Improvements in battery operated electric machines

0001The present invention relates to improvements in battery operated electric machines and in particular to battery operated mowers.

0002It has been found that sealed lead acid batteries may be used as a suitable power source for lawn mowers or the like. Such batteries have the required performance characteristics to operate satisfactorily as a power source for an electric motor driving cutting blades of lawn or grass cutting machine and they are capable of repeatedly being recharged. They do, however, have the disadvantage that if they are used in conditions in which their discharge voltage drops too rapidly then the normal life expectancy of the battery is drastically reduced.

0003When the term "battery" or "battery means" is used hereinafter, it is intended to identify a battery or group of batteries that have this characteristic.

0004It is therefore an object of the present invention to provide control apparatus in the power supply system for battery powered machines, particularly lawn or grass mowers, which will prevent the battery from being rapidly discharged to the extent that the discharge capacity or life of the battery is substantially minimised (or ended).

0005Under certain possible adverse (to the battery) conditions, it is desirable to be able automatically to prevent use of the machine and thereby further discharge of the battery voltage levels. Typically, such situations arise where the work implement (cutting blades in the case of a mower) are obstructed for some reason. In the case of a mower this can occur as a result of the blades engaging an immovable object such as a rock or by excessively heavy grass conditions. In such circumstances, because of high current loading, the discharge voltage level drops rapidly but is also quickly recovered (if the obstruction exists only momentarily) to a level below but close to the level prior to the obstruction occurring. A similar characteristic occurs at start up under normal conditions. However, if the obstruction is more than transient, then the voltage recovery is very slow to recover if at all to levels well below the voltage level prior to the obstruction occurring. The present invention therefore aims to provide a means for disabling the machine to prevent battery damage upon an obstruction to the work implement being recognised without affecting the operation of the machine under normal start up conditions.

0006Accordingly, the present invention provides control apparatus for a rechargeable battery means of a battery powered lawn or grass mower, said control apparatus including monitoring means to monitor during use of the lawn or grass mower voltage discharge levels of the battery means and disabling means to disable said battery means from said mower, characterised in that the control apparatus includes means for establishing a predetermined reference voltage level and for recognising a rapid drop in discharge voltage level of the battery means at a rate higher than normal operational voltage level drop, said disabling means being arranged to disable said battery means from said mower if the voltage discharge level of said battery means as monitored by said monitoring means does not return to a voltage level greater than a control level being a preset differential below said reference voltage level within a predetermined period of time.

0007Conveniently the aforesaid predetermined period of time is determined from commencement of said rapid drop in voltage level.

0008In a preferred embodiment, the predetermined reference voltage level may be the voltage level sensed prior to said rapid drop in voltage level.

0009In an alternative preferred embodiment, the reference voltage level may be the voltage level sensed at each point in time that operation of the machine commences. For example, with a lawn mower, the first reference voltage level would be the battery voltage level first sensed when the handle operating switch is first moved to an operational position. Thereafter, if the mower is stopped, for example to empty the grass catcher, then the reference voltage is the voltage level sensed when the handle operating switch is reactivated to restart the mower.

0010The control apparatus is preferably also arranged to disable said battery from the machine upon the monitored discharge voltage of the battery dropping below a preset minimum regardless of the circumstances.

0011Battery means also have the disadvantage that if they are used to a stage where their discharge voltage drops below a certain limit then they cannot be recharged or the normal life expectancy of the battery is drastically reduced. The point at which this occurs does, however, depend to some extent on the rate of discharge of the battery which also depends on the conditions of use. In a lawn mower situation, it is conceivable that a user of the mower might wish to over extend the battery simply to finish a particular area prior to being forced to wait for a reasonably extended period necessary for recharging the battery. However, if this is done, the battery life will either be substantially shortened or immediately ended requiring the acquisition of a new battery for future operation of the mower. Clearly this is an undesirable circumstance which should be avoided if at all possible. In known prior art arrangements, over current sensing control devices have been used to disable the battery when current is drawn from the battery above a certain rate; however, these arrangements do not protect against battery failure (or life reduction) as a result of voltage discharge below the predetermined limits imposed by the battery manufacturer.

