Controlled power fade for battery power devices

• US 9,692,157 B2
• Filed: 07/05/2016
• Issued: 06/27/2017
• Est. Priority Date: 04/07/2010
• Status: Active Grant

• Current Assignee: Black & Decker Incorporated (Stanley Black & Decker, Inc.), Stanley Black & Decker, Inc.
• Original Assignee: Black & Decker Incorporated (Stanley Black & Decker, Inc.)
• Inventors: Brotto, Daniele C., Forster, Michael K., Leh, Jason K., Lin, Wing W.
• Primary Examiner(s): Ro, Bentsu
• Assistant Examiner(s): DINH, THAI T
• Application Number:
  US15/201,869
• Publication Number:
  US 20160315489A1
• Time in Patent Office: 357 Days
• Field of Search: 318139, 318430, 318443, 318454, 318455, 318478, 318479, 318490, 318599, 320116, 320118, 320132, 320134, 320145
• 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: B25F 5/021 with guiding devices guiding devices for hand tools on stands or supports B25H1/0078
• CPC Class Codes: G01R 31/3646 for indicating electrical conditions or variables, e.g. visual or audible indicators
• CPC Class Codes: G01R 31/374 with means for correcting the measurement for temperature or ageing
• CPC Class Codes: G01R 31/3835 involving only voltage measurements
• CPC Class Codes: G01R 31/385 Arrangements for measuring battery or accumulator variables for monitoring G01R31/382
• CPC Class Codes: H01H 2009/065 Battery operated hand tools in which the battery and the switch are directly connected
• CPC Class Codes: H01H 9/061 enclosing a continuously variable impedance
• CPC Class Codes: H01M 10/441 for several batteries or cells simultaneously or sequentially
• CPC Class Codes: H01M 10/448 End of discharge regulating measures
• 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 2010/4278 Systems for data transfer from batteries, e.g. transfer of battery parameters to a controller, data transferred between battery controller and main controller
• 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: H01R 12/7005 Guiding, mounting, polarizing or locking means; Extractors for printed circuit boards H05K
• CPC Class Codes: H01R 13/112 forked sockets having two legs
• CPC Class Codes: H02J 7/00034 Charger exchanging data with an electronic device, i.e. telephone, whose internal battery is under charge
• CPC Class Codes: H02J 7/00041 in response to measured battery parameters, e.g. voltage, current or temperature profile
• CPC Class Codes: H02J 7/0013 acting upon several batteries simultaneously or sequentially H02J7/1423 takes precedence
• CPC Class Codes: H02J 7/0019 : using switched or multiplexed charge circuits
• CPC Class Codes: H02J 7/0025 : Sequential battery discharge in systems with a plurality of batteries
• CPC Class Codes: H02J 7/0029 : with safety or protection devices or circuits
• CPC Class Codes: H02J 7/00306 : Overdischarge protection
• CPC Class Codes: H02J 7/0031 : using battery or load disconnect circuits H02J9/002 takes precedence
• CPC Class Codes: H02J 7/0045 : concerning the insertion or the connection of the batteries
• CPC Class Codes: H02J 7/0048 : Detection of remaining charge capacity or state of charge [SOC]
• CPC Class Codes: H02J 7/0063 : with circuits adapted for supplying loads from the battery
• 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: H02P 3/08 : for stopping or slowing a dc motor
• CPC Class Codes: H02P 31/00 : Arrangements for regulating or controlling electric motors not provided for in groups H02P1/00 - H02P5/00, H02P7/00 or H02P21/00 - H02P29/00
• CPC Class Codes: H02P 7/285 : controlling armature supply only
• CPC Class Codes: H02P 7/29 : using pulse modulation
• CPC Class Codes: Y02E 60/10 : Energy storage using batteries
• CPC Class Codes: Y02P 70/50 : Manufacturing or production processes characterised by the final manufactured product

Abstract

A method is provided for operating a power tool having a motor powered by a battery. The method includes: delivering power from the battery to the motor in accordance with an operator input; detecting a condition of the power tool indicating a shutdown of the power is imminent; and fading the power delivered from the battery to the motor, in response to the detected condition, through the use of a controller residing in the power tool.

