Hybrid electric lawnmower

• US 7,479,754 B2
• Filed: 10/17/2006
• Issued: 01/20/2009
• Est. Priority Date: 10/17/2006
• Status: Active Grant

• Current Assignee: Mtd Products Incorporated (Stanley Black & Decker, Inc.)
• Original Assignee: DESA IP, LLC
• Inventors: Lucas, Delbert E., Lucas, Justin, Lucas, Ryan Jay
• Primary Examiner(s): Duda; Rina I
• Application Number:
  US11/550,104
• Publication Number:
  US 20080089673A1
• Time in Patent Office: 826 Days
• Field of Search: 318/599, 318/811, 318/139, 56/101, 56/106, 56/108, 56/111
• US Class Current: 318/599
• CPC Class Codes: A01D 34/78 electric
• CPC Class Codes: A01D 69/025 Electric hybrid systems

Abstract

A hybrid electric lawnmower is described which includes an electric motor operating the blade and the ability to drive the motor from either 120 VAC line voltage or from a battery pack. There is a user selectable power selection switch for switching between DC or AC power and also a boost and conserve feature which allows for increased speed of the blade as necessary. Running the mower at the conserve setting prolongs battery pack duration per charge.

Claims

1. A hybrid mower with boost and conserve power feature, comprising:

a mower deck with a rotating blade affixed to an electric DC motor;

a power control module, in electrical control of said motor, said power control module in electrical connection with an AC power input line and a battery pack, said power control module having a power selection switch for selectively connecting at least one of said AC power input line and said battery pack with said DC motor for causing said DC motor to mechanically rotate the mower blade;

a power controller on said power control module converting AC power from said AC power input line to DC power; and

a boost conserve switch on said power control module adjusting a power output of said power control module to a first power output and a second power output, said first power output representing a conserve power feature on said DC motor and said second power output representing a boost power feature on said DC motor,

wherein said mower is configured with an AC power plug for allowing the mower to be electrically connected with and to receive the AC power input line voltage from a household power socket.

2. The hybrid mower of claim 1, wherein said power control module controls the motor speed of said DC motor by selecting said first power output or said second power output through said boost conserve switch.

3. The hybrid mower of claim 1, wherein said power controller is electrically positioned between said AC power input line and said DC power output of said power inverter.

4. The hybrid mower of claim 3, wherein said power controller is a rectifier and filter combination.

5. The hybrid mower of claim 1, wherein said power controller includes a step down controller.

6. The hybrid mower of claim 5, wherein said step down controller includes a voltage rectifier and a pulse width modulator.

7. The hybrid mower of claim 2, wherein said DC motor speed for said second power output is above about 15,000 feet per minute blade speed and said DC motor speed for said first power output speed is below about 14,000 feet per minute blade speed.

8. The hybrid mower of claim 2, wherein said DC motor has a voltage input above 70 volts at said first power output of said power control module and about 60 volts at said second power output of said power control module.

9. The hybrid mower of claim 1, wherein said boost conserve switch is operative when said power source switch electrically connects said battery pack to said DC motor.

10. The hybrid mower of claim 9, wherein said boost conserve switch is operative to engage a secondary battery in series with an output voltage of said power control module.

11. The hybrid mower of claim 1, wherein said boost conserve switch is operative to engage a secondary battery in series with an output voltage of said power control module.

12. A hybrid mower with a boost conserve feature, comprising:

an AC power line-fed step down controller configured for receiving AC power line voltage via an AC power line input, said step down controller further configured for modifying the AC power line voltage to a DC output voltage;

a power selection switch operative to selectively connect a DC motor to at least one of said DC output voltage of said AC power line-fed step down controller or to a DC output voltage of a battery pack;

a boost conserve switch operative to add a secondary battery in series with said battery pack;

said DC motor configured for mechanically turning a cutting blade on a mower housing in response to said power selection switch connecting the DC motor to the AC power line-fed step down controller, the DC motor further configured for mechanically turning said cutting blade in response to said power selection switch connecting the DC motor to the battery pack,

wherein said mower is configured with an AC power plug for allowing the mower to be electrically connected with and to receive the AC power line voltage from a household power socket.

13. The hybrid mower of claim 12, wherein said step down controller includes an inverter.

14. The hybrid mower of claim 13, wherein said inverter is a full bridge rectifier.

15. The hybrid mower of claim 12, wherein said step down controller includes a rectifier in combination with a pulse width modulation circuit.