0012Therefore, preferably the disabling means is arranged to disable the battery means from said mower upon said voltage discharge level dropping below a predetermined minimum level for the battery means, said disabling means preventing reuse of the machine until the battery means has been recharged, preferably through a complete recharging regime.

0013Conveniently, the battery powered machine includes a motor adapted to drive a work implement such as cutting blades in the case of a mower.

0014Preferably, the monitoring means includes a microprocessor controller adapted repeatedly to sample the voltage discharge level of the battery during functional use of the battery powered machine with said disabling means being activated immediately the voltage level drops below said predetermined minimum level.

0015In accordance with a further aspect of the present invention, a safety mechanism for an electrically powered mower adapted to prevent inadvertent operation of the motor of the mower is provided. In European Patent Application No.466,306, there is disclosed a similar safety system incorporating a key member adapted to be inserted to actuate a switch mechanism from a normal circuit open position, preventing mower operation, to a circuit closed position when inserted allowing mower operation. One disadvantage of this arrangement is that the key member is in fact only an external actuator requiring a switch mechanism within the mower housing which adds certain costs to the overall assembly. Furthermore, only partial removal of the key member could result in the switch mechanism being opened allowing the key member to remain in position for possible inadvertent reactivation in undesirable circumstances.

0016It is a further object of the present invention to provide a disabling system of the aforementioned kind which will avoid the costs of this separate switch mechanism and which will also prevent inadvertent reactivation in undesirable circumstances.

0017The present invention also provides a control means for a mower comprising an electric motor adapted to drive a cutter mechanism and electrical connection means between a power source and said motor, said control means including switch means being opened upon removing a switch operating member from said mower and being closed by operationally inserting said switch operating member into said mower, said control means being characterised by said switch operating member forming a part of the electrical connection means when operationally inserted to close said switch means. Conveniently, said operating member comprises an electrically conductive blade element adapted to be inserted between a pair of plate contact members whereby when the switch means is closed, electrical contact is established between the two plate contact members via said blade element. Thus, the operating member needs to be removed completely to open the switch means. Each of the plate contact members may be mounted for at least limited movement relative to said blade element to increase the degree of electrical contact between each contact member and the blade element.

0018Where the source of power comprises a rechargeable battery, it is desirable to provide a recharging connection means adjacent the aforesaid switch means whereby in the closed position, an enlarged head portion of the operating member may cover both the switch means and the recharging connection means thereby protecting same and preventing inadvertent connection of the recharging means to an external source of power when the switch operating member is inserted.

0019In accordance with a still further aspect of the present invention there is provided a lawn or grass mower including an electric motor driving a cutting means and a rechargeable battery means for powering said electric motor, said mower further including recharging means adapted for connection to an external power source and when so connected, said recharging means is adapted to pass said battery through a defined recharging regime prior to allowing reuse of said mower. The defined recharging regime preferably comprises a first trickle charging stage from a nominally flat condition of said battery means until the battery means achieves a first predetermined voltage level, a second charging stage where the battery means is charged at close to or at a maximum charge rate possible for said battery means until a second predetermined over charge voltage level for the battery means is achieved, thereafter maintaining charging of said battery means for a predetermined period of time while ensuring battery voltage does not exceed an upper limit for said battery means greater than said second predetermined over charge voltage level.

0020The control systems, described above have been developed primarily for use in an electrically powered mower. In relation to this mower development, it has been proposed to use principles disclosed in Australian Patent No. 610546 in the construction of the mower deck. In this prior art specification it is proposed generally to provide an increasing cavity volume adjacent the mower blades that increases both in height and radially outwardly as the blades approach the outlet chute to the mower catcher. Such arrangements provide an outwardly and upwardly inclined skirt over a significant proportion of the circumference of the deck which has been found to be operationally valuable but very difficult to make commercially with a one piece moulded or otherwise formed deck without the use of very expensive forming machinery. Thus, in accordance with a further aspect of the present invention, a mower deck is proposed comprising a one piece moulded or otherwise formed deck housing member having a mowing cavity with an inner facing wall extending upwardly and outwardly from a lower zone of the deck around at least a part of the periphery of the mowing cavity, and a false wall forming member adapted to be mounted in said cavity to extend the peripheral length of said part of the deck having said upwardly and outwardly inclined inner facing wall. Conveniently, the separate false wall forming member is located adjacent to an outlet opening from said deck adapted in use to lead to a mower catcher.

