Power tool including secondary energy storage

Patent metadata

Field	Value
Publication number	US-2025286481-A1
Application number	US-202519069875-A
Country	US
Kind code	A1
Filing date	Mar 4, 2025
Priority date	Mar 7, 2024
Publication date	Sep 11, 2025
Grant date	—

Abstract

Examples provide a power tool including a power input interface electrically connectable to a power source; a motor; a DC-DC power converter electrically connected to the motor; a secondary energy storage device electrically connected to the DC-DC power converter; and a controller electrically connected to the DC-DC power converter, the controller configured to control the DC-DC power converter to route a braking current generated by the motor to the secondary energy storage device during a regenerative braking operation.

First claim

What is claimed is:

1 . A power tool comprising:
a power input interface electrically connectable to a power source; a motor; a DC-DC power converter electrically connected to the motor; a secondary energy storage device electrically connected to the DC-DC power converter; and a controller electrically connected to the DC-DC power converter, the controller configured to control the DC-DC power converter to provide a current generated by the motor to the secondary energy storage device, the current being generated during motor braking.

2 . The power tool of claim 1 , wherein the DC-DC power converter is configured to regulate power provided to the secondary energy storage device from the motor during motor braking.

3 . The power tool of claim 1 , wherein the DC-DC power converter is a bidirectional DC-DC power converter configured to regulate power discharged from the secondary energy storage device.

4 . The power tool of claim 1 , further comprising:
a power switching network electrically connected to the motor and the DC-DC power converter, wherein the controller is configured to control the power switching network to perform motor braking.

5 . The power tool of claim 4 , wherein the controller is further configured to selectively provide energy stored in the secondary energy storage device to one selected from a group consisting of the motor and the power source.

6 . The power tool of claim 5 , wherein the controller is configured to selectively provide the energy stored in the secondary energy storage device to the motor as a motor plugging current during a braking operation of the motor.

7 . The power tool of claim 5 , wherein the controller is configured to selectively provide the energy stored in the secondary energy storage device to the motor as supplementary power for driving the motor.

8 . The power tool of claim 7 , wherein the controller is configured to provide power from the power source and the supplementary power from the secondary energy storage device to the motor at startup.

9 . The power tool of claim 7 , wherein the controller is configured to provide the supplementary power in response to determination that a voltage of the power source is below a threshold during a driving operation of the motor.

10 . The power tool of claim 7 , wherein the controller is configured to provide the supplementary power in response to determination that a power demand of the motor is greater than a threshold.

11 . The power tool of claim 7 , further comprising:
a user input interface; wherein the controller is further configured to
receive user input via the user input interface indicating that a boost operation is requested, and
selectively provide the energy stored in the secondary energy storage device to the motor as supplementary power for driving the motor in response to determining that the boost operation is requested.

12 . The power tool of claim 1 , wherein the controller is configured to selectively provide energy stored in the secondary energy storage device to the power source in response to determining that the motor is in an idle state.

13 . The power tool of claim 1 , wherein the secondary energy storage device includes at least one selected from the group consisting of a capacitor, a supercapacitor, a battery cell, and a power tool battery pack.

14 . The power tool of claim 1 , wherein the power source is a removable battery pack.

15 . A power tool comprising:
a battery pack interface electrically connectable to a battery pack; a motor; a DC-DC power converter electrically connected to the motor; a secondary energy storage device electrically connected to the DC-DC power converter; and a controller electrically connected to the DC-DC power converter, the controller configured to control DC-DC power converter to provide a braking current generated by the motor to the secondary energy storage device during motor braking.

16 . The power tool of claim 15 , wherein the controller is further configured to
responsive to determining that a first operating condition of the power tool is met, selectively provide energy stored in the secondary energy storage device to the motor, responsive to determining that the first operating condition of the power tool is not met and that a second operating condition of the power tool is met, selectively provide the energy stored in the secondary energy storage device to the battery pack, and responsive to determining that the first operating condition and the second operating condition are not met, selectively enable the energy stored in the secondary energy storage device to dissipate.

17 . A method for operating a power tool including a power input interface electrically connectable to a power source, a motor, a DC-DC power converter, and a secondary energy storage device, the method comprising:
controlling the DC-DC power converter to provide a braking current generated by the motor to the secondary energy storage device during motor braking.

18 . The method of claim 17 , further comprising:
selectively providing energy stored in the secondary energy storage device to one selected form a group consisting of the motor and the power source.

19 . The method of claim 18 , wherein the energy stored in the secondary energy storage device to the motor is selectively provided to the motor as a motor plugging current during a braking operation of the motor.

20 . The method of claim 18 , wherein the energy stored in the secondary energy storage device to the motor is selectively provided to the motor as supplementary power for driving the motor.

Assignees

• Milwaukee Electric Tool Corp

Inventors

• Woodbury Kerry J
• Fieldbinder Douglas R

Classifications

• B25F5/00

  Details or components of portable power-driven tools not particularly related to the operations performed and not otherwise provided for · CPC title

• H02P3/14 Primary

  by regenerative braking · CPC title