Patent Publication Number: US-2019176727-A1

Title: Portable power source with removable battery pack

Description:
FIELD 
     The present disclosure relates to a portable power source with a removable battery pack and related methods of use. 
     BACKGROUND 
     This section provides background information related to the present disclosure which is not necessarily prior art. 
     Modern vehicles often include one or more electrical control systems that enable the complex functionality of the vehicle. Such electrical control systems can include an engine control system, a transmission control system, a brake control system, a body control system, a suspension control system, a telematics control system, a climate control system, a safety control system and the like. The electrical control systems can be installed into a vehicle during the assembly process. The software, settings, parameters and/or control algorithms associated with the electrical control systems can be programmed into the electrical control systems during the assembly of the vehicle. 
     In order to program the software, settings, parameters and/or control algorithms into the electrical control systems, the electrical control systems need to have a sufficient power source to energize the electrical control systems during the programming process. Disadvantages exist in current systems and methods of providing sufficient power to the electrical control systems during the programming process. In some existing systems and methods, a vehicle&#39;s primary battery is used to program the electrical control systems of the vehicle. In such existing systems and methods, the use of the vehicle&#39;s primary battery is inflexible in that the programming process must be located in the vehicle assembly process after the vehicle&#39;s primary battery is installed. In addition, the vehicle&#39;s primary battery is partially discharged as a result of the programming process. Due to these disadvantages and others, there exists a need to provide a low-cost, reliable, power source to energize the electrical control systems of a vehicle during the assembly process. 
     SUMMARY 
     This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features. 
     In one example in accordance with the present disclosure, a portable power source can be used during the assembly of a vehicle. The example portable power source can include a housing with a docking port and a rechargeable battery pack removably received in the docking port. The rechargeable battery pack can be configured to provide electrical power for programming one or more electrical control systems of the vehicle. The example portable power source can also include a pair of cables connected to the housing and electrically coupled to the rechargeable battery pack. The pair of cables can be configured to removably connect to battery leads of the vehicle. 
     The example portable power source can further include a status indicator mounted on the housing that is configured to indicate an operating condition, a low-level charge condition and a fault condition. The example power source can also include a power source controller located inside the housing and electrically coupled to the rechargeable battery pack, the pair of cables and the status indicator. The power source controller, in one example, is configured to monitor a battery voltage of the rechargeable battery pack and monitor an output current being delivered to the pair of cables. 
     In one example method in accordance with the present disclosure, a method of powering a vehicle on an assembly line for programming one or more electrical control systems of the vehicle is contemplated. The example method may include connecting a portable power source to battery leads of the vehicle to electrically connect the power source to the one or more electrical control systems of the vehicle. The example method also may include determining, by the power source controller, if the battery voltage of the battery pack is greater than a first predetermined voltage threshold and interrupting the electrical connection of the power source to the one or more electrical control systems of the vehicle and causing the status indicator to indicate the low-level charge condition and the fault condition if the battery voltage is not greater than the first predetermined voltage threshold. 
     In another example in accordance with the present disclosure, a portable power source for powering one or more electrical control systems of a vehicle during programming thereof while the vehicle moves through multiple stages of an assembly line is provided. The portable power source comprises a housing sized to fit inside a battery tray of the vehicle. The housing includes a docking port for removably receiving a rechargeable battery pack therein. The power source also includes a pair of cables for electrically coupling the portable power source to battery leads of the vehicle and a switching voltage regulator controller electrically coupled to the pair of cables that is operable to transform battery power to output power for powering the one or more electrical control systems of the vehicle. The power source also includes a power source controller electrically coupled to the docking port and the switching voltage regulator. The power source controller is operable to activate or deactivate the voltage controller in response to sensor signals received from a plurality of battery connection points on the docking port. 
     Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. 
    
    
     
       DRAWINGS 
       The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure. 
         FIG. 1  is an illustration of an example portable power source in accordance with present disclosure; 
         FIG. 2  is a block diagram of the example portable power source of  FIG. 1 ; 
         FIG. 3  is a block diagram of an example power source controller that can be used in the power source of  FIG. 1 ; 
         FIG. 4  is a circuit diagram of an example power source controller that can be used in the power source of  FIG. 1 ; 
         FIG. 5  is a circuit diagram showing example connection circuits that can be used to connect the example power source controller of  FIG. 4  to a battery pack, a battery pack voltage monitor and a battery temperature monitor; 
         FIG. 6  is a circuit diagram showing example circuits that include an example reverse polarity protector, a first regulator and a second regulator that can be used in the power source of  FIG. 1 ; 
         FIG. 7  is a circuit diagram showing an example status indicator that can be used in the power source of  FIG. 1 ; 
         FIG. 8A  is a circuit diagram showing an example regulator activation circuit that can be used in the voltage regulator of the example power source of  FIG. 1 ; 
         FIG. 8B  is a circuit diagram showing an example regulator pairing circuit that can be used in the voltage regulator of the example power source of  FIG. 1 ; 
         FIG. 8C  is a circuit diagram showing an example first regulator circuit that can be used in the voltage regulator of the example power source of  FIG. 1 ; 
         FIG. 8D  is a circuit diagram showing an example second regulator circuit that can be used in the voltage regulator of the example power source of  FIG. 1 ; 
         FIG. 8E  is a circuit diagram showing an example third regulator circuit that can be used in the voltage regulator of the example power source of  FIG. 1 ; 
         FIG. 8F  is a magnified view of the regulator controller used in the example regulator circuits of  FIGS. 8C, 8D and 8E ; 
         FIG. 9  is circuit diagram showing example current sensors and a short circuit and over current protector that can be used in the example power source of  FIG. 1 ; 
         FIG. 10  is circuit diagram showing an example fan connection circuit that can be used in the example power source of  FIG. 1 ; 
         FIG. 11  is a circuit diagram showing an example output reverse polarity protection that can be used in the example power source of  FIG. 1 ; 
         FIG. 12  is circuit diagram showing an example output voltage monitor that can be used in the example power source of  FIG. 1 ; 
         FIG. 13  is a circuit diagram showing a first output circuit and a second output circuit that can be used in the example power source of  FIG. 1 ; 
         FIGS. 14A and 14B  are flow charts illustrating one example method of using the example power source of  FIG. 1 ; and 
         FIG. 15  is another example method of using the example portable power source of  FIG. 1 . 
