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CHARGER INCLUDING MULTIPLE ADJUSTABLE POWER SOURCES

20260031632 ยท 2026-01-29

    Inventors

    Cpc classification

    International classification

    Abstract

    A battery pack charger includes a housing, a first and a second battery pack receptacle for receiving a battery pack, a first and a second power supply, and a controller. The controller is electrically coupled to the first and the second power supplies to enable the controller to configure the first and the second power supplies to provide an amount of charging current. The battery pack charger includes a set of charging circuits electrically coupled to the first and second power supplies to receive the amount of charging current from the first and the second power supplies. The controller configured to direct all of or less than all of the amount of charging current from the first power supply to the first battery pack receptacle and all of or less than all of the amount of charging current from the second power supply to the first battery pack receptacle.

    Claims

    1. A battery pack charger, comprising: a housing; a first battery pack receptacle incorporated in the housing for receiving a battery pack; a second battery pack receptacle incorporated in the housing for receiving a battery pack; a first power supply housed within the housing; a second power supply housed within the housing; a controller housed within the housing, the controller electrically coupled to the first power supply to enable the controller to configure the first power supply to provide a first amount of charging current and electrically coupled to the second power supply to configure the second power supply to provide a second amount of charging current; and one or more switches electrically coupled to the first power supply and the second power supply to receive and direct the first amount of charging current from the first power supply and the second amount of charging current from the second power supply and electrically coupled to the controller to enable the controller to configure the one or more switches to direct all of or less than all of the first amount of charging current from the first power supply to the first battery pack receptacle and all of or less than all of the second amount of charging current from the second power supply to the first battery pack receptacle and all of or less than all of the first amount of charging current from the first power supply to the second battery pack receptacle and all of or less than all of the second amount of charging current from the second power supply to the second battery pack receptacle.

    2. The battery pack charger, as recited in claim 1, wherein the one or more switches directs all of the first amount of charging current from the first power supply and all of the second amount of charging current from the second power supply to the first battery pack receptacle.

    3. The battery pack charger, as recited in claim 2, wherein the one or more switches directs all of the first amount of charging current from the first power supply and less than all of the second amount of charging current from the second power supply to the first battery pack receptacle and less than all of the second amount of charging current from the second power supply to the second battery pack receptacle.

    4. The battery pack charger, as recited in claim 1, wherein the one or more switches include a first switch and a second switch to direct the first amount of charging current from the first power supply and the second amount of charging current from the second power supply to the first battery pack receptacle and/or the second battery pack receptacle.

    5. The battery pack charger, as recited in claim 4, further comprising a power input circuit configured to receive power from a power source and supply power to the first power supply and to the second power supply.

    6. The battery pack charger, as recited in claim 5, wherein the power input circuit is configured to supply the first power supply with a first amount of power and the second power supply with a second amount of power.

    7. The battery pack charger, as recited in claim 4, wherein the one or more switches are electrically connected to a first parallel switch connecting the first switch with the second switch to control the first amount of charging current from the first power supply to the second battery pack receptacle and the second amount of charging current from the second power supply to the first battery pack receptacle.

    8. The battery pack charger, as recited in claim 1, further comprising a third power supply electrically coupled to the controller, wherein the controller configures the third power supply to provide a third amount of charging current.

    9. The battery pack charger, as recited in claim 8, further comprising a third battery pack receptacle incorporated in the housing for receiving a battery pack.

    10. The battery pack charger, as recited in claim 9, wherein the one or more switches include a first switch, a second switch, and a third switch to direct the first amount of charging current from the first power supply, the second amount of charging current from the second power supply, and the third amount of charging current from the third power supply to one or more selected from a group consisting of the first battery pack receptacle, the second battery pack receptacle, and the third battery pack receptacle.

    11. The battery pack charger, as recited in claim 10, further comprising: a first parallel switch connecting the first switch with the second switch to control the amount of charging current from the first and second power supplies to the first and second battery pack receptacles, and a second parallel switch connecting the third switch with the first switch and the second switch to control the amount of charging current from the first and second power supplies to the third battery pack receptacle and from the third power supply to the first and second battery pack receptacles.

    12. A battery pack charger, comprising: a housing; a first battery pack receptacle provided on the housing and configured to removably receive a first battery pack; a second battery pack receptacle provided on the housing and configured to removably receive a second battery pack; a first power supply provided in the housing; a second power supply provided in the housing; a first switch electrically connected to the first battery pack receptacle and configured to selectively connect the first battery pack receptacle to one of the first power supply and the second power supply; a second switch electrically connected to the second battery pack receptacle and configured to selectively connect the second battery pack receptacle to one of the first power supply and the second power supply; and a third switch electrically connected between the first switch and the second switch and configured to selectively form a bridge between a first current path between the first power supply and the first battery pack receptacle and a second current path between the second power supply and the second battery pack receptacle.

    13. The battery pack charger of claim 12, further comprising a controller electrically coupled to the first switch, the second switch, and the third switch and configured to control the first switch, the second switch, and the third switch to provide all of or less than all of a first amount of charging current from the first power supply to the first battery pack receptacle and all of or less than all of a second amount of charging current from the second power supply to the first battery pack receptacle and all of or less than all of the first amount of charging current from the first power supply to the second battery pack receptacle and all of or less than all of the second amount of charging current from the second power supply to the second battery pack receptacle.

    14. The battery pack charger of claim 12, further comprising a power input circuit configured to receive power from a power source and supply power to the first power supply and to the second power supply.

    15. A battery pack charger, comprising: a housing; a first battery pack receptacle incorporated in the housing for receiving a battery pack; a second battery pack receptacle incorporated in the housing for receiving a battery pack; a first AC to DC power supply housed within the housing; a second AC to DC power supply housed within the housing; a processing unit housed within the housing, the processing unit electrically coupled to the first power supply to enable the processing unit to configure the first power supply to provide an amount of charging current and electrically coupled to the second power supply to configure the second power supply to provide an amount of charging current; and a bridge assembly circuit housed within the housing, the bridge assembly circuit electrically coupled to the first power supply and the second power supply to receive the amount charging current from the first power supply and the amount of charging current from the second power supply and electrically coupled to the processing unit to enable the processing unit to configure the bridge assembly circuit to direct all of or less than all of the amount of charging current from the first power supply to the first battery pack receptacle and all of or less than all of the amount of charging current from the second power supply to the first battery pack receptacle and all of or less than all of the amount of charging current from the first power supply to the second battery pack receptacle and all of or less than all of the amount of charging current from the second power supply to the second battery pack receptacle.

