US20160298635A1

US20160298635A1 - Portable electrically powered debris blower apparatus

Info

Publication number: US20160298635A1
Application number: US15/100,854
Authority: US
Inventors: Guan Su; Carlos Miralles; David Koplow
Original assignee: Alare Technologies LLC; Green Station LLC
Current assignee: Alare Technologies LLC; Green Station LLC
Priority date: 2014-09-15
Filing date: 2015-09-15
Publication date: 2016-10-13
Also published as: WO2016044268A1; CN106714642A

Abstract

There is provided a portable, electrically powered debris blower that includes a noise reducing and energy efficient design. The debris blower includes a blower that is powered by a portable power supply, such as electrochemical battery cells. The blower includes an air intake, a curved blower housing that acts as an air inlet guide tube, an axial fan, and an air exhaust. To reduce noise and vibration output from the blower, the blower further includes a noise and vibration reducing material covering the inside walls of the blower, vibration and noise isolating mounts supporting the axial fan within the blower, and the air inlet is angled towards the ground with respect to the axis of the axial fan.

Description

FIELD OF THE INVENTION

The present disclosure relates generally to an apparatus for removing debris and more particularly to an improved portable electrically powered debris blower apparatus.

BACKGROUND

Devices for clearing indoor and outdoor debris from yards, sidewalks, and other working environments enable homeowners and professional landscapers to sweep areas using high velocity air. Conventional motorized debris blower devices include a fan powered by an internal combustion engine, typically a one-, two-, or four-stroke engine. Such commercial grade devices have enough power to allow an operator to quickly remove debris and a large fuel tank to carry enough fuel for several hours of continuous operation.
These conventional blower devices, however, are notorious for creating noise and air pollution. The whine from the engine in existing debris blower designs creates a noise hazard both for the operator and individuals in close proximity to the blower while in operation. Due to the noise from the engine, the operator is required to wear ear protection. The engines also release harmful carbon monoxide and other pollutants into the atmosphere. Two-stroke engines have been shown to emit contaminants comparable to large automobiles. See How bad for the environment are gas powered leaf blowers? Brian Palmer, The Washington Post, Sep. 16, 2013. The problems inherent with these designs are so great that they have prompted some cities to ban the use of gasoline-powered debris blowers in favor of hiring temporary workers to manually clear debris. See Takoma Park bans gas powered leaf blowers used by public works staff, Allison Bryan, Gazette.Net, Jan. 19, 2011.
Despite the problems inherent with conventional blower devices, cities continue to use them because of a lack of an acceptable substitute. Existing electric debris blowers are not as powerful as their gasoline-powered counterparts and are therefore disfavored in industry. See id. Increasing the power output of existing electric blowers increase the noise of the devices and decreases the operating range of the devices making them less useful.

SUMMARY OF THE INVENTION

In view of the foregoing, there is a need for a debris blower that provides sufficient power at acceptable noise levels to the community. There is also a need for a debris blower that can provide continuous use for an entire work day to clear large areas.
Accordingly, disclosed herein is an portable, electrically-powered debris blower that includes a noise reducing and power efficient design, substantially as shown in and/or described in connection with at least one of the figures.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a perspective view of the debris blower being used by an operator, according to a first embodiment of the present disclosure.

FIG. 2 illustrate a perspective view of the blower, according to the first embodiment of the present disclosure.

FIG. 3 illustrates a perspective view of the underside of the blower, according to the first embodiment of the present disclosure.

FIG. 4 illustrates a side view of the blower, according to the first embodiment of the present disclosure.

FIG. 5 illustrates a cross sectional view of the inside of the blower, according to the first embodiment of the present disclosure.

FIG. 6 illustrates a detailed perspective view of the inside of the blower, according to the first embodiment of the present disclosure.

FIG. 7A illustrates a first example of an inlet design for the blower, according to some embodiments of the present disclosure.

FIG. 7B illustrates a second example of an inlet design for the blower, according to some embodiments of the present disclosure.

FIG. 7C illustrates a third example of an inlet design for the blower, according to some embodiments of the disclosure.

FIG. 7D illustrates a fourth example of an inlet design for the blower, according to some embodiments of the present disclosure.

FIG. 8 illustrates the measured power efficiency the blower, according to some embodiments of the present disclosure.

FIG. 9 illustrates a perspective view of the debris blower being used by an operator, according to a second embodiment of the present disclosure.

FIG. 10 illustrates a perspective view of the underside of the blower, according to the second embodiment of the present disclosure.

FIG. 11 illustrates a cross sectional view of the inside of the blower, according to the second embodiment of the present disclosure.

FIG. 12 illustrates a cross sectional view of the axial fan assembly 9′, according to the second embodiment of the present disclosure.

FIG. 13 illustrates a detailed cross sectional view of the inside of the blower, according to the second embodiment of the present disclosure.

FIG. 14 illustrates a detailed perspective view of the inside of the blower, according to the second embodiment of the present disclosure.

FIG. 15A illustrates an exploded view of the inside of the blower, according to the second embodiment of the present disclosure.

FIG. 15B illustrates a view of the inside of the blower, according to the second embodiment of the present disclosure.

FIG. 16 illustrates an example of an inlet design for the blower, according to some embodiments of the present disclosure.

FIG. 17 illustrates a power control board for use with the blower, according to some embodiments of the present disclosure.

FIG. 18 illustrates a power control board for use with the blower, according to some embodiments of the present disclosure.

FIG. 19 illustrates a process flow for operation of the blower and data collection according to some embodiments.

