CONCRETE VIBRATOR SYSTEM

A concrete vibrator system comprises a vibrating head including a shaft. The shaft has a center of mass that is radially offset from a rotational axis of the shaft. The vibrating head also includes an onboard electric motor configured to provide torque to the shaft, causing the shaft to rotate. The concrete vibrator system further comprises a portable power unit including a battery pack configured to provide electrical current to the motor. A cable extends between the portable power unit and the vibrating head. The cable is configured to transmit electrical current from the battery pack to the motor and a motor control signal from the portable power unit to the motor.

FIELD OF THE INVENTION

The present invention relates to power tools, and more particularly to concrete vibrators.

BACKGROUND OF THE INVENTION

Concrete vibrators are typically used to spread poured concrete around a framework, such as rebar, in a construction operation. Such concrete vibrators are typically powered by an internal combustion engine, which can be difficult to carry by an operator using the concrete vibrator while on a worksite.

SUMMARY OF THE INVENTION

The present invention provides, in one aspect, a concrete vibrator system comprising a vibrating head. The vibrating head includes a shaft having a center of mass radially offset from a rotational axis of the shaft. The vibrating head further includes an onboard electric motor configured to provide torque to the shaft, thereby causing the shaft to rotate. The vibrating head is connected via a cable to a portable power unit including a battery pack configured to provide electrical current to the motor. The cable is configured to transmit electrical current from the battery pack to the motor and a motor control signal from the portable power unit to the motor.

The present invention provides, in another aspect, a concrete vibrator system comprising a power source and a cable having a first end and a second end. The first end is electrically connected to the power source, and the cable is configured to transmit electrical current from the power source. The concrete vibrator system further comprises a first vibrating head and a second vibrating head different from the first vibrating head. The first and second vibrating heads are interchangeably removably couplable to the second end of the cable.

The present invention provides, in another aspect, a modular concrete vibrator system comprising a battery receptacle unit configured to selectively interchangeably receive a first battery pack and a second battery pack. Each battery pack is configured to provide electrical current to a motor. The modular concrete vibrator system further comprises a motor control unit configured to generate a control signal for transmission. The motor control unit is integrated in a common housing with the battery receptacle unit. The common housing includes an electrical connection configured to selectively interchangeably receive a first cable and a second cable, each cable configured to transmit electrical current and to transmit the control signal. The modular concrete vibrator system further comprises a first vibrating head and a second vibrating head. Each vibrating head is configured to selectively interchangeably couple to the first cable and to selectively interchangeably couple to the second cable.

The present invention provides, in another aspect, a power tool assembly comprising a power tool including a housing and an electric motor within the housing. The motor includes a rotatable shaft and a radial bearing supporting the rotatable shaft. The power tool further includes a bearing retainer having a first pocket in which the radial bearing is received to support the radial bearing relative to the housing. The power tool assembly further comprises a cable that is configured to supply electrical current to the electric motor. An end of the cable includes a first electrical connector. The power tool assembly further comprises a second electrical connector that is received within a second pocket in the bearing retainer. The second electrical connector is selectively connectable to the first electrical connector to electrically connect the electric motor to the cable.

DETAILED DESCRIPTION

With reference toFIG.1, a portable power unit10includes a frame or backpack14, a battery receptacle unit18, a battery pack22attached to the battery receptacle unit18, a pair of handles26to facilitate hand-carrying the unit18(the second handle26being shown inFIG.2), a motor control unit30, and a motor control unit guard34. The backpack14generally defines a backpack plane and includes straps or other rigging (not shown) to allow a user to carry the portable power unit10on the user's back while the portable power unit10is in use or between uses of the portable power unit10. The straps may include one, two, or more shoulder straps and one or more waist straps. The battery receptacle unit18includes a battery receptacle35on a front side36of the unit18to which the battery pack22is attachable, with the backpack14being attached to a rear side37of the unit18.

With continued reference toFIG.1, the battery receptacle35includes a channel, an electrical terminal, and a latching mechanism. The channel cooperates with a corresponding shaped rail on the battery pack22to attach the battery pack22to the battery receptacle35. When the battery pack22is attached to the battery receptacle35, the electrical terminal on the battery receptacle35and a corresponding electrical terminal on the battery pack22are electrically connected to each other. The latching mechanism protrudes from a surface of the battery receptacle35and is configured to engage the battery pack22to maintain engagement between the battery pack22and the battery receptacle35. Thus, the battery pack22is connectable to and supportable by the battery receptacle35such that the battery pack22is supportable by the unit18and the backpack14when worn by a user.

With continued reference toFIG.1, the battery pack22includes a battery pack housing containing a plurality of battery cells. In some embodiments, the battery cells, and therefore the battery pack22, may have a nominal voltage of up to about 80 V. In some embodiments, the battery cells have a nominal voltage of up to about 120 V. In some embodiments, each of the battery cells has a diameter of up to about 21 mm and a length of up to about 71 mm. In some embodiments, the battery pack22includes up to twenty battery cells. In some embodiments, the battery cells are connected in series. In some embodiments, the battery cells are operable to output a sustained operating discharge current of between about 40 A and about 60 A. In some embodiments, each of the battery cells has a capacity of between about 3.0 Ah and about 5.0 Ah.