     
    
    
     Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings. 
     DETAILED DESCRIPTION 
     Example embodiments will now be described more fully with reference to the accompanying drawings. 
     As shown in  FIG. 1 , one example portable power source  30  includes a housing  32 , a battery pack  34 , and a pair of cables  36 . As shown, the power source  30  is portable such that it can be easily carried and transported by a user. In the example shown, the housing  32  is a rectangular enclosure that is used to enclose the various other components and electronic circuitry as will be described. The housing  32  can be sized so that it can be located in a battery tray  44  of a vehicle. As can be appreciated, the battery tray  44  defines a battery compartment and is sized to hold a typical automobile battery  46 . The typical automobile battery  46  is an engine cranking battery in that it can be used to start the engine of the vehicle. The housing  32  has a smaller footprint than the battery  46  so that the power source  30  can reside in the battery tray  44  during the assembly of the vehicle and can be used to energize the electrical control systems of the vehicle before the battery  46  is installed in the vehicle. In other examples of the power source  30 , the housing  32  can have other shapes and sizes so that the power source  30  can be integrated into the vehicle assembly process or into other testing and/or repair processes. 
     As further shown, the housing  32  includes a docking port  38 , a switch  40  and a status indicator  42 . The docking port  38  is connected at a top portion of the housing  32  and includes one or more rails  54  that are configured to receive and retain the battery pack  34  to the housing. The docking port  38  also includes one or more battery connection points  56  or a connection jack that electrically couples the battery pack  34  to the power source  30 . As further described below, the docking port  38  can include multiple battery connection points  56  that correspond to a battery of the battery pack  34  that includes multiple battery terminals. The battery connection points  56  couple to the multiple battery terminals to electrically couple the housing  32  to the battery pack  34 . The docking port  38  also permits the battery pack  34  to be removed from the housing  32  for charging, repair or replacement as desired. 
     In the example shown, the housing  32  includes one docking port  38 . In other examples, the housing  32  can include two or more docking ports  38 . It may be desirable, depending on the application and the electrical requirements thereof, to provide a power source  30  with two or more batteries or battery packs in the battery pack  34 . In still other examples, the docking port  38  can be electrically coupled to the power source using a flexible cable. In such examples, the housing  32  can be separate from the docking port  38  and/or the housing  32  can include connectors that permit the docking port  38  to be removably connected to the housing  32  to customize the power source  30  to the various needs in differing applications. 
     The switch  40  is positioned adjacent to the docking port  38  on a top portion of the housing  32  in the example shown. In other embodiments, the switch  40  can be positioned in other locations but is preferably located in a position that is easily accessible by a user. The switch  40  permits a user to activate the power source  30 . In this example, the switch  40  is a toggle switch. In other examples, other types of switches can be used including push buttons, slide switches, rotary switches and the like. In still other examples, the power source  30  can include a user input interface other than or in addition to a switch. In such other examples, the power source  30  can include a touch screen or a wireless interface that can be used in connection with the activation of the power source  30  or other functionality of the power source  30  as will be described. 
     The status indicator  42 , in the example shown in  FIG. 1 , is a light panel positioned on a top portion of the housing  32 . The status indicator  42 , in this example, includes three LED lights. The status indicator  42  includes a green light, a yellow light and a red light. The status indicator  42  is used to display a condition of the power source  30  and/or a condition of the battery pack  34 . For example and as will be further described below, the status indicator  42  is used to display an operating condition, a low-level charge condition and/or a fault condition. In other examples of the power source  30 , the status indicator  42  can include more or less lights, other types of visual or auditory indicators or other indicators to indicate, to a user, the condition of the power source  30  and/or the condition of the battery pack  34 . In one such alternate example, the status indicator can be a display screen that can display words, symbols or other indicators. The status indicator  42  can also be combined with the switch  40  on a touch screen, for example. 
     In examples of the power source  30  that include more than one battery pack  34 , the status indicator  42  can include additional lights (or other additional indicators). Such additional lights can correspond to the additional battery packs  34 . In one such alternate example, a second battery pack  34  is included in the power source  30 . The status indicator  42 , in such an example, can include a second series of lights. The second series of lights can be used to indicate the operating condition, the low-level charge condition and the fault condition of the second battery pack  34 . 
     The pair of cables  36  or output terminals extend outward from the housing  32 . The pair of cables  36 , in this example, is a pair of electrical wires capable of transmitting the electrical power from the power source  30  to the vehicle. In the example shown, the pair of cables  36  includes a first wire that terminates at a positive connector  50  and a second wire that terminates at a negative connector  52 . As can be appreciated, the positive connector  50  and the negative connector  52  are configured to removably connect to battery leads  48  of the vehicle. In the example shown, the positive connector  50  and the negative connector  52  are alligator-type clip connectors. The positive connector  50  and/or the negative connector  52  can be other types of electrical connectors as well. The positive connector  50  and the negative connector  52  can be used to connect the power source  30  at other locations or to other terminals in order to electrically couple the power source  30  at other locations or to other electrical systems. 