DETAILED DESCRIPTION

The following description contains specific information pertaining to embodiments in the present disclosure. The drawings in the present application and their accompanying detailed description are directed to merely exemplary embodiments. Unless noted otherwise, like or corresponding elements among the figures may be indicated by like or corresponding reference numerals. Moreover, the drawings and illustrations in the present application are generally not to scale, and are not intended to correspond to actual relative dimensions.
FIG. 1 illustrates a perspective view of a debris blower 100 being used by an operator, according to a first embodiment of the present disclosure. The debris blower of FIG. 1 includes power supply 50, blower 1, and power cord 8. Blower 1 includes an air intake 2, air inlet guide duct 4, and an air exhaust tube 7. Power supply 50 is used to provide electrical power to blower 1, which will be described in more detail with reference to FIG. 5.
As illustrated in FIG. 1, in some embodiments, power supply 50 may be configured to be carried on the operator's back using one or more straps 51. The straps 51 may be connected to one or more of the operator's shoulders and/or waist as shown in the illustrated embodiment. The straps 51 are constructed out of heavy duty materials as is known in the art. In some embodiments, the straps 51 may be constructed out of nylon. In some embodiments (not illustrated), the power supply 50 may be configured to be carried on the operator's waist, for example attached to an operator's belt. In some embodiments, the power supply 50 may be detached from the operator and carried, pushed, or pulled on a moveable platform. Power supply 50 may be contained in a single unit as illustrated in the embodiment in FIG. 1, or may be distributed in multiple separate units. When distributed as multiple separate packs, power supply 50 may be configured to be carried on multiple locations on the operator.
As illustrated in FIG. 1, in some embodiments, blower 1 is held in the operator's hand. Blower 1 may be used by the operator to discharge air at a high rate of speed when electrical power is supplied from power supply 50 to blower 1 via power cord 8. In order to discharge air at a high rate of speed, the air first enters air intake 2, accelerates through air inlet guide duct 4, and is then discharged out through air exhaust tube 7, which is explained in greater detail below. As such, the operator is able to direct the air discharged from blower 1 by pointing air exhaust tube 7 in any desired direction.
Power supply 50 includes a housing 52 and one or more energy storage units 54. Housing 52 is used to contain the one or more energy storage units 54. Energy storage unit 54 may consist of various types of systems, including batteries and fuel cells. In some embodiments, energy storage unit 54 may include a rechargeable battery containing electrochemical cells. In some embodiments, the electrochemical cells may be a lithium ion battery. Power supply 50 may be the sole power source for blower 1, or may be used in conjunction with other power sources. Power supply 50 may be used in conjunction with electromechanical power generation systems, such as a generator, solar power converter, or thermoelectric converter. In some embodiments, the debris blower 100 may be used without power supply 50 by connecting power cord 8 to a standard power socket being supplied by a building. In such embodiments, power cord 8 may be attached to an extension cord (not shown) in order to provide a larger proximity of use for the debris blower.
FIG. 2 illustrates a perspective view of the blower 1, according to the first embodiment of the present disclosure. Blower 1 of FIG. 2 includes air intake 2, integrated stand 3, air inlet guide duct 4, handle 5, trigger switch 6, exhaust tube 7, and power cord 8.
As illustrated in FIG. 2, blower 1 includes handle 5 which is used by the operator to hold blower 1 in his or her hand during operation of the debris blower. As shown in the illustrated embodiments, handle 5 is placed on the top of blower 1 to give the operator control of the air that is discharged from blower 1 during operation. As further illustrated in FIG. 2, handle 5 includes trigger switch 6. Trigger switch 6 is used to adjust the amount of power that is supplied to blower 1 from the power supply 50 or an alternate power source via power cord 8 by adjusting the amount of pressure applied to the trigger switch 6. For example, an operator can fully depress trigger switch 6 to supply blower 1 with the maximum amount of power, thus causing the greatest rate and volume of air to be discharged from blower 1. In another example, the operator can partially depress trigger switch 6 to supply less than maximum power to blower 1, thus causing a lower rate and volume of discharged air as compared to fully depressing trigger switch 6. As will be discussed in greater detail below, the input from the operator on trigger switch 6 is interpreted using power control board 13, 13′.
Also illustrated in FIG. 2, blower 1 includes integrated stand 3. Integrated stand 3 of blower 1 is used when the operator places blower 1 on the ground or another surface. As illustrated in FIG. 2, integrated stand 3 includes a lip that is positioned beneath air inlet guide duct 4. The lip of integrated stand 3 thus protects air inlet guide duct 4 from hitting the ground, which can cause damage to air inlet guide duct 4. Furthermore, the lip of integrated stand 3 also keeps blower 1 in an upright position while blower 1 is resting on the ground or another surface.
FIG. 3 illustrates a perspective view of the underside of the blower 1, according to the first embodiment of the present disclosure. Blower 1 of FIG. 3 includes air intake 2, integrated stand 3, air inlet guide duct 4, handle 5, trigger switch 6, air exhaust tube 7, and power cord 8.
As illustrated in FIGS. 3 and 5, air intake 2 of blower 1 can include curved edges 62. The curved edges 62 of air intake 2 can be flared outward to increase the amount of air that enters air inlet guide duct 4 during operation of blower 1. Furthermore, the curved edges 62 around the air intake 2 allow ambient air to enter the guide duct smoothly, minimizing flow separation around the curved edges 62.
Also illustrated in FIG. 3, air intake 2 may include a grate that can be used to prevent debris (such as leaves or other material) from entering blower 1 during operation. The grate may include perpendicular elements that cross each other to form rectangular openings for the air. In some embodiments, the grate may include circular, triangular, or other shaped openings. Furthermore, the openings of the grate can be large to maximize the amount of air that enters air intake 2, or the openings of the grate can be smaller to keep even small debris from entering air intake 2.
The cross-section of air intake 2 of blower 1 may take many different shapes. As illustrated in the embodiment of FIG. 3, the cross-section of air intake 2 includes a rectangular shape with rounded corners. Blower 1 includes this shape for the cross-section of air intake 2 in order to maximize the amount of air that enters air intake 2. In some embodiments, the cross-section of air intake 2 may include, but is not limited to, a circular shape, an elliptical shape, or a square shape with rounded corners.
FIG. 4 illustrates a side view of the blower 1, according to the first embodiment of the present disclosure. Blower 1 of FIG. 4 includes air intake 2, integrated stand 3, air inlet guide duct 4, handle 5, trigger switch 6, and air exhaust tube 7.
FIG. 5 illustrates a cross sectional view of blower 1, according to the first embodiment of the present disclosure. Blower 1 of FIG. 5 includes air intake 2, integrated stand 3, air inlet guide duct 4, handle 5, trigger switch 6, air exhaust tube 7, power cord 8, axial fan assembly 9, inlet absorbing material 10, exhaust absorbing material 11, isolation mounts 12, and power control board 13, 13′.
As illustrated in FIG. 5, blower 1 includes axial fan assembly 9 housed inside air inlet guide duct 4. Axial fan assembly 9 may be located proximate to the location where air inlet guide duct 4 is attached to air exhaust tube 7. Axial fan assembly 9 is used by blower 1 to accelerate the air that enters air intake 2 through air inlet guide duct 4 and out air exhaust tube 7. For example, when power is provided to blower 1 from power supply 50 or an alternate power source, a fan rotor of axial fan assembly 9 starts to rotate causing air to enter through air intake 2. In such an example, the air is then accelerated by axial fan assembly 9 up through air inlet guide duct 4 and air exhaust tube 7 where it is discharged.
A measure of the efficiency of the blower can be considered as a ratio of the output air flow rate (e.g., in cubic feet per minute) to the power consumed (e.g., in watts). To maximize blower efficiency, it is advantageous to accelerate the air forced through the blower with the least amount of drag possible. In order to ensure that the maximum volume of air is discharged from blower 1 at the highest discharge velocity, air inlet guide duct 4 includes a cross-section that gradually tapers from air intake 2 towards the direction of air flow (i.e., towards axial fan assembly 9). The gradually tapering air inlet guide duct 4 allows the air to gradually accelerate with minimal drag, therefore increasing the overall blower efficiency. For example, the cross-section of air intake 2 may be approximately 125% to 500% larger than the cross-section of air inlet guide duct 4 where axial fan assembly 9 is located.
Also illustrated in FIG. 5, axial fan assembly 9 may be mounted within blower 1 using isolation mounts 12. Isolation mounts 12 are used to mount axial fan assembly 9 within blower 1 in a manner that reduces the noise of blower 1 during operation. As such, isolation mounts 12 may include springs or other mounting elements that absorb the vibrations made by axial fan assembly 9 while blower 1 is in use. For example, axial fan assembly 9 may be mounted within blower 1 using a number of springs located around axial fan assembly 9. In such an example, the springs will absorb the vibrations made by axial fan assembly 9 while blower 1 is being used, thus reducing the noise made by blower 1.
