POWER UNIT INCLUDING MULTIPLE BATTERY PACKS FOR USE WITH OUTDOOR POWER EQUIPMENT

Abstract

A power unit operable to power equipment, the power unit including an electric motor, multiple removable and rechargeable battery packs, multiple switching elements, and a control unit. Each of the switching elements is connected between one of the battery packs and the electric motor and operate in one of an open position or a closed position. The control unit is operable to manage the position of the switching elements. The control unit is configured to determine whether one or more battery packs are supplying power for the electric motor, measure a voltage of each of the battery packs, determine whether each of the voltage measurements is within a predetermined value to each other, calculate a pulse width modulated (PWM) signal for each of the switching elements, assign each PWM signal to one of the switching elements, and apply each of the PWM signals to the assigned switching element.

Claims

1-20. (canceled)

21. A lawn mower comprising: a plurality of battery packs, each of the plurality of battery packs being removable and rechargeable; an electric motor powered by the plurality of battery packs; a drivetrain driven by the electric motor; a switching element connected to each of the plurality of battery packs, each of the switching elements is configured to transition between an open position and a closed position to control a discharge rate of a respective one of the plurality of battery packs; and a control unit configured to control a position of the switching elements, the control unit being configured to: determine whether one or more of the plurality of battery packs is discharging; in response to determining that more than one of the plurality of battery packs are discharging, measure a voltage of each of the discharging battery packs; calculate a pulse width modulated signal for each of the switching elements that are connected to the discharging battery packs; and apply the pulse width modulates signals to the corresponding switching elements that are connected to the discharging battery packs; wherein the control unit is further configured to stop any of the plurality of battery packs from discharging upon detecting that a state of charge is less than a threshold value, and wherein the threshold value is greater than zero percent.

22. The lawn mower of claim 21, wherein the pulse width modulated signals are all calculated based on the voltage measurement of one of the discharging battery packs.

23. The lawn mower of claim 21, wherein the pulse width modulated signals are calculated individually, each being based on the voltage measurement of the discharging battery pack connected to the switching element.

24. The lawn mower of claim 23, wherein the pulse width modulated signal for each of the switching elements is further based on a difference between a maximum voltage measurement of the discharging battery packs and a minimum voltage measurement of the discharging battery packs.

25. The lawn mower of claim 21, further comprising: a second electric motor powered by the plurality of battery packs; and a mower blade driven by the second electric motor.

26. The lawn mower of claim 21, wherein each of the switching elements includes at least one of metal-oxide-semiconductor field-effect transistors (MOSFETs), insulated gate bipolar transistors (IGBTs), transistors, and relays.

27. The lawn mower of claim 21, wherein the pulse width modulated signals are calculated based on an amount of battery packs.

28. The lawn mower of claim 21, wherein the control unit is further configured to provide an indication if a single battery pack is discharging.

29. A lawn mower comprising: a plurality of battery packs, each of the plurality of battery packs being removable and rechargeable; an electric motor powered by the plurality of battery packs; a mower blade driven by the electric motor; a switching element connected to each of the plurality of battery packs, each of the switching elements is configured to transition between an open position and a closed position to control a discharge rate of a respective one of the plurality of battery packs; and a control unit configured to control a position of the switching elements, the control unit being configured to: determine whether one or more of the plurality of battery packs is discharging; in response to determining that more than one of the plurality of battery packs are discharging, measure a voltage of each of the discharging battery packs; calculate a pulse width modulated signal for each of the switching elements that are connected to the discharging battery packs; and apply the pulse width modulates signals to the corresponding switching elements that are connected to the discharging battery packs; wherein the control unit is further configured to stop any of the plurality of battery packs from discharging upon detecting that a state of charge is less than a threshold value, and wherein the threshold value is greater than zero percent.

30. The lawn mower of claim 29, wherein the pulse width modulated signals are all calculated based on the voltage measurement of one of the discharging battery packs.

31. The lawn mower of claim 29, wherein the pulse width modulated signals are calculated individually, each being based on the voltage measurement of the discharging battery pack connected to the switching element.

32. The lawn mower of claim 31, wherein the pulse width modulated signal for each of the switching elements is further based on a difference between a maximum voltage measurement of the discharging battery packs and a minimum voltage measurement of the discharging battery packs.