    16. The battery pack charger, as recited in claim 15, wherein the bridge assembly circuit directs all of the amount of charging current from the first power supply and all of the amount of charging current from the second power supply to the first battery pack receptacle.

    17. The battery pack charger, as recited in claim 16, wherein the bridge assembly circuit directs all of the amount of charging current from the first power supply and less than all of the amount of charging current from the second power supply to the first battery pack receptacle and less than all of the amount of charging current from the second power supply to the second battery pack receptacle.

    18. The battery pack charger, as recited in claim 15, wherein the bridge assembly circuit comprises at least one current limiting circuit.

    19. The battery pack charger, as recited in claim 15, wherein the bridge assembly circuit comprises a first switch and a second switch to direct the amount of charging current from the first power supply and the amount of charging current from the second power supply to the first battery pack receptacle and/or the second battery pack receptacle.

    20. The battery pack charger, as recited in claim 19, further comprising a power input circuit configured to receive power from a power source and supply power to the first power supply and to the second power supply.

    Description

    BRIEF DESCRIPTION OF THE DRAWINGS

    [0030] FIG. 1 illustrates a multi-bay battery pack charger, according to embodiments described herein.

    [0031] FIG. 2 illustrates a multi-bay battery pack charger, according to embodiments described herein.

    [0032] FIG. 3 illustrates a battery pack, according to embodiments described herein.

    [0033] FIG. 4 illustrates a control system for the multi-bay battery pack charger of FIG. 1 or FIG. 2, according to embodiments described herein.

    [0034] FIG. 5 illustrates a schematic diagram of charging control circuitry for the multi-bay battery pack charger of FIG. 1 or FIG. 2, according to embodiments described herein.

    [0035] FIG. 6 illustrates a schematic diagram of charging control circuitry for the multi-bay battery pack charger of FIG. 2, according to embodiments described herein.

    [0036] FIG. 7 illustrates a schematic diagram of charging control circuitry for the multi-bay battery pack charger of FIG. 2, according to embodiments described herein.

    [0037] FIG. 8 is a process for providing a low power charging current to a first battery pack and a second battery pack, according to embodiments described herein.

    [0038] FIG. 9 is a process for providing a high power charging current to a first battery pack, according to embodiments described herein.

    [0039] FIG. 10 is a process for providing a requested charging current to at least two battery packs, according to embodiments described herein.

    DETAILED DESCRIPTION

    [0040] Embodiments described herein relate to a battery pack charger that can output various charging currents from power supplies based on a requested charge configuration.

    [0041] FIG. 1 illustrates a battery pack charger 100. The battery pack charger 100 includes a housing 105, interface portions 110, 115, and a cord 120. The interface portions 110, 115 electrically connect the battery pack charger 100 to one or more battery packs (e.g., battery pack 215) through charging circuits. For example, charging circuits provides power to at least one battery pack from at least one power supply that receives power from a power input circuit (see FIGS. 5-7). The cord 120 allows the battery pack charger 100 to receive power from an external power source (e.g., a conventional wall outlet).

    [0042] In some embodiments, the battery pack charger 100 may charge multiple battery packs with various power ratings at once. For example, interface portion 110 may be a six Amperes (Amps) power supply for charging batteries with a six amp power rating and interface portion 115 may be a 12 amp power supply for charging batteries with a 12 amp power rating. As another example, the battery pack charger 100 may include circuitry such that a battery pack with an 18 amp power rating may be charged by one of the interface portions 110, 115. As will be described in detail below, the charging circuits may include or be connected to switches that enable the power supplies to provide various output powers to various battery packs depending on a user input.

    [0043] FIG. 2 illustrates a multi-bay battery pack charger 200. The multi-bay battery pack charger (charger) 200 includes a housing 205 and battery receptacles 210 for receiving battery packs 215. The charger 200 is configured to distribute power to the battery packs 215. The battery packs 215 are configured to provide power to peripheral devices. The peripheral devices may be handheld power tool or the like. The charger 200 is also configured to receive power from a power source and use the power from the power source to distribute charging power to the battery packs 215. In some embodiments, the power source is a DC power source, for example, a photovoltaic cell (e.g., a solar panel) or one or more batteries. In other embodiments, the power source is an AC power source, for example, a conventional wall outlet.

    [0044] The battery receptacles 210 are positioned on the exterior of the housing 205 and are configured to receive the battery packs 215. In the illustrated embodiment, the battery packs 215 are slide-on style battery packs. Accordingly, the battery receptacles 210 include guide rails to receive the slide-on style battery packs and latching mechanisms to secure the two components together. In the illustrated embodiment, the battery packs 215 may be six volt battery packs, 12 Volt battery pack and/or 18 Volt battery packs, etc., and can have a lithium-based chemistry.

    [0045] FIG. 3 illustrates a battery pack 215 that is configured to receive power from the charger 100, 200. The battery pack 215 includes a housing 305 and an interface portion 310 for connecting the battery pack 215 to a device (e.g., a power tool) or a battery pack charger (e.g., charger 100, 200).

    [0046] FIG. 4 illustrates a control system 400 for the charger 100, 200. The control system includes a controller 405. The controller 405 is electrically and/or communicatively connected to a variety of modules or components of the charger 100, 200. For example, the illustrated controller 405 is electrically connected to a fan control 410, a user interface 415, battery pack interfaces 420, charging circuits 425, power supplies 428, a power input circuit 430, current sensors 435, and voltage sensors 440. The controller 405 includes combinations of hardware and software that are operable to, among other things, control the operation of the charger 100, 200. The fan control 410 operates a fan 485. In some embodiments, the user interface 415 includes a touchscreen. In some embodiments, the user interface 415 includes various components (e.g., switches, buttons, levers, dials, etc.) that allow a user to interface with and control the charger 100.