Also illustrated in FIG. 5, blower 1 includes inlet absorbing material 10 mounted within air inlet guide duct 4 and exhaust absorbing material 11 mounted within air exhaust tube 7. Each of inlet absorbing material 10 and exhaust absorbing material 11 may include a material placed within blower 1 that is used to reduce the noise of blower 1 and/or the vibrations of blower 1 while blower 1 is being used. For example, each of inlet absorbing material 10 and exhaust absorbing material 11 may include, but are not limited to, rubber, foam, or any other sound reducing and/or dampening material that can be placed within blower 1 to reduce the sound and/or vibrations made by blower 1 while in use. Furthermore, the inlet absorbing material 10 may be made of open-cell and/or closed-cell foam. An inner surface of the open-cell and/or closed-cell foam facing the air flow may be textured. For example, open-cell foam may be made with micro open pores located on the surface of the foam that trap sound energy. For example, the surface of closed-cell foam may be molded with a textured surface that traps sound energy, such as wedges, pyramids, an egg crate shape, or other geometric shapes that include peaks and valleys. The textured open-cell or closed-cell foam can create a small layer of stagnant air bubbles at the surface of the foam to help maintain laminar (steady) air flow within air inlet guide duct 4. In some embodiments, the entire surface of the inlet absorbing material 10 may be textured. In some embodiments, only a portion of the inlet absorbing material 10 may be textured. In some embodiments, only a rear surface 10 a of the inlet absorbing material 10 facing the axial fan assembly 9 is textured (FIG. 5).
Also illustrated in FIG. 5, blower 1 includes power control board 13, 13′. Power control board 13, 13′ may include electronic control circuitry that controls the amount of power that is provided to blower 1 during operation, collects data corresponding to the operation of blower 1, and transmits the data to other electronic devices. Power control board 13, 13′ will be discussed in greater detail below with regard to FIGS. 17 and 18.
FIG. 6 illustrates a detailed perspective view of inside the blower 1, according to the first embodiment of the present disclosure. Blower 1 of FIG. 6 includes air intake 2, integrated stand 3, air inlet guide duct 4, handle 5, trigger switch 6, air exhaust tube 7, power cord 8, axial fan assembly 9, inlet absorbing material 10, exhaust absorbing material 11, isolation mounts 12, and power control board 13, 13′.
As a preliminary note to FIGS. 7A, 7B, 7C, and 7D (hereinafter FIGS. “7A-7D”), it should be noted that each of FIGS. 7A-7D illustrate different configurations that may be used for blower 1, according to some embodiments of the present disclosure. As such, the configurations for blower 1 as illustrated in FIGS. 7A-7D include different angles for air intake 2 relative to the axis of axial fan assembly 9, and angles for the inlet plane of air intake 2 relative to inlet flow direction of the air. Furthermore, while each of the configurations illustrated in FIGS. 7A-7D may be used in conjunction with the blower 1, the configuration as illustrated in FIG. 7D is preferred as it provides the best noise reduction and energy efficiency of any of the configurations shown in FIGS. 7A-7D.
Furthermore, it should be noted that blower 1 a, air intake 2 a, and axial fan assembly 9 a of FIG. 7A correspond respectively to blower 1, air intake 2, and axial fan assembly 9 according to a first configuration. Blower 1 b, air intake 2 b, and axial fan assembly 9 b of FIG. 7B correspond respectively to blower 1, air intake 2, and axial fan assembly 9 according to a second configuration. Blower 1 c, air intake 2 c, and axial fan assembly 9 c of FIG. 7C correspond respectively to blower 1, air intake 2, and axial fan assembly 9 according to a third configuration. Finally, blower 1 d, air intake 2 d, and axial fan assembly 9 d of FIG. 7D correspond respectively to blower 1, air intake 2, and axial fan assembly 9 according to a fourth configuration.
FIG. 7A illustrates a first example of an inlet design for the blower 1 a, according to some embodiments of the present disclosure. Blower 1 a of FIG. 7A includes air intake 2 a, axial fan assembly 9 a, acoustic waves 20 a (illustrated by the dashed curved lines), air flow direction arrows 21 a, axis of axial fan assembly 22 a (illustrated by the dashed straight line), and inlet plane 23 a.
As illustrated in the embodiment of FIG. 7A, blower 1 a includes a configuration that includes air intake 2 a and axial fan assembly 9 a aligned along the axis of axial fan assembly 22 a. By using the configuration as illustrated in FIG. 7A, blower 1 a includes the least restrictive air flow design as the air is able to travel unhindered through blower 1 a, as indicated by air flow direction arrows 21 a. Compared to other potential alignments between air intake 2 a and axial fan assembly 9 a, the configuration in FIG. 7A requires the least amount of input power to achieve desired flow rates. The configuration of FIG. 7A, however, results in the greatest amount of noise to the operator and the environment. Axial fan assembly 9 a produces acoustic waves 20 a sent out to the operator and the environment during operation. As illustrated in FIG. 7A, in this configuration, inlet plane 23 a points towards the operator while blower 1 a is in use, producing the most amount of undesirable noise while in operation.
FIG. 7B illustrates a second example of an inlet design for the blower, according to some embodiments of the present disclosure. Blower 1 b of FIG. 7B includes air intake 2 b, axial fan assembly 9 b, acoustic waves 20 b (illustrated by the dashed curved lines), air flow direction arrows 21 b, axis of axial fan assembly 22 b (illustrated by the dashed straight line), inlet plane 23 b, and angle of inlet duct 24 b.
As illustrated in the embodiment of FIG. 7B, blower 1 b includes a configuration where air intake 2 b is oriented at an angle relative to the axis of axial fan assembly 22 b, depicted as angle 24 b. In the illustrated embodiment, while in operation, air intake 2 b is oriented at a downward angle relative to the axis of axial fan assembly 22 b such that air inlet plane 23 b is oriented partially towards the ground during operation. As illustrated, acoustic waves 20 b are deflected towards the ground and away from the operator during operation. The result is a reduction in unwanted noise to the operator relative to the configuration in FIG. 7A. The configuration of FIG. 7B, however, has more restricted air flow than the configuration of FIG. 7A. In the configuration of FIG. 7B, the air must travel a longer distance and undergo a directional change from the intake. The result is a greater amount of input energy required for the configuration of FIG. 7B to achieve the same air flow rates as the configuration of FIG. 7A.
FIG. 7C illustrates a third example of an inlet design for the blower, according some embodiments of the disclosure. Blower 1 c of FIG. 7C includes air intake 2 c, axial fan assembly 9 c, acoustic waves 20 c (illustrated by the dashed curved lines), air flow direction arrows 21 c, axis of axial fan assembly 22 c, (illustrated by the dashed straight line), inlet plane 23 c, and angle of inlet duct 24 c.
As illustrated in the embodiment of FIG. 7C, blower 1 c includes a configuration that has an increased angle of inlet duct 24 c relative to the embodiments of FIGS. 7A and 7B. The configuration of FIG. 7C orients air intake 2 c more parallel to the ground relative to the axis of axial fan assembly 22 c than the embodiments of FIGS. 7A and 7B. The orientation in FIG. 7C results in greater noise reduction than the embodiments in FIGS. 7A and 7B as acoustic waves 22 c are directed substantially towards the ground and away from the operator during operation. The configuration of FIG. 7C, however, has yet more restricted air flow than the configurations of FIGS. 7A and 7B. In the configuration of FIG. 7C, the air must travel an even longer distance and undergo a greater directional change from the intake than the embodiments of FIGS. 7A and 7B. The result is a greater amount of input energy required for the configuration of FIG. 7C to achieve the same air flow rates as the configurations of FIGS. 7A and 7B.
FIG. 7D illustrates a fourth example of an inlet design for the blower, according some embodiments of the present disclosure. Blower 1 d of FIG. 7D includes air intake 2 d, axial fan assembly 9 d, acoustic waves 20 d, (illustrated by the dashed curved lines), air flow direction arrows 21 d, axis of axial fan assembly 22 d, (illustrated by the dashed straight line), inlet plane 23 d, angle of inlet duct 24 d, and angle of inlet plane 25 d.
As illustrated in the embodiment of FIG. 7D, blower 1 d includes a configuration that has an increased angle of inlet duct 24 d relative to the embodiments of FIGS. 7A and 7B, but less than the angle of inlet duct 24 c in the embodiment of FIG. 7C. The orientation in FIG. 7D results in greater noise reduction than the embodiments in FIGS. 7A and 7B, but it has less noise reduction than the embodiment in FIG. 7C.
FIG. 8 illustrates the measured power efficiency of the debris blower 100 according to some embodiments compared to an existing off-the-shelf battery-powered leaf blower. As an example, to achieve an air flow rate of 340 cubic feet per minute (CFM), the new design consumes approximately 240 W of power vs. the existing design that uses 560 W.
The table below presents the operating sound pressure levels of some embodiments, measured per ANSI B 157.2 at various angles from the nozzle. At half throttle, the average sound pressure level is 56.4 dB(A), which is significantly less than the 64 dB(A) advertised sound pressure level of the competition operating at the same flow rate. At full throttle, the average sound pressure level of the preferred embodiment is 62.5 dB(A).


