Cordless power tool system

• US 9,871,484 B2
• Filed: 01/25/2017
• Issued: 01/16/2018
• Est. Priority Date: 05/18/2014
• Status: Active Grant

• Current Assignee: Black & Decker Incorporated (Stanley Black & Decker, Inc.)
• Original Assignee: Black & Decker Incorporated (Stanley Black & Decker, Inc.)
• Inventors: White, Daniel J., Velderman, Matthew J., Seman, Jr., Andrew E
• Primary Examiner(s): Ro, Bentsu
• Assistant Examiner(s): Bouziane, Said
• Application Number:
  US15/414,720
• Publication Number:
  US 20170149372A1
• Time in Patent Office: 356 Days
• 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 10/0445 Multimode batteries, e.g. containing auxiliary cells or electrodes switchable in parallel or series connections
• CPC Class Codes: H01M 10/4207 for several batteries or cells simultaneously or sequentially
• CPC Class Codes: H01M 10/425 Structural combination with electronic components, e.g. electronic circuits integrated to the outside of the casing printed circuits H05K1/00
• CPC Class Codes: H01M 10/441 for several batteries or cells simultaneously or sequentially
• CPC Class Codes: H01M 10/46 Accumulators structurally combined with charging apparatus circuits for charging H02J7/00
• CPC Class Codes: H01M 2220/30 Batteries in portable systems, e.g. mobile phone, laptop
• CPC Class Codes: H01M 50/213 adapted for cells having curved cross-section, e.g. round or elliptic H01M50/209, H01M50/216 take precedence
• CPC Class Codes: H01M 50/244 Secondary casings; Racks; Suspension devices; Carrying devices; Holders characterised by their mounting method
• 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 50/588 outside the batteries, e.g. incorrect connections of terminals or busbars
• CPC Class Codes: H01M 50/597 Protection against reversal of polarity
• CPC Class Codes: H02J 5/00 Circuit arrangements for transfer of electric power between ac networks and dc networks H02J3/36 takes precedence
• CPC Class Codes: H02J 7/00045 Authentication, i.e. circuits for checking compatibility between one component, e.g. a battery or a battery charger, and another component, e.g. a power source
• CPC Class Codes: H02J 7/0013 acting upon several batteries simultaneously or sequentially H02J7/1423 takes precedence
• CPC Class Codes: H02J 7/0024 Parallel/serial switching of connection of batteries to charge or load circuit
• CPC Class Codes: H02J 7/0029 with safety or protection devices or circuits
• CPC Class Codes: H02J 7/0045 concerning the insertion or the connection of the batteries
• CPC Class Codes: H02J 7/007 : Regulation of charging or discharging current or voltage
• CPC Class Codes: H02J 7/00714 : in response to battery charging or discharging current
• CPC Class Codes: H02J 7/02 : for charging batteries from ac mains by converters
• CPC Class Codes: H02J 7/36 : Arrangements using end-cell switching
• CPC Class Codes: H02P 25/14 : Universal motors H02P25/12 takes precedence
• CPC Class Codes: H02P 27/08 : with pulse width modulation
• CPC Class Codes: H02P 29/00 : Arrangements for regulating or controlling electric motors, appropriate for both AC and DC motors arrangements for starting electric motors H02P1/00; arrangements for stopping or slowing electric motors H02P3/00; control of motors that can be connected to two or more different electric power supplies H02P4/00; regulating or controlling the speed or torque of two or more electric motors H02P5/00; vector control H02P21/00
• CPC Class Codes: H02P 29/024 : Detecting a fault condition, e.g. short circuit, locked rotor, open circuit or loss of load
• CPC Class Codes: H02P 29/0241 : the fault being an overvoltage
• CPC Class Codes: H02P 29/032 : Preventing damage to the motor, e.g. setting individual current limits for different drive conditions
• 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 power tool system includes a first power tool having a first power tool rated voltage, a second power tool having a second power tool rated voltage that is different from the first power tool rated voltage, and a first battery pack coupleable to the first power tool and to the second power tool. The first battery pack is switchable between a first configuration having a first battery pack rated voltage that corresponds to the first power tool rated voltage such that the first battery pack enables operation of the first power tool, and a second configuration having a convertible battery pack rated voltage that corresponds to the second power tool rated voltage such that the battery pack enables operation of the second power tool.

Claims

1. A power tool system, comprising:

a first battery pack comprising a first plurality of battery cells and configured to provide only a first operating voltage;

a second battery pack comprising a second plurality of battery cells and configured to provide the first operating voltage and a second operating voltage that is different from the first operating voltage;

a first power tool comprising a first set of power terminals and configured (1) to operate at the first operating voltage, (2) to mechanically and electrically couple with the first battery pack such that the first battery pack provides the first operating voltage to the first power tool, and (3) to mechanically and electrically couple with the second battery pack such that the second battery pack provides the first operating voltage to the first power tool; and

a second power tool comprising a second set of power terminals and configured (1) to operate at the second operating voltage, and (2) to mechanically and electrically couple with the second battery pack such that the second battery pack provides the second operating voltage to the second power tool.

2. The power tool system, as recited in claim 1, wherein the second power tool will not mechanically and electrically couple with the first battery pack.

3. The power tool system, as recited in claim 1, wherein the first operating voltage is approximately 18 to 20 volts and the second operating voltage is approximately 54 to 60 volts.

4. The power tool system, as recited in claim 1, wherein the first operating voltage is approximately 18 to 20 volts and the second operating voltage is approximately 36 to 40 volts.

