modulated drive signal;

and

wherein a duty cycle of said PWM drive signal is reduced in accordance with the degree by which said current exceeds that threshold value and is thereafter increased in predetermined increments when said excessive load is removed.

8. The system of claim 6, further comprising a display mounted on said vegetation cutter for providing a visual indication to a user thereof of a state of charge of said battery.

9. The system of claim 8, wherein said display comprises a light emitting diode display including a plurality of light emitting diodes illuminated by signals from said controller in accordance with the state of charge of said battery.

10. An energy management system for use with a cordless, battery powered electric vegetation cutter having a cutting implement driven by an electric motor and a battery for supplying power to said electric motor, the system comprising:

a user adjustable throttle control for setting the speed of said electric motor to a user selected reference speed;

a controller responsive to said throttle control for generating a drive signal for driving said electric motor in accordance with said user selected reference speed and for monitoring battery current drawn by said electric motor;

said controller operating to incrementally decrease said drive signal to said electric motor if said battery current exceeds a pre-determined threshold value indicating an excessive load, to thereby reduce the speed of said electric motor, and to continue to decrease said drive signal as long as said battery current is detected to be above said pre-determined threshold value, and to begin incrementally increasing said drive signal as soon as said battery current drops below said pre-determined threshold value such that said drive signal is increased at least close to a magnitude that said drive signal was at prior to said battery current exceeding said predetermined threshold value.

11. The system of claim 10, further comprising a plurality of field effect transistors responsive to said drive signal for controlling the application of said battery current to said electric motor.

12. The system of claim 11, further comprising a display for providing an indication of a state-of-charge of said battery to a user of said vegetation cutter.