    [0047] The controller 405 includes a plurality of electrical and electronic components that provide power, operational control, and protection to the components and modules within the controller 405 and/or charger 100, 200. For example, the controller 405 includes, among other things, a processing unit 445 (e.g., a microprocessor, a microcontroller, an electronic controller, an electronic processor, or another suitable programmable device), a memory 450, input units 455, and output units 460. The processing unit 445 includes, among other things, a control unit 465, an arithmetic logic unit (ALU) 470, and a plurality of registers 475 (shown as a group of registers in FIG. 4), and is implemented using a known computer architecture (e.g., a modified Harvard architecture, a von Neumann architecture, etc.). The processing unit 445, the memory 450, the input units 455, and the output units 460, as well as the various modules or circuits connected to the controller 405 are connected by one or more control and/or data buses (e.g., common bus 480). The control and/or data buses are shown generally in FIG. 4 for illustrative purposes. The use of one or more control and/or data buses for the interconnection between and communication among the various modules, circuits, and components would be known to a person skilled in the art in view of the embodiments described herein.

    [0048] The memory 450 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 445 is connected to the memory 450 and executes software instructions that are capable of being stored in a RAM of the memory 450 (e.g., during execution), a ROM of the memory 450 (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 charger 100, 200 can be stored in the memory 450 of the controller 405. 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 405 is configured to retrieve from the memory 450 and execute, among other things, instructions related to the control processes and methods described herein. In other constructions, the controller 405 includes additional, fewer, or different components.

    [0049] The battery pack interfaces 420 include 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 charger 100 with a battery pack (e.g., battery pack 215). For example, the battery pack interfaces 420 are configured to receive power through the charging circuits 425 via the power input circuit 430. The battery pack interfaces 420 are also configured to communicatively connect to the controller 405 via one or more communications lines 490.

    [0050] In some embodiments, the controller 405 is configured to control the transfer of power to the charging circuits 425 based on detected power conditions in the charger 100. For example, the current sensors 435 and the voltage sensors 440 communicate to the controller 405 the amount of current and voltage available in the charger 100, respectively. The individual charging circuits 425 can communicate, to the controller, the amount of power needed by the battery packs 215 as well as the power rating of the battery packs 215 that are electrically connected to the respective charging circuits 425.

    [0051] The controller 405 is configured to control switches coupled to power supplies 428 to output a requested power from at least one charging circuit 425 to the battery pack(s) 215. In some embodiments, the controller 405 controls the switches based on an input received at the user interface 415. For example, when the battery pack includes two charging ports (e.g., battery pack 215), a user may wish to use a high-power configuration that charges a first battery pack at a first interface using multiple power supplies 428. In other words, the first battery pack can receive power from a first power supply and a second power supply to be charged according to a high-power configuration. As another example, a user may wish to use a low-power configuration that charges both the first battery pack and the second battery pack using the first power supply and the second power supply, respectively. The high-power configuration fully charges the first battery pack at a faster rate than the low-power configuration.

    [0052] FIG. 5 illustrates a schematic diagram 500 of the charger 100 of FIG. 1 or charger 200 of FIG. 2. The schematic diagram includes the power input circuit 430, the user interface 415, the controller 405, a first power supply 505 (e.g., a 6 Amp power supply), a second power supply 510 (e.g., a 12 Amp power supply), switches 515A, 515B, 515C, charging circuit A 520, charging circuit B 525, and battery packs 215A, 215B. Although a 6 Amp power supply and a 12 Amp power supply are illustrated, different Amp values for the power supplies can also be used, the power supplies can have the same Amp rating, etc. The power input circuit 430 receives power from an external power source (e.g., a conventional wall outlet, one or more batteries, etc.) or an internal power source (e.g., one or more battery cells). The power input circuit 430 provides power to the power supplies 505, 510. The power input circuit includes circuitry that supplies the six amp power supply 505 with a first amount of power to supply six Amps to a battery pack and circuitry that supplies the 12 amp power supply 510 with a second amount of power to supply 12 Amps to a battery pack. In some embodiments, the power input circuit 430 includes a circuit breaker as branch circuit protection. In other embodiments, the power input circuit 430 includes a fuse, an overload relay, etc. The switches 515A, 515B, 515C may be mechanical switches, transistors, or the like.

    [0053] The controller 405 receives inputs from the user interface 415. A user may interact with the user interface 415 to set the charge rate of the charging circuits 520, 525. A user may choose a low-power configuration or a high-power configuration. For example, the user interface 415 may include buttons (e.g., on a screen) that correspond with an off configuration, low-power configuration, a first high-power configuration, and a second high-power configuration. Other power configurations may be contemplated. In some embodiments, the controller 405 receives inputs from an external device (e.g., a mobile phone, computer, tablet, etc.) that controls the charge rate of the charging circuits 520, 525.

    [0054] When a low-power configuration is input by a user at the user interface 415, the controller 405 controls switch 515A and switch 515C to close and switch 515B to open. Accordingly, the power from the six amp power supply 505 flows to charging circuit A 520, which then charges the first battery pack 215A using six Amps of current and the power from the 12 amp power supply 510 flows to charging circuit B 525, which then charges the second battery pack 215B using 12 Amps of current. In some embodiments, the first battery pack 215A and the second battery pack 215B have the same power rating. For example, both battery packs 215A, 215B may be rated for 12 Amps of current, such that the second battery pack 215B may reach full charge faster than the first battery pack 215A. In some embodiments, the first battery pack 215A may be rated for six Amps of current and the second battery pack 215B may be rated for 12 Amps of current, such that both battery packs 215A, 215B reach full charger at approximately the same time.

    [0055] When a first high-power configuration is input by a user at the user interface 415, the controller 405 controls switches 515A and 515B to close and switch 515C to open. Accordingly, the power from the six amp power supply 505 and the 12 amp power supply 510 flows to charging circuit A 520, which then charges the first battery pack 215A using 18 Amps of current. Charging circuit B 525 does not receive any power. In some embodiments, the battery pack receiving 18 Amps of current may be a high-capacity, high-output battery pack that requires 18 Amps of current to be charged. As noted above, the values of 6 Amps and 12 Amps are merely used for illustrative purposes, and other current ratings can be used (e.g., any current rating between 1 Amp and 30 Amps).

