Patent Description:
The present invention relates to a concrete vibrator system.

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.

<CIT> discloses a concrete vibrator system.

The disclosure provides, in one aspect not covered by the present invention, 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 disclosure provides, in another aspect not covered by the present invention, 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 disclosure provides, in another aspect not covered by the present invention, 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 disclosure provides, in another aspect not covered by the present invention, 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.

The present invention provides, according to claim <NUM>, a concrete vibrator system.

The portable power unit includes a battery receptacle unit to which the battery pack is removably coupled and a motor control unit configured to transmit the motor control signal to the motor.

The motor control unit may be removable from the battery receptacle unit.

The motor control unit may be coupled to the battery receptacle unit via a plurality of latches.

Each latch may include at least one hook and at least one projection, and wherein the at least one hook may be on the battery receptacle unit and the at least one projection may be on the motor control unit.

The motor control unit may include a first electrical connection configured to selectively electrically couple the cable to the motor control unit.

The motor control unit may include a second electrical connection configured to selectively electrically couple the motor control unit to the battery receptacle unit.

The motor control unit may be coupled to the battery receptacle unit via a sub-flush electronics connection.

The sub-flush electronics connection may be an interface between a male protrusion on the motor control unit and a female recess within the battery receptacle unit.

A plurality of bolts may attach the motor control unit to the battery receptacle unit.

The battery receptacle unit may include a plurality of first bores and a plurality of threaded inserts respectively provided within the plurality of first bores, and wherein each of the plurality of bolts threads into one of the plurality of threaded inserts.

The motor control unit may include at least one protruding ear, and wherein the at least one protruding ear may include at least one second bore.

At least one of the plurality of bolts may pass through the at least one second bore.

The battery receptacle unit and the motor control unit are integrated in a common housing.

The system may further comprise a remote control configured to communicate with the motor control unit and prompt the motor control unit to transmit the motor control signal to the motor.

In addition to the remote control, the portable power unit may include a user interface on the housing with which a user may prompt the motor control unit to transmit the motor control signal to the motor.

Both the remote control and the user interface may be operable to prompt the motor control unit to vary a rotational speed of the motor.

The system may further comprise a work light coupled to one of the portable power unit or the vibrating head, wherein the remote control may be configured to selectively activate the work light.

The system may further comprise a backpack to which the portable power unit may be attached to facilitate transport of the portable power unit while the vibrating head is in use.

The vibrating head may be a first vibrating head, and wherein the first vibrating head may be detachable from the portable power unit and replaceable with a second vibrating head.

The first vibrating head may have a first diameter and the second vibrating head has a second diameter, and wherein the first diameter may be different from the second diameter.

The system may further comprise a temperature sensor configured to detect a temperature of the motor.

The temperature sensor may be located on one of the motor or the cable.

The portable power unit may be configured to deactivate the motor in response to the temperature of the motor exceeding a threshold temperature.

The battery pack may have a nominal voltage of up to about <NUM> V.

The present disclosure provides, in another aspect not covered by the present invention, a power tool assembly comprising:.

The power tool may include an eccentric mass rotated by the motor to vibrate the housing.

The first pocket may be located on a first side of the bearing retainer, and wherein the second pocket may be located on an opposite, second side of the bearing retainer such that the bearing retainer may be located between the motor and the second electrical connector.

The bearing retainer may include a flange extending radially outward from the first pocket and a plurality of positioning fingers axially extending from the flange and equidistantly spaced about the flange.

The positioning fingers may be engaged with the housing to support the bearing retainer within the housing.

The power tool assembly may further comprise:.

The bearing retainer may include a flange extending radially outward from the first pocket, and wherein the flange may include an opening through which the electrical wire is routed.

The motor may include a plurality of windings, and wherein the second electrical connector may include a plurality of commutation terminals electrically connected with the windings.

