BAIL BAR DETECTION FOR A LAWNMOWER
20230049667 · 2023-02-16
Inventors
- Daniel R. Ertl (Brookfield, WI, US)
- Caleb N. Hille (West Chester, OH, US)
- Tyler L. Graham (Milwaukee, WI, US)
- Christopher S. Bullington (Milwaukee, WI, US)
Cpc classification
International classification
Abstract
A battery powered lawnmower having a blade motor coupled to at least one blade, a user input device configured to receive a blade motor control signal and a bail control bar. The bail control bar is coupled to a position sensor configured to determine a position of the bail control bar. The battery powered lawnmower further includes a controller coupled to the position sensor and configured to control an operation of the blade motor. The controller is configured to receive a blade motor control command and determine a position of the bail control bar based on data provided by the position sensor. The controller is further configured to, in response to determining that the bail control bar is in a closed position, control the blade motor based on the received blade motor control command.
Claims
1. A battery powered lawnmower comprising: a blade motor coupled to at least one blade; a user input device configured to receive a blade motor control signal; a bail control bar; a position sensor configured to determine a position of the bail control bar; and a controller connected to the position sensor and configured to control an operation of the blade motor, the controller configured to: receive a blade motor control command, determine the position of the bail control bar based on a signal output by the position sensor, and control, in response to determining that the bail control bar is in a closed position, the blade motor based on the received blade motor control command.
2. The battery powered lawnmower of claim 1, wherein the position sensor is a Hall effect sensor assembly including a Hall effect sensor and a magnet.
3. The battery powered lawnmower of claim 2, wherein the bail control bar is coupled to a handle assembly of the battery powered lawnmower via a linkage, and wherein the magnet is coupled to the linkage and configured to rotate with respect to the Hall effect sensor in response to the bail control bar being moved between one of the closed position and an open position.
4. The battery powered lawnmower of claim 3, wherein the magnet is configured to be positioned closest to the Hall effect sensor where the bail control bar is in the closed position.
5. The battery powered lawnmower of claim 1, further comprising: a handle, wherein the handle includes a recessed portion configured to receive the bail control bar when the bail control bar is in the closed position.
6. The battery powered lawnmower of claim 1, further comprising: a plurality of wheels; and a drive motor coupled to at least one of the plurality of wheels and configured to rotate the at least one wheel in at least one direction.
7. The battery powered lawnmower of claim 6, wherein the controller is further configured to: receive a drive motor control command; determine the position of the bail control bar based on the signal output by the position sensor; and control, in response to determining that the bail control bar is in the closed position, the drive motor based on the received drive motor control command.
8. The battery powered lawnmower of claim 1, wherein the controller is further configured to: detect a transition of the bail control bar from the closed position to an open position based on the signal output by the position sensor; and stop the operation of the blade motor based on detecting the bail control bar transitioning to the open position.
9. A method of operating a battery powered lawnmower, the method comprising: receiving, at a controller of the battery powered lawnmower, a blade motor control command from one or more user interfaces; determining, by the controller, a position of a bail control bar based on a position signal provided by a position sensor configured to detect the position of the bail control bar; and controlling, via the controller, a blade motor based on the received blade motor control command in response to determining that the bail control bar is in a closed position.
10. The method of claim 9, wherein the position sensor is a Hall effect sensor assembly including a Hall effect sensor and a magnet.
11. The method of claim 10, wherein the bail control bar is coupled to a handle assembly of the battery powered lawnmower via a linkage, and wherein the magnet is coupled to the linkage to rotate with respect to the Hall effect sensor in response to the bail control bar being moved between one of the closed position and an open position.
12. The method of claim 11, wherein the magnet is configured to be positioned closest to the Hall effect sensor where the bail control bar is in the closed position.
13. The method of claim 9, wherein the battery powered lawnmower further includes a handle, wherein the handle includes a recessed portion configured to receive the bail control bar in the closed position.
14. The method of claim 9, further comprising: receiving a drive motor control command; determining the position of the bail control bar based on the position signal; and controlling a drive motor based on the received drive motor control command in response to determining that the bail control bar is in the closed position.
15. The method of claim 14, further comprising driving, using the drive motor, one or more wheels coupled to the battery powered lawnmower.
16. The method of claim 9, further comprising: detecting a transition of the bail control bar from the closed position to an open position based on the position signal; stopping an operation of the blade motor based on detecting the bail control bar transitioning to the open position.
17. A battery powered lawnmower comprising: a blade motor coupled to at least one blade; a user input device configured to receive at a blade motor control signal; a bail control bar; a handle assembly including a handle housing and a handle, wherein the handle includes a recessed portion configured to receive the bail control bar when the bail control bar is in a closed position; a Hall effect sensor assembly configured to determine a position of the bail control bar, wherein the Hall effect sensor assembly includes a Hall effect sensor and a magnet; and a controller connected to the Hall effect sensor and configured to control an operation of the blade motor, the controller is configured to: receive a blade motor control command, determine the position of the bail control bar based on a signal output by the Hall effect sensor, and control, in response to determining that the bail control bar is in the closed position, the blade motor based on the received blade motor control command.