     As previously described, the docking port  38  is configured to receive the battery pack  34 . The battery pack  34  can be a rechargeable lithium-ion battery pack, in one example. One such type of battery pack suitable for use with the power source  30  is a rechargeable battery pack used in cordless power tools or other cordless equipment. For example, a 20 volt, 9.0 Amp-hour power tool battery (or tool battery pack) can be used as the battery pack  34 . In other examples, multiple 20 volt, 9.0 Amp-hour batteries (or battery packs) can be used as the battery pack  34 . In other examples, a different suitable battery (or batteries) can be used as the battery pack  34 . 
     One example battery pack  34  can include at least six battery terminals and the docking port  38  includes at least six corresponding battery connection points  56 . The battery pack  34  can include one or more electrochemical cells. The battery pack  34  can also include one or more internal electrical circuits such as a temperature sensor (e.g. a thermistor) and/or a voltage sensor. The six battery terminals can be used to electrically couple the electrochemical cells, the temperature sensor, the voltage sensor and/or other internal battery circuits to the power source  30  through the battery connection points  56  on the docking port  38 . The battery terminals can also be used to electrically couple the battery pack  34  to the housing  32  and/or to the pair of cables  36 . In other examples, the docking port  38  can include a connection jack with the six battery terminals or a connection jack with more or less than six battery terminals. The battery connection points  56  and/or the connection jack electrically couples the battery pack  34  to the power source  30 . As can be appreciated, if other battery packs  34  are used that have more or less than six battery terminals, the docking port  28  can include a corresponding quantity of battery connection points  56 . 
     As shown in the example of  FIG. 3 , the controller  62  is coupled to the battery pack temperature monitor  60  and the battery pack voltage monitor  64 . As shown, the battery pack temperature monitor  60  and/or the battery pack voltage monitor  64  can optionally be located inside an individual battery (or battery pack)  58  of the battery pack  34 . In other examples, there can be multiple battery pack temperature monitors  60  and/or multiple battery pack voltage monitors  64  located inside each battery (or battery pack)  58  of a plurality of batteries (or a plurality of battery packs)  58   a  through  58   n.    
     During the assembly process of the vehicle, the power source  30  can be used to energize one or more electrical control systems of the vehicle in order to program such electrical control systems. The process of programming the electrical control systems of the vehicle can take 30 minutes or more. It is important that the power source  30  delivers suitable output power to energize the one or more electrical systems of the vehicle during the programming process without interruption. If the output power is interrupted and/or the electrical control systems of the vehicle are de-energized during the programming process, the electrical control systems can be corrupted causing significant delays in the assembly process. 
     In this context, the battery pack  34  of the power source  30  can preferably deliver suitable output power to energize the electrical control systems of the vehicle without interruption during the entire programming process. In another example, the battery pack  34  of the power source  30  can deliver suitable output power to energize the electrical control systems of two vehicles without the need for recharging the battery pack  34 . In still another example, the power source  30  includes two or more rechargeable tool battery packs that can permit the power source  30  to be used on a vehicle assembly line for an entire shift without the need for recharging the battery pack  34 . As can be appreciated, it can be desirable to provide output power for multiple vehicle programming cycles to multiple vehicles during the assembly process using a single battery pack  34  without the need to recharge the battery pack  34  after each vehicle programming cycle. 
     In one example of the power source  30 , the battery pack  34  has a sufficient capacity to deliver 12 volts at 7 Amps for at least 30 minutes. In another example, the battery pack  34  has sufficient capacity to deliver 12 volts at 7 Amps for at least 60 minutes. In still another example, the battery pack  34  has a sufficient capacity to deliver 12 volts at 7 Amps for at least 8 hours. In other examples, the battery pack  34  can have other capacities in order to deliver suitable output power as may be needed. 
     Referring now to  FIG. 2 , an example power source  30  is illustrated. As shown, the example power source  30  includes the removable battery pack  34 , the switch  40  and the status indicator  42  mounted to the housing  32 . The other components, as shown in  FIG. 2 , can be positioned inside the housing  32 . As can be appreciated, one or more of the components shown inside the housing  32  can be mounted on the housing  32  or the housing  32  can be separated into one or more separate modular housings (not shown) that can be electrically coupled to one another to deliver the same or similar functionality as described. 
     As shown, the battery pack  34  is coupled to the voltage regulator  72 . The voltage regulator  72  transforms and regulates the output power from the removable battery pack  34  into the output power needed to energize the output  84 . In one example, the output  84  is the one or more electrical control systems of the vehicle. The voltage regulator  72  can be any suitable power regulator. In one example, as further shown in  FIGS. 8A-F , a 12 volt buck-boost switching voltage regulator controller or buck-boost converter circuit is used. The 12 volt buck-boost voltage regulator, in the example shown, is connected to the controller  62  using the regulator activation circuit  92 . The voltage regulator  72  can include one or more synchronous converter circuits. In the example shown, the voltage regulator  72  includes the first regulator circuit  96  ( FIG. 8C ), the second regulator circuit  98  ( FIG. 8D ) and the third regulator circuit  100  ( FIG. 8E ). The first regulator circuit  96 , the second regulator circuit  98  and the third regulator circuit  100  can be coupled in parallel to one another using the oscillator circuit  94  ( FIG. 8B ). The voltage regulator  72  is configured in this manner to deliver output power with a current in the range of 5-30 Amps. 
