Cordless power system with system component identification and/or battery pack control

• US 7,723,952 B2
• Filed: 10/14/2005
• Issued: 05/25/2010
• Est. Priority Date: 10/18/2004
• Status: Expired due to Fees

• Current Assignee: Black & Decker Incorporated (Stanley Black & Decker, Inc.)
• Original Assignee: Black & Decker Incorporated (Stanley Black & Decker, Inc.)
• Inventors: Francis, Jeffrey J., Carrier, David A., Brotto, Daniele C., Phillips, Steven J., Seman, Andrew E. Jr., White, Daniel J., Yahnker, Christopher R., Watson, James B., Trinh, Danh T.
• Primary Examiner(s): Tso; Edward
• Assistant Examiner(s): WILLIAMS, ARUN C
• Application Number:
  US11/251,368
• Publication Number:
  US 20060087285A1
• Time in Patent Office: 1,684 Days
• Field of Search: 320/106, 320/110, 320/112, 320/113, 320/114, 320/115, 307/64, 307/65, 307/66, 307/85, 307/86, 307/87, 307/150, 307/151, 307/152, 307/153, 307/154, 307/155, 310/50, 340/636.1
• US Class Current: 320/114
• 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: B25F 5/02 Construction of casings, bodies or handles B25F5/006, B25F5/008 take precedence
• CPC Class Codes: H01M 10/052 Li-accumulators
• CPC Class Codes: H01M 10/0525 Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries
• CPC Class Codes: H01M 10/4207 for several batteries or cells simultaneously or sequentially
• CPC Class Codes: H01M 10/4257 Smart batteries, e.g. electronic circuits inside the housing of the cells or batteries
• CPC Class Codes: H01M 10/441 for several batteries or cells simultaneously or sequentially
• CPC Class Codes: H01M 50/204 Racks, modules or packs for multiple batteries or multiple cells
• CPC Class Codes: H01M 50/247 specially adapted for portable devices, e.g. mobile phones, computers, hand tools or pacemakers
• CPC Class Codes: H01M 50/296 characterised by terminals of battery packs terminals of batteries H01M50/543
• CPC Class Codes: H01M 6/42 Grouping of primary cells into batteries H01M6/40 takes precedence
• CPC Class Codes: H02J 7/00 Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries
• CPC Class Codes: H02J 7/00036 Charger exchanging data with battery
• CPC Class Codes: H02J 7/00047 with provisions for charging different types of batteries
• CPC Class Codes: H02J 7/0042 characterised by the mechanical construction
• CPC Class Codes: H02J 7/0063 with circuits adapted for supplying loads from the battery
• CPC Class Codes: H02J 7/0068 Battery or charger load switching, e.g. concurrent charging and load supply H02J7/0013 takes precedence
• CPC Class Codes: H02J 7/00711 with introduction of pulses during the charging process
• CPC Class Codes: H02J 7/00714 in response to battery charging or discharging current
• CPC Class Codes: H02J 7/007182 in response to battery voltage
• CPC Class Codes: H02J 7/007194 : of the battery
• CPC Class Codes: Y02E 60/10 : Energy storage using batteries

Abstract

A cordless system has cordless system components that include a cordless device, such as a cordless power tool, a battery pack and a charger. The battery pack is mated with either the cordless device to provide power to operate the cordless device or to the charger to charge the battery cells in the battery pack. In an aspect, the cordless system has an identification and communication system by which the battery pack identifies and communicates information about the battery pack to the cordless device or to the charger to which the battery pack is mated. In an, the battery pack of the cordless system is capable of multiple modes, such as controlling the cordless device and controlling the charger. In an aspect, the battery pack validates the cordless device or charger to which it is mated. in an aspect of the invention, the cordless system uses any of a wired interface, radio frequency interface, an optical interface or a magnetic interface to communicate information between the battery pack and the cordless device or charger to which the battery pack is mated. In an aspect, female terminals are used in a terminal block of the battery pack to protect against foreign objects contacting the terminals. In aspect, the terminals in the terminal block of the battery pack are staggered or scattered to reduce the likelihood of a short circuit. In an aspect of the invention, the battery pack has a trap door that closes when the battery pack is not mated to a cordless device or charger to protect the terminal block of the battery pack. In an aspect of the invention, multi-spring, split contact terminals are used in the terminal block of at least one of the cordless system components. In an aspect of the invention, the battery cells are Lithium Ion battery cells.