    [0056] When a second high-power configuration is input by a user at the user interface 415, the controller 405 controls switches 515B and 515C to close and switch 515A to open. Accordingly, the power from the six amp power supply 505 and the 12 amp power supply 510 flows to charging circuit B 525, which then charges the second battery pack 215B using 18 Amps of current. Charging circuit A 520 does not receive any power.

    [0057] In some embodiments, the battery pack receiving the output from both power supplies 505A, 505B (e.g., in the high-power configurations) reaches a full charge faster than when both the battery packs receive power from their respective power supplies (e.g., in the low-power configuration).

    [0058] In some embodiments, the switches 515A, 515B, 515C may all be open when the charger 100, 200 is in the off configuration or no battery packs 215 are attached to the charger 100, 200.

    [0059] In some embodiments, a user may wish to conserve power from the power input circuit 430 and, thus, may wish for only one battery pack to receive charging power. For example, the user may choose an input on the user interface 415 that communicates to the controller 405 to charge the first battery pack 215A only. In this example, switch 515A is closed and switches 515B and 515C are open. As another example, the user may choose an input on the user interface 415 that communicates to the controller 405 to charge the second battery pack 215B only. In this example, switch 515C is closed and switches 515A and 515B are open.

    [0060] Tables 1-6, below, are examples of the various power output configurations that may be implemented by the charger 100, 200, and more specifically, by the circuit components in the schematic diagram 500. In some embodiments, the user interface 415 may include inputs (e.g., buttons, switches, etc.) corresponding to each power output configuration. Switch designations of S.sub.A, S.sub.B, and S.sub.C correspond to switches 515A, 515B, and 515C, respectively.

    TABLE-US-00001 TABLE 1 Power Output Circuitry Switch Combinations Battery Packs Output Power Output A S.sub.A ON Battery Pack 1 A S.sub.B OFF S.sub.C ON Power Output B S.sub.A ON Battery Pack 2 B S.sub.B OFF S.sub.C ON

    TABLE-US-00002 TABLE 2 Power Output Circuitry Switch Combinations Battery Packs Output Power Output A S.sub.A ON Battery Pack 1 A + B S.sub.B ON S.sub.C OFF Power Output B S.sub.A ON Battery Pack 2 0 S.sub.B ON S.sub.C OFF

    TABLE-US-00003 TABLE 3 Power Output Circuitry Switch Combinations Battery Packs Output Power Output A S.sub.A OFF Battery Pack 1 0 S.sub.B ON S.sub.C ON Power Output B S.sub.A OFF Battery Pack 2 A + B S.sub.B ON S.sub.C ON

    TABLE-US-00004 TABLE 4 Power Output Circuitry Switch Combinations Battery Packs Output Power Output A S.sub.A ON Battery Pack 1 A S.sub.B OFF S.sub.C OFF Power Output B S.sub.A ON Battery Pack 2 0 S.sub.B OFF S.sub.C OFF

    TABLE-US-00005 TABLE 5 Power Output Circuitry Switch Combinations Battery Packs Output Power Output A S.sub.A OFF Battery Pack 1 0 S.sub.B OFF S.sub.C ON Power Output B S.sub.A OFF Battery Pack 2 B S.sub.B OFF S.sub.C ON

    TABLE-US-00006 TABLE 6 Power Output Circuitry Switch Combinations Battery Pack Output Power Output A S.sub.A OFF Battery Pack 1 0 S.sub.B OFF S.sub.C OFF Power Output B S.sub.A OFF Battery Pack 2 0 S.sub.B OFF S.sub.C OFF

    [0061] FIG. 6 illustrates a schematic diagram 600 of the charger 200 of FIG. 2. The schematic diagram 600 incudes the power input circuit 430, the user interface 415, the controller 405, a first power supply 605 (e.g., a 6 Amp power supply), a second power supply 610 (e.g., a 6 Amp power supply), a third power supply 615 (e.g., a 12 Amp power supply), switches 635A, 635B, 635C, 635D, 635E, charging circuit A 620, charging circuit B 625, charging circuit C 630, and battery packs 215A, 215B, 215C. The power input circuit 430 receives power from an external power source (e.g., a conventional wall outlet, one or more batteries, etc.) or an internal power source (e.g., one or more battery cells). The power input circuit 430 provides power to the power supplies 605, 610, 615. The power input circuit includes circuitry that supplies the six amp power supplies 605, 610 with a first amount of power to supply six Amps to battery packs and circuitry that supplies the 12 amp power supply 615 with a second amount of power to supply 12 Amps to a battery pack. In some embodiments, the power input circuit 430 includes a circuit breaker as branch circuit protection. In other embodiments, the power input circuit 430 includes a fuse, an overload relay, etc. The switches 635A, 635B, 635C, 635D, 635E may be mechanical switches, transistors, or the like. The values of 6 Amps and 12 Amps are merely used for illustrative purposes, and other current ratings can be used (e.g., any current rating between 1 Amp and 30 Amps).

    [0062] Similar to the schematic diagram 500, the controller 405 in the schematic diagram 600 receives inputs from the user interface 415. A user may interact with the user interface 415 to set the charge rate of the charging circuits 620, 625, 630. A user may choose a low-power configuration, a medium power configuration, or a high-power configuration. For example, the user interface 415 may include buttons (e.g., on a screen) that correspond with an off configuration, low-power configuration, a first medium power configuration, a second medium power configuration, a first high-power configuration, a second high-power configuration, and a third high power configuration. Other power configurations may be contemplated as well. In some embodiments, the controller 405 receives inputs from an external device (e.g., a mobile phone, computer, tablet, etc.) that controls the charge rate of the charging circuits 620, 625, 630.

    [0063] When a low-power configuration is input by a user at the user interface 415, the controller 405 controls switches 635A, 635C, 635E to close and switches 635B, 635D to open. Accordingly, the power from the first six amp power supply 605 flows to charging circuit A 620, which then charges the first battery pack 215A using six Amps of current, the power from the second six amp power supply 610 flows to charging circuit B 625, which then charges the second battery pack 215B using six Amps of current, and the power from the 12 amp power supply 615 flows to charging circuit C 630, which then charges the third battery pack 215C using 12 Amps of current. In some embodiments, the first battery pack 215A, the second battery pack 215B, and the third battery pack 215C have the same power rating. For example, the battery packs 215A, 215B, 215C may be rated for 12 Amps of current, such that the third battery pack 215C may reach full charge faster than the first and second battery packs 215A, 215B. In some embodiments, the first battery pack 215A may be rated for six Amps of current and the second and third battery packs 215B, 215C may be rated for 12 Amps of current, such that the first and third battery packs 215A, 215C reach full charge at approximately the same time. In some embodiments, the second battery pack 215B may be rated for six Amps of current and the first and third battery packs 215A, 215C may be rated for 12 Amps of current, such that they second and third battery packs 215B, 215C reach full charge at the same time. In some embodiments, in the low-power configuration, the charger 200 operates as described but only closes switches 635A, 635C, 635E if a battery pack is detected by the charger 200 (e.g., based on communication with the battery pack).