18. The battery powered lawnmower of claim 17, wherein the bail control bar is coupled to the handle housing via a linkage, and wherein the magnet is coupled to the linkage and configured to rotate with respect to the Hall effect sensor in response to the bail control bar being moved between one of the closed position and an open position.
19. The battery powered lawnmower of claim 18, wherein the magnet is configured to be positioned closest to the Hall effect sensor when the bail control bar is in the closed position.
20. The battery powered lawnmower of claim 17, wherein the controller is further configured to: detect a transition of the bail control bar from the closed position to an open position based on the signal output by the Hall effect sensor; and stop the operation of the blade motor based on detecting the bail control bar transitioning to the open position from the closed position.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION
[0024]
[0025]
[0026] Turning now to
[0027] As will be described in more detail below, the bail control bar 28 is coupled to a controller of the lawnmower 10, and is configured as a failsafe device, such that a user must maintain the bail control bar 28 in the closed position in order to initiate operation of a blade motor and/or drive motors. Furthermore, upon release of the bail control bar 28 causing the bail control bar 28 to transition to the open position, the controller will stop operation of the blade and/or drive motors, as will be described in more detail below.
[0028] A controller 200 for the lawnmower 10 is illustrated in
[0029] The controller 200 includes a plurality of electrical and electronic components that provide power, operational control, and protection to the components and modules within the controller 200 and/or lawnmower 10. For example, the controller 200 includes, among other things, a processing unit 205 (e.g., a microprocessor, an electronic processor, an electronic controller, a microcontroller, or another suitable programmable device), a memory 225, input units 230, and output units 235. The processing unit 205 includes, among other things, a control unit 210, an arithmetic logic unit (“ALU”) 215, and a plurality of registers 220 (shown as a group of registers in
[0030] The memory 225 is a non-transitory computer readable medium and includes, for example, a program storage area and a data storage area. The program storage area and the data storage area can include combinations of different types of memory, such as a ROM, a RAM (e.g., DRAM, SDRAM, etc.), EEPROM, flash memory, a hard disk, an SD card, or other suitable magnetic, optical, physical, or electronic memory devices. The processing unit 205 is connected to the memory 225 and executes software instructions that are capable of being stored in a RAM of the memory 225 (e.g., during execution), a ROM of the memory 225 (e.g., on a generally permanent basis), or another non-transitory computer readable medium such as another memory or a disc. Software included in the implementation of the lawnmower 10 can be stored in the memory 225 of the controller 200. The software includes, for example, firmware, one or more applications, program data, filters, rules, one or more program modules, and other executable instructions. The controller 200 is configured to retrieve from the memory 225 and execute, among other things, instructions related to the control processes and methods described herein. In other embodiments, the controller 200 includes additional, fewer, or different components.
[0031] The controller 200 drives the motor 280 to rotate the blades 20 in response to a user's actuation of the paddles 26. In some examples, the motor 280 is referred to as the blade motor. Depression of the paddles 26 actuates the contactless switch to indicate that the paddles 26 are being depressed. The paddle position sensors 159 are configured to sense a position of the paddles 26 (e.g., the magnitude of depression of the paddles), which outputs a signal to the controller 200 to drive the motor 280, and therefore the blades 20. In some embodiments, the controller 200 is configured to control a power switching network 255 (e.g., a field-effect transistor (“FET”) switching bridge) to drive the motor 280 in response to the sensed values received from the position sensors 159 and/or contactless switch 158. For example, the power switching network 255 may include a plurality of high side switching elements (e.g., FETs) and a plurality of low side switching elements. The controller 200 may control each of the plurality of high side switching elements and the plurality of low side switching elements to drive each phase of the motor 280.
[0032] In response to determining that the paddles 26 are released, the controller 200 may be configured to control the power switching network 255 to apply a braking force to the motor 280. For example, the power switching network 255 may be controlled to more quickly deaccelerate the motor 280. In some embodiments, the controller 200 is configured to drive an auxiliary motor 290 which may be configured to drive the plurality of wheels 22. For example, the motor 280 is controlled to drive the blades 20, and the auxiliary motor 290 is controlled to drive the plurality of wheels 22 to provide a power drive functionality to the lawnmower 10. The auxiliary motor may be controlled via an auxiliary power switching network 295.