Claims

1. A method of controlling a power tool in a cordless power tool system having a plurality of system components including a battery pack and the cordless power tool, the cordless power tool having a controller, the method comprising determining with the power tool controller a level of intelligence of the battery pack including whether the battery pack includes a controller and upon determining that the battery pack includes a controller, determining with the power tool controller and the battery pack controller which of the power tool controller and battery pack controller control a discharge profile of the battery pack, and upon determining that the battery pack does not include a controller, controlling the discharge profile of the battery pack with the power tool controller.

2. The method of claim 1 including initializing discharge parameters with the controller that controls the discharge profile of the battery pack, reading user input with that controller and, with that controller, setting a speed and the discharge profile of the battery pack to control a motor of the power tool based on the discharge parameters and the user input.

3. The method of claim 2 wherein reading the user input includes reading a signal from a trigger switch.

4. The method of claim 1 wherein upon determining that the battery pack does not include a controller, determining with the power tool controller whether the battery pack includes an EEPROM or analog identification component and with the power tool controller reading the EEPROM or analog identification component and initializing discharge parameters based on the information read from the EEPROM or analog identification component.

5. The method of claim 4 including reading with the power tool controller a signal from a trigger switch and setting a speed and the discharge profile based on the signal from the trigger switch and the discharge parameters to control a speed of the power tool motor.

6. A cordless power tool system, comprising:

a battery pack and a power tool coupled to the battery pack;

the power tool including a controller;

the power tool controller configured to check the battery pack to determine if the battery pack includes any of a controller, EEPROM or analog identification component; and

whereupon upon the power tool controller determining that the battery pack includes a controller, the battery pack controller and the power tool controller determine whether the power tool controller or the battery pack controller controls a discharge profile of the battery pack.

7. The system of claim 6 wherein whichever of the battery pack controller and the power tool controller that is controlling the discharge profile of the battery pack initializes discharge parameters.

8. The system of claim 7 wherein the power tool controller reads a user input and the one of the battery pack controller and power tool controller that is controlling the discharge profile of the battery pack sets a speed and discharge profile of the battery pack for controlling a motor of the power tool based on the user input and discharge parameters.

9. The system of claim 8 wherein the user input is a signal from a trigger switch.

10. The system of claim 6 wherein the power tool controller, upon determining that the battery pack level of intelligence includes the EEPROM or analog identification component, is configured to read the EEPROM or analog identification component and initialize discharge parameters based on information read from the EEPROM or analog identification component.

11. The system of claim 10 wherein the power tool controller reads a user input and sets a speed and a discharge profile of the battery pack for controlling a motor of the power tool based on the user input and the discharge parameters.

12. The system of claim 11 wherein the user input is a signal from a trigger switch.

13. The system of claim 6 wherein the battery pack includes a hybrid analog/digital identification and communication system.

14. The system of claim 6 wherein the battery pack includes a digital identification and communication system that communicates only digitally with the system component to which the battery pack is coupled.

15. The system of claim 14 wherein the battery pack includes analog identification components coupled to the digital identification and communication system that identify parameters of the battery pack to the digital identification and communication system.

16. The system of claim 6 wherein the battery pack includes an analog only identification and communication system.

17. The system of claim 6 wherein the battery pack includes a mechanical identification system.

18. The system of claim 17 wherein the mechanical identification system includes switch actuating elements that actuate switches in the system component to which the battery pack is coupled.