With reference toFIGS.1and2, the motor control unit30is selectively attachable to the battery receptacle unit18. The motor control unit30includes a first (rear) side38athat is configured to face the backpack14when the motor control unit30is attached to the battery receptacle unit18and a second (front) side38bopposite the first side38a. The motor control unit30further includes a third (top) side38cextending generally perpendicular to the backpack plane and between the rear side38aand the front side38b. The top side38cis facing the battery receptacle unit18when the motor control unit30is attached thereto. In the illustrated embodiment, the motor control unit30is surrounded and protected by the motor control unit guard34such that the front side38bis recessed into the guard34. In other embodiments, the motor control unit30may not be recessed into the guard34. Further, in the illustrated embodiment, the motor control unit guard34is tubular and defines a U-shape when viewed from a direction that is transverse to the backpack14. In other embodiments, the motor control unit guard34may have a variety of different shapes.

With continued reference toFIG.2, the motor control unit30includes a first electrical connection42configured to selectively attach the motor control unit30to a first end of a cable. The motor control unit30also includes a control panel43and an on/off switch44. The control panel43may include an arming button and a remote pairing button. The motor control unit30may also include a docking port to selectively receive a remote45. In other embodiments, the remote45may be selectively docked at other locations on the portable power unit10. Further, the motor control unit30and the battery receptacle unit18include a second electrical connection46a,46bconfigured to selectively electrically connect the motor control unit30to the battery receptacle unit18.

With continued reference toFIG.2and with reference toFIG.3, the embodiment ofFIG.1includes one or more mechanical latches that selectively attach the motor control unit30to the battery receptacle unit18. In some embodiments, such as the embodiment ofFIG.1, two mechanical latches50a,50bare provided for this purpose, each mechanical latch50a,50bincluding a respective projection54a,54band a respective hook58a,58b. In this embodiment, the projections54a,54bare provided on the top side38cof the motor control unit30and the hooks58a,58bare provided on the battery receptacle unit18. In this embodiment of the portable power unit10, the electrical connections46a,46bare simultaneously made with the latches50a,50bmechanically connecting the motor control unit30to the battery receptacle unit18. With reference toFIG.3, the motor control unit30includes an electronic controller62in communication with the first electrical connection42, the control panel43, the on/off switch44, and the second electrical connection46a,46b. In other embodiments, some of which are described herein, the motor control unit30may be coupled to the battery receptacle unit18via a variety of different mechanical and electrical means.

In operation, and with reference toFIGS.1-3, a power tool is electrically connectable to a second end of the cable that connects to the first electrical connection42of the motor control unit30. In one embodiment, a plurality of power tools may be connectable to the first electrical connection42. In that embodiment, a single motor control unit30can power and control whichever of the plurality of power tools is electrically connected to the motor control unit30via the cable. In another embodiment, each power tool includes its own motor control unit30, and the motor control units30are interchangeable in the portable power unit10to allow the portable power unit10to power and control various power tools. In that embodiment, the portable power unit10can power and control whichever of the plurality of power tools has its particular motor control unit30coupled to the battery receptacle unit18.

With continued reference toFIGS.1-3and with reference toFIGS.4and5, a portable concrete vibrator, such as a high-cycle concrete vibrator66, may be powered and controlled by the portable power unit10, thereby forming a concrete vibrator system. The high-cycle concrete vibrator66includes a whip70, a whip connection74that electrically connects the whip70to a power cable, and a vibrating head78. The vibrating head78contains an onboard electric motor82which, in some embodiments, is a brushless direct current (“BLDC”) electric motor82that is configured to rotate a drive shaft84to which an eccentric mass86is affixed (FIG.5). The electric motor82may include a plurality of windings. The eccentric mass86is supported at each end by bearings90a,90b. The drive shaft84has a center of mass (i.e., an eccentric mass86) that is radially offset from a rotational axis of the drive shaft84, and the electric motor82is configured to provide torque to the drive shaft84, thereby causing the drive shaft84and the eccentric mass86to rotate. Electrical wiring (not shown) transmits electrical current from the motor control unit30to the motor82via the whip70and power cable.

With continued reference toFIG.5, the electric motor82includes a rotor and a stator. The stator may be press-fit to a housing110of the vibrating head78such that the housing110serves as a heat sink for the electric motor82. The vibrating head78also includes a rotational speed-sensing printed circuit board (PCB)88operable to detect a rotational speed of the rotor, and therefore a rotational speed of the drive shaft84and of the eccentric mass86. The whip70has one or more connectors that plug into the rotational speed-sensing PCB88to provide electrical current to the PCB88and also to transmit a rotational speed signal to the motor control unit30.

In operation, and with reference toFIGS.1-5, a user may wear the portable power unit10as a backpack while operating a tool such as the high-cycle concrete vibrator66. Specifically, a user may hold the whip70and use the vibrating head78to vibrate concrete while electrical power and control signals are delivered to the high-cycle concrete vibrator66from the motor control unit30, which is connected to the battery receptacle unit18. The on/off switch44may include three positions: “on,” “off,” and “remote.” To shut off power to the motor control unit30, the user would toggle the on/off switch44to the “off” position. To allow the motor control unit30to be controlled by the remote45, the user would toggle the on/off switch44to the “remote” position, thereby allowing the remote45to control whether the motor control unit30is on or off (e.g., whether or not the motor control unit30is armed) and whether the tool, such as the vibrator66, is activated. To arm the motor control unit30without using the remote45, the user would toggle the on/off switch44to an “on” state in which electrical current from the battery pack22is supplied to the controller62, thereby waking the controller62and readying the controller62to accept an input from the control panel43. Then, using the control panel43, the user could activate a tool such as the vibrator66by pressing a button on the control panel43to selectively activate the tool or to allow the tool to be selectively activated by actuating another switch. Activating the tool and/or the motor82may allow the motor82to rotate at a predefined rotational speed coinciding with a pre-set vibrational frequency. To pair the remote45with the motor control unit30, the user may press the remote pairing button on the control panel43, thereby allowing wireless communication between the remote45and the motor control unit30. Output of the rotational speed-sensing PCB88is transmitted through the whip70and cable to the motor control unit30, which, based on the feedback from the PCB88, may adjust the rotational speed of the motor82as necessary to ensure that the vibration frequency of the vibrator66remains consistent as the vibrating head78is plunged into wet concrete.