The bearing retainer may include a flange extending radially outward from the first pocket, and wherein the flange may include an opening through which commutation wires are routed to electrically connect the windings with the commutation terminals.

The embodiments of <FIG>, <FIG> disclose a concrete vibrator system according to the invention.

Before any embodiments are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments, according to the claims.

With reference to <FIG>, a portable power unit <NUM> includes a frame or backpack <NUM>, a battery receptacle unit <NUM>, a battery pack <NUM> attached to the battery receptacle unit <NUM>, a pair of handles <NUM> to facilitate hand-carrying the unit <NUM> (the second handle <NUM> being shown in <FIG>), a motor control unit <NUM>, and a motor control unit guard <NUM>. The backpack <NUM> generally defines a backpack plane and includes straps or other rigging (not shown) to allow a user to carry the portable power unit <NUM> on the user's back while the portable power unit <NUM> is in use or between uses of the portable power unit <NUM>. The straps may include one, two, or more shoulder straps and one or more waist straps. The battery receptacle unit <NUM> includes a battery receptacle <NUM> on a front side <NUM> of the unit <NUM> to which the battery pack <NUM> is attachable, with the backpack <NUM> being attached to a rear side <NUM> of the unit <NUM>.

With continued reference to <FIG>, the battery receptacle <NUM> includes a channel, an electrical terminal, and a latching mechanism. The channel cooperates with a corresponding shaped rail on the battery pack <NUM> to attach the battery pack <NUM> to the battery receptacle <NUM>. When the battery pack <NUM> is attached to the battery receptacle <NUM>, the electrical terminal on the battery receptacle <NUM> and a corresponding electrical terminal on the battery pack <NUM> are electrically connected to each other. The latching mechanism protrudes from a surface of the battery receptacle <NUM> and is configured to engage the battery pack <NUM> to maintain engagement between the battery pack <NUM> and the battery receptacle <NUM>. Thus, the battery pack <NUM> is connectable to and supportable by the battery receptacle <NUM> such that the battery pack <NUM> is supportable by the unit <NUM> and the backpack <NUM> when worn by a user.

With continued reference to <FIG>, the battery pack <NUM> includes a battery pack housing containing a plurality of battery cells. In some embodiments, the battery cells, and therefore the battery pack <NUM>, may have a nominal voltage of up to about <NUM> V. In some embodiments, the battery cells have a nominal voltage of up to about <NUM> V. In some embodiments, each of the battery cells has a diameter of up to about <NUM> and a length of up to about <NUM>. In some embodiments, the battery pack <NUM> includes 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 <NUM> A and about <NUM> A. In some embodiments, each of the battery cells has a capacity of between about <NUM> Ah and about <NUM> Ah.

With reference to <FIG> and <FIG>, the motor control unit <NUM> is selectively attachable to the battery receptacle unit <NUM>. The motor control unit <NUM> includes a first (rear) side 38a that is configured to face the backpack <NUM> when the motor control unit <NUM> is attached to the battery receptacle unit <NUM> and a second (front) side 38b opposite the first side 38a. The motor control unit <NUM> further includes a third (top) side 38c extending generally perpendicular to the backpack plane and between the rear side 38a and the front side 38b. The top side 38c is facing the battery receptacle unit <NUM> when the motor control unit <NUM> is attached thereto. In the illustrated embodiment, the motor control unit <NUM> is surrounded and protected by the motor control unit guard <NUM> such that the front side 38b is recessed into the guard <NUM>. In other embodiments, the motor control unit <NUM> may not be recessed into the guard <NUM>. Further, in the illustrated embodiment, the motor control unit guard <NUM> is tubular and defines a U-shape when viewed from a direction that is transverse to the backpack <NUM>. In other embodiments, the motor control unit guard <NUM> may have a variety of different shapes.