Angle from	Sound Pressure Level dB(A)

Nozzle	50% Throttle (380 CFM)	100% Throttle (520 CFM)

0	57	63
45	55	61
90	55	61
135	56	61
180	60	68
225	59	65
270	54	60
315	55	61
Average	56.4	62.5

In the embodiment of FIG. 7D, the angle of inlet plane 25 d includes an angle that is less than 90 degrees. Furthermore, the angle of inlet duct 24 d may include an angle between 0-59 degrees, with a preferred angle of 50 degrees.
A second embodiment of the debris blower will be described with reference to FIGS. 9-15B. Parts which are similar to those of the first embodiment of the debris blower have the same reference numerals, and the descriptions thereof will not be repeated.
FIG. 9 illustrates a perspective view of a debris blower 100′ being used by an operator, according to the second embodiment of the present disclosure. The debris blower 100′ of FIG. 8 includes a power supply 50, blower 1′, and a power cord 8. The blower 1′ includes an air intake 2′, air inlet guide duct 4′, and an air exhaust tube 7′. The power supply 50 is used to provide electrical power to blower 1′.
As illustrated in FIG. 9, in some embodiments, the blower 1′ can include a harness 14. In some embodiments, the harness 14 can be used to carry the weight of the blower 1′. The harness 14 can be used to allow the weight of the blower 1′ to be carried by certain parts of the operator's body to enable all-day operation of the blower 1′ by a single operator with minimal or no fatigue (e.g., 8 hours or more of continuous use). In some embodiments, the harness 14 can be worn and carried by a user's back, shoulder(s), arm(s), and/or waist. In some embodiments, the harness 14 can be worn by more than one body part. For example, the harness 14 can be carried by an operator's shoulders and waist. In some embodiments, the harness 14 can be attached to a user's belt. In some embodiments, the blower 1′ can be held in the operator's hand. In some embodiments, a portion of the weight of blower 1′ can be carried by a harness and a portion of the weight of blower 1′ can be carried by a user's hand. In some embodiments, the harness 14 can be used by the operator to direct the air discharged from blower 1′ by pointing the air exhaust tube 7′ in any desired direction. In some embodiments, the operator can direct the direction of the air discharged from the blower 1′ using their hand.
The harness 14 can be attached to the blower 1′ using one or more mounting tabs 15. In the illustrated embodiment, two mounting tabs 15 are shown. In some embodiments, more than two mounting tabs 15 can be used or a single mounting tab 15 may be used. As depicted in FIGS. 9 and 11, the mounting tabs 15 can be attached to the air inlet guide duct 4 and can be attached to an upper surface of the air inlet guide duct 4. In some embodiments, the mounting tabs 15 can be attached to different components of the blower 1′ and/or can be attached to different surfaces of the blower 1′. Preferably, the mounting tabs 15 are attached to the blower 1′ such that the harness 14 does not tangle when the user changes the direction of the air discharged from blower 1′. In some embodiments, the harness 14 can be attached to blower 1′ using a different connector than the mounting tabs 15. For example, the harness 14 can be attached to the blower 1′ using snaps, pins, clips, or the like. In some embodiments, the harness 14 can be attached to the blower 1′ using a sleeve that fits around blower 1′. In some embodiments, the harness 14 can be attached to the blower 1′ using multiple types of connectors.
FIG. 10 illustrates a perspective view of the underside of the blower 1′, according to the second embodiment of the present disclosure. The blower 1′ of FIG. 10 includes an air intake 2′, integrated stand 3, air inlet guide duct 4′, handle 5, trigger switch 6, exhaust tube 7′, power cord 8, and harness 14.
FIG. 11 illustrates a cross sectional view of blower 1′, according to the second embodiment of the present disclosure. The blower 1′ includes an air intake 2′, integrated stand 3, air inlet guide duct 4′, handle 5, trigger switch 6, air exhaust tube 7′, power cord 8, axial fan assembly 9′, inlet absorbing material 10′, outlet absorbing material 11′, isolation mounts 12′, and power control board 13, 13′. The air inlet guide duct 4′ includes a proximal end 4 a′ and a distal end 4 b′. The proximal end 4 a′ of the air inlet guide duct 4′ is located at the back of the air inlet guide duct 4′ relative to the working position of the blower 1′, proximate the air intake 2′ where air enters the air inlet guide duct 4′. The distal end of the air inlet guide duct 4′ is located at the front of the air inlet guide duct 4′ relative to the working position of the blower 1′, proximate the location where the air inlet guide duct 4′ is attached to the air exhaust tube 7′.
As illustrated in FIG. 11, the blower 1′ includes an axial fan assembly 9′. The axial fan assembly 9′ is used by the blower 1′ to accelerate the air that enters the air intake 2′ through the air inlet guide duct 4′ and out the air exhaust tube 7′. For example, when power is provided to the blower 1′ from the power supply 50 or an alternate power source, a fan rotor 17 of axial fan assembly 9′ (shown in FIG. 12) starts to rotate causing air to enter through the air intake 2′. In such an example, the air is then accelerated by the axial fan assembly 9′ up through the air inlet guide duct 4′ and the air exhaust tube 7′ where it is discharged. As illustrated in FIGS. 9-11, while in operation, air intake 2′ is oriented at a downward angle relative to the axis of axial fan assembly 9′ such that the air intake 2′ is oriented partially towards the ground during operation.
The power cord 8 is used to transfer electrical power from the power supply 50 or an alternate power source to the blower 1′. The power cord 8 can include a connector 8 a that plugs into a receptacle 8 b in the proximal end 4 a′ of the air inlet guide duct 4′, as shown in FIG. 11. The blower 1′ can include internal electrical cabling (not illustrated) that connects the receptacle 8 b to power control board 13, 13′. As described more fully with respect to FIG. 12, power control board 13, 13′ can be electrically connected to the motor 16.
The axial fan assembly 9′ can constitute a significant portion of the weight of the blower 1′ and the location of the axial fan assembly 9′ inside the blower 1′ can provide a desired center of gravity and balance to the blower 1′. As will be described more fully below, the location of the axial fan assembly 9′ inside the blower 1′ can additionally provide sound dampening properties. The axial fan assembly 9′ can be located inside the air inlet guide duct 4′ and can be located proximate to the distal end 4 b′ of the air inlet guide duct 4′. In some embodiments, the axial fan assembly 9′ can be located closer to the distal end 4 b′ of the air inlet guide duct 4′ than the location where the handle 5 is mounted. In other words, the handle 5 can be located closer to a rear end of the blower 1′ than the axial fan assembly 9′.
FIG. 12 illustrates a cross sectional view of the axial fan assembly 9′, according to the second embodiment of the present disclosure. As shown in FIG. 12, the axial fan assembly 9′ can include a motor 16, a rotor 17, an intake funnel 18, a motor fairing 19, and a fan housing 26. When power is supplied to the motor 16, the motor 16 causes the fan rotor 17 to rotate, thereby moving a column of air through the blower 1′. The motor 16 can be a direct current (DC) or alternating current (AC) electric motor as is known in the art. In some embodiments, the motor 16 can be a three-phase AC electric motor. The fan rotor 17 contains one or more fan blades and is connected to the motor 16 by a shaft 42 that is connected to a collet at the center of the fan rotor 17.
With respect to FIG. 12, the fan housing 26 contains the motor 16 and the fan rotator 17. The motor 16 can be connected to the fan housing 26 via one or more fasteners, clamps, epoxy, adhesive, and/or other connectors. A rear surface 45 of the motor 16 can include threaded holes for connecting the motor 16 to the fan housing 26. During operation of the blower 1′, the fan housing 26 is stationary such that it does not rotate with the fan rotor 17. As will be described in greater detail below with respect to FIGS. 15A-B, the fan housing 26 can be positioned in the blower 1′ via one or more tabs 43. The fan housing 26 can be made out of a thermoplastic material, polymer, or any other suitable material that can withstand the elevated temperatures of the motor 16 in operation, as well as the moisture, ultraviolet rays, and wear and tear of an outside operating environment.
The fan housing 26 can include an intake funnel 18. As illustrated in FIG. 12, the intake funnel 18 is positioned at the rear end of the fan housing 26 behind the fan rotor 17, upstream of the fan rotor 17 relative to the air flow path. The intake funnel 18 provides a transition for the air flow from the air inlet guide duct 4′ into the fan housing 26. As shown in FIGS. 12 and 13, the intake funnel 18 is flared outward towards the inlet absorbing material 10′ in the interior of the air inlet guide duct 4′. The maximum outer diameter of the intake funnel 18 can be sized to accommodate and be received by the inlet absorbing material 10′ with little to no air gaps between the intake funnel 18 and the adjacent section of the inlet absorbing material 10′. The inner surface of the intake funnel 18 can have a smooth surface finish and the outer surface of the intake funnel 18 can have a tight fit with the inlet absorbing material 10′ to maximize the amount of air flow that enters the fan housing 26 and minimize undesired parasitic losses of air flow. The intake funnel 18 can press into the inlet absorbing material 10′ to yield a tight seal that minimizes disturbance to the accelerating air flow. Such a configuration can provide a smooth air transition from the air inlet duct 4′ into the fan housing 26. In some embodiments, intake funnel 18 can be attached to the fan housing 26 via one or more fasteners, clamps, epoxy, adhesive, and/or other connectors. In some embodiments, the intake funnel 18 can be integrally formed with the fan housing 26 as a monolithic piece. The intake funnel 18 can be made out of a thermoplastic material, polymer, or any other suitable material that can withstand the elevated temperatures of the motor 16 in operation, as well as the moisture, ultraviolet rays, and wear and tear of an outside operating environment.
The fan housing 26 can include one or more stator vanes 27 as shown in FIGS. 12 and 15B. As illustrated in FIG. 12, the stator vanes 27 are positioned at the front end of the fan housing 26 and in front of the fan rotor 17, downstream of the fan rotor 17 relative to the air flow path, such that the air accelerated by the fan rotor 17 is forced through the stator vanes 27. The stator vanes 27 are stationary during operation of the blower 1′ such that they do not rotate with the fan rotor 17. During operation of the blower 1′, the rotating force of fan rotor 17 can cause the accelerated air flow to swirl in a direction of the rotating blades, e.g., clockwise or counterclockwise. Such a rotational force can reduce the energy of the air flow and reduce the sweeping power (e.g., flow rate) of the blower at a given fan speed. To counteract the rotational force added to the accelerated air flow and even out the air flow, the stator vanes 27 can be angled relative to fan housing 26 at a direction opposite to that of the rotation of the fan rotor 17. In other words, the angled orientation of the stator vanes 27 can make the outlet column of air adjust from a substantially swirled flow to a substantially straight flow. The stator vanes 27 can additionally provide stability to the air accelerated by the fan rotor 17 and smooth out turbulent flow. The stator vanes 27 can be integrally formed with the fan housing 26 as a monolithic piece.