     In the example shown, the first regulator circuit  96 , the second regulator circuit  98  and/or the third regulator circuit  100  can be coupled to the oscillator circuit  94  for phase-locked operation. In such a configuration, the first regulator circuit  96  and the second regulator circuit  98  can deliver power signals with differing phase angles (e.g. 180 degrees out of phase from each other) for phase-locked operation. The third regulator circuit  100  can also be similarly coupled to the oscillator circuit  94  for phase-locked operation as well. In other examples, the first regulator circuit  96 , the second regulator circuit  98  and/or the third regulator circuit  100  can use an internal clock to operate in a phase-locked manner. 
     The voltage regulator  72 , in the example shown, uses a high efficiency, synchronous 4-switch buck boost controller such as model number LTC3789 manufactured by Linear Technology of Milpitas, Calif. (as shown in  FIG. 8F ). In other examples, other suitable regulator controllers can be used. 
     The reverse polarity protector  70  and the switch  40  are connected between the voltage regulator  72  and the battery pack  34 . The switch  40  electrically connects and disconnects the battery pack  34  from the voltage regulator  72 . As previously discussed, any suitable toggle, push button or rotary switch can be used. The reverse polarity protector  70  protects the components of the power source  30  from a circumstance in which the battery pack  34  (or other energy source) is coupled to the power source  30  with the polarity reversed. A diode or other reverse polarity protection circuit can be used for this purpose. 
     One example reverse polarity protector circuit is shown in  FIG. 7 . As shown, this example reverse polarity protector  70  includes a 200 volt, 8 Amp surface mount diode array. 
     Referring back to  FIG. 2 , a first regulator  66  and a second regulator  68  are connected between the reverse polarity protector  70  and a controller  62 . The first regulator  66  and the second regulator  68  are also electrically coupled to the battery pack  34  and can supply a regulated power source to the controller  62  and/or to the cooling fan  78 . In one example (as shown in  FIG. 6 ), the first regulator  66  is a suitable 10 volt regulator such as a wide temperature three-pin adjustable regulator (e.g., model no. LM317EMPX manufactured by Texas Instruments of Dallas, Tex.) and the second regulator  68  is a suitable 5 volt regulator such as a low dropout regulator (e.g., model no. MCP1804 manufactured by Microchip Technology Inc. of Chandler, Ariz.). In other examples, other types or other regulators with different regulated outputs can also be used. In addition, the first regulator  66  and the second regulator  68  can be combined into a single regulator or more than two regulators can be used. 
     The controller  62  receives power from the first regulator  66  and/or the second regulator  68  and can interact with the other components of the power source  30  to deliver the functionality as will be described. In one example shown in  FIGS. 2 and 3 , the controller  62  is a suitable micro-controller. The micro-controller can include one or more processors  88  coupled to non-transitory memory  86 . The non-transitory memory  86  can have instructions stored thereon to carry out the functionality described below. In other examples, the controller  62  can be a combination of circuits, hardware and/or software such as an application specific integrated circuit or a system on a chip. One example of the controller  62  is shown in  FIG. 4 . In the example shown, the controller  62  is a Flash-based, 8-bit, CMOS microcontroller such as model number PIC16F887T-I/PT manufactured by Microchip Technology Inc. of Chandler, Ariz. 
     Referring back to  FIG. 2 , the controller  62 , as shown in this example, is coupled to the voltage regulator  72 , a battery pack temperature monitor  60 , a battery pack voltage monitor  64 , a cooling fan  78 , a current sensor  74 , a short circuit and over current protector  76 , an output voltage monitor  82  and the status indicator  42 . The controller  62  can send and receive control signals (as indicated in the dashed lines) from these elements in order to carry out the methods and functionality as described below. 
     The battery pack temperature monitor  60  and the battery pack voltage monitor  64  are coupled to the controller  62  and to the battery pack  34 . The battery pack temperature monitor  60  can be any suitable temperature sensor such as a thermocouple, thermistor or the like. As shown in  FIG. 2 , the battery pack temperature monitor  60  (or elements thereof) can be included in the housing  32 . As shown in  FIG. 5  and as previously described, a battery temperature sensor (e.g., a thermistor) can be located inside the battery pack  34  and connected via the circuit shown in  FIG. 5  to the controller  62 . 
     The battery pack temperature monitor  60  can send a signal to the controller  62  and the controller  62 , in turn, can determine a temperature of the battery pack  34  during operation of the power source  30 . The controller  62  can then take further actions (e.g., interrupt the connection of the battery pack  34  to the output  84  by moving a switch in the voltage regulator  72  from an on state to an off state) if the signal from the battery pack temperature monitor  60  indicates that the battery pack  34  is above a predetermined temperature threshold. The controller  62  can interrupt the connection of the battery pack  34  from the output  84  to prevent the battery pack  34  from being damaged. 
     The battery pack voltage monitor  64  can be any suitable voltage sensor and/or related circuitry. The battery pack voltage monitor  64  (or elements thereof) can be located in the housing  32  or located in the battery pack  34 . In one example, the battery pack voltage sensor is located inside the battery pack  34 . The battery pack voltage sensor is then connected to the controller  62  using the circuit shown in  FIG. 5 . 
     In the example battery pack  34  that includes six battery terminals, the battery pack  34  can be connected to the controller using the battery connector  110  shown in  FIG. 5 . The battery connector  110  can connect the internal circuits such as a battery temperature sensor and a battery voltage sensor that are located inside the battery pack  34  to the controller  62 . 