0021Preferred embodiments of the present invention are hereinafter described with reference to the accompanying drawings, in which:- <ul id="ul0001" list-style="none" compact="compact"><li>Figure 1 is a typical wiring assembly diagram of a preferred embodiment of one aspect of the present invention;</li><li>Figure 2 is a typical circuit diagram of the apparatus shown in Figure 1;</li><li>Figures 3A and 3B are illustrative graphical representations of differing embodiments of typical normal and abnormal voltage discharge levels of the battery of Figures 1 and 2 used in a mower application;</li><li>Figure 4 is illustrative graphical representations for the various charging stages of a battery controlled by apparatus according to the present invention;</li><li>Figure 5 is a block diagram illustrating the control functions of the apparatus according to the present invention;</li><li>Figures 6 and 6A are partly exploded perspective views of a mower incorporating aspects of the present invention, and</li><li>Figures 7A to 7D are illustrative sectional views through the mower deck at positions A to D in Figure 6.</li></ul>

0022Referring to Figures 1 and 2 of the drawing, a preferred embodiment of the present invention is depicted comprising a motor (10) adapted to operate mower cutting blades of any configuration (not illustrated). The motor (10) is powered by a rechargeable battery (11) such as a sealed lead acid battery nominally of 12 volts. A slider switch (12) is provided on the mower handle which must be activated by the mower user for power to be supplied from the battery (11) to the motor (10). If the operator removes his closing grip on the handle bar switch (12), then the switch automatically moves to an open condition preventing the battery (11) from supplying power to the motor (10). The circuit arrangement further includes a controller (13) in the form of a printed circuit board (PCB) and a motor disabling relay (14) controlled by the controller (13). The controller (13) senses loaded and unloaded battery terminal voltage and the status of the handle switch (12). The controller (13) further calculates rate of battery discharge during a discharge regime, i.e. during normal mower operation, and acts to operate the motor disabling relay (14) should the battery terminal voltage drop below a preset minimum voltage or should the control recognise a rapid drop in voltage (at a rate far greater than a normal use discharge rate) which is not recovered to a level greater than a preset differential ΔV (typically 1.6 volt differential) below a predetermined reference voltage within a predetermined time period Δ<b>t</b>. This reference voltage may be the voltage level sensed at the time of operating the handle bar switch (12), or immediately prior to the abnormal rapid drop. Figure 3A illustrates normal and abnormal voltage discharge situations during use of a mower wherein the reference voltage level set is the voltage level sensed immediately before the abnormal rapid voltage drop. For example, the voltage level at start up with a fully charged battery may be nominally at 12 volts. At start up under normal circumstances there would be rapid drop in sensed voltage level (full line 21) followed by a rapid recovery (full line 22) to a level approximating the start up voltage level. If, however, something might be obstructing the mower blades, (for example a rock or long grass) then the voltage recovery curve might follow the broken line (23) and (24), i.e. after the expiry of the interval Δt; the battery would be immediately disabled, that is electrically disconnected from its load, the motor (10). If we assume, however, that no such problem arises during start up, then the battery would be discharged in normal use following a curve such as indicated by full line (25). Again, if the mower blades strike an obstruction during use then there will again be a rapid drop, for example from (26) following line (27) which could be recovered following line (28) if temporary or following broken line (29) if it is more than a mere transitory obstruction. Thus, during use, in such circumstances, if the voltage level is recovered to a voltage level greater than ΔV below the voltage level at the commencement of the rapid drop at (26) within a time period Δt, then normal use is continued. However, if the Δt time period expires before this voltage level is recovered (e.g. broken line 29), then the battery is electrically disconnected from the motor at the expiry of the Δt period (point 30). As is also shown in Figure 3A, if the battery discharge voltage drops below a predetermined minimum V_<b>L</b> (nominally 6 volts in this illustration), either due to an abnormal voltage drop (line 31) or simply as a result of normal battery discharge (line 32), then the battery is immediately disabled, i.e. electrically disconnected from the motor, for example at point 33 or 34. This electrical disconnection is in each case performed by the relay 14. The controller 13 is then arranged such that the relay 14 cannot be reactivated until after a defined battery recharging regime has been completed.