16. The hybrid mower of claim 12, wherein said mower further has an interlock handle switch actuatable to engage and disengage said DC motor from said battery pack or said step down controller.

17. The hybrid mower of claim 12, wherein said secondary battery output voltage is about six volts.

18. The hybrid mower of claim 12, wherein said secondary battery is integrated with said battery pack.

19. The hybrid mower of claim 12, wherein said secondary battery is in series with said DC output voltage of said step down controller, said boost conserve switch operative to add said secondary battery output voltage to said DC motor.

20. An electric lawnmower, comprising:

a mower deck with a DC motor electrically connected to a mower handle safety switch, a power selection switch in electrical connection with said mower handle safety switch and to both a battery pack and an AC power line-fed power controller, an AC power line connected to said power controller, said power controller configured for converting power provided from said AC power line to a DC output voltage, and said power controller configured with a step down controller for modifying the DC output voltage to generate a modified DC output for said power controller, said power selection switch operable to selectively and electrically connect said battery pack to said DC motor for causing said motor to mechanically rotate a cutting blade of the mower, said power selection switch operable to selectively and electrically connect said AC power line-fed power controller to said DC motor for causing said motor to mechanically rotate the cutting blade of the mower, wherein said mower is configured with an AC power plug for allowing the mower to be electrically connected with and to receive AC power input line voltage from a household power socket.

21. The electric lawnmower of claim 20, wherein said step down controller includes a pulse width modulation controller.

22. The electric mower of claim 21, further comprising:

a boost switch integrated with said step down controller to selectively increase said modified DC output of said power controller upon activation of said boost switch.

23. The electric lawnmower of claim 22, wherein said boost switch modifies an input timing signal in said pulse width modulation controller.

24. The electric mower of claim 20, further comprising

a secondary battery in series with said battery pack, said secondary battery connected in series with said battery pack upon activation of a boost conserve switch.

25. The electric mower of claim 21, wherein said pulse width modulation controller includes a CMOS micro-controller and an IGBT.

26. A hybrid mower, comprising:

a DC motor electrically connected to a power supply and attached to a rotatable blade below a mower deck;

said power supply operable to electrically connect said DC motor to at least one of;

a battery pack and an AC electrical line for causing the DC motor to mechanically rotate said mower blade, said power supply has a power selection switch representing said electrical connection to said battery pack or said AC electrical line;

said power supply also having a boost conserve switch actuatable to a first and a second position and operable when said DC motor is in electrical connectivity with said battery pack, said first position running said DC motor at a first speed, said second position running said DC motor at a second speed, said first speed being greater than said second speed,

wherein said mower is configured with an AC power plug for allowing the mower to be electrically connected with and to receive AC power input line voltage from a household power socket.

27. The hybrid mower of claim 26, wherein said power supply has a voltage inverter and a step down controller.

28. The hybrid mower of claim 27, further comprising:

a secondary battery in electrical connection with said boost conserve switch, said secondary battery brought into electrical connection with said motor when said boost conserve switch is in said first position.

29. The hybrid mower of claim 27, wherein said boost conserve switch is electrically connected to said power supply providing an input to said step down controller.

30. The hybrid mower of claim 29, wherein said inverter is a full bridge rectifier.

31. The hybrid mower of claim 27, wherein said step down controller is one of a diode based voltage controller, a triac controller or a MOSFET based controller.

32. An electric lawn mower having a blade drive motor electrically connected to a first and a second power supply, comprising:

an AC input line providing 120 VAC to a hybrid AC to DC controller, said hybrid controller being an AC input line-fed hybrid controller said hybrid controller connected to a power selection switch;

a battery pack providing greater than about 60 volts DC to said power selection switch;

an electric motor electrically connected to said power selection switch, wherein said power selection switch is operable to electrically connect said electric motor to said battery pack for causing the electric motor to mechanically rotate a cutting blade of the mower via electrical power provided by the battery pack, said power selection switch being further operable to electrically connect said electric motor to said AC input line-fed hybrid controller for causing the electric motor to mechanically rotate the cutting blade of the mower via electrical power provided by the AC input line-fed hybrid controller;

a boost and conserve switch operable to increase the voltage supplied to said electric motor by a predefined amount, said increase in voltage supplied to said electric motor increasing the rotational speed of said motor, said boost and conserve switch electrically connected to a DC voltage source providing said increase in voltage,

wherein said mower is configured with an AC power plug for allowing the mower to be electrically connected with and to receive AC power input line voltage from a household power socket.