In operation, and with continued reference toFIGS.1-5, the use of the portable power unit10may have a benefit of reducing an amount of weight that must be carried by the arms of the user when operating the high-cycle concrete vibrator66. The high-cycle concrete vibrator66may be interchangeable with other tools such that the same portable power unit10, or at least the same battery receptacle unit18, can be used to power and control a plurality of different power tools.

With reference toFIGS.6-8, another embodiment of a high-cycle concrete vibrator114includes a whip118that is configured to selectively attach to and detach from a modular vibrating head122. The modular vibrating head122includes a connector capsule126within the modular vibrating head122that electrically interfaces with a whip connector130within the whip118. The connector capsule126includes a plurality of connector terminal pins131a,131b,131c. The connector terminal pins131a,131b,131care configured to interface with a plurality of connector terminal recesses in the whip connector130(a connector terminal recess132cbeing shown inFIG.7) to provide electrical communication between the connector capsule126and the whip connector130. Further, a support pin133on the connector capsule126is inserted into a support pin recess135in the whip connector130to prevent relative rotation between the connector capsule126and the whip connector130. A head collar134partially surrounds the whip connector130and provides a mechanical connection and seal between the modular vibrating head122and the whip118. The mechanical connection may comprise a threaded interface between external threads on the modular vibrating head122and internal threads on the head collar134. A whip fitting138is positioned at least partially within the whip118and provides a fixing point between the head collar134and the whip118. A grommet142within the whip118surrounds a multi-conductor electrical cable146and provides strain relief thereto.

In operation, and with reference toFIGS.6-8, the modular vibrating head122may be selectively removable from the whip118such that another modular vibrating head (which may be of the same or different construction) may be attached to the whip118. Such interchangeability allows a user to change the diameter of the modular vibrating head122and the length of the whip118independently. To interchange the modular vibrating head122for another, the collar134is unscrewed and the head122is pulled from the whip118, disconnecting the capsule126from the whip connector130. Then, a new vibrating head is connected to the whip118using the reverse procedure.

With reference toFIG.9and with continued reference toFIG.6, a first modular vibrating head150and a second modular vibrating head154may be interchangeably connectable to the whip118. The first modular vibrating head150may have a diameter of about 58.42 mm (2.3 inches) and the second modular vibrating head154may have a diameter of about 45.72 mm (1.8 inches). In other embodiments, different vibrating heads may be used which have a diameter between 45.72 mm and 58.42 mm, greater than 58.42 mm, or less than 45.72 mm. In some embodiments, a vibrating head may have a diameter of about 48.26 mm (1.9 inches). In some embodiments, a vibrating head may have a diameter of approximately 40 mm, approximately 50 mm, or approximately 60 mm.

With reference toFIG.10, an embodiment of a portable power unit162includes a frame or backpack166, a battery receptacle unit170, a battery pack174attached to the battery receptacle unit170, a handle178to facilitate hand-carrying the portable power unit162, a motor control unit182, and a motor control unit guard186. The backpack166generally defines a backpack plane and includes straps or other rigging190to allow a user to carry the portable power unit162on the user's back while the portable power unit162is in use or between uses of the portable power unit162. The battery receptacle unit170, which may also be called a power box, includes a battery receptacle194on a front side198of the unit162to which the battery pack174is attachable, with the backpack166being attached to a rear side202of the unit162. The battery pack174may attach to the battery receptacle unit170in a similar manner to how the battery pack22attaches to the battery receptacle unit18as shown in, for example,FIG.1.

With reference toFIGS.10-12, the motor control unit182is selectively attachable to the battery receptacle unit170. The motor control unit182includes a first (rear) side206athat is configured to face the backpack166when the motor control unit182is attached to the battery receptacle unit170and a second (front) side206bopposite the first side206a. The motor control unit182further includes a third (top) side206cextending generally perpendicular to the backpack plane and between the rear side206aand the front side206b. The top side206cis facing the battery receptacle unit170when the motor control unit182is attached thereto. The motor control unit182is surrounded and protected by the motor control unit guard186such that the front side206bis recessed into the guard186. In the illustrated embodiment, the motor control unit guard186is tubular.

With continued reference toFIGS.11and12, the motor control unit182includes a sub-flush electronics connection210. The sub-flush electronics connection210is an interface between a male protrusion214in the form of a rigid connector on the motor control unit182and a female recess218within the battery receptacle unit170. The sub-flush electronics connection210is configured to selectively electrically connect the motor control unit182to the battery receptacle unit170by plugging the male protrusion214into the female recess218on the battery receptacle unit170. The sub-flush electronics connection210protects the electrical connection between the motor control unit182and the battery receptacle unit170. The motor control unit182also includes a control panel222, an on/off switch226, and a first electrical connection230configured to selectively attach a first end of a cable234(shown inFIG.13) to the motor control unit182.