Claims

1. A method for operating a power tool having a motor powered by a battery pack, the method being executed via a controller residing in the power tool, the method comprising:

setting the duty cycle of a pulse width modulated (PWM) control signal for driving the motor to a first PWM value in accordance with a desired rotational speed of the motor;

delivering power from the battery pack to the motor in accordance with the control signal;

monitoring a parameter associated with at least one of battery operation or tool operation while power is delivered from the battery pack to the motor;

detecting a condition of the parameter indicative of a shutdown condition; and

fading the power delivered from the battery to the motor, in response to the detected condition, wherein the fading step comprises;

computing a second PWM value based on a value of the parameter, and

setting the duty cycle of the control signal to the second PWM value when the second PWM value is less than the first PWM value, and retaining the duty cycle at the first PWM value set in accordance with the desired rotational speed of the motor when the second PWM value is more than the first PWM value.

2. The method of claim 1, wherein fading of the power delivered is by an amount that is computed as a function of a value of the parameter.

3. The method of claim 1, wherein fading of the power delivered further comprises decreasing the power delivered as a function of the value of the parameter, where the function is at least one of linear, step, exponential or polynomial.

4. The method of claim 1, wherein the parameter is voltage of the battery, comprising:

initiating fading of the power delivered when the battery voltage falls below a voltage fade threshold and decreasing the power delivered linearly as a function of the battery voltage until the battery voltage falls below a voltage cutoff threshold.

5. The method of claim 1, wherein the parameter is temperature in the power tool, the method comprising:

initiating fading of the power delivered when the temperature exceeds a temperature fade threshold and decreasing the power delivered linearly as a function of the temperature until the temperature exceeds a temperature cutoff threshold.

6. The method of claim 1, wherein the parameter is temperature in the battery pack, the method comprising:

fading of the power delivered when the temperature exceeds a temperature fade threshold and decreasing the power delivered linearly as a function of the temperature until the temperature exceeds a temperature cutoff threshold.

7. The method of claim 6, wherein the battery pack includes a positive terminal, a negative terminal, a temperature sense terminal, battery cells coupled to the positive and negative terminals, and a temperature sensor electrically coupled to the positive terminal.

8. A power tool system comprising:

a tool assembly having a motor;

a battery pack that selectively couples to the tool assembly and operates to provide power to the motor;

a discharge control module that regulates power provided to the motor by setting a duty cycle of pulse width modulated (PWM) control signal of a switch disposed in series with the motor to a first PWM value in accordance with a desired rotational speed of the motor, wherein the discharge control module is configured to monitor a parameter associated with at least one of battery operation or tool operation while power is delivered from the battery pack to the motor, detect a condition of the parameter indicative of a shutdown condition, and fade the power delivered from the battery to the motor by adjusting the duty cycle of the control signal by an amount based on a value of the parameter,

wherein the discharge control module computes a second PWM value based on the value of the parameter, sets the duty cycle of the control signal to the second PWM value when the second PWM value is less than the first PWM value, and retains the duty cycle at the first PWM value set in accordance with the desired rotational speed of the motor when the second PWM value is more than the first PWM value.

9. The power tool system of claim 8, wherein the discharge control module fades the power delivered by decreasing the power delivered as a function of the value of the parameter, where the function is at least one of linear, step, exponential or polynomial.

10. The power tool system of claim 8, wherein the discharge control module monitors voltage of the battery, initiates fading of the power delivered when the battery voltage falls below a voltage fade threshold and decreases the power delivered linearly as a function of the battery voltage until the battery voltage falls below a voltage cutoff threshold.

11. The power tool system of claim 8, further comprising a temperature sensor disposed in the tool assembly, wherein the discharge control module is configured to receive a temperature measure from the temperature sensor, initiate fading of the power delivered when the temperature exceeds a temperature fade threshold and decrease the power delivered linearly as a function of the temperature until the temperature exceeds a temperature cutoff threshold.

12. The power tool system of claim 8, further comprising a temperature sensor disposed in the battery pack and in data communication with the discharge control module, wherein the discharge control module is configured to monitor temperature in the battery pack, initiate fading of the power delivered when the temperature exceeds a temperature fade threshold and decrease the power delivered linearly as a function of the temperature until the temperature exceeds a temperature cutoff threshold.

13. The power tool of claim 12, wherein the battery pack includes a positive terminal, a negative terminal, a temperature sense terminal, battery cells coupled to the positive and negative terminals, and a temperature sensor electrically coupled to the positive terminal.

14. The power tool of claim 8, wherein the switch is disposed in series with battery cells of the battery pack.

15. The power tool system of claim 8, wherein the discharge control module resides in the tool assembly.

16. The power tool system of claim 8, wherein the discharge control module resides in the battery pack.