As illustrated in FIG. 12, the axial fan assembly 9′ can include a motor heat sink 28. The motor heat sink 28 can have a tight fit around the motor 16 to prevent the motor 16 from overheating. The motor heat sink 28 is configured to draw heat out away from the motor 16 and transfer heat out of the air exhaust tube 7′ through the air flow. The motor heat sink 28 can be attached to the motor 16 by set screws and can be a metal material or any other thermally conductive material.
The axial fan assembly 9′ can include a motor fairing 19 as illustrated in FIGS. 12 and 15A-B. The motor fairing 19 is positioned in front of the fan housing 26 and in front of the fan rotor 17, downstream of the fan rotor 17 relative to the air flow path, such that the air accelerated by the fan rotor 17 flows past the motor fairing 19. The motor fairing 19 tapers towards the air exhaust tube 7′ to maintain laminar and/or attached air flow as the accelerated air exits the air exhaust tube 7′. In some embodiments, the motor fairing 19 can be cone shaped. As shown in FIGS. 15A-B, the pylon 29 includes a low profile that is substantially parallel to the air flow. The motor fairing 19 can be mounted to the motor 16 and/or can be mounted to the motor heat sink 28 using one or more fasteners, clamps, epoxy, adhesive, and/or other connectors. In some embodiments, the motor fairing 19 and the heat sink 28 can be integrally formed as a monolithic piece. In some embodiments, the motor fairing 19 can be made out of a thermoplastic material, polymer, or any other suitable material that can withstand the elevated temperatures of the motor in operation, as well as the moisture, ultraviolet rays, and wear and tear of an outside operating environment.
The motor fairing 19 can include a pylon 29 containing a motor power transfer board 29 a. The motor power transfer board 29 a serves to connect electrical signals sent from power control board 13 and/or a separate electronic speed controller circuit 59 (not illustrated) to the motor 16. The motor power transfer board 29 a contains terminals at the top end to connect electrical wires 46 a to power control board 13 and/or speed controller circuit 59. The motor power transfer board 29 a additionally contains terminals at the bottom to connect electrical wires 46 b to the motor 16.
FIGS. 13-15B illustrate views of the inside of the blower 1′, all according to the second embodiment. As shown in FIGS. 13-15B, the blower 1′ can include the axial fan assembly 9′, isolation mounts 12′, inlet absorbing material 10′, and exhaust absorbing material 11′.
As shown in FIGS. 13-15B, the air inlet guide duct 4′ can be a two piece construction made out of two separable sections with mounting holes 49 to join the sections together. As further shown in FIGS. 13-15B, the air exhaust tube 7′ can be positioned in an overlapping section 55 of the inlet guide duct 4′. The outer diameter of the air exhaust tube 7′ can be sized to fit within the overlapping section 55 such that when the sections of the air inlet guide duct 4′ are joined, the air exhaust tube 7′ is press fit into the air inlet guide duct 4′.
As depicted in FIGS. 15A-B, the axial fan assembly 9′ can be located within the blower 1′ using the isolation mounts 12′. The isolation mounts 12′ can be attached to the axial fan assembly 9′ using epoxy and/or adhesive. The isolation mounts 12′ can be used to support the axial fan assembly 9′ within blower 1′ such that the axial fan assembly 9′ is not rigidly affixed to blower 1′. For example, isolation mounts 12′ can surround at least a portion of the outer surface of axial fan assembly 9′ and the isolation mounts 12′ can be press fit into a cavity in the air inlet guide duct 4′. Adjacent the isolation mounts 12′, the air inlet guide duct 4′ can include a series of ribs 47 (see FIG. 15A) that project from an inner wall of the inlet guide duct 4′ and receive the isolation mounts 12′. The isolation mounts 12′ can be sized such that the series of ribs 47 contacts the isolation mounts 12′ with a press fit or friction fit. The friction fit helps prevent axial translation of the axial fan assembly 9′ along the length of the air inlet guide duct 4′. The series of ribs 47 can press into and deform the material of the isolation mounts 12′. The use of the isolation mounts 12′ can reduce both the noise of the blower 1′ and dampen vibrations while in operation because the isolation mounts 12′ are not rigidly affixed to blower 1′. In some embodiments, the isolation mounts 12′ can be a ring-shaped foam rubber elastomeric material. In some embodiments, the isolation mounts 12′ can take the shape of strips or longitudinal spaced rings. In some embodiments, the isolation mounts 12′ can be steel springs.
The location and placement of the axial fan assembly 9′ within blower 1′ is depicted in FIGS. 15A-B. Because the axial fan assembly 9′ is not rigidly affixed to blower 1′, the axial fan assembly 9′ may be subject to rotational and translational forces during operation. To prevent movement of the axial fan assembly 9′ inside blower 1′ while in operation, the axial fan assembly 9′ includes tab 43. FIG. 15B depicts the tab 43 in a configuration where the axial fan assembly 9′ is unmated to the right half of air inlet guide duct 4′ and also in a configuration where the axial fan assembly 9′ is mated to the right half of air inlet guide duct 4′. The tab 43 projects from top of the axial fan assembly 9′ and includes an elongate body 43 a with two side ribs 43 b. The tab 43 is substantially rigid. Shown adjacent the tab 43 are two ribs 47 in the air inlet guide duct 4′. The side ribs 43 b of the tab 43 are spaced apart and are wider than the spacing of the ribs 47 such that the ribs 47 can sit between the side ribs 43 b. When mated, sidewalls 47 a of the ribs 47 sit between the side ribs 43 b to prevent translation of the motor assembly. The two ribs 47 each contain a slot 48 to receive the tab 43 in the mated configuration. The slot 48 is sized to have a depth such that the tab 43 can fit inside the slot 48. When mated, a front surface 43 c of the tab 43 sits flush with a front surface 47 b of the ribs 47. The front surface 43 c of the tab 43 and the front surface 47 b of the ribs 47 can then be mated to the left half of the air inlet guide duct 4′ (not shown). When the left half of the air inlet guide duct 4′ is joined, ribs of the left half of the air inlet guide duct 4′ (not shown) press against the front surface 43 c of the tab 43 and the front surface 47 b of the ribs 47 of the right half of the air inlet guide duct 4′ to prevent rotation of the axial fan assembly 9′. In some embodiments, the axial fan assembly 9′ can include multiple tabs 43 and a different number of ribs 47. The width of the tab 43 between the side ribs 43 b may be sized to receive only one rib 47 or multiple ribs 47.
The axial fan assembly 9′ may be installed in blower 1′ as follows. The tab 43 of the axial fan assembly 9′ is aligned and placed inside the slot 48 of the right half of the air inlet guide duct 4′. The tab 43 is placed such that the ribs 47 are located inside of the side ribs 43 b of the tab 43. The tab 43 is also placed such that the front surface of the tab 43 c is flush with the front surface 47 b of the ribs 47 of the right half of the air inlet guide duct 4′. The left half of the air inlet guide duct 4′ (not shown) is placed such that ribs of the left half press against the front surface of the tab 43 c and the front surface 47 b of the right half of the air inlet guide duct 4′. The separate halves of the air inlet guide duct 4′ are joined together via mounting holes 49. Axial fan assembly 9′ is therefore installed in such a manner that it is not rigidly affixed to either the left half or the right half of the air inlet guide duct 4′.
As depicted in FIGS. 13-15B, the blower 1′ can include inlet absorbing material 10′ and exhaust absorbing material 11′. As further depicted in FIGS. 13-15B, the inlet absorbing material 10′ and the exhaust absorbing material 11′ can each be a two piece construction made out of two separable sections (e.g., a left section and a right section). The inlet absorbing material 10′ and the exhaust absorbing material 11′ can be sized and shaped to match the shape of the inner surface of the inlet guide duct 4′ and can be attached to the inlet guide duct 4′ using epoxy and/or adhesive. The use of the inlet absorbing material 10′ and the exhaust absorbing material 11′ can reduce both the noise of the blower 1′ and dampen vibrations while in operation. In some embodiments, the inlet absorbing material 10′ and the outlet absorbing material 11′ can be a foam rubber elastomeric material. The inlet absorbing material 10′ and the outlet absorbing material 11′ can be open-cell and/or close-cell foam and can be textured as described above.
FIG. 16 illustrates an example of an intake design for the blower 1′, according to some embodiments of the present disclosure. The blower 1′ of FIG. 16 includes an air intake 2′, axial fan assembly 9′, center axis of inlet duct 21′, axis of axial fan assembly 22′, inlet plane 23′, angle of the inlet duct 24′ relative to the axis of the axial fan assembly, and angle of the inlet plane 25′ relative to the axis of the axial fan assembly. As depicted in FIG. 16, the angle of the inlet duct 24′ and the angle of the inlet plane 25′ may be independently set such that the inlet plane 23′ is not perpendicular to the center axis of the inlet duct 21′. The angle of the inlet duct 24′ may be between 1 to 59 degrees. The angle of the inlet plane 25′ may be any angle less than 90 degrees.
FIG. 17 illustrates a power control board 13 for use with the blower 1, 1′, according to some embodiments of the present disclosure. Power control board 13 of FIG. 17 may include a processor 30, display 31, input interface 32, clock 34, memory 35, and communication interface 36. Power control board 13 may further include a power controller 37, programmable timer 38, and data collection 39. Also illustrated in FIG. 17 is an operator device 40 in communication with power control board 13. Operator device 40 includes debris blower software application 41 and a wired or wireless communication interface (not shown) to communication with power control board 13 and other external devices.
Processor 30 may be configured to access memory 35 to store received input or to execute commands, processes, or programs stored in memory 35. Processor 30 may correspond to a microprocessor, a controller, or a similar hardware processing device, or a plurality of hardware devices. Memory 35 is a sufficient memory capable of storing commands, processes, and programs for execution by processor 30. In some embodiments, memory 35 may be instituted as ROM, RAM, flash memory, and/or any sufficient memory capable of storing a set of commands. In some embodiments, memory 35 may correspond to a plurality of memory types or modules. As described more fully below, memory 35 may also store data corresponding to operational characteristics of the blower, such as sensor data measured from one or more sensors.
Also illustrated in FIG. 17, power control board 13 includes display 31 and input interface 32. Input interface 32 may comprise any device capable of accepting operator input for use with power control board 13 of blower 1, 1′. Display 31 may comprise any type of display hardware built into power control board 13, such as a liquid crystal display (LCD) screen. In some embodiments, display 31 may also be touch sensitive and may serve as input interface 32.