With continued reference toFIGS.11and12, the battery receptacle unit170includes a plurality of first bores, each first bore housing a threaded insert238. In the illustrated embodiment, two threaded inserts238are each housed within a respective first bore on a first side242aof the battery receptacle unit170, and two threaded inserts238are each housed within a respective first bore on a second side242bof the battery receptacle unit170. The motor control unit182includes two protruding ears246a,246b. Each of the two protruding ears246a,246bextends upward from the motor control unit182in a direction toward the battery receptacle unit170. Each of the two protruding ears246a,246bincludes a plurality of second bores250, each second bore250configured to receive a bolt254. Each one of the second bores250is configured to align with a respective one of the threaded inserts238when the motor control unit182is electrically connected to the battery receptacle unit170. In other words, when the male protrusion214is fully received within the female recess218, each second bore250is aligned with a threaded insert238such that a bolt254may be passed into each of the second bores250and threaded into a threaded insert238. When installed, the bolts254are configured to attach and hold the motor control unit182to the battery receptacle unit170.

In operation, and with reference toFIG.13, an operator258may attach the rigging190to a body of the operator258such that the portable power unit162is ergonomically supported by the operator258while the portable power unit162is used to power and control, for example, a high-cycle concrete vibrator66(FIG.4), a high-cycle concrete vibrator114(shown inFIG.6), or another tool.

With reference toFIG.14, an embodiment of a portable power unit310includes a battery receptacle unit314, a battery pack318attached to the battery receptacle unit314, a handle322to facilitate hand-carrying the portable power unit310, and a motor control unit326. The portable power unit310may be similar to the portable power units10,162except as shown or noted and may be configured as a backpack as described herein. The motor control unit326is selectively connectable to the battery receptacle unit314via a two-step connection process that includes a mechanical interface330and an electrical interface334. The mechanical interface330physically attaches the motor control unit326to the battery receptacle unit314. The mechanical interface330may include latches, bolts, screws, or the like. The electrical interface334provides electrical communication between a female connector338and a male socket342. The female connector338is connected to a cable346that electrically connects the female connector338to the battery receptacle unit314. In operation, electrical current flows through the cable346, through the female connector338, across the electrical interface334, through the male socket342, and into the electrical systems of the motor control unit326, thereby powering the motor control unit326and any tools controlled by the motor control unit326.

With reference toFIG.15, a portable power unit410includes a frame or backpack414(FIG.16), a battery receptacle unit418, a battery pack422attached to the battery receptacle unit418, a handle426to facilitate hand-carrying the unit418, and a motor control unit430. The portable power unit410may be similar to the other portable power units described herein, except for certain aspects. For example, the motor control unit430is integrated into the battery receptacle unit418. In other words, the motor control unit430and the battery receptacle unit418share a common contiguous housing420. In other words, the common contiguous housing420may house both power electronics as well as control electronics, which are used for powering and controlling, for example, the vibrating head78. Other than being integrated into the battery receptacle unit418, the motor control unit430may be similar to the other motor control units described herein. For example, the motor control unit430includes a control panel434, an on/off switch438, and a first electrical connection442configured to selectively attach a first end of a cable446(shown inFIGS.16-18) to the motor control unit430. The common contiguous housing420includes bump guards454a,454bon bottom and front edges of the motor control unit430to protect the motor control unit430from contact with other objects (FIGS.16-18). In operation, the power unit410may be used to power a high-cycle concrete vibrator.

The motor control unit430includes a docking port448on a side of the motor control unit430to dock a remote control450. The docking port448may be located, for example, generally below the battery receptacle unit418and, accordingly, generally below the battery pack422when the battery pack422is mounted to the battery receptacle unit418. In other embodiments, the docking port448may be mounted to the battery receptacle unit418or in another location. The remote control450may be mounted to the docking port448in a variety of different manners. For example, the remote control450may be mounted to the docking port448by a clip, such as a spring clip. The spring clip may be attached to the remote control450such that when the user slides the remote control450into the docking position, the spring clip engages the docking port448, and in some embodiments, engages with a recess in the docking port448to frictionally retain the remote control450in the docking position until the user overcomes the frictional force applied by the spring clip to remove the remote control450from the docking port448. The remote control450may be used to communicate with the motor control unit430and prompt the motor control unit430to transmit a motor control signal to a motor such as, for example, one of the motors82,514. In addition to the remote control, the portable power unit410may include a user interface (e.g., the control panel434) on a housing such as the common contiguous housing420, and the user may operate the user interface to prompt the motor control unit430to transmit the motor control signal to the motor. In some embodiments, one or both of the remote control450or the user interface may be operable to prompt the motor control unit430to vary a rotational speed of the motor.

