Automatic output power limiting electrical device

• US 7,088,066 B2
• Filed: 06/21/2004
• Issued: 08/08/2006
• Est. Priority Date: 06/21/2004
• Status: Expired due to Fees

• Current Assignee: THOR Power Corporation
• Original Assignee: THOR Power Corporation
• Inventors: Haller, William R.
• Primary Examiner(s): Donovan, Lincoln
• Assistant Examiner(s): COLON SANTANA, EDUARDO
• Application Number:
  US10/873,536
• Publication Number:
  US 20050280385A1
• Time in Patent Office: 778 Days
• Field of Search: 318/700, 318/729, 318799-811, 318720-724, 318/254, 318/439, 318599-603, 318/434, 318/798, 318/139, 318/432, 388809-823, 388/904, 388/918, 388/930, 388/937, 388/907.5, 323/201, 173/2, 173/217, 173/176, 173/4, 173/5, 173/7, 173/11, 814/67, 814/69
• US Class Current: 318/432
• CPC Class Codes: H02M 1/0022 the disturbance parameters being input voltage fluctuations
• CPC Class Codes: H02M 1/10 Arrangements incorporating converting means for enabling loads to be operated at will from different kinds of power supplies, e.g. from ac or dc
• CPC Class Codes: H02P 23/26 Power factor control [PFC]
• CPC Class Codes: H02P 29/40 Regulating or controlling the amount of current drawn or delivered by the motor for controlling the mechanical load
• CPC Class Codes: Y10S 388/93 Load or torque
• CPC Class Codes: Y10S 388/937 Hand tool

Abstract

An eletrical device derives power from an incoming power source to produce output plower to drive the device. The device includes circuitry that determines at lehst one characteristic of the incoming power source, and adjusts the output power used to drive the device based on the characteristic or characteristics of the incoming power source.

Claims

1. An electrically powered device deriving power from an incoming ac power source to produce output power to drive the device regardless of whether the incoming ac power source is of a first type of vower source or a second type of power source, the first type of power source having a higher voltage and lower frequency than the second type of power source having a lower voltage and higher frequency than the first type of power source, the device comprising:

a first input power line and a second input power line, said first and second input power lines being connected to said incoming power source and having opposite polarity;

first circuitry, connected to the second input power line, that determines the current drawn from the incoming power source; and

second circuitry that receives a signal from said first circuitry indicative of the current drawn from the incoming power source and that modulates the voltage on the first input power line to drive the device, based on at least the signal from said first circuitry indicative of the current drawn from of the incoming power source, using a high output power if it is determined that the incoming power source is a higher voltage and lower frequency power source and using a low output power if it is determined that the incoming power source is a lower voltage and higher frequency power source.

2. The device of claim 1, wherein the device comprises at least one brushless DC motor and wherein the second circuitry that drives the device drives the at least one brushless DC motor with DC output power.

3. The device of claim 2, wherein the device is a power tool.

4. The device of claim 1, wherein the first circuitry that determines the current drawn from the incoming power source comprises at least one controller adapted for:

sensing the current drawn from the incoming power source and comparing the current to one or more previously set reference values; and

providing a control signal for adjusting the power output to drive the device based on the type incoming power source.

5. The device of claim 4, wherein the at least one controller provides a control signal to increase the output power to drive the device based on at least the signal from said first circuitry indicative of the current drawn from the incoming power source.

6. The device of claim 4, wherein the controller determines the current drawn from the incoming power and provides a control signal for adjusting the power output to drive the device based on the current drawn from the incoming power source.

7. The electrically powered device of claim 1, wherein the device derives power from the incoming AC power source to produce DC output power to drive the device, the device comprising:

at least one brushless DC motor; and

at least one controller adapted for;

determining the current drawn from the incoming AC power source, and

adjusting the DC output power to drive the at least one brushless DC motor based on at least the current drawn from the incoming AC power source.

8. The electrically powered device of claim 1, wherein the device derives power from the incoming AC power source to produce DC output power to drive the device, the device comprising:

at least one brushless DC motor; and

at least one controller adapted for;

determining at least one of a voltage and a frequency of the incoming AC power source, and

increasing the DC output power to drive the at least one brushless DC motor, if it is determined that the incoming power source is a high voltage and low frequency power source.

9. A device for driving an electrically powered device regardless of whether an incoming ac power source is of a first type of power source or a second type of power source, the first type of power source having a higher voltage and lower frequency than the second type of power source having a lower voltage and higher frequency than the first type of power source, comprising:

a first input input power line of positive polarity and a second input power line of negative polarity, said first and second input power lines being connected to said incoming power source;

first circuitry, connected to the second input power line, that determines the current drawn from the incoming power source; and

second circuitry that receives a signal from said first circuitry indicative of the current drawn from the incoming power source and that provides an output signal based on the at least the signal from said first circuitry indicative of the current drawn from the incoming power source and modulating the voltage on the first input power line to drive the device, using a high output power level if it is determined that the incoming power source is a higher voltage and lower frequency power source, and using a low output power level if it is determined that the incoming power source is a lower voltage and higher frequency power source.

10. The device of claim 9, wherein the electrically powered device comprises at least one brushless DC motor and wherein the second circuitry that drives the device drives the at least one brushless DC motor with DC output power.

11. The device of claim 9, wherein the first circuitry for determining the current drawn from the incoming power source comprises at least one controller adapted for:

sensing the current drawn from the incoming power source and comparing the current to one or more previously set reference values; and

providing a control signal for adjusting the power output to drive the electrically powered device based on the type of incoming power source.

12. The device of claim 11, wherein the at least one controller provides a control signal to increase the output power to drive the electrically powered device based on at least the signal from said first circuitry indicative of the current drawn from the incoming power source.

13. The device of claim 11, wherein the controller determines current drawn from the incoming power source and provides a control signal for adjusting the power output to drive the electrically powered device based on at least current drawn from the incoming power source.

14. A method for driving an electrically powered device regardless of whether an incoming ac power source is of a first type of power source or a second type of power source, the first type of power source having a higher voltage and lower frequency than the second type of power source having a lower voltage and higher frequency than the first type of power source, comprising:

determining at least the current drawn from the incoming power source on a first input power line or second input power line, the first and second input power lines having opposite polarity; and

modulating power on the first input power line to drive the electrically powered device based on at least the current drawn from the incoming power source, using a high output power level if it is determined that the incoming power source is a higher voltage and lower frequency power source, and using a low output power level if it is determined that the incoming power source is a lower voltage and higher frequency power source.

15. The method of claim 14, wherein the electrically powered device comprises at least one brushless DC motor and wherein the output power is adjusted to drive the at least one brushless DC motor with DC output power.

16. The method of claim 14, wherein the step of determining the current drawn from the incoming power source comprises sensing the current drawn from the incoming power source and comparing the current drawn from the incoming power source to one or more previously set reference values;

and

wherein the step of modulating the power output to drive the electrically powered device comprises providing a control signal to drive the electrically power device based on the current drawn from the incoming power source.

17. The method of claim 14, wherein the output power to drive the electrically powered device is increased based on the current drawn from the incoming power source.