33. The lawn mower of claim 29, wherein each of the switching elements includes at least one of metal-oxide-semiconductor field-effect transistors (MOSFETs), insulated gate bipolar transistors (IGBTs), transistors, and relays.

34. The lawn mower of claim 29, wherein the pulse width modulated signals are calculated based on an amount of battery packs.

35. The lawn mower of claim 29, wherein the control unit is further configured to provide an indication if a single battery pack is discharging.

36. A commercial turf equipment comprising: a plurality of battery packs, each of the plurality of battery packs being removable and rechargeable; an electric motor powered by the plurality of battery packs; an implement driven by the electric motor; a switching element connected to each of the plurality of battery packs, each of the switching elements is configured to transition between an open position and a closed position to control a discharge rate of a respective one of the plurality of battery packs; and a control unit configured to control a position of the switching elements, the control unit being configured to: determine whether one or more of the plurality of battery packs is discharging; in response to determining that more than one of the plurality of battery packs are discharging, measure a voltage of each of the discharging battery packs; calculate a pulse width modulated signal for each of the switching elements that are connected to the discharging battery packs; and apply the pulse width modulates signals to the corresponding switching elements that are connected to the discharging battery packs; wherein the control unit is further configured to stop any of the plurality of battery packs from discharging upon detecting that a state of charge is less than a threshold value, and wherein the threshold value is greater than zero percent.

37. The commercial turf equipment of claim 36, wherein the pulse width modulated signals are all calculated based on the voltage measurement of one of the discharging battery packs.

38. The commercial turf equipment of claim 36, wherein the pulse width modulated signals are calculated individually, each being based on the voltage measurement of the discharging battery pack connected to the switching element.

39. The commercial turf equipment of claim 36, wherein the implement is a blower.

40. The commercial turf equipment of claim 36, wherein the implement is a vacuum.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] The drawings illustrate the best mode presently contemplated of carrying out the disclosure. In the drawings:

[0015] FIG. 1 is a perspective view of a piece of outdoor power equipment, according to an exemplary embodiment;

[0016] FIG. 2 is a schematic illustration of a power unit of the outdoor power equipment of FIG. 1 including multiple battery packs and switching elements;

[0017] FIG. 3 is a flow chart illustrating a method of operating power equipment, according to an exemplary embodiment; and

[0018] FIG. 4 is a flow chart illustrating a method of balancing power among multiple batteries, according to an exemplary embodiment.

DETAILED DESCRIPTION

[0019] FIG. 1 illustrates a handheld battery powered piece of outdoor power equipment 10. FIG. 1 illustrates only one embodiment of the possible type of outdoor power equipment that can be battery powered. In the embodiment shown in FIG. 1, the outdoor power equipment 10 is a handheld edger 12, although other equipment is contemplated. The edger 12 includes an electric motor 14 and two or more battery packs 16 that power the electric motor 14. An electric power head 18 serves as the replacement for a small internal combustion engine of the type frequently used on a wide variety of portable power equipment. In one exemplary embodiment, the electric motor 14 is an 800-watt electric motor and each of the two battery pack is an 82-volt, 2-4 amp-hour battery. Other power levels, voltages and battery capabilities are contemplated as being within the scope of the present disclosure. As an example, the battery voltage could range from 12-volts to voltages greater than 82-volts; the battery capacity could be more or less than 2-4 amp-hours and the motor power could be more or less than 800 watts.

[0020] The powerhead 18 includes a battery receptacle 20 that is designed to securely hold two or more battery packs 16 in the position shown. Each battery pack 16 is electrically connected to the motor 14 through the battery receptacle 20 to provide power to the electric motor 14. The battery packs 16 include specifically designed latches and contacts such that the battery packs can be securely retained within the battery receptacle 20 while providing the required electrical connections to the battery cells contained within the battery pack.