With reference toFIG.19, the portable power unit410, and specifically the motor control unit430, may include a power and/or control PCB458, which may be referred to simply as a power PCB458or as a control PCB458, for controlling a flow of electrical current from the battery pack422to, among other things, a power tool such as the vibrator66(FIG.4). The power PCB458may be positioned below the battery receptacle unit418and, therefore, below the battery pack422when the battery pack422is mounted to the battery receptacle unit418. The portable power unit410, and specifically the motor control unit430, may further include a user interface PCB462located, for example, below the battery receptacle unit418and, therefore, below the battery pack422when the battery pack422is mounted to the battery receptacle unit418. The power PCB458may include electronic switches (e.g., field effect transistors) to commutate a motor such as one of the motors82,514. The power PCB458may include microprocessors for receiving sensor inputs and/or user inputs from the control panel434and/or from the user interface PCB462. In some embodiments, the functions of the power PCB458and the user interface PCB462are combined and performed by, for example, a single PCB. In some embodiments, the functions of the power PCB458and the user interface PCB462are divided and performed by three or more PCBs.

With returning reference toFIGS.15and18, the portable power unit410includes a mode selector switch466that may include, for example, three positions: “on,” “off,” and “remote.” To shut off power to the motor control unit430and/or to shut off power to a power tool such as a high cycle concrete vibrator that is connected to the motor control unit430, the user may toggle the mode selector switch466to the “off” position. To allow the motor control unit430to be controlled by the remote control450, the user may toggle the mode selector switch466to the “remote” position, thereby allowing the remote control450to control whether the motor control unit430is on or off (e.g., whether the motor control unit430is armed) and whether the power tool, such as, for example, the vibrator66(FIG.4), is activated.

With continued reference toFIGS.15and18, to arm the motor control unit430without using the remote control450, the user may toggle the mode selector switch466to an “on” state in which electrical current from the battery pack422is supplied to the power PCB458and/or to the user interface PCB462, thereby waking the power PCB458and/or the user interface PCB462and readying the power PCB458and/or the user interface PCB462to accept an input from the control panel434. Then, using the control panel434, the user could activate a tool such as the vibrator66(FIG.4) by pressing a button on the control panel434to selectively activate the tool or to allow the tool to be selectively activated by actuating another switch. Activating the tool and/or the motor82(FIG.5) may allow the motor82to rotate at a predefined rotational speed coinciding with a pre-set vibrational frequency. In some embodiments, the motor control unit430may be configured such that the user may arm a tool such as the vibrator66and activate the tool such as the vibrator66in a single step (e.g., by pressing a single button on the control panel434or by pressing a single button on the remote control450). In some embodiments, the motor control unit430may be configured such that the user may arm the motor control unit430and activate a tool such as the vibrator66in a single step (e.g., by pressing a single button or actuating a single switch such as the mode selector switch466). In some embodiments, “arming” refers to waking a controller such as a PCB and readying the controller to accept an input. To pair the remote control450with the motor control unit430, the user may press a remote pairing button452(FIG.30) on the control panel434, thereby allowing wireless communication between the remote control450and the motor control unit430. Output of the rotational speed-sensing PCB88(FIG.5; see also the Hall-effect board524ofFIG.22) is transmitted through the whip70(see also the whip534ofFIG.22) to the motor control unit30, which, based on the feedback from the PCB88, may adjust the rotational speed of the motor82as necessary to ensure that the vibration frequency of the vibrator66remains consistent as the vibrating head78is plunged into wet concrete.

With reference toFIG.20, the remote control450is capable of wirelessly transmitting a signal to the power PCB458and/or to the user interface PCB462in response to a user depressing a button on the remote control450such as a power button470. The signal is wirelessly transmitted to the motor control unit430to activate and deactivate a motor such as the motor82in the vibrating head78(FIG.5). In some embodiments, the motor control unit430, and more specifically the power PCB458and/or the user interface PCB462, may include feedback control capable of detecting physical properties of wet concrete in which a vibrating head such as the vibrating head78is submerged and then adjusting the speed of the motor82to optimize a frequency of vibration of the vibrating head78. Such feedback control may be continuously active as long as the motor82remains activated, allowing the frequency of vibration of the vibrating head78to be adjusted contemporaneously with movement of the vibrating head78throughout the wet concrete.

With continued reference toFIG.20, additionally or alternatively, the remote control450is capable of controlling the speed of the motor82with a joystick474on the remote control450. Input from the joystick474may be transmitted wirelessly to the motor control unit430to adjust the speed of the motor82. In some embodiments, the joystick474may be toggled in a first direction (e.g., toward the right from the frame of reference of FIG. to increase the speed of the motor82, and toggling the joystick474in an opposite, second direction (e.g., toward the left from the frame of reference ofFIG.20) may decrease the speed of the motor82. Similarly, the joystick474may be toggled in a vertical direction (i.e., up or down from the frame of reference ofFIG.20) to adjust the motor82between a forward rotational direction and a reverse rotational direction, respectively. Also, in some embodiments, depressing or clicking the joystick474(i.e., into the page from the frame of reference ofFIG.20) may adjust the motor82between a fast-operating mode and a slow-operating mode, with the speed setting in each mode being preselected from the manufacturer or being user-configurable. Additionally or alternatively, the remote control450may utilize a dial potentiometer (not shown) to set or adjust the speed of the motor82. In the illustrated embodiment, the forward/reverse control and speed control of the motor82is integrated using the single joystick474. However, in alternate embodiments, the forward/reverse control and speed control of the motor82may be performed by separate switches or buttons. The remote control450is configured to receive user input and transmit the user input to the power PCB458and/or the user interface PCB462. At least one of the power PCB458or the user interface PCB462may be configured to receive the user input and adjust the operation of the motor based on the user input.