Also illustrated in FIG. 17, power control board 13 includes communication interface 36. In some embodiments, communication interface 36 includes any device that is capable of both transmitting data with a transmitter and receiving data with a receiver as is known in the art. In such embodiments, processor 30 of power control board 13 is thus configured to control communication interface 36 to communicate with other electronic devices, such as operator device 40. For example, communication interface 36 may utilize one or more of Wireless Fidelity (Wi-Fi), Worldwide Interoperability for Microwave Access (WiMax), ZigBee, Bluetooth, Bluetooth low energy, Algorithm Division Multiple Access (CDMA), Evolution-Data Optimized (EV-DO), Global System for Mobile Communications (GSM), Long term Evolution (LTE), and other types of wired or wireless technology. In some embodiments, communication interface 36 may include a universal serial bus (USB) port.
For example, blower 1, 1′ may utilize communication interface 36 of power control board 13 to communicate with operator device 40. Operator device 40 may include a computer, a mobile phone, a tablet, or any other device capable of executing debris blower software application 41 to communicate with blower 1, 1′. An operator may thus be able to use debris blower software application 41 on operator device 40 to transmit and receive data with power control board 13 of blower 1. For example, and as will be described in greater detail below, an operator in possession of operator device 40 may utilize debris blower software application 41 via the processor 30 to connect to power control board 13 of blower 1, 1′ in order to perform different activities, such as, but not limited to, data retrieval, system diagnostics, trouble shooting, performance parameter adjustment, and system software updates.
Also illustrated in FIG. 17, power control board 13 include a power controller 37. In some embodiments, power controller 37 may be implemented as a hardware power control circuit. In some embodiments, power controller 37 may be implemented as a software process operating on processor 30 as is known in the art. In some embodiments power controller may include an electronic speed controller circuit 59. Power control board 13 may utilize power controller 37 to control the operations of blower 1, 1′ via the electronic speed controller circuit 59. For example, and as discussed above, an operator of blower 1 may adjust the power supplied to blower 1, 1′ from the power supply 50 via trigger switch 6. Power controller 37 is thus configured to determine how much power to supply to blower 1 based on how far the operator of blower 1, 1′ presses down on trigger switch 6. For example, in some embodiments, the further the operator presses down on trigger switch 6, the more power that power controller 37 will supply to blower 1, 1′.
Power controller 37 may further be configured to prevent damage to blower 1, 1′. For example, in some embodiments, processor 30 may utilize power controller 37 to monitor one or more of battery voltage, current flow, motor temperature, and electronic speed controller temperature. In such embodiments, if one or more of battery voltage, current flow, motor temperature, and electronic speed controller temperature exceeds a pre-determined range, power controller 37 (e.g., under control of the processor 30) may attenuate the power to, or turn off the power to, blower 1, 1′ to prevent damage.
Furthermore, power controller 37 may be configured to maximize the operational life of the power supply 50 of the debris blower. For example, in some embodiments where the power supply 50 includes batteries, power controller 37 may include a software process that is tailored to maximize the battery life of the power supply 50 by limiting the battery discharge profile based on an operator selectable battery chemistry. In such embodiments, the operator is able to use blower 1, 1′ for longer time periods since the power controller 37 is limiting the battery discharge profile of the battery. For example, the power controller 37 may receive data from a voltage sensor monitoring the voltage of the battery cells. As is known in the art, the voltage of the battery cells for a given battery type is correlated to the current charge capacity of the cell. The power controller 37 may limit the battery discharge profile of a battery to a given range, for example 30% to 80% of the capacity of the battery, by monitoring and limiting the voltage of the battery cells. If the battery cell voltage falls outside of a set range while discharging, the power controller 37 may cut off power to prevent battery over-discharge.
Also illustrated in FIG. 17, power control board 13 includes a programmable timer 38. Power control board 13 may utilize programmable timer 38 to put blower 1, 1′ in a “sleep” modes to conserve energy and unwanted battery drain. For example, programmable timer 38 may use clock 34 to determine that blower 1 has been operating longer than a pre-defined time period, where clock 34 includes a timer built into power control board 13. In such an example, after determining that blower 1, 1′ has been operating for longer than the pre-defined time period, programmable timer 38 may automatically put blower in a “sleep” mode by shutting blower 1, 1′ off.
Also illustrated in FIG. 17, power control board 13 can include a data collection device 39. Power control board 13 may utilize data collection device 39 to collect data corresponding to the operations of blower 1, 1′. For example, power control board 13 may utilize data collection device 39 to collect data corresponding to cumulative energy usage, battery voltage, current flow, motor temperature, and electronic speed controller temperature. In such an example, power control board 13 may utilize clock 34 to record times that correspond to the data collection. Power control board 13 may then compare the cumulative energy use of blower 1, 1′ with gasoline counterparts to determine the efficiency of blower 1, 1′ via power controller 37. Furthermore, power control board 13 may use battery voltage, current flow, motor temperature, and electronic speed controller temperature levels for diagnostic purposes. Data collection device 39 may include various known sensors or equivalent circuits such as temperature sensors, power sensors, current sensors, and/or voltage sensors for various data collection purposes. The data collection device 39 may be implemented as a hardware control circuit or may be implemented as a software process as is known in the art.
It should be noted that, as discussed above, blower 1, 1′ may use power control board 13 to transmit and receive data with operator device 40. In some embodiments, blower 1, 1′ may utilize power control board 13 to transmit data within data collection device 39 to operator device 40. In such embodiments, the operator may then utilize debris blower application 41 of operator device 40 to monitor the performance of blower 1, 1′ based on the data. The operator may further utilize debris blower software application 41 of operator device 40 to change the controls of blower 1 to increase the performance of blower 1, 1′ based on the data.
FIG. 18 illustrates a power control board 13′ for use with the blower 1, 1′, according to some embodiments of the present disclosure. Parts which are similar to those of the embodiment of FIG. 17 have the same reference numerals, and the descriptions thereof will not be repeated.
Power control board 13′ of FIG. 18 may include processor 30, current sensor 56, voltage sensor 57, clock 34′, memory 35, temperature sensor 58′, power controller 37, internal user interface 60 a, and a communication interface 36 a. Also illustrated in FIG. 18, an operator device 40′ is in communication with power control board 13′. Operator device 40′ includes a communication interface 36 b, an external user interface 60 b, and a debris blower software application 41′.
As illustrated in FIG. 18, power control board 13′ includes an internal user interface 60 a. The internal user interface 60 a can be used to perform various functions locally on board the blower, including: data retrieval, system diagnostics, trouble shooting, performance parameter adjustment, and system software updates. The internal user interface 60 a can include a display 31 a and an input interface 32 a. The input interface 32 a can be any type of input hardware built into power control board 13′, such as a keyboard or joystick. The display 31 a can be any type of display hardware built into power control board 13′, such as a liquid crystal display (LCD) screen. In some embodiments, the display 31′ may also be touch sensitive and may serve as an input interface 32′. In some embodiments, the internal user interface 60 a can be part of power control board 13′. In some embodiments, the internal user interface 60 a can be separate components wired to power control board 13′.
Also illustrated in FIG. 18, power control board 13′ also includes communication interface 36 a. In some embodiments, communication interfaces 36 a, 36 b include any device that is capable of both transmitting data with a transmitter and receiving data with a receiver as described with respect to FIG. 17. The blower 1, 1′ may utilize communication interface 36 a of power control board 13′ to communication with the communication interface 36 b of the operator device 40′ and to other devices, as described with respect to FIG. 17.
Power control board 13′ can include an interface to trigger switch 6. As described above, trigger switch 6 is used to adjust the amount of power that is supplied to blower 1, 1′ from the power supply 50 via power cord 8 by adjusting the amount of pressure applied to trigger switch 6. In some embodiments, trigger switch 6 can be a potentiometer and/or voltage divider circuit with a push button or level that allows an operator to select a speed of the motor 16 corresponding to a desired air flow volume. In some embodiments, trigger switch 6 can output a proportional controlled analog signal. In some embodiments, trigger switch 6 can output digital signals. The power controller 37 may include an electronic speed controller circuit 59. Trigger switch 6 may be electrically wired to the electronic speed controller circuit 59, which generates the electrical signals sent to the motor 16 to control the speed of the motor 16. The electronic speed controller circuit 59 can operate using pulse width modulation (PWM) digital control. In some embodiments, the electronic speed controller circuit 59 can be part of power control board 13′. In some embodiments, the electronic speed controller circuit 59 can be a separate component wired to power control board 13′.
As illustrated in FIG. 18, power control board 13′ can include one or more sensors 61 or sensor inputs 61 a, including a current sensor 56, a voltage sensor 57, temperature sensors 58, and the outputs from the electronic speed controller circuit 59. The current sensor 56 can be used to measure the current flowing from the power supply 50 to the blower 1, 1′, and can be measured off of the electrical wires entering power control board 13′. The current sensor 56 can be a hall effect sensor, an in-line current measurement, or the like. The voltage sensor 57 can be used to measure the voltage from the power supply 50 to the blower 1, 1′, and can be measured off of the electrical wires entering power control board 13′. The voltage sensor 57 can be a voltage divider circuit or the like. The temperature sensors 58 can be placed on various components in blower 1, 1′ and can be used to measure the temperature of various components, including the motor temperature, power supply temperature, and the electronic speed controller temperature. The temperature sensors can be thermocouples, thermistors, resistance temperature detectors (RTDs), or the like. In some embodiments, the sensors 61 and sensor inputs 61 a described above can be part of power control board 13′. In some embodiments, the sensors 61 and sensor inputs 61 a can be separate components wired to power control board 13′.
