The present disclosure relates to outdoor power equipment with an electrical starting motor and associated controls. More specifically, the present disclosure relates to an internal combustion engine having an electrical starting motor for starting the internal combustion engine.
Presently, many different types of outdoor power equipment include electronic starting circuits that allow the user to start the internal combustion engine of the outdoor power equipment through either a key switch or a push button. However, this often requires additional wiring and/or controls to be added to the outdoor power equipment. This can create additional cost and complexity when adding an internal combustion motor with electronic start to various outdoor power equipment applications.
The present disclosure relates to systems and methods for starting an internal combustion motor associated with outdoor power equipment, as described in the embodiments listed herein.
One embodiment of the invention relates to a lawn mower. The lawn mower includes an internal combustion engine, and an electric motor configured to start the internal combustion engine. The lawn mower further includes a brake mechanism and a release mechanism movable to an engaged position to release the brake mechanism. The lawn mower further includes a switch actuation by, the release mechanism, a pull rope, and a sensor configured to output a signal based on the pull rope being actuated. The lawn mower further includes a control module coupled to the switch and the sensor, wherein the switch is configured to provide inputs to the control module when the release mechanism is in the engaged position, and the sensor is configured to provide an input to the control module when the pull rope is actuated, and wherein the control module turns on the electric motor in response to the signals from the sensor and the switch.
Another embodiment of the invention relates to outdoor power equipment. The outdoor power equipment includes an internal combustion engine, an electric motor configured to start the internal combustion engine, and an implement driven by the internal combustion engine. The outdoor power equipment further includes a release mechanism movable to an engaged position to put the implement in a ready-to-run condition in which the implement is ready to be driven by the internal combustion engine. The outdoor power equipment further includes a switch actuated by the release mechanism and a sensor configured to detect actuation of a manual starting mechanism. The outdoor power equipment further includes a control module coupled to the switch and the sensor so that the switch provides a signal to the control module when release mechanism is in the engaged position, and the sensor provides a signal indicating actuation of the manual starting mechanism. The control module is further configured to turn on the electric motor to start the internal combustion engine in response to the signal from the switch and the sensor both being provided to the control module.
Another embodiment of the invention relates to a method of starting an internal combustion engine. The method includes receiving a first signal at a control module indicating that a release mechanism has been actuated and receiving a second signal at the control module indicating that a pull rope of the internal combustion engine has been pulled by at least a predetermined distance. The method further includes energizing an electric starting motor to start the internal combustion engine based on receiving the second signal after the first signal has been received, and where the first signal is still present at the control module when the second signal is received by the control module.
Another embodiment of the invention relates to a method of starting an internal combustion engine. The method includes detecting movement of a starter rope coupled to the internal combustion engine, detecting the status of an operator presence sensor, and activating an electric starter motor selectively coupled to the internal combustion engine based on receiving the second signal after the first signal has been received, and where the first signal is still present at the control module when the second signal is received by the control module.
Various other features, objects and advantages of the invention will be made apparent from the following description taken together with the drawings.
The disclosure will become more fully understood from the following detailed description, taken in conjunction with the accompanying figures, in which:
The present disclosure is directed to a starting system for an internal combustion engine used with various types of outdoor power equipment. The drawing figures depict the use of the intelligent battery pack with a lawn mower. However, it should be understood that the battery pack and starting system could be utilized with other types of outdoor power equipment such as riding tractors, snow throwers, pressure washers, tillers, log splitters, zero-turn radius mowers, walk-behind mowers, riding mowers, stand-on mowers, pavement surface preparation devices, industrial vehicles such as forklifts, utility vehicles, commercial turf equipment such as blowers, vacuums, debris loaders, over-seeders, power rakes, aerators, sod cutters, brush mowers, sprayers, spreaders, etc.