With reference toFIG.21, the portable power unit410and/or a whip such as the whip70and/or a vibrating head such as the vibrating head78may be provided with a work light478to illuminate an area of wet concrete in which the vibrating head78is immersed. The light478may be capable of changing between a spot illumination mode, in which the light generated by the component on which the light478are mounted, which may be the portable power unit410, is cast about a relatively small area, and a flood illumination mode, in which the light generated by the component on which the light478are mounted is cast about a relatively large area. The work light478may also be deactivated if not needed. In the illustrated embodiment, the remote control450includes a light mode selection button482that allows a user to switch between the spot illumination mode, the flood illumination mode, and an “off” mode in which some or all lights are deactivated. In other words, in some embodiments, the work light478may be coupled to one of the portable power unit410or the vibrating head78, and the remote control450may be configured to selectively activate the work light478. The remote control450also includes a brightness control button486that allows a user to adjust the brightness of the work light478between multiple different levels. For example, the brightness control button486may be depressed by a user to sequentially adjust the work light478between two or more brightness levels.

The remote control450may include an onboard rechargeable power source (i.e., a battery, not shown). As such, the remote control450may be charged by connection with a receptacle onboard the portable power unit410or another tool with which the battery pack422is interchangeable. Alternatively, the remote control450may be charged via a USB cable, through an inductive charger, or through another charger with the battery remaining onboard the remote control450. As a further alternative, the remote control450may contain a removable and/or replaceable battery.

With continued reference toFIG.21, the remote control450may communicate with the portable power unit410with a wireless communication protocol, such as Bluetooth Low Energy (“BTLE”), standard Bluetooth, radio frequency communication such as 433 MHz, Wi-Fi, infrared, or standard cellular communication frequencies (2G, 3G, 4G, 5G, or LTE services). The remote control450may include a transmitter490configured to send messages to a receiver494on the portable power unit410. A communications link between the transmitter490of the remote control450and the receiver494of the portable power unit410may be established via a Universal Asynchronous Receiver-Transmitter (“UART”), a Serial Peripheral Interface (“SPI”), or a RS485 communications link. Another communications link that may be used includes a hardware link where a signal generated by one of portable power unit410or remote control450activates a physical switch on the other of the portable power unit410and the remote control450. In other embodiments, the remote control450may be a wired communication device receiving power and communicating through a wired connection with the portable power unit410.

Additionally or alternatively, a signal may be generated by the power PCB458and/or the user interface PCB462of the portable power unit410to indicate the running state (for example, on/off status, direction, and/or speed) of the motor82. This signal may be sent by a transmitter498of the portable power unit410and may be received by a receiver502of the remote control450for communicating the signal to the user via an indicator506on the remote control450. Thus, the indicator506may communicate to a user of the portable power unit410the running state of a concrete vibrator motor such as the motor82(FIG.5). In the illustrated embodiment, the indicator506is an LED configured to illuminate, for example, when the motor82is activated. Alternatively or additionally, the indicator506may provide an audible or tactile signal to the user.

When using the remote control450, a first user carrying the portable power unit410may be responsible for submerging and moving a vibrating head such as, for example, the vibrating head78throughout a region of wet concrete, while a second user may hold the remote control450and be responsible for adjusting the frequency of vibration of the vibrating head78to account for variations in the consistency of the wet concrete, or to adjust the vibrating head78for use with wet concrete in different stages of dryness. In this manner, the user carrying the portable power unit410needs only to concentrate on placement of the vibrating head78within the wet concrete. Alternatively, the same user responsible for submerging and moving the vibrating head78may also hold the remote control450and be responsible for adjusting the frequency of the vibrating head78. This allows a single user to adjust the frequency of vibration of the vibrating head78based on tactile feedback from the vibrating head78due to the consistency of the wet concrete. Additionally or alternatively, a single user can operate the portable power unit410by submerging the vibrating head78in wet concrete and controlling the frequency of vibration of the vibrating head78using the remote control450, all while carrying the portable power unit410with, for example, the rigging190(FIG.13).

With reference toFIG.22, another vibrating head510is shown that may be interchangeable with any of the previously described vibrating heads for use with the portable power unit10,410. For example, the vibrating head510may be used as a high cycle concrete vibrator with the portable power unit410and controlled by the motor control unit430and further may be controllable via instructions transmitted to and/or from the remote control450. The vibrating head510includes an onboard electric motor514that may be a brushless DC motor. The motor514may include a rotor shaft518that is coupled for corotation with an eccentric mass522such that a rotation of the motor514induces a vibration in the vibrating head510, thereby allowing the vibrating head510to function as a concrete vibrator. The vibrating head510may include a rotational speed sensor523, such as a Hall-effect sensor or Hall-effect sensor array located on a Hall-effect circuit board524, for sensing a rotational speed of the rotor shaft518, and therefore a rotational speed of the motor514, and transmitting a signal representing the rotational speed of the rotor shaft518to the motor control unit430. The rotor shaft518is rotatably supported at or near an end of the rotor shaft518by a rotor bearing526. The bearing526may be partially or entirely surrounded and supported by a bearing retainer530.