[0033] The indicators 245 are also connected to the controller 200 and receive control signals from the controller 200 to turn on and off or otherwise convey information based on different states of the lawnmower 10. The indicators 245 include, for example, one or more light-emitting diodes (LEDs), or a display screen. The indicators 245 can be configured to display conditions of, or information associated with, the lawnmower 10. For example, the indicators 245 may be configured to provide an indication of whether the lawnmower 10 is in a condition to allow the user to activate the motor 280 and/or the auxiliary motor 290, such as when the bail control bar 28 is in the closed position.
[0034] The battery pack interface 250 is connected to the controller 200 and is configured to couple with the battery pack 100. The battery pack interface 250 includes a combination of mechanical (e.g., a battery pack receiving portion) and electrical components configured to and operable for interfacing (e.g., mechanically, electrically, and communicatively connecting) the lawnmower 10 with the battery pack 100. The battery pack interface 250 is coupled to the power input unit 260. The battery pack interface 250 transmits the power received from the battery pack 100 to the power input unit 260. The power input unit 260 includes active and/or passive components (e.g., voltage step-down controllers, voltage converters, rectifiers, filters, etc.) to regulate or control the power received through the battery pack interface 250 and to the controller 200. In some embodiments, the battery pack interface 250 is also coupled to the power switching network 255. The operation of the power switching network 255, as controlled by the controller 200, determines how power is supplied to the motor 280.
[0035] As described above, in some embodiments, the lawnmower 10 is a battery-powered lawnmower.
[0036]
[0037] The battery pack controller 300 includes a plurality of electrical and electronic components that provide power, operational control, and protection to the components and modules within the battery pack controller 300 and/or the battery pack 100. For example, the controller 200 includes, among other things, a processing unit 335 (e.g., a microprocessor, a microcontroller, or another suitable programmable device), a memory 340, input units 345, and output units 350. The processing unit 335 includes, among other things, a control unit 355, an arithmetic logic unit (“ALU”) 360, and a plurality of registers 365 (shown as a group of registers in
[0038] The memory 340 is a non-transitory computer readable medium and includes, for example, a program storage area and a data storage area. The program storage area and the data storage area can include combinations of different types of memory, such as a read-only memory (“ROM”), a read-only memory (RAM) (e.g., dynamic RAM (“DRAM”), synchronous DRAM (“SDRAM”), etc.), electrically erasable programmable ROM (“EEPROM”), flash memory, a hard disk, an secure digital (“SD”) card, or other suitable magnetic, optical, physical, or electronic memory devices. The processing unit 335 is connected to the memory 340 and executes software instructions that are capable of being stored in a RAM of the memory 340 (e.g., during execution), a ROM of the memory 340 (e.g., on a generally permanent basis), or another non-transitory computer readable medium such as another memory or a disc. Software included in the implementation of the battery pack 100 can be stored in the memory 340 of the controller 300. The software includes, for example, firmware, one or more applications, program data, filters, rules, one or more program modules, and other executable instructions. The battery pack controller 300 is configured to retrieve from the memory 340 and execute, among other things, instructions related to the control processes and methods described herein. In other constructions, the battery pack controller 300 includes additional, fewer, or different components.
[0039] The interface 310 includes a combination of mechanical components (e.g., rails, grooves, latches, etc.) and electrical components (e.g., one or more terminals) configured to and operable for interfacing (e.g., mechanically, electrically, and communicatively connecting) the battery pack 100 with another device (e.g., a power tool, a battery pack charger, the lawnmower 10, etc.). For example, the interface 310 is configured to receive power via a power line between the one or more battery cells 305 and the interface 310. The interface 310 is also configured to communicatively connect to the battery pack controller 300.
[0040] As noted above, the bail control bar 28 is configured to prevent operation of the motor 280 and/or auxiliary motor 290 in response to the bail control bar 28 being in the open position. One or more sensors 285 provide an indication of the position of the bail control bar 28 to the controller 200. In one embodiment, the one or more sensors 285 may include a Hall effect sensor; however, other sensors, such as proximity sensors, inductive sensors, contact switches, reed switches, and/or other sensors may be used to provide data to the controller 200 indicative of the position of the bail control bar 28.
[0041] Turning now to
[0042] The bail control bar 28 is configured to rotate about an axis of rotation A1 at an associated rotation point 806. The magnet 804 is coupled to a linkage 808 of the bail control bar 28 and is configured to move along with a movement of the bail control bar 28 with respect to the hall sensor 802. For example, the bail control bar's 28 axis of rotation A1 and rotation point 806 are linked to the magnet 804 and cause the magnet 804 to move between open and closed positions with respect to the hall sensor 802. The magnet 804 may be moved between a closed position of the bail control bar 28 (where the magnet is in range of/detectable by the sensor) and an open position (where the magnet is not in range of/not detectable by the Hall effect sensor 802). The controller 200 of the lawnmower receives the signal from sensor 285 (e.g., via a user interface cable), and is able to determine/detect whether the bail control bar 28 is in the closed position or the open position.