    [0064] When a first medium-power configuration is input by a user at the user interface 415, the controller 405 controls switches 635A, 635B, 635E to close and switches 635C, 635D to open. Accordingly, the power from the first six amp power supply 605 and the second six amp power supply 610 flows to charging circuit A 620, which then charges the first battery pack 215A using twelve Amps of current and the power from the 12 amp power supply 615 flows to charging circuit C 630, which then charges the third battery pack 215C using 12 Amps of current.

    [0065] When a second medium-power configuration is input by a user at the user interface 415, the controller 405 control switches 635B, 635C, 635E to close and switches 635A, 635D to open. Accordingly, the power from the first six amp power supply 605 and the second six amp power supply 610 flows to charging circuit B 625, which then charges the second battery pack 215B using twelve Amps of current and the power from the 12 amp power supply 615 flows to charging circuit C 630, which then charges the third battery pack 215C using 12 Amps of current.

    [0066] When a first high-power configuration is input by a user at the user interface 415, the controller 405 controls switches 635A, 635B, 635D to close and switches 635C, 635E to open. Accordingly, the power from the first six amp power supply 605, the second six amp power supply 610, and the 12 amp power supply 615 flows to charging circuit A 620, which then charges the first battery pack 215A using 24 Amps of current. Charging circuit B 625 and charging circuit C do not receive any power. In some embodiments, the battery pack receiving 24 Amps of current may be a high-capacity, high-output battery pack that requires 24 Amps of current to be charged.

    [0067] When a second high-power configuration is input by a user at the user interface 415, the controller 405 controls switches 635B, 635C, 635D to close and switches 635A, 635E to open. Accordingly, the power from the first six amp power supply 605, the second six amp power supply 610, and the 12 amp power supply 615 flows to charging circuit B 625, which then charges the second battery pack 215B using 24 Amps of current. Charging circuit A 620 and charging circuit C 630 do not receive any power.

    [0068] When a third high-power configuration is input by a user at the user interface 415, the controller 405 controls switches 635B, 635D, 635E to close and switches 635A, 635C to open. Accordingly, the power from the first six amp power supply 605, the second six amp power supply 610, and the 12 amp power supply 615 flows to charging circuit C 630, which then charges the third battery pack 215C using 24 Amps of current. Charging circuit A 620 and charging circuit B 625 do not receive any power.

    [0069] In some embodiments, the battery pack receiving the output from the power supplies 605, 610, 615 (e.g., in one of the high-power configurations) reaches a full charge faster than when each of the battery packs receive power from their respective power supplies (e.g., in the low-power configuration) and when in one of the medium-power configurations.

    [0070] In some embodiments, the switches 635A, 635B, 635C, 635D, 635E may all be open when the charger 200 is in the off configuration or no battery packs 215 are attached to the charger 200.

    [0071] In some embodiments, a user may wish to conserve power from the power input circuit 430 and, thus, may wish for only one battery pack to receive charging power. For example, the user may choose a button on the user interface 415 that communicates to the controller 405 to charge the first battery pack 215A only. In this example, switch 635A is closed and switches 635B, 635C, 635D, 635E are open. As another example, the user may choose a button on the user interface 415 that communicates to the controller 405 to charge the second battery pack 215B only. In this example, switch 635C is closed and switches 635A, 635B, 635D, 635E are open. As another example, the user may choose a button on the user interface 415 that communicates to the controller 405 to charge the third battery pack 215C only. In this example, switch 635E is closed and switches 635A, 635B, 635C, 635D are open.

    [0072] FIG. 7 illustrates a schematic diagram 700 of the charger 200 of FIG. 2. The schematic diagram 700 incudes the power input circuit 430, the user interface 415, the controller 405, a first power supply 705 (e.g., a low or 6 Amp power supply), a second power supply 710 (e.g., a medium or 9 Amp power supply), a third power supply 715 (e.g., a high or 12 Amp power supply), switches 735A, 735B, 735C, 735D, 735E, charging circuit A 720, charging circuit B 725, charging circuit C 730, and battery packs 215A, 215B, 215C. In the illustrated embodiment, each of the power supplies 705, 710, 715 has a different current rating. The power input circuit 430 receives power from an external power source (e.g., a conventional wall outlet, one or more batteries, etc.) or an internal power source (e.g., one or more battery cells). The power input circuit 430 provides power to the power supplies 705, 710, 715. The power input circuit includes circuitry that supplies the six amp power supply 705 with a first amount of power to supply six Amps to battery packs, circuitry that supplies the nine amp power supply 710 with a second amount of power to supply nine Amps to battery packs, and circuitry that supplies the 12 amp power supply 715 with a third amount of power to supply 12 Amps to a battery pack. In some embodiments, the power input circuit 430 includes a circuit breaker as branch circuit protection. In other embodiments, the power input circuit 430 includes a fuse, an overload relay, etc. The switches 735A, 735B, 735C, 735D, 735E may be mechanical switches, transistors, or the like. The values of 6 Amps, 9 Amps, and 12 Amps are merely used for illustrative purposes, and other current ratings can be used (e.g., any current rating between 1 Amp and 30 Amps).

    [0073] Similar to the schematic diagrams 500, 600, the controller 405 in the schematic diagram 700 receives inputs from the user interface 415. A user may interact with the user interface 415 to set the charge rate of the charging circuits 720, 725, 730. A user may choose a low-power configuration, a medium power configuration, or a high-power configuration. For example, the user interface 415 may include buttons (e.g., on a screen) that correspond with an off configuration, low-power configuration, a first medium power configuration, a second medium power configuration, a first high-power configuration, a second high-power configuration, and a third high power configuration. Other power configurations may be contemplated as well. In some embodiments, the controller 405 receives inputs from an external device (e.g., a mobile phone, computer, tablet, etc.) that controls the charge rate of the charging circuits 720, 725, 730.