With continued reference to <FIG>, the motor control unit <NUM> includes a first electrical connection <NUM> configured to selectively attach the motor control unit <NUM> to a first end of a cable. The motor control unit <NUM> also includes a control panel <NUM> and an on/off switch <NUM>. The control panel <NUM> may include an arming button and a remote pairing button. The motor control unit <NUM> may also include a docking port to selectively receive a remote <NUM>. In other embodiments, the remote <NUM> may be selectively docked at other locations on the portable power unit <NUM>. Further, the motor control unit <NUM> and the battery receptacle unit <NUM> include a second electrical connection 46a, 46b configured to selectively electrically connect the motor control unit <NUM> to the battery receptacle unit <NUM>.

With continued reference to <FIG> and with reference to <FIG>, the embodiment of <FIG> includes one or more mechanical latches that selectively attach the motor control unit <NUM> to the battery receptacle unit <NUM>. In some embodiments, such as the embodiment of <FIG>, two mechanical latches 50a, 50b are provided for this purpose, each mechanical latch 50a, 50b including a respective projection 54a, 54b and a respective hook 58a, 58b. In this embodiment, the projections 54a, 54b are provided on the top side 38c of the motor control unit <NUM> and the hooks 58a, 58b are provided on the battery receptacle unit <NUM>. In this embodiment of the portable power unit <NUM>, the electrical connections 46a, 46b are simultaneously made with the latches 50a, 50b mechanically connecting the motor control unit <NUM> to the battery receptacle unit <NUM>. With reference to <FIG>, the motor control unit <NUM> includes an electronic controller <NUM> in communication with the first electrical connection <NUM>, the control panel <NUM>, the on/off switch <NUM>, and the second electrical connection 46a, 46b. In other embodiments, some of which are described herein, the motor control unit <NUM> may be coupled to the battery receptacle unit <NUM> via a variety of different mechanical and electrical means.

In operation, and with reference to <FIG>, a power tool is electrically connectable to a second end of the cable that connects to the first electrical connection <NUM> of the motor control unit <NUM>. In one embodiment, a plurality of power tools may be connectable to the first electrical connection <NUM>. In that embodiment, a single motor control unit <NUM> can power and control whichever of the plurality of power tools is electrically connected to the motor control unit <NUM> via the cable. In another embodiment, each power tool includes its own motor control unit <NUM>, and the motor control units <NUM> are interchangeable in the portable power unit <NUM> to allow the portable power unit <NUM> to power and control various power tools. In that embodiment, the portable power unit <NUM> can power and control whichever of the plurality of power tools has its particular motor control unit <NUM> coupled to the battery receptacle unit <NUM>.

With continued reference to <FIG> and with reference to <FIG> and <FIG>, a portable concrete vibrator, such as a high-cycle concrete vibrator <NUM>, may be powered and controlled by the portable power unit <NUM>, thereby forming a concrete vibrator system. The high-cycle concrete vibrator <NUM> includes a whip <NUM>, a whip connection <NUM> that electrically connects the whip <NUM> to a power cable, and a vibrating head <NUM>. The vibrating head <NUM> contains an onboard electric motor <NUM> which, in some embodiments, is a brushless direct current ("BLDC") electric motor <NUM> that is configured to rotate a drive shaft <NUM> to which an eccentric mass <NUM> is affixed (<FIG>). The electric motor <NUM> may include a plurality of windings. The eccentric mass <NUM> is supported at each end by bearings 90a, 90b. The drive shaft <NUM> has a center of mass (i.e., an eccentric mass <NUM>) that is radially offset from a rotational axis of the drive shaft <NUM>, and the electric motor <NUM> is configured to provide torque to the drive shaft <NUM>, thereby causing the drive shaft <NUM> and the eccentric mass <NUM> to rotate. Electrical wiring (not shown) transmits electrical current from the motor control unit <NUM> to the motor <NUM> via the whip <NUM> and power cable.