0023Figure 3B illustrates a possible alternative to that of Figure 3A. In this case the predetermined reference voltage is the voltage level sensed at each point the mower is restarted. For example, if the mower has been used for a period of time and then stopped (for any reason), the battery level will have dropped through this use to point A. If the mower is reactivated, the sensed voltage level at this point of activation becomes the reference voltage Vref until such time as the mower is stopped and again reactivated. If there is a sudden drop in voltage (as discussed above with reference to Figure 3A) then so long as the voltage level is recovered to a level greater than ΔV below Vref, then normal operation continues. If this recovery does not occur within the period Δt then the battery is disabled immediately. Thus, the difference between Figures 3A and 3B is that in Figure 3A, the reference voltage is always the sensed voltage level immediately before any abnormal voltage drop whereas in Figure 3B, the reference voltage is the sensed voltage level at start up of the machine immediately before the rapid voltage drop.

0024The control system conveniently includes two visual displays comprising a power on LED (15) and charge required LED (16). The power on LED (15) illuminated when the charger (17) is connected to a power source (commonly a conventional 240V alternating supply) via a suitable transformer (18) and plug (19). The charge required LED (16) commences to flash and a warning buzzer or beeper sounds when the relay (14) has been activated indicating recharging of the battery is required. When the power on LED (15) is activated indicating the battery has been connected to a power source via the charger (17), the charge required LED (16) remains continuously illuminated until the charging regime is completed. Should the battery not be connected to a power source as aforesaid when recharging is required, the aforesaid warning sound and light is continued for a predetermined period of time and is thereafter continued with a longer period between each illumination of the LED (16) and sounding of the warning buzzer, beeper or the like until the battery terminal voltage drops to a second preset level V_<b>X</b> below V_<b>L</b> where the battery charge is protected by discontinuing the warning light and sounds. Typically V_<b>X</b> might be set at nominally one volt below V_<b>L</b>.

0025Figure 4 of the accompanying drawings illustrates a typical preferred charge, charge regime for the control apparatus of the present invention. If the battery is in a nominally flat condition, it cannot accept a high charge rate. Therefore it is a trickle charged until voltage V_<b>T</b> is reached. The circuit then switches to a bulk charge regime where the battery can be charged at close to or at the maximum charge rate possible. As the battery voltage builds up to V_<b>23</b>, the circuit changes to stage 3, the "overcharge" stage (point C on the charge voltage curve). When the battery reaches point D on the voltage curve, the charging current begins to taper off (charge current curve). Upon reaching point E, the battery voltage is equal to V_<b>oc</b> (overcharge voltage) and the circuit switches abruptly to stage 4. At this point a timer (say 3 hours) is started and the current is modulated to ensure that the battery voltage does not exceed say 15.2 volts. This ensures that the battery receives sufficient overcharge to ensure 100% discharge capacity. At the end of the predetermined time, all current is stopped. The battery terminal voltage will drop quickly to say 13.2 volts, the "natural" voltage of the cell stack. Prom this point, the battery will 'self-discharge' at a very low rate until a predetermined voltage of say 12 volts. At this point the charger will reinitiate the charge regime. Of course, because the battery is only slightly discharged, the charger will cycle through the first stages quite quickly until the timer is again initiated. A full predetermined (say three hours) time will be imposed again. At stage 5, the charge required LED (16) is deactivated with the power LED (15) still activated and the relay (14) is enabled to allow the motor to be reconnected to the battery for further use as may be required. A second option would be to charge until point E on the voltage curve and then leave the charger on at say 13.8 volts for continuous 'float' charging. In this mode, after a predetermined time in 'float', the "charge-required" LED (16) would be deactivated to signal that the unit is ready for use, and the relay (14) would be enabled to allow further use.