     The battery pack voltage monitor  64  can send a signal to the controller  62  that indicates a battery voltage level of the battery pack  34 . The controller  62  can receive such signals from the battery pack voltage monitor  64  during operation of the power source  30 . As will be further described below, the controller  62  can determine, after receiving the signal(s) from the battery pack voltage monitor  64 , whether subsequent actions need to be taken or if the voltage level of the battery pack  34  is at or above one or more predetermined voltage thresholds such that the connection of the battery pack  34  to the output  84  should be disconnected and/or whether the power source  30  should indicate a change in condition of the voltage level of the battery pack  34  via the status indicator  42  to the user. 
     As shown in  FIG. 2 , the controller  62  is also coupled to the cooling fan  78 . The controller  62  can send a control signal to the cooling fan  78  in order to energize or de-energize the cooling fan  78 . In one example, the controller  62  can be connected to the cooling fan using the fan connection circuit  102  shown in  FIG. 10 . In one example, the controller  62  instructs the cooling fan  78  to turn on when the power source  30  is in operation. In other examples, the controller  62  can determine when one or more of the components is at an elevated temperature and then signal the cooling fan  78  to turn on when the elevated temperature is reached. Similarly, the controller  62  can signal the cooling fan  78  to turn off when a component is no longer at or above the elevated temperature. 
     The short circuit and over current protector  76 , in the example shown, is connected between the current sensor  74  and the controller  62 . The short circuit and over current protector  76  prevents damaging current levels at the output  84 . Any suitable short circuit and/or over current protector can be used. An example short circuit and over current protector  76  is shown in  FIG. 9  and its operation is further described below. 
     Referring back to  FIG. 2 , the output voltage monitor  82  is connected between the output  84  and the controller  62 . The output voltage monitor  82  can send a signal to the controller  62  that the controller  62  can be used to determine the voltage of the output power being delivered by the power source  30 . The output voltage monitor  82  differs from the battery pack voltage monitor  64  in that the output voltage monitor  82  assists the controller  62  in monitoring the voltage level of the output power being delivered by the power source  30  while the battery pack voltage monitor  64  assists the controller  62  in monitoring the voltage level of the battery pack  34 . Since the energy of the battery pack  34  is being transformed and/or regulated by the voltage regulator  72  before being delivered to the output  84 , the voltage level of the battery pack  34  is different from the voltage level of the output power being delivered to the output  84 . The output voltage monitor  82  can include any suitable voltage sensor. In one example, the output voltage monitor  82  can include the circuit shown in  FIG. 12 . 
     In addition to monitoring the voltage level of the output power, the controller  62  can determine a current level of the output power being delivered to the output  84 . The current sensor  74  is coupled to the controller  62  and is positioned in series between the voltage regulator  72  and the output  84 . One example includes a first current sensor  74   a  and a second current sensor  74   b  coupled to the current sensor as shown in  FIG. 9 . The current sensors  74   a,b  can send a signal (or signals) to the controller  62  that the controller  62  can use to determine the current level of the output power being delivered to the output  84 . 
     The controller  62  can compare the current level to one or more predetermined current thresholds and take action as desired. In one example, the controller  62  can compare the current level to a predetermined current threshold and if the current level is greater than the predetermined current threshold, the controller  62  can interrupt the circuit between the battery pack  34  and the output  84 . It may be desirable to take such action to prevent damage from occurring to the battery pack  34  or to other components of the power source  30 . 
     While not shown in  FIG. 2 , the power source  30  can include other components to provide further flexibility and/or further functionality. As previously described, the power source  30 , in another example, can include one or more wireless transceivers that can couple the power source to a wireless communication protocol. Such examples can permit the power source  30  to be coupled (wirelessly or otherwise) to the internet, to one or more remote servers or to other mobile computing devices. Such a transceiver can permit the power source  30  to transmit or receive data regarding the operation of the power source  30  and/or the output  84 . 
     In still another example, the power source  30  can include one or more input connectors such as a USB, Mini-USB or Micro-USB port. Such an input connector can permit a user to couple an external storage device and/or an external computing device to the power source  30 . In this manner, the controller  62  can be reconfigured, reprogrammed or a user can download data regarding the operation of the power source  30 . In still other examples, other communication, connectors and interfaces can be included in power source  30  to further permit the power source  30  to interact with external computing device or to be reconfigured, reprogrammed, updated or maintained as desired. 
     Referring now to  FIGS. 14A and 14B , one example method of using the power source  30  is shown. In the example, a method  200  of powering a vehicle during an assembly process of the vehicle is shown. By using the example method  200 , a user can power the vehicle in order that one or more electrical control systems of the vehicle can be programmed. 
     As shown, the example method  200  begins at step  202 . At  202 , a fully-charged battery pack  34  is installed into the docking port  38  of the power source  30 . While not shown, the battery pack  34  can be charged using a suitable charger. In an embodiment in which the battery pack  34  is a rechargeable power tool battery pack, a stand-alone battery charger can be used to charge the battery pack. In this manner, a user can be charging one or more battery packs  34  so that a fully-charged battery pack  34  is always available for use. As can be appreciated, this can be particularly advantageous in the context of vehicle assembly so that the power source  30  can continuously be used on the assembly line without interruption by swapping depleted battery packs  34  with fully-charged battery packs  34 . 