As illustrated in FIG. 18, power control board 13′ can include a clock 34′. The clock 34′ can be used to keep track of the current time and coordinate the actions of power control board 13′, such as the desired frequency for obtaining sensor 61 data and for sending data over the communication interface 36 a. The clock 34′ can include an oscillator, such as a 32 khz oscillator, and can be fed into a real-time clock circuit. The clock 34′ can include its own backup battery independent of the power supply 50. The clock 34′ can act as a timer.
Power control board 13′ can include hardware circuitry or software processes configured to prevent damage to the blower 1, 1′ via the power controller 37. For example, in some embodiments, processor 30 can utilize the sensors 61 or sensor inputs 61 via a software process on power controller 37 to monitor one or more of battery voltage, current flow, motor temperature, and electronic speed controller temperature. In some embodiments, if one or more of the battery voltage, current flow, motor temperature, and electronic speed controller temperature exceeds a pre-determined range, power control board 13′ via the power controller 37 may attenuate the power to, or turn off the power to, blower 1, 1′ to prevent damage.
Power control board 13′ may be configured to maximize the operational life of the power supply 50 of the debris blower via power controller 37. For example, in some embodiments where the power supply 50 includes batteries, power control board 13′ may include a software process that is tailored to maximize the battery life of the power supply 50 by limiting the battery discharge profile based on an operator selectable battery chemistry. In such embodiments, the operator is able to use blower 1 for longer time periods since the power control board 13′ is limiting the battery discharge profile of the battery. For example, the power control board 13′ may receive data from a voltage sensor monitoring the voltage of the battery cells. As is known in the art, the voltage of the battery cells for a given battery type is correlated to the current charge capacity of the cell. For example, a lithium-ion battery cell may charge up to 4.2V/cell at 100% capacity. Power control board 13′ can limit the battery discharge profile of a battery to a given range, for example 30% to 80% of the capacity of the battery, by monitoring and limiting the voltage of the battery cells via power controller 37. If the battery cell voltage exceeds a given threshold while charging, power control board 13′ via power controller 37 can cut off power to prevent the battery from overcharging. Similarly, if the battery cell voltage falls below a given threshold while discharging, power control board 13′ via power controller 37 can cut off power to prevent battery over-discharge.
Power control board 13′ can include a programmable timer 38. Power control board 13′ may utilize programmable timer 38 to put blower 1, 1′ in a “sleep” modes to conserve energy and unwanted battery drain. For example, programmable timer 38 may use clock 34′ to determine that blower 1, 1′ has been operating longer than a pre-defined time period, where clock 34′ includes a timer built into power control board 13′. In such an example, after determining that blower 1, 1′ has been operating for longer than the pre-defined time period, programmable timer 38 may automatically put blower in a “sleep” mode by shutting blower 1 off.
As will be described with reference to FIG. 19, power control board 13′ may collect data corresponding to cumulative energy usage, battery voltage, current flow, motor temperature, and electronic speed controller temperature. For example, power control board 13 may utilize clock 34 to record the running time of blower 1, 1′ via power controller 37. Power control board 13 may then compare the cumulative energy use of blower 1 with gasoline counterparts to determine the efficiency of blower 1. Furthermore, power control board 13 may use battery voltage, current flow, motor temperature, and electronic speed controller temperature for diagnostic purposes.
FIG. 19 illustrates a process flow for operation of the blower and data collection according to some embodiments. As shown, the power control board can monitor one or more operational characteristics of the debris blower 100, 100′, store the characteristics in memory, report and display the characteristics using internal user interface 60 a, and transmit the characteristics to an operator device 40, 40′ or other external device. The operational characteristics can include the voltage supplied from the power supply 50, the current supplied from the power supply 50, the power supplied, cumulative energy usage, the electric motor temperature, the battery temperature, and/or the temperature of the electronic speed controller circuit 59.
At block 200, the system is initialized, which may occur when the system is powered on. At block 210, the system runs a main system loop while the system is powered on. The main system loop can be run as parallel and/or sequential operations as depicted in FIG. 19. As illustrated in FIG. 19, in some embodiments, the main system loop can broken down into three parallel branches. In some embodiments, all of the blocks in the main system loop can be run sequentially. When operations are run in parallel, the parallel operations may be run at different frequencies to minimize energy consumption of the power supply 50 and to maximize the operation time of the blower. For example, block 270 may be run less frequently than block 220.
At block 220, communications over communication interfaces 36, 36 a, and/or 36 b can be processed. The communications process can include external commands received by an operator device 40, 40′ and/or internal commands received by internal user interface 60 a.
At block 230, sensor data from the one or more sensors 61 or sensor inputs 61 a can be obtained. For example, current, voltage, and/or temperature can be measured using the onboard current sensor 56, voltage sensor 57, and temperature sensors as described above. The clock 34, 34′ can obtain time information that corresponds to the gathered sensor measurements and this time information can stored in memory 35. As such, the history of sensor data for the time that the blower is in operation can be obtained, recalled, and displayed using the internal user interface 60 a. The sensor data can also be transmitted to the operator device 40, 40′ or other external device and displayed using external user interface 60 b or other user interface.
At block 240, power supplied from power supply 50 to the blower 1, 1′ can be measured. The measured power supplied may be calculated by multiplying the voltage supplied by the current supplied as is known in the art. The measured power supplied can be stored in memory 35. Time information that corresponds to the measured power supplied may be the same time information that corresponds to the respective current and sensor measurements. The measured power supplied for the time that the blower is in operation can be recalled and displayed using the internal user interface 60 a. The measured power supplied can also be transmitted to the operator device 40, 40′ or other external device and displayed using external user interface 60 b or other user interface. and/or external user interface 60 b.
At block 250, the electronic speed controller 59 can process throttle inputs from the trigger switch 6 and send control signals to the motor 16 as described above.
At block 260, the blower 1, 1′ can be powered off if an error or fault code is detected. For example, as described above, voltage, current, and temperature measurements are obtained while the blower is in operation. If one of these measured sensor values falls outside of a predefined range in memory, the blower 1, 1′ can be powered off and a fault code can be recorded in a log. For example, if the measured temperature exceeds a set threshold, power to blower 1, 1′ via power controller 37 can be turned off.
At block 270, cumulative energy usage can be determined in watt hours. The power supplied to the blower 1, 1′ and the time information corresponding to the power supplied can be obtained as described with respect to block 240. Energy supplied over a given time period (e.g., every second) can be calculated by multiplying the power supplied over the time period by the length of the time period. For an interval of one second, the energy supplied in watt hours may be calculated by multiplying the power supplied over this period by 1/3600. Cumulative energy usage of the blower 1, 1′ can be determined by summing the energy supplied over a specified time period (e.g., one hour or one day). Cumulative energy usage can be stored in memory 35. In some embodiments, energy usage can be calculated every second while the blower 1, 1′ is in operation and cumulative energy usage since the blower 1, 1′ was initialized at block 200 can be determined. The cumulative energy usage for the time that the blower is in operation can be recalled and displayed using the internal user interface 60 a. The cumulative energy usage can also be transmitted to the operator device 40, 40′ or other external device and displayed using external user interface 60 b or other user interface.
It should be noted that, as discussed above, blower 1,1′ may use power control board 13′ to transmit and receive data with operator device 40 or other devices. In some embodiments, blower 1, 1′ may utilize power control board 13′ to transmit data stored in memory to operator device 40. An operator may utilize debris blower application 41 of operator device 40 to monitor the performance of blower 1, 1′ based on the data. An operator may utilize internal user interface 60 a of power control board 13′ to monitor the performance of blower 1, 1′ based on the data. The operator may further utilize debris blower software application 41 of operator device 40 and/or internal user interface 60 a to change the controls of blower 1, 1′ to modify the performance of blower 1 based on the data.
The foregoing description of the preferred embodiments of the present disclosure has shown, described and pointed out the fundamental novel features of the inventions. The various devices, methods, procedures, and techniques described above provide a number of ways to carry out the described embodiments and arrangements. Of course, it is to be understood that not necessarily all features, objectives or advantages described are required and/or achieved in accordance with any particular embodiment described herein. Also, although the invention has been disclosed in the context of certain embodiments, arrangements and examples, it will be understood by those skilled in the art that the invention extends beyond the specifically disclosed embodiments to other alternative embodiments, combinations, sub-combinations and/or uses and obvious modifications and equivalents thereof. Accordingly, the invention is not intended to be limited by the specific disclosures of the embodiments herein.