Still referring to
In some embodiments, the starter system is integrated with a bail 126 of the lawn mower 110. A brake mechanism (e.g., friction brake, ignition interrupt switch or circuit, etc.) may be holding the blade or other tool, locking the crankshaft of the engine 112, or otherwise preventing operation of the power equipment. As such, releasing of the brake mechanism eases operation of the lawn mower 110 or other outdoor power equipment by reducing the steps necessary for activation. Furthermore. and as will be discussed in more detail below, a second input, such as actuation of the pull rope 125 may further be used to start the engine 112, in combination with the actuation of the bail
In general, integration of the starter system with a handle of outdoor power equipment allows the operator to start the engine from the rear of the outdoor power equipment, such as several feet from the powered tool of the outdoor power equipment (e.g. snow thrower auger, lawn mower blades). Further, the integration supports an electronic starting system for a walk behind mower that can be engage by a user without actuation of a key or push-button.
According to some embodiments, the starter system further includes an energy storage device 130 (e.g. a battery, capacitor, etc.) and a controller 132, The energy storage device 130 may include one or more batteries (e.g. lead acid, NiCd, Li-Ion, etc.), capacitors (e.g. super capacitors), or other devices. The batteries may be removable batteries. In some embodiments, the batteries may be power tool batteries configured to be received in a receiver mounted to the internal combustion engine 112 or the lawn mower 110. In one embodiment, the energy storage device 130 may be located on the internal combustion engine 112. In other embodiments, the energy storage device 130 may be located on the lawn mower 110. When the operator engages the starter system, the linkage 124 communicates one input to controller 132, either directly or indirectly. Similarly, and as will be discussed in more detail below, a second input signal may be provided to the controller 132, either directly or indirectly, when the user further engages the pull rope 125. The controller may then electrically connect the energy storage device 130 to power the starter motor 120. In some embodiments, the controller 132 is further coupled to one or more sensors within the engine 112 (e.g. a speed sensor, an ignition sensor, etc.), and may be configured to disengage the motor 120 (e.g. cuts power to the motor 120 via high-side switching of the electrical power source 130, and/or low-side switching of the ground or common side of the electrical power source 130) when it is determined by the controller 132 that the engine 112 is running at a sufficient speed.
In some embodiments, the motor 120, the energy storage device 130, and the controller 132 are fastened directly to the engine 112, which may be configured for efficient assembly of outdoor power equipment using the engine 112. As such, the starter system in some embodiments may come fully assembled with the engine 112, and ready for connection to a linkage configured to provide a signal from the handle (e.g., linkage 124). Accordingly, the manufacturer need only attach the engine 112 to the deck or corresponding feature and attach the tool to the power takeoff of the engine. In any such case, considerable time and effort may be saved during the manufacturing process and a potential source of manufacturing difficulty may be removed (i.e., that associated with the fastening and electrical connection of the components of the starter system during assembly of the outdoor power equipment). In still other embodiments, some or all of the starter assembly may be fastened to the deck of a lawn mower or corresponding feature of other power equipment.
Referring to
In some embodiments, the outdoor power equipment 200 includes a handle 214 having a release mechanism 216, where the release mechanism 216 is configured to allow a user to release the brake 212 from the handle 214. The release mechanism 216 may allow a user to release the brake 212 by engaging the bail (or other element) with a linkage connected to the brake 212, or by disengaging an element blocking movement of the bail. The handle 214 may be coupled to the engine 202 and tool 204 directly, or via an intermediary member (e.g., deck 114 as shown in
According to one embodiment, the outdoor power equipment 200 may further include a pull rope sensor 222. The pull rope sensor 222 is configured, to monitor a movement of the pull rope (e.g. pull rope 125 in
In some embodiments, the pull rope sensor 222 may be a hall effect sensor. The hall effect sensor may be configured to detect the passing of one or more magnets on a rewind assembly. Thus, when the operator pulls the pull rope, causing the rewind assembly to rotate, thereby passing the one or more magnets within the fixed position of the hall effect sensor. In some embodiments, the one or more magnets may be embedded into the rewind assembly.