[0021] FIG. 2 is a schematic illustration of the power unit 30 that includes a plurality of battery packs 16 that could be used to power a wide variety of end products. These end products may include outdoor power equipment, portable jobsite equipment, standby or portable power supplies, recreational or sporting equipment, and vehicles. Outdoor power equipment includes lawn mowers, riding tractors, snow throwers, pressure washers, tillers, log splitters, zero-turn radius mowers, walk-behind mowers, riding mowers, stand-on mowers, pavement surface preparation devices, industrial vehicles such as forklifts, utility vehicles, commercial turf equipment such as blowers, vacuums, debris loaders, overseeders, power rakes, aerators, sod cutters, brush mowers, sprayers, spreaders, etc. Outdoor power equipment may, for example, use an electric motor to drive an implement, such as a rotary blade of a lawn mower, a pump of a pressure washer, the auger a snow thrower, and/or a drivetrain of the outdoor power equipment. Portable jobsite equipment includes portable light towers, mobile industrial heaters, and portable light stands. Standby or portable power supplies include standby generators, portable generators, and stand-alone power supplies such as a backpack power supply for powering handhold power tools (e.g., leaf blowers, string trimmers, etc.). Recreational or sporting equipment includes ice augers, trolling motors, fish finders, boat anchor winches, bilge pumps, and fish well aerators. Vehicles include automobiles, trucks, motorcycles and other over-the road vehicles, boats such as fishing and recreational boats, snowmobiles, golf carts, and recreational off-highway vehicles such as all-terrain vehicles and utility task vehicles.

[0022] For outdoor power equipment, the power unit 30 allows the end user to manage the run time, load capability, or other operating characteristics of the outdoor power equipment by equipping the power unit 30 with a plurality of battery packs 16. The power unit 30 is able to selectively connect each of the battery backs 16 to the electrical load 32 to optimize the power available from the battery packs 16.

[0023] Each battery pack 16 includes a number of battery cells enclosed within an outer housing. In some embodiments, the battery cells are Lithium ion cells. The cells are arranged with groups of cells connected in series (S) and with groups of cells connected in parallel (P) (e.g., in a 20S5P configuration, a 14S6P a configuration, a 13S6P configuration, etc.). By providing groups of cells arranged in parallel with one another, the battery pack 16 is able to maintain system voltage, even when experiencing losses in capacity. If the cells were only connected in series, a break amongst the series connections would cause the system voltage provided by the battery module to drop.

[0024] FIG. 2 further illustrates the electrical connections utilized to power one or more electrical loads 32, such as a motor. In the embodiment shown in FIG. 2, a control unit 34, which could be one of many different types of microprocessors or microcontrollers, is used to control the state of three individual switching elements 36a, 36b and 36n. Since the number of battery packs 16 and the corresponding number of switching elements can vary, the reference character “n” is used to represent an unknown or variable number. In the embodiment shown, three battery packs 16 and switching elements 36 are shown. The state of each of the individual switching elements 36 is controlled by the control unit 34 through a control line 38. Although multiple control lines 38 (e.g., 38a-38n) are shown in FIG. 2, it should be understood that a single control line 38 could be utilized while operating within the scope of the present disclosure. In addition, the switching elements 36a-36n could be either a single element (metal-oxide-semiconductor field-effect transistor (MOSFET), insulated gate bipolar transistor (IGBT), a different transistor, relay, etc.) or could be a combination of two switching devices.

[0025] In one contemplated embodiment of the present disclosure, each of the switching elements 36a-36n is a high current MOSFET that can transition between an open and closed position through a control commands from the control unit 34. Although a MOSFET is described in one embodiment as a switching element 36, it should be understood that different types of switching elements could be utilized while operating within the scope of the present disclosure.

[0026] As illustrated in FIG. 2, the first switch 36a provides a connection between the battery pack 16a and ground through the load 32. The second switch 36b provides a connection between the battery pack 16b and ground through the load 32. The third switch 36n provides a connection between the battery pack 16n and ground through the load 32. Although three switches and battery packs 16 are shown, as few as two battery packs or a larger number of battery packs and switches could be used, up to the number “n”. A capacitor 42 is shown connected between the switching elements 36 and ground to reduce any noise in the circuit. The control unit 34 is operable to selectively open and close each of the individual switching elements 36 as desired to control the discharging of the battery packs 16. Since the switching elements 36 are contemplated as being MOSFETS, the control unit 34 can open and close the switching elements 36 at rapid rates to selectively control the rate of discharge of the battery packs 16 to the motor.