    [0074] When a low-power configuration is input by a user at the user interface 415, the controller 405 controls switches 735A, 735C, 735E to close and switches 735B, 735D to open. Accordingly, the power from the six amp power supply 705 flows to charging circuit A 720, which then charges the first battery pack 215A using six Amps of current, the power from the nine amp power supply 710 flows to charging circuit B 725, which then charges the second battery pack 215B using nine Amps of current, and the power from the 12 amp power supply 715 flows to charging circuit C 730, which then charges the third battery pack 215C using 12 Amps of current. In some embodiments, the first battery pack 215A, the second battery pack 215B, and the third battery pack 215C have the same power rating. For example, the battery packs 215A, 215B, 215C may be rated for 12 Amps of current, such that the third battery pack 215C may reach full charge faster than the first and second battery packs 215A, 215B. In some embodiments, the first battery pack 215A may be rated for six Amps of current and the second and third battery packs 215B, 215C may be rated for 12 Amps of current, such that the first and third battery packs 215A, 215C reach full charge at approximately the same time. In some embodiments, the second battery pack 215B may be rated for six Amps of current and the first and third battery packs 215A, 215C may be rated for 12 Amps of current, such that they second and third battery packs 215B, 215C reach full charge at approximately the same time. In some embodiments, the first battery pack 215A may be rated for six Amps of current, the second battery pack 215B may be rated for nine Amps of current, and the third battery pack 215C may be rated for 12 Amps of current, such that each battery pack 215A, 215B, 215C reaches full charge at approximately the same time. In some embodiments, in the low-power configuration, the charger 200 operates as described but only closes switches 735A, 735C, 735E if a battery pack is detected by the charger 200 (e.g., based on communication with the battery pack).

    [0075] When a first medium-power configuration is input by a user at the user interface 415, the controller 405 controls switches 735A, 735B, 735E to close and switches 735C, 735D to open. Accordingly, the power from the six amp power supply 705 and the nine amp power supply 710 flows to charging circuit A 720, which then charges the first battery pack 215A using 15 Amps of current and the power from the 12 amp power supply 715 flows to charging circuit C 730, which then charges the third battery pack 215C using 12 Amps of current.

    [0076] When a second medium-power configuration is input by a user at the user interface 415, the controller 405 control switches 735B, 735C, 735E to close and switches 735A, 735D to open. Accordingly, the power from the six amp power supply 705 and the nine amp power supply 610 flows to charging circuit B 725, which then charges the second battery pack 215B using 15 Amps of current and the power from the 12 amp power supply 715 flows to charging circuit C 730, which then charges the third battery pack 215C using 12 Amps of current.

    [0077] When a first high-power configuration is input by a user at the user interface 415, the controller 405 controls switches 735A, 735B, 735D to close and switches 735C, 735E to open. Accordingly, the power from the six amp power supply 705, the nine amp power supply 710, and the 12 amp power supply 715 flows to charging circuit A 720, which then charges the first battery pack 215A using 27 Amps of current. Charging circuit B 725 and charging circuit C do not receive any power. In some embodiments, the battery pack receiving 27 Amps of current may be a high-capacity, high-output battery pack that requires 27 Amps of current to be charged.

    [0078] When a second high-power configuration is input by a user at the user interface 415, the controller 405 controls switches 735B, 735C, 735D to close and switches 735A, 735E to open. Accordingly, the power from the six amp power supply 705, the nine amp power supply 710, and the 12 amp power supply 715 flows to charging circuit B 725, which then charges the second battery pack 215B using 27 Amps of current. Charging circuit A 720 and charging circuit C 730 do not receive any power.

    [0079] When a third high-power configuration is input by a user at the user interface 415, the controller 405 controls switches 735B, 735D, 735E to close and switches 735A, 735C to open. Accordingly, the power from the six amp power supply 705, the nine amp power supply 710, and the 12 amp power supply 715 flows to charging circuit C 730, which then charges the third battery pack 215C using 27 Amps of current. Charging circuit A 720 and charging circuit B 725 do not receive any power.

    [0080] In some embodiments, the battery pack receiving the output from the power supplies 705, 710, 715 (e.g., in one of the high-power configurations) reaches a full charge faster than when each of the battery packs receive power from their respective power supplies (e.g., in the low-power configuration) and when in one of the medium-power configurations.

    [0081] In some embodiments, the switches 735A, 735B, 735C, 735D, 735E may all be open when the charger 200 is in the off configuration or no battery packs 215 are attached to the charger 200.

    [0082] In some embodiments, a user may wish to conserve power from the power input circuit 430 and, thus, may wish for only one battery pack to receive charging power. For example, the user may choose a button on the user interface 415 that communicates to the controller 405 to charge the first battery pack 215A only. In this example, switch 735A is closed and switches 735B, 735C, 735D, 735E are open. As another example, the user may choose a button on the user interface 415 that communicates to the controller 405 to charge the second battery pack 215B only. In this example, switch 735C is closed and switches 735A, 735B, 735D, 735E are open. As another example, the user may choose a button on the user interface 415 that communicates to the controller 405 to charge the third battery pack 215C only. In this example, switch 735E is closed and switches 735A, 735B, 735C, 735D are open.

    [0083] Tables 7-24, below, are examples of the various power output configurations that may be implemented by the charger 200, and more specifically, by the circuit components in the schematic diagrams 600, 700. In some embodiments, the user interface 415 may include inputs (e.g., buttons, switches, etc.) corresponding to each power output configuration. Switch designations of S.sub.A, S.sub.B, S.sub.C, S.sub.D, and S.sub.E correspond to switches 635A, 635B, 635C, 635D, and 635E, respectively, or 735A, 735B, 735C, 735D, and 735E, respectively.