With continued reference to <FIG>, the electric motor <NUM> includes a rotor and a stator. The stator may be press-fit to a housing <NUM> of the vibrating head <NUM> such that the housing <NUM> serves as a heat sink for the electric motor <NUM>. The vibrating head <NUM> also includes a rotational speed-sensing printed circuit board (PCB) <NUM> operable to detect a rotational speed of the rotor, and therefore a rotational speed of the drive shaft <NUM> and of the eccentric mass <NUM>. The whip <NUM> has one or more connectors that plug into the rotational speed-sensing PCB <NUM> to provide electrical current to the PCB <NUM> and also to transmit a rotational speed signal to the motor control unit <NUM>.

In operation, and with reference to <FIG>, a user may wear the portable power unit <NUM> as a backpack while operating a tool such as the high-cycle concrete vibrator <NUM>. Specifically, a user may hold the whip <NUM> and use the vibrating head <NUM> to vibrate concrete while electrical power and control signals are delivered to the high-cycle concrete vibrator <NUM> from the motor control unit <NUM>, which is connected to the battery receptacle unit <NUM>. The on/off switch <NUM> may include three positions: "on," "off," and "remote. " To shut off power to the motor control unit <NUM>, the user would toggle the on/off switch <NUM> to the "off" position. To allow the motor control unit <NUM> to be controlled by the remote <NUM>, the user would toggle the on/off switch <NUM> to the "remote" position, thereby allowing the remote <NUM> to control whether the motor control unit <NUM> is on or off (e.g., whether or not the motor control unit <NUM> is armed) and whether the tool, such as the vibrator <NUM>, is activated. To arm the motor control unit <NUM> without using the remote <NUM>, the user would toggle the on/off switch <NUM> to an "on" state in which electrical current from the battery pack <NUM> is supplied to the controller <NUM>, thereby waking the controller <NUM> and readying the controller <NUM> to accept an input from the control panel <NUM>. Then, using the control panel <NUM>, the user could activate a tool such as the vibrator <NUM> by pressing a button on the control panel <NUM> to selectively activate the tool or to allow the tool to be selectively activated by actuating another switch. Activating the tool and/or the motor <NUM> may allow the motor <NUM> to rotate at a predefined rotational speed coinciding with a pre-set vibrational frequency. To pair the remote <NUM> with the motor control unit <NUM>, the user may press the remote pairing button on the control panel <NUM>, thereby allowing wireless communication between the remote <NUM> and the motor control unit <NUM>. Output of the rotational speed-sensing PCB <NUM> is transmitted through the whip <NUM> and cable to the motor control unit <NUM>, which, based on the feedback from the PCB <NUM>, may adjust the rotational speed of the motor <NUM> as necessary to ensure that the vibration frequency of the vibrator <NUM> remains consistent as the vibrating head <NUM> is plunged into wet concrete.

In operation, and with continued reference to <FIG>, the use of the portable power unit <NUM> may 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 vibrator <NUM>. The high-cycle concrete vibrator <NUM> may be interchangeable with other tools such that the same portable power unit <NUM>, or at least the same battery receptacle unit <NUM>, can be used to power and control a plurality of different power tools.

With reference to <FIG>, another embodiment of a high-cycle concrete vibrator <NUM> includes a whip <NUM> that is configured to selectively attach to and detach from a modular vibrating head <NUM>. The modular vibrating head <NUM> includes a connector capsule <NUM> within the modular vibrating head <NUM> that electrically interfaces with a whip connector <NUM> within the whip <NUM>. The connector capsule <NUM> includes a plurality of connector terminal pins 131a, 131b, 131c. The connector terminal pins 131a, 131b, 131c are configured to interface with a plurality of connector terminal recesses in the whip connector <NUM> (a connector terminal recess 132c being shown in <FIG>) to provide electrical communication between the connector capsule <NUM> and the whip connector <NUM>. Further, a support pin <NUM> on the connector capsule <NUM> is inserted into a support pin recess <NUM> in the whip connector <NUM> to prevent relative rotation between the connector capsule <NUM> and the whip connector <NUM>. A head collar <NUM> partially surrounds the whip connector <NUM> and provides a mechanical connection and seal between the modular vibrating head <NUM> and the whip <NUM>. The mechanical connection may comprise a threaded interface between external threads on the modular vibrating head <NUM> and internal threads on the head collar <NUM>. A whip fitting <NUM> is positioned at least partially within the whip <NUM> and provides a fixing point between the head collar <NUM> and the whip <NUM>. A grommet <NUM> within the whip <NUM> surrounds a multi-conductor electrical cable <NUM> and provides strain relief thereto.