5. The power tool system, as recited in claim 1, further comprising a first battery pack charger configured to be able to charge the first battery pack and the second battery pack.

6. The power tool system, as recited in claim 5, wherein the first battery pack charger is configured to charge the first battery pack and the second battery pack at the first operating voltage.

7. The power tool system, as recited in claim 1, wherein the second battery pack automatically provides the first operating voltage to the first power tool when coupled to the first power tool, and automatically provides the second operating voltage to the second power tool when coupled to the second power tool.

8. The power tool system, as recited in claim 7, wherein the second battery pack includes a first electrical configuration to automatically provide the first operating voltage to the first power tool when coupled to the first power tool, and a second, different electrical connection configuration to automatically provide the second operating voltage to the second power tool when coupled to the second power tool.

9. The power tool system, as recited in claim 7, wherein the first power tool includes a first electrical connection configuration such that the second battery pack automatically provides the first operating voltage to the first power tool when coupled to the first power tool, and the second power tool includes a second, different electrical connection configuration such that the second battery pack automatically provides the second operating voltage to the second power tool when coupled to the second power tool.

10. A power tool system comprising:

a first battery pack providing only a first rated voltage;

a second battery pack operable in a first operating state in which the second battery pack provides the first rated voltage and in a second operating state in which the second battery pack provides a second rated voltage that is different than the first rated voltage;

a first power tool having a first power supply interface, the first power tool capable of operating at the first rated voltage when the first power supply interface is coupled to either the first battery pack or to the second battery pack such that the second battery pack is operable in the first operating state; and

a second power tool having a second motor, a second motor control circuit, and a second power supply interface, the second power tool capable of operating at the second rated voltage when the second power supply interface is coupled to the second battery pack such that the second battery pack is operable in the second operating state.

11. A power tool system, as recited in claim 10, further comprising a third power tool having a third power supply interface, the third power tool being configured for operation at a third rated voltage that is a whole number multiple of the second rated voltage when the third power supply interface is coupled to a plurality of the second battery packs.

12. The power tool system, as recited in claim 11, wherein the third power tool is further configured for operation at an AC mains rated voltage when the third power supply interface is coupled to an AC mains power supply.

13. The power tool system, as recited in claim 10, wherein the first rated voltage is a low rated voltage and the second rated voltage is a medium rated voltage.

14. The power tool system, as recited in claim 10, wherein the first rated voltage is approximately 18 to 20 volts and the second rated voltage is between approximately 36 and 60 volts.

15. The power tool system, as recited in claim 14, further comprising a third power tool having a third power supply interface, the third power tool operable at a third rated voltage of between approximately 108 and 240 volts.

16. The power tool system, as recited in claim 15, wherein the third rated voltage corresponds to a magnitude of the AC mains rated voltage.

17. The power tool system, as recited in claim 10, further comprising a first battery pack charger configured to be able to charge the first battery pack and the second battery pack.

18. The power tool system, as recited in claim 10, wherein the second battery pack is automatically operable in the first operating state when the second battery pack is coupled to the first power tool and is automatically operable in the second operating state when the second battery pack is coupled to the second power tool.

19. The power tool system, as recited in claim 18, wherein the second battery pack includes a first electrical configuration to automatically provide the first operating voltage to the first power tool when coupled to the first power tool, and a second, different electrical connection configuration to automatically provide the second operating voltage to the second power tool when coupled to the second power tool.

20. The power tool system, as recited in claim 18, wherein the first power tool includes a first electrical connection configuration such that the second battery pack automatically provides the first operating voltage to the first power tool when coupled to the first power too, and the second power tool includes a second, different electrical connection configureation such that teh second battery pack atuomatically provides the second operating voltage to the second power tool when coupled to the second power tool.

21. The power tool system, as recited in claim 20, wherein the first rated voltage is approximately 18 to 20 volts and the second rated voltage is approximately 36 to 40 volts.

22. The power tool system, as recited in claim 20, further comprising a first battery pack charger configured to be able to charge the first battery pack and the second battery pack.

23. The power tool system, as recited in claim 22, wherein the first battery pack charger is configured to charge the first batter pack and the second battery pack at the first rated voltage.

24. The power tool system, as recited in claim 23, wherein the second battery pack includes a first electrical configuration to automatically provide first rated voltage to the first power tool when coupled to the first power tool, and a second, different electrical connection configuration to automatically provide the second rated voltage to the second power tool when coupled to the second power tool.

25. The power tool system, as recited in claim 23, wherein the first power tool includes a first electrical connection configuration such that the second battery pack automatically provides the first rated voltage to the first power tool when coupled to the first power tool, and the second power tool includes a second, different electrical connection configuration such that the second battery pack automatically provides the second rated voltage to the second power tool when coupled to the second power tool.

26. A power tool system comprising:

a first battery pack providing only a first rated voltage;

a second battery pack capable of providing the first rated voltage and capable of providing a second rated voltage that is different than the first rated voltage;

a first power tool having a first motor, a first motor control circuit, and a first power supply interface, the first power tool configured to receive the first rated voltage when the first power supply interface is coupled to either the first battery pack or to the second battery pack; and

a second power tool having a second motor, a second motor control circuit, and a second power supply interface, the second power tool configured to receive and cause the second battery pack to provide the second rated voltage when the second power supply interface is coupled to the second battery pack.

27. The power tool system, as recited in claim 26, wherein the second power tool will not mechanically and electrically couple with the first battery pack to receive the first rated voltage.