    TABLE-US-00007 TABLE 7 Power Output Circuitry Switch Combinations Battery Packs Output Power Output A S.sub.A ON Battery Pack 1 A S.sub.B OFF S.sub.C ON S.sub.D OFF S.sub.E ON Power Output B S.sub.A ON Battery Pack 2 B S.sub.B OFF S.sub.C ON S.sub.D OFF S.sub.E ON Power Output C S.sub.A ON Battery Pack 3 C S.sub.B OFF S.sub.C ON S.sub.D OFF S.sub.E ON

    TABLE-US-00008 TABLE 8 Power Output Circuitry Switch Combinations Battery Packs Output Power Output A S.sub.A ON Battery Pack 1 A S.sub.B OFF S.sub.C ON S.sub.D ON S.sub.E OFF Power Output B S.sub.A ON Battery Pack 2 B + C S.sub.B OFF S.sub.C ON S.sub.D ON S.sub.E OFF Power Output C S.sub.A ON Battery Pack 3 0 S.sub.B OFF S.sub.C ON S.sub.D ON S.sub.E OFF

    TABLE-US-00009 TABLE 9 Power Output Circuitry Switch Combinations Battery Packs Output Power Output A S.sub.A ON Battery Pack 1 A + B S.sub.B ON S.sub.C OFF S.sub.D OFF S.sub.E ON Power Output B S.sub.A ON Battery Pack 2 0 S.sub.B ON S.sub.C OFF S.sub.D OFF S.sub.E ON Power Output C S.sub.A ON Battery Pack 3 C S.sub.B ON S.sub.C OFF S.sub.D OFF S.sub.E ON

    TABLE-US-00010 TABLE 10 Power Output Circuitry Switch Combinations Battery Packs Output Power Output A S.sub.A OFF Battery Pack 1 0 S.sub.B ON S.sub.C ON S.sub.D OFF S.sub.E ON Power Output B S.sub.A OFF Battery Pack 2 A + B S.sub.B ON S.sub.C ON S.sub.D OFF S.sub.E ON Power Output C S.sub.A OFF Battery Pack 3 C S.sub.B ON S.sub.C ON S.sub.D OFF S.sub.E ON

    TABLE-US-00011 TABLE 11 Power Output Circuitry Switch Combinations Battery Packs Output Power Output A S.sub.A ON Battery Pack 1 A S.sub.B OFF S.sub.C OFF S.sub.D ON S.sub.E ON Power Output B S.sub.A ON Battery Pack 2 0 S.sub.B OFF S.sub.C OFF S.sub.D ON S.sub.E ON Power Output C S.sub.A ON Battery Pack 3 B + C S.sub.B OFF S.sub.C OFF S.sub.D ON S.sub.E ON

    TABLE-US-00012 TABLE 12 Power Output Circuitry Switch Combinations Battery Packs Output Power Output A S.sub.A ON Battery Pack 1 A + B + C S.sub.B ON S.sub.C OFF S.sub.D ON S.sub.E OFF Power Output B S.sub.A ON Battery Pack 2 0 S.sub.B ON S.sub.C OFF S.sub.D ON S.sub.E OFF Power Output C S.sub.A ON Battery Pack 3 0 S.sub.B ON S.sub.C OFF S.sub.D ON S.sub.E OFF

    TABLE-US-00013 TABLE 13 Power Output Circuitry Switch Combinations Battery Packs Output Power Output A S.sub.A OFF Battery Pack 1 0 S.sub.B ON S.sub.C ON S.sub.D ON S.sub.E OFF Power Output B S.sub.A OFF Battery Pack 2 A + B + C S.sub.B ON S.sub.C ON S.sub.D ON S.sub.E OFF Power Output C S.sub.A OFF Battery Pack 3 0 S.sub.B ON S.sub.C ON S.sub.D ON S.sub.E OFF

    TABLE-US-00014 TABLE 14 Power Output Circuitry Switch Combinations Battery Packs Output Power Output A S.sub.A OFF Battery Pack 1 0 S.sub.B ON S.sub.C OFF S.sub.D ON S.sub.E ON Power Output B S.sub.A OFF Battery Pack 2 0 S.sub.B ON S.sub.C OFF S.sub.D ON S.sub.E ON Power Output C S.sub.A OFF Battery Pack 3 A + B + C S.sub.B ON S.sub.C OFF S.sub.D ON S.sub.E ON

    TABLE-US-00015 TABLE 15 Power Output Circuitry Switch Combinations Battery Packs Output Power Output A S.sub.A ON Battery Pack 1 A S.sub.B OFF S.sub.C OFF S.sub.D OFF S.sub.E OFF Power Output B S.sub.A ON Battery Pack 2 0 S.sub.B OFF S.sub.C OFF S.sub.D OFF S.sub.E OFF Power Output C S.sub.A ON Battery Pack 3 0 S.sub.B OFF S.sub.C OFF S.sub.D OFF S.sub.E OFF

    TABLE-US-00016 TABLE 16 Power Output Circuitry Switch Combinations Battery Packs Output Power Output A S.sub.A OFF Battery Pack 1 0 S.sub.B OFF S.sub.C ON S.sub.D OFF S.sub.E OFF Power Output B S.sub.A OFF Battery Pack 2 B S.sub.B OFF S.sub.C ON S.sub.D OFF S.sub.E OFF Power Output C S.sub.A OFF Battery Pack 3 0 S.sub.B OFF S.sub.C ON S.sub.D OFF S.sub.E OFF

    TABLE-US-00017 TABLE 17 Power Output Circuitry Switch Combinations Battery Packs Output Power Output A S.sub.A OFF Battery Pack 1 0 S.sub.B OFF S.sub.C OFF S.sub.D OFF S.sub.E ON Power Output B S.sub.A OFF Battery Pack 2 0 S.sub.B OFF S.sub.C OFF S.sub.D OFF S.sub.E ON Power Output C S.sub.A OFF Battery Pack 3 C S.sub.B OFF S.sub.C OFF S.sub.D OFF S.sub.E ON

    TABLE-US-00018 TABLE 18 Power Output Circuitry Switch Combinations Battery Packs Output Power Output A S.sub.A ON Battery Pack 1 A S.sub.B OFF S.sub.C ON S.sub.D OFF S.sub.E OFF Power Output B S.sub.A ON Battery Pack 2 B S.sub.B OFF S.sub.C ON S.sub.D OFF S.sub.E OFF Power Output C S.sub.A ON Battery Pack 3 0 S.sub.B OFF S.sub.C ON S.sub.D OFF S.sub.E OFF