     At step  204 , the pair of cable  36  is connected to the battery leads  48  of the vehicle that needs to be powered for programming. In the context of a vehicle assembly process, the housing  32  of the power source  30  can be placed into the battery tray  44  of the vehicle. Since the vehicle&#39;s automotive battery has not been installed at this stage of vehicle assembly, the battery tray  44  is empty. The housing  32  can be placed in the battery tray  44  and the pair of cables  36  can be connected to the battery leads  48  of the vehicle using, for example, the positive connector  50  and the negative connector  52 . In other examples and in other contexts, the power source  30  can be positioned elsewhere in the vehicle and can be coupled to the vehicle&#39;s electrical control systems using alternate connectors. 
     At step  206 , a user moves the switch  40  to the “ON” position. In this manner the user initiates the power source  30 . In other examples, the user can initiate the power source  30  using a different input device and/or can initiate the power source  30  remotely if the power source  30  is connected (wirelessly or otherwise) to other computing devices. 
     Once the power source  30  is initiated, the battery pack  34  provides power to the controller  62  and to the various sensors, monitors and other components of the power source  30  using the first regulator  66  and/or the second regulator  68 . At step  208 , the controller  62  determines if the battery voltage is greater than a first predetermined voltage threshold (e.g., Level  1 , as shown in  FIG. 14A ). The controller  62 , in the example power source  30  shown in  FIG. 2 , receives a signal from the battery pack voltage monitor  64 . Using this signal, the controller  62  is able to determine the battery voltage of the battery pack  34  and can then compare this battery voltage to the first predetermined voltage threshold. 
     The first predetermined voltage threshold is a voltage threshold of the battery pack  34  that ensures that the power source  30  can deliver output power to the vehicle&#39;s electrical control systems for a sufficient period of time to fully program the electrical control system(s). As stated above, it is undesirable to interrupt the output power to the vehicle&#39;s electrical control system(s) during programming. In one example vehicle, the programming of the vehicle&#39;s electrical control systems lasts for approximately 30 minutes. If the power source  30  is used to power this vehicle&#39;s electrical control systems during programming, the first predetermined threshold ensures that the power source  30  can deliver the output power for at least 30 minutes. In an example power source  30  using a 20 volt, 9 Amp-hour power tool battery or tool battery pack, the first predetermined voltage threshold can be 19 volts. In other examples, the first predetermined voltage threshold can be other values. 
     If the controller  62  determines that the battery voltage is greater than the first predetermined threshold, the method  200  continues to step  210 . If the controller  62  determines that the battery voltage is not greater than the first predetermined threshold, the controller  62  turns on the red LED light and the yellow LED light on the status indicator  42 . The red LED light is an indication of a fault condition of the power source  30 . The yellow LED light is an indication of a low-level charge condition of the battery pack  34 . The controller  62  indicates the fault condition and the low-level charge condition because the power source  30  should not be used with the current battery pack  34  if the battery voltage is not greater than the first predetermined voltage threshold. This would indicate that the battery pack  34  does not have a sufficient capacity to provide output power to the vehicle&#39;s electrical control systems for a complete programming cycle. 
     After indicating the fault condition and the low-level charge condition (i.e., the red LED light and the yellow LED light), a user moves the switch  40  to the “OFF” position. Since the red LED light and the yellow LED light are illuminated on the status indicator  42 , a user would know that the battery pack  34  does not have a sufficient capacity. At step  216 , the battery pack  34  is removed from the docking port  38  and can be re-charged or an alternate battery pack  34  can be used to re-start the method  200  at step  202 . 
     Referring back to step  208 , the method  200  continues if the controller  62  determines that the battery voltage is greater than the first predetermined voltage threshold. At step  210 , the controller  62  activates (i.e., turns on) the voltage regulator  72 . The voltage regulator  72  receives the input signal from the battery pack  34  and transforms the battery pack signal to the output power that is suitable to power the electrical control systems of the vehicle. At this step, the vehicle&#39;s electrical control system(s) begin to draw power from the battery pack  34 . 
     At step  218 , the controller  62  determines if the output current of the output power flowing to the vehicle&#39;s electrical control system(s) is greater than a predetermined current threshold. In the example power source  30  of  FIG. 2 , the current sensor  74  sends a signal to the controller  62 . The controller  62  uses this signal to determine the output current of the output power flowing to the vehicle&#39;s electrical control systems. If the controller  62  determines that the output current is not greater than the predetermined current threshold, the method  200  continues at step  220 . 
     If the controller  62  determines that the output current is greater than the predetermined current threshold, the controller  62  deactivates (turns off) the voltage regulator  72  at step  222 . At step  224 , the controller  62  further turns on the red LED light (or otherwise indicates the fault condition). As this stage of the method  200 , the user would know that a fault has occurred given the fault condition indicated on the status indicator  42  and would move the switch to the “OFF” position (step  226 ) and identify and correct the fault (step  228 ) before attempting to restart the power source  30  at step  206  as shown. 
     The foregoing determination of the output current by the controller  62  can identify when a short circuit may be present. For example, there may be short circuit in the vehicle&#39;s electrical control system(s), between the pair of cables  36  and/or between the battery leads  48 . The controller  62  can determine if such a short circuit condition exists and turn off the power source  30  before it or the vehicle&#39;s electrical controls system(s) is damaged. In one example the predetermined current threshold is 30 Amps. In other examples, the predetermined current threshold can be more than or less than 30 Amps. 
     When the vehicle&#39;s electrical control system(s) begins to draw power from the battery pack  34 , there can be an initial in-rush of current that can cause a spike in the output current of the power source  30 . For this reason, the example method can include a time delay between the time that the controller  62  determines if the output current is greater than the predetermined current threshold and when the controller  62  deactivates the voltage regulator  72  at step  222 . In the example shown, the method  200  includes a two second delay. In other examples, the time delay can be more than or less than a two second delay. The controller  62  includes a timer that can cause the time delay between actions in the method  200 . 