Turning to
While
In other embodiments, an optical sensor may be positioned to detect a movement of the pull rope 310. For example, the pull rope 310 may be configured to have an alternating color pattern which can be detected by the optical sensor. Optical sensors may include, photodiodes, photoelectric sensors, image sensors, optical switches, camera (e.g. CCD, CMOS, etc.) sensors, or other applicable optical sensors. In other embodiments, a magnet may be embedded in the pull rope 308. The pull rope may then be configured to run through an aperture which can detect the magnetic field and provide a signal to the control system. Other sensors or devices, such as switches, pressure sensors, centrifugal motion sensors, infrared sensors, time of flight sensors, and/or other sensors which can detect a pull of the pull rope by the operator.
Returning now to
According to some embodiments, the control system 220 is configured to receive additional inputs from the speed sensor 210 or another component of the engine 112 (e.g., the ignition circuit). The speed sensor 210 or other component provides the control system 222 with information associated with the speed of the engine 112. When the engine 112 is running at a sufficient speed, the control system 222 then disengages the motor 206 (e.g., turns off, disconnects, cuts power to, etc.).
In further embodiments, the control system 222 associated with the start system may receive additional or different inputs used to control starting of the engine, such as, input from a sensor configured to indicate whether the outdoor power equipment has moved recently. Movement of an axle or wheels of such outdoor power equipment may trigger a sensor that provides a signal to the control system. The signal, in combination with an electric timer providing time-related context for the movement, may serve as an additional indicator that the operator intends to activate the engine 202. In other embodiments, the control system 222 in includes a tinier and is configured to deactivate the motor 206 if the engine has not started within a predetermined amount of time. In some contemplated embodiments, the control system 222 includes a temperature sensor and is configured to prime the engine with an automated primer pump or adjust the choke or throttle plate if ambient temperature is above or below a predetermined temperature, if a portion of the engine is above or below a predetermined temperature, or if the difference between ambient and engine temperature is above or below a predetermined, value. In still other embodiments, the control system 222 may also provide a signal output to the operator, such as a visible indicator on a display coupled to the handle or engine, or an audible alert. In some embodiments, the signal output may include an error message, a low-fuel message, a replace-oil message, or another such message.
In some embodiments, a motor, such as motor 206 may be configured to assist the operator in actuating the pull rope. For example, when actuation of the pull rope is detected, as described above, the motor 206 may be configured to actuate to provide additional force to the crank shaft, thereby reducing the effort required by the operator pulling the pull rope. This can allow for a smaller staring motor and associated battery to be used, while still increasing the ease of starting the outdoor equipment.
According to some embodiments, the circuits of
Turning now to
If the release mechanism activation signal is determined to still be active at process block 610, the starter motor is energized at process block 612. At process block 614 the process determines if a minimum speed of the engine has been reached. In one embodiment, the minimum speed may be 1000 RPM. However, minimum speed values of more than 1000 RPM or less than 1000 RPM are also contemplated. If the minimum speeds have been reached, the starter motor is stopped at process block 616, as described above. If the minimum speed is determined to not have been reached at process block 614, the system then determines if a timer has expired at process block 618. In one embodiment, the timer may be five seconds. However, in other embodiments, the timer may be more than five seconds or less than five seconds, as applicable. In some examples, the timer value is determined based on a rating of the starting motor and/or battery. If the timer is determined not to have expired, the process returns to process block 614.
This written description uses examples to disclose the invention, including the best mode and to enable any person skilled in the art to make and use the invention. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.
The construction and arrangement of the apparatus, systems and methods as shown in the various exemplary embodiments are illustrative only. Although only a few embodiments have been described in detail in this disclosure, many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.). For example, some elements shown as integrally formed may be constructed from multiple parts or elements, the position of elements may be reversed or otherwise varied and the nature or number of discrete elements or positions may be altered or varied. Accordingly, all such modifications are intended to be included within the scope of the present disclosure. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions and arrangement of the exemplary embodiments without departing from the scope of the present disclosure.
This application claims the benefit of U.S. Provisional Application No. 62/574,167, filed Oct. 18, 2017, which is incorporated herein by reference in its entirety.
Filing Document | Filing Date | Country | Kind |
---|---|---|---|
PCT/US2018/056330 | 10/17/2018 | WO | 00 |
Number | Date | Country | |
---|---|---|---|
62574167 | Oct 2017 | US |