[0043]
[0044] Conversely,
[0045]
[0046] The output signal from the Hall effect sensor 802 may be processed by the controller 200 to allow the drive or blade motors to be activated via their respective controls (when the bail control bar 28 is in the closed position) or allow the motors to be disabled (when the bail control bar 28 is in an open position) regardless of the state of the respective controls of the motors in the system.
[0047] The lawnmower 10 may operate in the OPEN state 1002 where the bail control bar 28 is in an open position. In the OPEN state 1002 the bail control bar 28 is open and the blade motor 280 and the auxiliary (e.g., drive) motor 290 are deactivated. The OPEN state 1002 may occur when the lawnmower 10 is not being used, or during a reset condition. Upon the bail control bar 28 being moved to the closed position, and the lawnmower 10 being put in an active state (e.g., having battery power, or receiving an activation input from a user, such as via one or more of the paddles 26 and/or one more inputs received via the input units 230), the lawnmower 10 transitions to the CLOSED state 1004. In the CLOSED state 1004, the blade motor 280 and/or auxiliary motors 290 are in an active state and can be operated in response to receiving an input, such as via the paddles 26. In response to the bail control bar 28 transitioning to the open position, the lawnmower 10 will return directly to the OPEN state 1002.
[0048] From the CLOSED state 1004, the lawnmower 10, upon receiving an input to activate either the blade motor 280 and/or the auxiliary motor 290, enters the RUNNING state 1008, wherein one or both of the blade motor 280 and/or the auxiliary motor 290 are operating (e.g., driving their respective loads). In response to the bail control bar 28 transitioning to the open position, the lawnmower 10 will return directly to the OPEN state 1002. In response to the blade motor 280 being transitioned to an OFF condition (e.g., the user disables the blade motor, the lawnmower 10 enters the DISABLED state, wherein only the auxiliary motor 290 may be operable. In response to the bail control bar 28 transitioning to the open position, the lawnmower 10 will return directly to the OPEN state.
[0049] Turning now to
[0050] At process block 1102, the lawnmower 10 operates in an OFF mode. At process block 1104, the controller 200 determines whether the lawnmower 10 is in an ON mode. The ON mode may be initiated by a user providing an input to the controller 200, such as via the contactless switch 158 of the paddles 26. In response to determining that the lawnmower is not in the ON mode, the lawnmower 10 remains in the OFF mode at process block 1102. In some embodiments, the OFF mode may be similar to the OPEN state 1002 described above. In response to determining that the lawnmower 10 is in the ON mode, the controller 200 transitions the lawnmower into a standby mode at process block 1108. The standby mode may be similar to the CLOSED state 1004 described above. For example, when operating in the standby mode, the lawnmower may be in an active condition (e.g., the controller 200 is active and ready to control one or more operations, such as motor rotation, of the lawnmower 10) and waiting for a user input to control one or more operations of the lawnmower, such as controlling rotation of the blade motor 280 and/or the auxiliary motor 290.
[0051] At process block 1110, the controller 200 determines whether one or more motor control commands have been received. The motor control commands may be received via the contactless switch 158 and/or position sensor 159. However, the motor control commands may also be received from one or more of the secondary sensor(s) 272, and/or via an input to the input units 230 of the controller 200. The motor control commands may be provided for the blade motor 280, the auxiliary (drive) motor 290, or both. In response to determining that no motor control command was received, the controller 200 continues to operate the lawnmower 10 in the standby mode at process block 1108. The motor control commands may provide a desired motor speed, a rotation direction, and/or other signal as required for a given application.
[0052] In response to determining that one or more motor control commands were received at the controller 200, the controller 200 then determines a position of the bail control bar 28 at process block 1112. Specifically, the controller 200 determines whether the bail control bar 28 is in a closed position (e.g., being gripped by a user) or in an open position. As described above, the controller 200 may determine a position of the bail control bar 28 based on information from the one or more position sensors 285, such as the Hall effect sensor 802 described above. In response to determining that the bail control bar 28 is in the open position, the controller 200 resumes operating the lawnmower 10 in the standby mode at process block 1108. In some examples, the controller 200 may provide an indication to a user, such as via the indicators 245, that the bail control bar 28 is not in the closed position, thereby preventing operation of the blade motor 280 and/or auxiliary motor 290. In response to the controller 200 determining that the bail control bar 28 is in the closed position, the controller 200 operates (e.g., rotates) the motors (i.e., the blade motor 280, the auxiliary motor 290, or a combination thereof) based on the received motor control commands. The controller 200 then returns to process block 1110 such that any changes to the motor control commands and/or change in position of the bail control bar are reflected in the operation of the lawnmower 10. For example, upon the bail control bar 28 moving from the closed position to the open position, the controller 200 stops rotation of the blade motor 280 and/or the drive motor 290.