With continued reference toFIG.22, the vibrating head510is connectable to an electrical cable534, which may be called a whip534, at an electrical connection538. The whip534may transmit electrical current to the motor514and may also transmit control signals. The whip534may include a bundle of wires (not shown) that are electrically connected to a first electrical connector (i.e., a whip electrical connector542) that is mounted to the whip534. The vibrating head510includes a second electrical connector (i.e., a vibrating head electrical connector546) that is selectively electrically connectable to the whip electrical connector542. The whip electrical connector542is electrically connected to the vibrating head electrical connector546when the vibrating head510is connected to the whip534. When the vibrating head510is disconnected from the whip534, the electrical connectors542,546are disconnected. The bearing retainer530supports the vibrating head electrical connector546within the vibrating head510. In some embodiments, the bearing retainer530may function as a stator mount. The bearing retainer530may be positioned within the vibrating head510between the rotor shaft518and the vibrating head electrical connector546. One of the whip electrical connector542or the vibrating head electrical connector546may include a male connector, and the other of the whip electrical connector542or the vibrating head electrical connector546may include a female connector. In some embodiments, each electrical connector542,546may include at least one male and at least one female component. The vibrating head electrical connector546may be positioned such that the circuit board524is supported at an end of the motor514that is proximate the vibrating head electrical connector546. One or more electrical wires (e.g., one wire, a plurality of wires, or a single multi-conductor cable) such as the electrical wire548interconnects the circuit board524and the vibrating head electrical connector546. An output of the sensor523may be transmitted through the electrical wire548to the second electrical connector546. One or more commutation wires549a,549b,549cmay electrically connect the motor514and the vibrating head electrical connector546, and the commutation wires549a,549b,549cmay be routed adjacent to or in a multi-conductor cable with the electrical wire548. In the illustrated embodiment, three commutation wires549a,549b,549care provided.

With reference toFIGS.23and24, the bearing retainer530includes a first wall550defining a first pocket (i.e., a bearing pocket554) and a second wall558opposite from the bearing pocket554and defining a second pocket (i.e., a connector pocket562). The first wall550supports the bearing526(FIG.22), and the second wall558supports the vibrating head electrical connector546. The first wall550and/or the bearing pocket554may be referred to as a rotor bearing retention portion, and the second wall558and/or the connector pocket562may be referred to as a connector retention portion. Inwardly extending protrusions566within the first wall550provide a press-fit connection with an outside diameter of the bearing526. The flange572may include one or more, and in the illustrated embodiment includes four, openings568a,568b,568c,568dthrough which the electrical wire548and/or the commutation wires549a,549b,549cmay be routed to electrically connect the circuit board524and the vibrating head electrical connector546and/or to electrically connect the motor514and the vibrating head electrical connector546. More specifically, the commutation wires549a,549b,549cmay electrically connect windings of the motor514and the vibrating head electrical connector546. In some embodiments, the electrical wire548and the one or more commutation wires549a,549b,549care routed through the same opening568a,568b,568c,568d, and in other embodiments, the electrical wire548and the one or more commutation wires549a,549b,549care routed through different openings568a,568b,568c,568d. Further, the bearing retainer530includes three positioning fingers570a,570b,570cthat rotationally constrain the bearing retainer530within the vibrating head510. The positioning fingers570a,570b,570cmay engage with a housing of the vibrating head510(see, e.g., the housing110ofFIG.5) to support the bearing retainer530within the housing. In other embodiments, more or fewer positioning fingers570a,570b,570cmay be used. The positioning fingers570a,570b,570cmay be equidistantly spaced apart about a flange572and may axially extend from the flange572. The flange572may extend radially outward from the bearing pocket554.

With reference toFIG.25, one of the positioning fingers570amay be shorter than the other of the positioning fingers570b,570c. Further, one of the positioning fingers570a,570b,570c, and in the illustrated embodiment, the positioning finger570a, may include a through hole574(FIG.24). The through hole574may have an axis that is parallel to a rotational axis of the rotor shaft518. Certain positioning fingers570a,570b,570c, and in the illustrated embodiment the positioning fingers570b,570c, may include blind holes578that are parallel or substantially parallel to the axis of the through hole574.

With reference toFIGS.26and27, the bearing retainer530includes a longitudinal axis A1. The longitudinal axis A1may pass through a center of the bearing pocket554, and the longitudinal axis A1may pass through a center of the connector pocket562. In the illustrated embodiment, the longitudinal axis A1passes through both the center of the bearing pocket554as well as the center of the connector pocket562. Further, the longitudinal axis A1may be parallel to and/or collinear with the longitudinal axis of the rotor shaft518when the bearing retainer530is installed within the vibrating head510. In the illustrated embodiment, the second wall558is supported in an axial direction of the longitudinal axis A1away from the flange572by four axial supports582. In other embodiments, the number of axial supports may be zero, one, two, three, five, or another number. In the illustrated embodiment, the bearing retainer530is configured to support the bearing526and the vibrating head electrical connector546in an electrical assembly pertaining to a concrete vibrator. In other embodiments, a bearing retainer such as the illustrated bearing retainer530may be used in an electrical assembly pertaining to other applications involving electric motors of various sizes such as, for example, electric motors in portable power tools such as drills, saws, etc. as well as in stationary electric motors.

