Portable power driven equipment with internal combustion engine combined battery charging and starting circuit where the battery is a removable battery pack

• US 8,159,078 B2
• Filed: 04/20/2009
• Issued: 04/17/2012
• Est. Priority Date: 04/21/2008
• Status: Active Grant

• Current Assignee: Black & Decker Incorporated (Stanley Black & Decker, Inc.)
• Original Assignee: Black & Decker Incorporated (Stanley Black & Decker, Inc.)
• Inventors: Usselman, Robert A., McFarland, Dalton E., Grant, Jeffrey P.
• Primary Examiner(s): Leung, Quyen
• Assistant Examiner(s): Quinones, Jose Gonzalez
• Application Number:
  US12/426,825
• Publication Number:
  US 20090284022A1
• Time in Patent Office: 1,093 Days
• Field of Search: 290/1.A, 290/30, 290/34, 290/36.R, 290/38.R, 290/16, 320/112, 320/114, 320/137
• US Class Current: 290/1.A
• CPC Class Codes: F02D 29/06 peculiar to engines driving electric generators
• CPC Class Codes: F02N 11/0862 characterised by the electrical power supply means, e.g. battery
• CPC Class Codes: F02N 11/14 Starting of engines by means of electric starters with external current supply F02N11/12 takes precedence
• CPC Class Codes: F02N 2011/0888 DC/DC converters
• CPC Class Codes: H02J 7/1415 with a generator driven by a prime mover other than the motor of a vehicle

Abstract

A portable generator system having a generator for generating an electrical output signal, an internal combustion engine for driving the generator, a starter for starting the internal combustion engine, an alternator for generating an AC signal for powering a charger assembly, a battery pack, and a charger subsystem. The charger system has a charger assembly that receives the AC signal and generates a DC charging signal for recharging the battery pack. The charger assembly has a first switch and a second switch. The first switch is used to apply an output of the battery to energize the starter. The second switch, when placed in a Start position, enables current from the battery pack to energize the starter while inhibiting the application of the DC charging signal to the battery pack. When placed in the Charge position, the second switch inhibits the battery pack output from energizing the starter while enabling the DC charging signal to be applied to the battery pack.

Claims

1. A portable generator system comprising:

a generator for generating an electrical output signal;

an internal combustion engine for driving the generator;

a starter for starting the internal combustion engine;

an alternator for generating an AC signal for powering a charger assembly;

a battery pack;

a charger system including;

a charger assembly adapted to receive the AC signal and to generate a DC charging signal for recharging the battery pack, the charger assembly including;

a first user controllable switch for applying an output of the battery to the energize the starter; and

a second user controllable switch coupling the alternator and the charger assembly that, when in a Start position, enables current from the battery pack to be used to energize the starter while inhibiting the supply of the AC signal to the charger assembly, and when in a Charge position inhibits the battery pack output from being used to energize the starter while enabling the AC to be applied to the charger assembly.

2. The portable generator system of claim 1, wherein the second user controllable switch inhibits application of the DC charging current to the battery pack by the inhibiting of the AC signal from the alternator to the charger assembly.

3. The portable generator system of claim 1, wherein the second user controllable switch inhibits the application of the DC charging current to the battery pack by interrupting a signal path between an input of the charger assembly and the alternator.

4. The portable generator system of claim 1, further comprising a metallic frame for supporting the internal combustion engine, the generator, the starter, the alternator, and the charger subsystem, and wherein the charger assembly is electrically coupled to the metallic frame.

5. The portable generator system of claim 1, further comprising a metallic frame for supporting the internal combustion engine, the generator, the starter, the alternator, and the charger subsystem, and wherein the charger assembly is electrically isolated from the metallic frame.

6. The portable generator system of claim 1, further comprising an isolation transformer coupled between the alternator and the charger assembly.

7. The portable generator system of claim 1, wherein the alternator includes an isolated winding for generating the AC signal.

8. The portable generator system of claim 1, wherein the alternator includes a non-isolated winding for generating the AC signal.