     At step  220 , the controller  62  determines if the battery voltage is greater than a second predetermined voltage threshold. The controller  62  can determine if the battery voltage is greater than the second predetermined threshold in a manner similar to that previously described at step  208 . For example, the battery pack voltage monitor  64  can send a signal to the controller  62  that the controller  62  uses to determine the battery voltage and then compares the battery voltage to the second predetermined voltage threshold. 
     If the controller  62  determines that the battery voltage is greater than the second predetermined voltage threshold, the method  200  continues at step  230 . If the controller  62  determines that the battery voltage is not greater than the second predetermined threshold, the method  200  proceeds to step  222 . The method continues at step  222  and a fault is corrected before the method  200  is restarted at step  206 . 
     The controller  62  determines if the battery voltage is greater than the second predetermined voltage threshold to ensure that the battery voltage does not fall below a cut-off level. If the battery charge falls below the cut-off level, the battery pack  34  can be permanently damaged. In an example battery pack  34  that uses a 20 volt, 9 Amp-hour power tool battery pack, the second predetermined voltage threshold (i.e., the cut-off level of the battery pack) can be 15 volts. In other examples, the second predetermined voltage threshold can be more than or less than 15 volts. 
     At step  230 , the controller  62  determines if a battery temperature of the battery pack  34  is greater than a predetermined temperature threshold. The controller  62  can, for example, receive a signal from the battery pack temperature monitor  60 . The controller  62  uses this signal to determine the temperature of the battery pack  34 . The controller  62  then compares the temperature of the battery pack  34  to the predetermined temperature threshold. If the controller  62  determines that the temperature of the battery pack  34  is not greater than the predetermined temperature threshold, the method  200  continues at step  232 . 
     If the controller  62  determines that the temperature of the battery pack  34  is greater than the predetermined temperature threshold, the controller  62  takes the same steps as previously described at step  222  (and the subsequent steps  224  and  226 ). Since a fault condition is indicated on the status indicator  42  by the controller  62  at step  224 , the user would identify and correct the fault at step  228  before attempting to restart the method  200  at step  206 . 
     The controller  62  determines if the temperature of the battery pack  34  is greater than the predetermined temperature threshold in order to prevent damage from occurring to the battery pack  34 . For example, if the battery pack  34  experiences a significant amount of current draw for an extended period of time, the battery pack  34  can begin to heat up. If the battery pack  34  heats to temperatures above the predetermined temperature threshold, the battery pack  34  can be permanently damaged. In addition, the battery pack  34  could damage the docking port  38  and/or other components of the power source  30 . 
     While not shown in  FIGS. 14A and 14B , the controller  62  can energize the cooling fan  78  in response to determining that the temperature of the battery pack  34  is greater than a predetermined cooling threshold. The controller  62  can determine, in response to the signal received from the battery pack temperature monitor  60 , that the battery pack is at an elevated temperature but has not yet reached the predetermined temperature threshold. In such an instance, the controller can energize the cooling fan  78  that can move air through the housing to cool the components of the power source  30  and/or the battery pack  34 . 
     At step  232 , the controller  62  determines if the battery voltage is greater than a third predetermined voltage threshold. The controller  62  can determine the battery voltage by interacting with the battery voltage monitor  64  as previously described. If the controller determines that the battery voltage is greater than the third predetermined voltage threshold, the method  200  continues at step  234 . 
     If the controller  62  determines that the battery voltage is not greater than the third predetermined voltage threshold, the method  200  proceeds to step  236 . At step  236 , the controller  62  turns on the yellow LED light (i.e., the low-level charge condition indicator) on the status indicator  42 . The controller  62  can additionally latch the yellow LED light. The controller  62  can latch the yellow LED light in an illuminated condition so that the light will stay illuminated until the user takes appropriate action to address the low-level charge condition. 
     The third predetermined voltage threshold corresponds to the low-level charge condition of the battery pack  34 . When the battery pack  34  does not have a voltage level above the third predetermined threshold, the battery pack  34  is nearing its end of life and does not have sufficient capacity to provide suitable output power for the programming of another vehicle&#39;s electrical control system(s). While the battery pack  34  may have sufficient capacity to complete the programming of the vehicle&#39;s electrical control system that is underway, the battery pack  34  should not be used for the programming of another vehicle without recharging. For this reason, the controller  62  indicates the low-level charge condition on the status indicator  42  by illuminating the yellow LED light in this example. This indicates to the user that the user should remove the battery pack  34  from the docking port and recharge the battery pack  34  when the reprogramming process that is currently underway is complete. In an example battery pack  34  that is a 20 volt, 9 Amp-hour power tool battery pack, the third predetermined voltage threshold can be 18 volts. In other examples, the third predetermined voltage threshold can be values greater than or less than 18 volts. 
     At step  234 , the controller  62  turns on the green LED light on the status indicator  42 . The green LED light, in this example, indicates the operating condition of the power source  30 . In the operating condition, the output current is not greater than the predetermined current threshold, the battery voltage is greater than the first predetermined threshold, the battery voltage is greater than the second predetermined threshold, the battery temperature is not greater than the predetermined temperature threshold and the battery voltage is greater than the third predetermined voltage threshold. In the operating condition, the power source  30  is able to provide suitable output power to the output  84  (i.e., the one or more vehicle electrical control systems) without the risks of damage to the battery pack  34 , the power source  30  and/or the vehicle&#39;s electrical control system(s). 