In operation, and with reference to <FIG>, the modular vibrating head <NUM> may be selectively removable from the whip <NUM> such that another modular vibrating head (which may be of the same or different construction) may be attached to the whip <NUM>. Such interchangeability allows a user to change the diameter of the modular vibrating head <NUM> and the length of the whip <NUM> independently. To interchange the modular vibrating head <NUM> for another, the collar <NUM> is unscrewed and the head <NUM> is pulled from the whip <NUM>, disconnecting the capsule <NUM> from the whip connector <NUM>. Then, a new vibrating head is connected to the whip <NUM> using the reverse procedure.

With reference to <FIG> and with continued reference to <FIG>, a first modular vibrating head <NUM> and a second modular vibrating head <NUM> may be interchangeably connectable to the whip <NUM>. The first modular vibrating head <NUM> may have a diameter of about <NUM> (<NUM> inches) and the second modular vibrating head <NUM> may have a diameter of about <NUM> (<NUM> inches). In other embodiments, different vibrating heads may be used which have a diameter between <NUM> and <NUM>, greater than <NUM>, or less than <NUM>. In some embodiments, a vibrating head may have a diameter of about <NUM> (<NUM> inches). In some embodiments, a vibrating head may have a diameter of approximately <NUM>, approximately <NUM>, or approximately <NUM>.

With reference to <FIG>, an embodiment of a portable power unit <NUM> includes a frame or backpack <NUM>, a battery receptacle unit <NUM>, a battery pack <NUM> attached to the battery receptacle unit <NUM>, a handle <NUM> to facilitate hand-carrying the portable power unit <NUM>, a motor control unit <NUM>, and a motor control unit guard <NUM>. The backpack <NUM> generally defines a backpack plane and includes straps or other rigging <NUM> to allow a user to carry the portable power unit <NUM> on the user's back while the portable power unit <NUM> is in use or between uses of the portable power unit <NUM>. The battery receptacle unit <NUM>, which may also be called a power box, includes a battery receptacle <NUM> on a front side <NUM> of the unit <NUM> to which the battery pack <NUM> is attachable, with the backpack <NUM> being attached to a rear side <NUM> of the unit <NUM>. The battery pack <NUM> may attach to the battery receptacle unit <NUM> in a similar manner to how the battery pack <NUM> attaches to the battery receptacle unit <NUM> as shown in, for example, <FIG>.

With reference to <FIG>, the motor control unit <NUM> is selectively attachable to the battery receptacle unit <NUM>. The motor control unit <NUM> includes a first (rear) side 206a that is configured to face the backpack <NUM> when the motor control unit <NUM> is attached to the battery receptacle unit <NUM> and a second (front) side 206b opposite the first side 206a. The motor control unit <NUM> further includes a third (top) side 206c extending generally perpendicular to the backpack plane and between the rear side 206a and the front side 206b. The top side 206c is facing the battery receptacle unit <NUM> when the motor control unit <NUM> is attached thereto. The motor control unit <NUM> is surrounded and protected by the motor control unit guard <NUM> such that the front side 206b is recessed into the guard <NUM>. In the illustrated embodiment, the motor control unit guard <NUM> is tubular.