With reference toFIG.28, the Hall-effect board524may be fastened to an inside of the vibrating head510by means of fasteners590. The Hall-effect board524may be a rotational speed-sensing PCB524. The Hall-effect board524may include notches588a,588b,588cthat are spaced, and in some embodiments equidistantly spaced, about a periphery of the Hall-effect board524. Each notch588a,588b,588cmay be configured to respectively receive one of the three positioning fingers570a,570b,570c(FIG.25). A temperature sensor such as a thermistor594may be located on the Hall-effect board524. The thermistor594measures an air temperature within the vibrating head510. The thermistor594sends a signal that is representative of the air temperature within the vibrating head510to at least one of the power PCB458and/or the user interface PCB462in the motor control unit430. The power PCB458and/or the user interface PCB462may operate to compare the air temperature as measured by the thermistor594to a desired air temperature or range of air temperatures. Further, the power PCB458and/or the user interface PCB462may correlate the air temperature as measured by the thermistor594to a core or coil temperature of the motor514. In other words, the thermistor594may detect a temperature of the motor514. In some embodiments, a desired core or coil temperature of the motor514may be below 180 degrees Celsius, for example. In other embodiments, for example, a desired core or coil temperature of the motor514may be below 170 degrees Celsius, below 150 degrees Celsius, below 130 degrees Celsius, or below 110 degrees Celsius. Further, a desired core or coil temperature of the motor514may be above, for example, 0 degrees Celsius, −20 degrees Celsius, etc.

With reference toFIG.29, a thermistor598may be located on a part of the cable534or whip534. In some embodiments, a thermistor such as one of the thermistors594,598may be located on the motor. For example, the thermistor598may be located, in some embodiments, on an end of the whip534such as on the whip electrical connector542. The thermistor598may function similarly to the thermistor594to communicate signals that represent an air temperature to the power PCB458and/or the user interface PCB462. The power PCB458and/or the user interface PCB462may evaluate the signal delivered by the thermistor598alone or in combination with the signal from the thermistor594. In other embodiments, more than two thermistors are provided or only a single thermistor is provided. In some embodiments, the thermistors may be positioned at different locations on the vibrating head510and/or on the whip534. In response to the temperature signals from the thermistors594,598, the power PCB458and/or the user interface PCB462may control the motor514to cease or to otherwise alter the operation of the motor514in response to the temperature signals provided by the thermistors594,598. In other words, the power PCB458and/or the user interface PCB462may cause the motor514to shut off if a temperature measured by the thermistor594and/or the thermistor598is outside of a desired temperature range. In some embodiments, the power PCB458and/or the user interface PCB462may cause the motor514to shut off if a temperature measured by the thermistor594and/or the thermistor598is outside of a desired temperature range for a certain (for example, a predetermined) period of time. In another aspect, the portable power unit410may be configured to deactivate the motor514in response to the temperature of the motor514exceeding a threshold temperature and/or in response to the temperature of the motor514being below a threshold temperature.

With continued reference toFIG.29, the whip electrical connector542may include a plurality and, in the illustrated embodiment three, commutation terminals602a,602b,602c, each for receiving a pin on another connector such as, for example, the vibrating head electrical connector546. The commutation terminals602a,602b,602cmay be electrically connected with windings of the motor514by the commutation wires549a,549b,549c. The whip electrical connector542may further include, for example, nine ports606a,606b,606c,606d,606e,606f,606g,606h,606i, each for receiving a pin on another connector. One or more of the ports602a,602b,602c,606a,606b,606c,606d,606e,606f,606g,606h,606imay be configured for transmitting the signals from the thermistors594,598to the power PCB458and/or to the user interface PCB462. In some embodiments, one or more additional ports606jmay be provided on the whip electrical connector542in order to transmit the signals from the thermistors594,598and/or from the sensor523to the power PCB458and/or to the user interface PCB462. In some embodiments, one or more of the ports602a,602b,602c,606a,606b,606c,606d,606e,606f,606g,606h,606imay be used to transmit the signals from the thermistors594,598and/or from the sensor523to the power PCB458and/or to the user interface PCB462. Other pins and ports may be provided on other connectors for a similar purpose.

With reference toFIG.30, the control panel434includes the on/off switch438(FIG.15), the remote pairing button452, a warning light610, and an authentication scanner614. The warning light610may function as a speed warning light610and may illuminate in a fashion determined by the power PCB458and/or the user interface PCB462. For example, the power PCB458and/or the user interface PCB462receives a speed signal from a sensor such as, for example, the Hall-effect board524. The speed signal may represent a rotational speed of the motor514. The speed warning light610may illuminate when the motor514is operating at a rotational speed that is outside of a desired range. For example, the speed warning light610may illuminate when the motor514is operating at a rotational speed of less than, for example, 10,000 RPM. The speed warning light610may illuminate when the motor514is operating at a rotational speed of less than another rotational speed that may be predetermined and/or when the motor514is operating at a rotational speed of greater than another rotational speed that may be predetermined. The warning light610may also function to enable a user to monitor the rotational speed of the motor during various conditions such as, for example, startup during relatively cold conditions. The warning light610may also indicate to the user that the motor514is operating at a temperature outside of a desired temperature range. Therefore, the warning light610may be controlled by the power PCB458and/or the user interface PCB462based at least in part on temperature signals received from the thermistor594and/or the thermistor598. To indicate that the motor514is operating at a temperature that is too hot or too cold, the warning light610may flash.

With continued reference toFIG.30, the authentication scanner614may read an identification device, such as an RFID card, carried by the user. In some embodiments, the portable power unit410may be configured such that the portable power unit410is not operable (or is partially inoperable) until the identification device carried by the user is scanned by the authentication scanner614.

Any of the portable concrete vibrators disclosed herein may be operable with any of the portable power units disclosed herein.

Functions performed by controllers such as printed circuit boards may be performed by controllers of other types and, in some embodiments, may be performed by a single controller or by multiple controllers.