     At step  240 , the controller  62  determines whether the vehicle assembly/programming process is complete. Alternatively, an operator may monitor the programming process to determine if the programming process is complete. If the programming process of the vehicle&#39;s electrical control system(s) is not complete, the method  200  returns to step  218  and the output current, the battery voltage of the battery pack  34  and the battery temperature of the battery pack  34  are monitored and compared against the predetermined current, temperature and voltage thresholds as previously described. 
     If the vehicle assembly/programming process is complete, the method  200  continues to step  242 . At step  242 , a user moves the switch  40  to the off position. The user can then disconnect the pair of cables  36  from the battery leads  48  at step  244  and the method  200  ends. While not shown, the user can then move the power source  30  to another vehicle and then restart the method  200  to program a second vehicle. If the controller  62  determined that battery voltage was not greater than the third predetermined voltage threshold, the status indicator  42  would be indicating the low-level charge condition at the conclusion of the programming process. If this occurred, the user could replace the battery pack  34  with a fully-charged battery pack before using the power source  30  to restart the method  200  with the second vehicle. The user could also re-charge the battery pack  34  that exhibited the low-level charge condition. 
     Referring now to  FIG. 15 , another example method  300  is shown. The example method  300  is similar to the example method  200 . The method  300  starts at step  302 . At step  302 , the power source  30  is connected to the vehicle. The power source  30  can be connected to the vehicle using any suitable connector or method and, in the example power source  30  of  FIG. 2 , is connected to the vehicle using the pair of cables  36 . 
     At step  304 , the controller  62  determines if the battery voltage is greater than the first predetermined voltage threshold. The controller  62  determines the battery voltage as previously described and then compares the battery voltage to the first predetermined voltage threshold. If the battery voltage is greater than the first predetermined voltage threshold, the method  300  continues at step  306 . If not, the controller  62  interrupts the connection of the battery pack  34  to the vehicle and indicates the low-level charge condition and fault condition on the status indicator  42 . The controller  62  can interrupt the connection of the battery pack  34  to the vehicle by instructing the voltage regulator  72  not to provide output power to the vehicle and/or by opening the circuit between the battery pack  34  and the vehicle. The user then takes appropriate action to correct the fault condition before the method  300  is restarted at step  304 . 
     At step  306 , the controller  62  supplies electrical power to the vehicle. The controller  62 , in one example, can instruct the voltage regulator  72  to begin providing electrical power to the vehicle and/or close the circuit between the battery pack  34  and the vehicle. After this occurs, the controller  62 , at step  310 , determines if the battery voltage is greater than the second predetermined voltage threshold. The controller  62  can make this determination as previously described. If the battery voltage of the battery pack  34  is greater than the second predetermined voltage threshold, the method  300  continues to step  312 . If not, the controller  62  interrupts the electrical connection to the vehicle and indicates the fault condition on the status indicator  42 . The user then takes appropriate action to correct the fault condition before the method  300  is restarted at step  304 . 
     At step  312 , the controller  62  determines if the battery voltage is greater than the third predetermined voltage threshold. If the battery voltage is greater than the third predetermined voltage threshold, the method continues at step  316 . If not, the controller  62  causes the low-level charge condition to be indicated on the status indicator  42  and the method  300  continues at step  306 . 
     At step  316 , the method  300  returns to step  306  if the process of programming the one or more electrical control systems of the vehicle is not complete. The controller  62  in combination with the monitors, sensors and other components of the power source  30  continue to compare the battery voltage to the predetermined voltage thresholds until the programming process is complete. Once the programming process is complete, the power source  30  can be disconnected from the vehicle at step  320  and the method  300  ends. 
     The foregoing example power source  30  and the related methods of use can be used to program one or more electrical control systems of a vehicle in an assembly environment. The power source  30  can be used to reliably program a vehicle&#39;s electrical control systems without the need for complex, cost-intensive equipment that is incorporated into existing conveyors or other vehicle assembly plant equipment. As can be appreciated, the power source  30  can also be used in other environments in which a reliable, portable power source is needed to power vehicles. Still further, the example power sources and related methods can also be used to power other equipment or other machines that may need temporary reliable power for repair, assembly or maintenance. 
     The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure. 
     Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail. 
     The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed. 
     When an element or layer is referred to as being “on,” “engaged to,” “connected to,” or “coupled to” another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. 
     Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments. 
     Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature&#39;s relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly. 
     In this application, including the definitions below, the term “module” or the term “controller” may be replaced with the term “circuit.” The term “controller” may refer to, be part of, or include: an Application Specific Integrated Circuit (ASIC); a digital, analog, or mixed analog/digital discrete circuit; a digital, analog, or mixed analog/digital integrated circuit; a combinational logic circuit; a field programmable gate array (FPGA); a processor circuit (shared, dedicated, or group) that executes code; a memory circuit (shared, dedicated, or group) that stores code executed by the processor circuit; other suitable hardware components that provide the described functionality; or a combination of some or all of the above, such as in a system-on-chip. 
     The controller may include one or more interface circuits. In some examples, the interface circuits may include wired or wireless interfaces that are connected to a local area network (LAN), the Internet, a wide area network (WAN), or combinations thereof. The functionality of any given controller of the present disclosure may be distributed among multiple controllers that are connected via interface circuits. For example, multiple controllers may allow load balancing. In a further example, a server (also known as remote, or cloud) module may accomplish some functionality on behalf of a client controller.