0026Figure 5 illustrates in block diagram form the control functions of the controller 13 during differing modes and conditions sensed by the control system. The functions are further indicated by the following table: <tables id="tabl0001" num="0001"><img file="EP0817352A2_D0001.tif" /></tables><tables id="tabl0002" num="0002"><img file="EP0817352A2_D0002.tif" /></tables>

0027Figures 6 and 6A illustrate a physical construction of a mower (40) including aspects of the present invention. The mower itself comprises a mower deck (41) supported on wheels (42) with a suitable height adjustment mechanism (not shown). A catcher assembly (43) is provided adapted to receive cut grass from the mower deck (41). The mower deck and catcher are conveniently moulded from suitable plastics material to achieve a desired light weight and strength although other materials might also be usable. The cutter blade assembly (44) is relatively conventional and is not shown in Figures 7, 7A but can be seen in Figures 8A to 8D. The assembly comprises a disc (45) with two or more blades (46) pivotally mounted thereto. Other known forms of cutter assemblies could also be employed. The disc (45) is driven by an electric motor (10) which is electrically connected to the battery (11). Electrical connecting leads (46) to (51) are shown in Figures 1 and 6.

0028As can be seen in Figures 6 and 6A, the leads (47), (48) are interconnected by a safety switch (20) which comprises a pair of plate contacts (62) which are permitted to have limited pivotal movement about pivot points (53) by providing slightly oversized holes (54) through which fasteners (68) pass. An actuating key (52) is provided having a flat electrically conductive blade (71) and an electrically insulating handle (72). By insertion of the blade (71) through the receiving slot in the insulating housing (66), the blade (71) is then forced between the two contact plates (62) to establish an electrical path there between. The pivot arrangement of the contact plates (62) enables full edge contact between these plates and the blade (71) rather than a point contact that might result in the case of minor misalignment of the parts during assembly, thereby improving the electrical connection between leads (47) and (48). The safety switch (20) is provided to ensure that the battery is totally disabled or isolated when the mower is not in use. For the mower to be used, the key (52) has to be first inserted to make the primary connection between the leads (47), (48).

0029The socket (55) for receiving the charging contact (56) of the transferer (18) is also provided adjacent to the safety switch (20). The hand (72) of the key (52) is advantageously enlarged so that when it is operationally inserted, it covers the charging socket (55) so that the socket is protected against ingress of dust, dirt or the like during use and also prevents the socket (55) from being inadvertently connected to an external power source while the mower is actually in a use mode.

0030As is shown in Figure 6, the motor (10) and the battery (11) are generally mounted within the upper cavity (57) in the deck (41). These are covered by cover members (58), (59) and a handle (60) is provided to which switch (12) is mounted.

0031The deck (41) is constructed with an internal cavity design based on principles disclosed in Australian Patent No. 610546, that is, it is desirable that as the blades (45) approach the outlet chute into the catcher (43), there should be increasingly upward and outward space into which the cut grass can be thrown. This is generally illustrated in Figures 7A to 7C. This not only improves mowing efficiency but assists in depositing the cut grass in the rear of the catcher (43), rather than causing an obstruction in the front of the catcher. This arrangement has been found to work well but to produce a one piece moulded or formed deck with this negative outer skirt angle, over a sufficient circumferential length, has proved to be very difficult without the use of very expensive forming machinery. This difficulty has been solved by one aspect of the present invention wherein a separate false wall forming member (80) is provided adjacent the outlet chute to the catcher (43).

0032This member (80) may conveniently be formed from metal sheet material and includes an inclined wall part (81) which is adapted to maintain the inclination of the outer skirt wall (for example as shown at (85) in Figure 7C) of the moulded deck cavity (86). The member (80) may also include a lower vertical section (82) and floor section (83) adapted to engage against the bottom edge zone of the deck skirt (87). As will be seen, in the cavity of the member (80), there is either no outward inclination of the skirt (87) or the angle might be slightly in the reverse direction to facilitate formation of the deck. The member (80) may also include a bridging transverse floor part (84) to overlie the connection between the catcher (43) and the deck (41).