Claims

What is claimed is:

1. A power tool comprising:

an electric motor;

a power supply for providing electric power to the power tool;

a power control board electrically coupled to the electric motor and the power supply for collecting data corresponding to operation of the power tool, the power control board comprising a power controller, a memory, one or more sensors for acquiring data, a timer, and a communication interface;

wherein the timer is to monitor running time of the electric motor over a time period, and the memory is to store data related to the running time;

wherein when the power tool is powered on, the power controller determines cumulative energy usage of the power tool over the time period based on measuring power supplied to the electric motor over the time period and the monitored running time of the electric motor over the time period;

wherein the memory is to store the cumulative energy usage; and

wherein the communication interface is to transmit the cumulative energy usage to a device.

2. The power tool according to claim 1, wherein the power tool comprises an electric debris blower comprising:

an air inlet guide duct defining an inlet of the electric debris blower and an air exhaust tube defining an outlet of the electric debris blower; and

an axial fan between the inlet and the outlet comprising the electric motor and a rotor, wherein the axial fan is to direct air along an air flow path from the inlet to the outlet.

3. The power tool according to claim 2, wherein the time period is an entire lifetime of the tool, and wherein when the power tool is powered on, the power controller determines usage of the power tool based on cumulative energy used by the power tool over the time period.

4. The power tool according to claim 3, wherein the usage of the power tool is based on a comparison of the cumulative energy used by the power tool over the time period to a gasoline powered tool.

5. The power tool according to claim 2, further comprising:

a current sensor coupled to electrical wires entering the power control board for measuring current supplied to the electric motor;

a voltage sensor coupled to electrical wires entering the power control board for measuring voltage supplied to the electric motor; and

a handle for orienting the power tool;

wherein the handle comprises the power control board, and

wherein measuring power supplied to the electric motor over the time period is based on measurements from the current sensor and the voltage sensor.

6. The power tool according to claim 2, wherein the time period is a total time since the power tool was powered on.

7. The power tool according to claim 2, wherein the communication interface is a Bluetooth interface.

8. The power tool according to claim 2, further comprising a display, wherein the power controller is to recall the cumulative energy usage and the display is to show the cumulative energy usage.

9. The power tool according to claim 2, wherein the power control board comprises a temperature sensor, the power controller is to monitor a temperature of the power control board, and wherein when the temperature of the power control board falls outside of a set range, the power controller is to attenuate or turn off power to the power tool and the memory is to store a fault code.

10. An electric debris blower comprising:

an air inlet guide duct defining an inlet of the electric debris blower and an air exhaust tube defining an outlet of the electric debris blower;

an axial fan between the inlet and the outlet comprising an electric motor and a rotor, wherein the axial fan is to direct air along an air flow path from the inlet to the outlet;

a power supply for providing electric power to the axial fan; and

a power control board electrically coupled to the axial fan and the power supply for collecting data corresponding to operation of the axial fan, the power control board comprising a power controller, a memory, one or more sensors for acquiring data, a timer, and a communication interface;

wherein the timer is to monitor running time of the electric motor and the memory is to store data related to the running time;

wherein the power controller is to monitor one or more operational characteristics of the electric debris blower and the memory is to store the one or more operational characteristics; and

wherein the communication interface is configured to report or transmit the one or more operational characteristics of the electric debris blower; and

further comprising an electronic speed controller to control speed of the axial fan and wherein the one or more operational characteristics of the electric debris blower comprises an electronic speed controller temperature.

11. An electric debris blower comprising:

a housing comprising an air inlet guide duct defining an inlet of the electric debris blower and an air exhaust tube defining an outlet of the electric debris blower;

a handle for directing the electric debris blower, the handle positioned between the inlet and the outlet;

an axial fan comprising an electric motor and a rotor and configured to direct air along an air flow path from the inlet to the outlet, the axial fan positioned between the handle and the outlet; and

one or more isolation mounts for reducing vibration of the blower during operation, the isolation mounts located between the housing and the axial fan.

12. The electric debris blower according to claim 11, wherein the isolation mounts surround at least a portion of a circumference of the axial fan and the isolation mounts are press fit between the housing and the axial fan.

13. The electric debris blower according to claim 11, wherein the housing comprises a plurality of ribs extending in a direction towards the isolation mounts and the isolation mounts are press fit between the plurality of ribs and the axial fan.

14. The electric debris blower according to claim 13, wherein at least one of the plurality of ribs includes a slot and the axial fan comprises a tab configured to be received in the slot.

15. The electric debris blower according to claim 11, wherein the handle is mounted to the air inlet guide duct, the axial fan is located in the inlet guide duct.

16. The electric debris blower according to claim 15, wherein the handle is located above the air inlet guide duct.

17. The electric debris blower according to claim 11, wherein the axial fan further comprises a fairing having an electrical connector for providing electrical power to the axial fan, the fairing located downstream of the rotor of the fan relative to air flow path.

18. The electric debris blower according to claim 11, wherein the isolation mounts are a rubber elastomeric material.

19. The electric debris blower according to claim 11, wherein the air inlet duct guide comprises an inlet absorbing material having a textured surface.

20. The electric debris blower according to claim 11, further comprising a power control board for collecting data corresponding to the operation of the axial fan, the power control board comprising a power controller, memory, a timer, and a communication interface, the power control board electrically coupled to the axial fan.