[0027] In addition to controlling the position of the switching elements 36, the control unit 24 is also configured to monitor the state of charge on each of the battery packs 16 in a conventional manner through the sensing lines 40. One method of monitoring the state of charge on each of the battery packs 16 is to monitor the voltage of the respective battery packs utilizing a voltage sensor. In an illustrative example, the maximum state of charge of the battery packs will be 82 volts. When the output of the battery pack 16 falls to 80 volts, the battery pack 16 will be at 80% charge. However, the determination of state of charge based on battery pack voltage is dependent on battery types, battery configurations, and other parameters. Accordingly, state of charge will be determined relative to the maximum voltage of the battery pack voltage. Percent of maximum change will be used in the following discussion to illustrate the discharging control by the control unit 34. By monitoring the state of charge on each of the individual battery packs 16, the control unit 34 will be able to selectively control the discharge rate of each of the individual battery packs 16.

[0028] In the embodiment shown in FIG. 2, the control unit 34 can control the opening and closing of the three MOSFET switches in order to vary the discharge rates of each of the three individual battery packs 16. For example, the switch 36a could be closed for a greater amount of time as compared to the switch 36b in order to connect the battery pack 16a to the motor for a greater amount of time.

[0029] One example method of controlling the state of the switching elements 36 is to utilize pulse width modulation on control signals from the control unit 34 to selectively open and close the switching elements 36 at the desired rate.

[0030] It is contemplated that the control unit 24 could control the discharge of the three battery packs 16 to either maximize performance or to maximize longevity. This selection could be presented to the user through a switch or selection device on the power equipment or on another type of user interface.

[0031] FIG. 3 illustrates one method of operating the control unit 34 to control the discharge of the plurality of battery packs 16. Although one method of operating the control unit 34 is disclosed in the embodiment of FIG. 3, it should be understood that the method illustrated in FIG. 3 is one preferred embodiment of the present disclosure.

[0032] Initially, in step 100, the control unit 34 determines whether a battery pack 16 has been inserted into the outdoor power equipment. The insertion of a battery pack 16 into the outdoor power equipment provides some type of indicator signal to the control unit 34, such as upon closing a switch or contact. Once the control unit 34 determines that a battery pack 16 has been inserted into the power equipment, the system proceeds to step 102 during which the control unit determines whether more than one battery pack 16 is present. If the system determines in step 102 that only a single battery pack 16 is present, the method disables the power balancing algorithm in step 104 and informs the user that the power balancing algorithm is not being utilized since only a single battery pack 16 is present. The power balancing algorithm of the present disclosure is used to enhance the amount of power available from multiple battery packs 16 and thus will not be used when only a single battery pack 16 is present.

[0033] If more than one battery pack 16 is present as indicated in step 102, the system moves to step 106, in which the control unit measures the battery voltage present at each of the battery packs 16. As indicated above, the battery voltage is measured using some type of voltage sensor and is relayed back to the control unit 34 through the series of control wires or communication lines. The battery voltage can be either an absolute value or can be expressed as a state of charge. Once the control unit 34 has determined the voltage of each of the battery packs 16, the system moves to step 108 and begins to run the power balancing algorithm. The details of the power balancing algorithm are illustrated in FIG. 4. The various measurements and PWM values are calculated based upon the number of batteries and the battery voltage on each of the battery packs 16. As shown in FIG. 4, variable n represents the number of batteries in parallel, variable V1 represents the voltage of battery 1, variable V2 represents the voltage of battery 2, variable Vn represents the voltage of battery n, variable PWM1 represents the PWM that battery 1 is subjected to, variable PWM2 represents the PWM that battery 2 is subjected to, variable PWMn represents the PWM that battery n is subjected to, and variable ΔV represents the value of the maximum voltage minus the minimum voltage measured of the n number of batteries in parallel.

[0034] As illustrated in FIG. 4, once the power balancing algorithm begins in step 108, the control method moves to step 110 in which the control unit determines whether the measured battery voltages on battery packs 1, 2 and up to n battery packs 16 have similar values relative to each other. The determination of the relative values of the voltages measured on each of the battery packs 16 can change depending upon the size of battery packs 16. If each of the three battery packs 16 has the same initial size, such as 82 volts, the control unit 34 determines in step 110 whether each of the battery packs 16 is at relatively the same level of charge. As an illustrative example, battery pack 16a may be at 80 volts, battery pack 16b may be at 78 volts while battery pack 16n may be at 81 volts.