    TABLE-US-00019 TABLE 19 Power Output Circuitry Switch Combinations Battery Packs Output Power Output A S.sub.A OFF Battery Pack 1 0 S.sub.B OFF S.sub.C ON S.sub.D OFF S.sub.E ON Power Output B S.sub.A OFF Battery Pack 2 B S.sub.B OFF S.sub.C ON S.sub.D OFF S.sub.E ON Power Output C S.sub.A OFF Battery Pack 3 C S.sub.B OFF S.sub.C ON S.sub.D OFF S.sub.E ON

    TABLE-US-00020 TABLE 20 Power Output Circuitry Switch Combinations Battery Packs Output Power Output A S.sub.A ON Battery Pack 1 A S.sub.B OFF S.sub.C OFF S.sub.D OFF S.sub.E ON Power Output B S.sub.A ON Battery Pack 2 0 S.sub.B OFF S.sub.C OFF S.sub.D OFF S.sub.E ON Power Output C S.sub.A ON Battery Pack 3 C S.sub.B OFF S.sub.C OFF S.sub.D OFF S.sub.E ON

    TABLE-US-00021 TABLE 21 Power Output Circuitry Switch Combinations Battery Packs Output Power Output A S.sub.A OFF Battery Pack 1 0 S.sub.B OFF S.sub.C OFF S.sub.D OFF S.sub.E OFF Power Output B S.sub.A OFF Battery Pack 2 0 S.sub.B OFF S.sub.C OFF S.sub.D OFF S.sub.E OFF Power Output C S.sub.A OFF Battery Pack 3 0 S.sub.B OFF S.sub.C OFF S.sub.D OFF S.sub.E OFF

    [0084] FIG. 8 is a process 800 for providing a low-power charging current to the first battery pack 215A and the second battery pack 215B of the schematic diagram 500 of FIG. 5. The process 800 begins with the charger 100, 200 receiving the first battery pack 215A and the second battery pack 215B (Block 805). In some embodiments, the controller 405 determines that the battery packs 215A, 215B have been received by the charger 100, 200 by at least one of sensing a current of the battery packs, sensing a voltage of the battery packs, a mechanical switch in the battery pack interfaces 420, communication with the battery packs, etc. At block 810, the controller 405 receives a low-power configuration user input. In some embodiments, the user input is received from a user interacting with the user interface 415. Alternatively or additionally, in some embodiments, the user input is received from an external device (e.g., a smart phone).

    [0085] At block 815, the controller 405 opens the parallel switch (e.g., switch 515B in schematic diagram 500 of FIG. 5) and closes the series switches (e.g., switches 515A, 515C in schematic diagram 500 of FIG. 5). The switches may be mechanical switches, transistors, etc. A first output charging current is provided to the first battery pack 215A and a second output charging current is provided to the second battery pack 215B (Block 820). In some embodiments, the first output charging current may be less than the second output charging current. For example, the first output charging current may be six Amps, and the second output charging current may be 12 Amps. In some embodiments, the first and second output charging currents may be the same.

    [0086] FIG. 9 is a process 900 for providing a high-power charging current to one of the first battery pack 215A and the second battery pack 215B of the schematic diagram 500 of FIG. 5. The process 900 begins with the charger 100, 200 receiving at least one of the first battery pack 215A and the second battery pack 215B (Block 905). In some embodiments, the controller 405 determines that the battery packs 215A, 215B have been received by the charger 100, 200 by at least one of sensing a current of the battery packs, sensing a voltage of the battery packs, a mechanical switch in the battery pack interfaces 420, communication with the battery packs, etc. At block 910, the controller 405 receives a high-power configuration user input. In some embodiments, the user input is received from a user interacting with the user interface 415. Alternatively or additionally, in some embodiments, the user input is received from an external device (e.g., a smart phone).

    [0087] At block 915, the controller 405 closes the parallel switch and the first series switch (e.g., switches 515A, 515B in schematic diagram 500 of FIG. 5) and opens the second series switch (e.g., switch 515C in schematic diagram 500 of FIG. 5). In some embodiments, based on the user input, the controller 405 closes the parallel switch and the second series switch (e.g., switches 515B, 515C in schematic diagram 500 of FIG. 5) and opens the first series switch (e.g., switch 515A in schematic diagram 500 of FIG. 5). The switches may be mechanical switches, transistors, etc. The sum of the first and second output charging currents is provided to the first battery pack 215A (Block 920). The second battery pack 215B does not receive any charging current. In the high-power configuration, a single battery pack is charged using both output charging currents, such that the single battery pack may be charged more quickly.

    [0088] FIG. 10 is a process 1000 for providing a requested charging current to at least two battery packs of the schematic diagrams 500, 600, 700 of FIGS. 5-7. The process 1000 begins with the charger 100, 200 receiving at least two battery packs (Block 1005). In some embodiments, the controller 405 determines that at least two battery packs have been received by the charger 200 by at least one of sensing a current of the battery packs, sensing a voltage of the battery packs, a mechanical switch in the battery pack interfaces 420, communication with the battery packs, etc. At block 1010, the controller 405 receives a user input. In some embodiments, the user input may be one of a low-power configuration, a medium power configuration, or a high-power configuration. For example, the user input may correspond to any one of the power output configurations illustrated by Tables 1-21. In some embodiments, Block 1010 may be skipped, and the controller 405 automatically controls the switches to provide power to the at least two battery packs. For example, based on at least one of a sensed or received power rating of the at least two battery packs and a charge level of the at least two battery packs, the controller 405 may control the switches to provide power to the battery packs.

    [0089] At block 1015, the controller 405 controls the switches to provide the requested power outputs to the at least two battery packs. The switches may be mechanical switches, transistors, etc. Based on the configuration of open and closed switches, the charging currents output to the at least two battery packs corresponds to the user input.

    [0090] Although the blocks of processes 800, 900, 1000 are illustrated serially and in a particular order in FIGS. 8, 9, and 10, in some embodiments, one or more of the blocks are implemented in parallel, are implemented in a different order than shown, or are bypassed.

    [0091] Thus, embodiments described herein provide, among other things, systems and methods for setting and providing at least one output charging current to at least one battery pack received by a multi-bay battery pack charger. Various features and advantages are set forth in the following claims.