9. A portable generator comprising:

an internal combustion engine;

a generator adapted to be driven by the internal combustion engine for generating AC power;

a starter for starting the internal combustion engine;

a battery socket assembly configured to supply an electrical signal to the starter to drive the starter during a start mode of operation of the generator;

a DC battery back adapted to be coupled to the battery socket assembly to provide DC power to the battery socket assembly, the DC power forming the electrical signal for powering the starter;

a first user engageable switch for controlling the application of DC power to the starter;

an alternator driven by the internal combustion engine and having an alternator winding for generating an AC signal;

a charger assembly responsive to the AC signal from the alternator winding, the charger assembly adapted to generate a DC charging current to recharge the battery pack when the battery pack is placed in the battery socket assembly;

a second user engageable switch in communication with the battery socket assembly, the second user engageable switch having;

a Charge position in which the AC signal from the alternator is applied to the charger assembly while the application of the DC power from the battery pack to the starter is inhibited, to thus enable a charging operation to be performed on the battery pack while disabling energization of the starter; and

a Start position in which the application of the AC signal to the charger assembly is inhibited while the application of the DC power from the battery pack to the starter is enabled, to thus inhibit a charging operation from being performed on the battery pack while enabling the DC power from the battery pack to be applied to the starter.

10. The generator of claim 9, further comprising a sensor for detecting the placement of the battery pack within the battery socket assembly and providing an electrical signal indicative thereof to the charger assembly.

11. The generator of claim 9, further comprising a charge indicator lamp for providing a visual indication that a charging operation is taking place on the battery pack.

12. The generator of claim 9, further comprising a starter solenoid responsive to the output from the battery socket assembly and controlled by the first switch for enabling the output from the battery socket assembly to be coupled to the starter.

13. The generator of claim 9, wherein the alternator winding comprises an isolated alternator winding.

14. The generator of claim 9, wherein the second switch, when in the Start position, inhibits application of the DC charging current to the battery pack by interrupting the AC signal from the alternating winding from being applied to the charger assembly.

15. The generator of claim 9, wherein the second switch, when in the Start position, inhibits application of the DC charging current to the battery pack by interrupting a signal path between the charger assembly and the alternator.

16. The generator of claim 9, wherein the generator includes a metal frame, and wherein the charger assembly is also electrically coupled to the metal frame.

17. The generator of claim 9, wherein the generator includes a metal frame, and wherein the charger assembly is electrically isolated from the metal frame.

18. A portable electrical generator system, comprising:

a wheeled frame supporting an internal combustion engine that drives a generator device supported on the frame, the generator device generating AC power, the internal combustion engine coupled to the generator device;

a starter device coupled to the internal combustion engine;

a control panel coupled to the frame having at least one AC outlet coupled to the generator device;

a charger assembly;

a charging control switch in communication with the charger assembly and moveable by a user between a Charge position and a Start position;

the frame supporting a battery receptacle electrically coupled to the starter, the battery receptacle configured to receive a cordless power tool battery pack;

the generator device having a winding coupled to the charger assembly through the charging control switch;

the charger assembly being electrically coupled to the battery receptacle;

the charging control switch, when in the Charge position and when the engine is running, coupling AC power provided by the winding to the charger assembly to energize the charger assembly, and

the charging control switch, when in the Start position, decoupling the AC power provided by the winding from the charger assembly to deenergize the charger assembly while enabling current from the battery pack to be applied to the starter.

19. The portable electrical generator system of claim 18, wherein the winding is electrically isolated from the frame.

20. A method for controlling charging of a battery pack used to start a portable generator, the method comprising:

Using an alternator winding of an alternator driven by an engine of the generator to produce an AC signal;

Using the AC signal to drive a charger assembly, the charger assembly operating to generate a DC charging signal for charging the battery pack;

Using a switch having a Start position and a Charge position, and configuring the switch relative to the battery pack and the charger assembly such that;

when in the Start position the switch inhibits the AC signal from being applied to the charger assembly, while enabling DC power from the battery pack to be used to energize a starter for starting the engine; and

when in the Charge position the switch enables the DC charging signal to be applied to the battery pack while inhibiting the battery pack from being used to apply DC power to energize the starter.