[0035] Since all of the measured voltages in the example above are relatively similar to each other, the system would then move to step 112 to assign a pulse width modulated signal (PWM1, PWM2 and PWMn) that will be applied by the control unit to each of the individual switches 36a, 36b and 36n. In a situation in which all three of the battery packs 16 have relatively the same charge, the pulse width modulated signals (PWM1) applied to switch 36a would be 100/3. The remaining pulse width modulated signals applied to the other battery packs 16, up to battery pack n, would all be the same since the battery voltages measured on each battery pack 16 are essentially the same, as shown, for example, in the below equations.

PWM1=100/n   (Equation 1)

PWM2=PWM1   (Equation 2)

PWMn=PWM2   (Equation 3)

[0036] The pulse width modulated signal assigned to each of the battery packs 16 and switching elements in step 112 would then be applied to each of the switches 36 to allow all three of the battery packs 16 to discharge to power the load 32. The system then moves to step 114 in which the control unit repeatedly checks the voltage on each of the battery packs 16 again after a predetermined amount of time. For example, the control unit checks the voltage on each of the battery packs 16 every sixty seconds. The power balancing algorithm 108 continues to run in this manner as will be further described in FIG. 3.

[0037] In step 110, if the control unit determines that the battery voltages are not relative to each other, the system moves to step 116 in which the pulse width modulated signals applied to the respective switch for each battery pack 16 is determined based upon the voltage level of the battery pack 16. In each determination, the ΔV is the maximum voltage of the plurality of battery packs 16 measured minus the minimum voltage of the battery packs 16. This value is then used to determine the pulse width modulated signal (PWM1, PWM2 and PWMn) for each battery pack 16 in the manner shown in FIG. 4. The various measurements and PWM values are calculated based upon the number of batteries and the battery voltage on each of the battery packs 16, as shown in the equations below.

PWM1=100−[100*(ΔV−MEASURED V1)/(ΔV)]  (Equation 4)

PWM2=100−[100*(ΔV−MEASURED V2)/(ΔV)]  (Equation 5)

PWMn=100−[100*(ΔV−MEASURED Vn)/(ΔV)]  (Equation 6)

[0038] After step 116, the system again returns to step 114, which allows the voltage to be determined after the predetermined amount of time (e.g., sixty seconds). As can be understood by the calculations in step 116, the operating algorithm allows the battery having the greatest state of charge to be active the most until the voltage difference between all three battery packs 16 is gradually reduced.

[0039] Referring back to FIG. 3, as the power balancing algorithm is running, the system also determines in step 120 whether the battery state of charge (SOC) is below a threshold value. For example, at step 120, the system determines whether a battery has a SOC less than 25% of the battery capacity. If the battery SOC is greater than the threshold value (e.g., 25%), the system continues to run the power balancing algorithm. However, if the system determines in step 120 that the battery SOC falls below the predetermined, threshold value, or any of the battery packs' SOC fall below the threshold value, the battery pack having a SOC less than the threshold value is turned off and the duty cycles for the remaining battery packs are adjusted. In this manner, the operating algorithm will remove a battery pack 16 once the SOC falls below the predetermined, threshold value.

[0040] In step 124, the method determines whether all of the batteries have a SOC that is less than the threshold value (e.g., 25%). If the system determines that not all of the batteries' SOC are below the threshold value, the system returns to the power balancing algorithm in step 108 and continues this process until the system determines in step 124 that all of the batteries have a SOC less than the threshold value. Once this occurs, the system moves to step 126 and the batteries are indicated as being depleted.

[0041] As can be understood by the operating descriptions in FIGS. 3 and 4, the control unit is able to balance the discharge of each of the three battery packs 16 to enhance the performance of the battery packs 16. This enhanced performance allows the battery packs 16 to operate utilizing two batteries at different voltages by switching back and forth between the two batteries so that the battery pack 16 with more voltage is not charging the other battery pack 16 with less voltage. Switching the power output between the plurality of battery packs 16 will allow the battery packs 16 to power larger pieces of equipment.

[0042] Although the embodiments shown illustrate three battery packs 16 connected in parallel, it is contemplated that additional battery packs 16 could be utilized while operating within the scope of the present disclosure. Adding an additional battery pack 16 in parallel with the three battery packs 16 will both increase the run-time and will slightly increase the voltage created by the parallel-connected battery packs. The addition of battery packs 16 in parallel will also increase the available power (increased current availability), which will increase runtime. The additional battery packs 16 connected in parallel will also allow the output voltage to remain at the desired level for a longer period of time.

[0043] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to make and use the invention. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.