With continued reference to <FIG> and <FIG>, the motor control unit <NUM> includes a sub-flush electronics connection <NUM>. The sub-flush electronics connection <NUM> is an interface between a male protrusion <NUM> in the form of a rigid connector on the motor control unit <NUM> and a female recess <NUM> within the battery receptacle unit <NUM>. The sub-flush electronics connection <NUM> is configured to selectively electrically connect the motor control unit <NUM> to the battery receptacle unit <NUM> by plugging the male protrusion <NUM> into the female recess <NUM> on the battery receptacle unit <NUM>. The sub-flush electronics connection <NUM> protects the electrical connection between the motor control unit <NUM> and the battery receptacle unit <NUM>. The motor control unit <NUM> also includes a control panel <NUM>, an on/off switch <NUM>, and a first electrical connection <NUM> configured to selectively attach a first end of a cable <NUM> (shown in <FIG>) to the motor control unit <NUM>.

With continued reference to <FIG> and <FIG>, the battery receptacle unit <NUM> includes a plurality of first bores, each first bore housing a threaded insert <NUM>. In the illustrated embodiment, two threaded inserts <NUM> are each housed within a respective first bore on a first side 242a of the battery receptacle unit <NUM>, and two threaded inserts <NUM> are each housed within a respective first bore on a second side 242b of the battery receptacle unit <NUM>. The motor control unit <NUM> includes two protruding ears 246a, 246b. Each of the two protruding ears 246a, 246b extends upward from the motor control unit <NUM> in a direction toward the battery receptacle unit <NUM>. Each of the two protruding ears 246a, 246b includes a plurality of second bores <NUM>, each second bore <NUM> configured to receive a bolt <NUM>. Each one of the second bores <NUM> is configured to align with a respective one of the threaded inserts <NUM> when the motor control unit <NUM> is electrically connected to the battery receptacle unit <NUM>. In other words, when the male protrusion <NUM> is fully received within the female recess <NUM>, each second bore <NUM> is aligned with a threaded insert <NUM> such that a bolt <NUM> may be passed into each of the second bores <NUM> and threaded into a threaded insert <NUM>. When installed, the bolts <NUM> are configured to attach and hold the motor control unit <NUM> to the battery receptacle unit <NUM>.

In operation, and with reference to <FIG>, an operator <NUM> may attach the rigging <NUM> to a body of the operator <NUM> such that the portable power unit <NUM> is ergonomically supported by the operator <NUM> while the portable power unit <NUM> is used to power and control, for example, a high-cycle concrete vibrator <NUM> (<FIG>), a high-cycle concrete vibrator <NUM> (shown in <FIG>), or another tool.

With reference to <FIG>, an embodiment of a portable power unit <NUM> includes a battery receptacle unit <NUM>, a battery pack <NUM> attached to the battery receptacle unit <NUM>, a handle <NUM> to facilitate hand-carrying the portable power unit <NUM>, and a motor control unit <NUM>. The portable power unit <NUM> may be similar to the portable power units <NUM>, <NUM> except as shown or noted and may be configured as a backpack as described herein. The motor control unit <NUM> is selectively connectable to the battery receptacle unit <NUM> via a two-step connection process that includes a mechanical interface <NUM> and an electrical interface <NUM>. The mechanical interface <NUM> physically attaches the motor control unit <NUM> to the battery receptacle unit <NUM>. The mechanical interface <NUM> may include latches, bolts, screws, or the like. The electrical interface <NUM> provides electrical communication between a female connector <NUM> and a male socket <NUM>. The female connector <NUM> is connected to a cable <NUM> that electrically connects the female connector <NUM> to the battery receptacle unit <NUM>. In operation, electrical current flows through the cable <NUM>, through the female connector <NUM>, across the electrical interface <NUM>, through the male socket <NUM>, and into the electrical systems of the motor control unit <NUM>, thereby powering the motor control unit <NUM> and any tools controlled by the motor control unit <NUM>.

With reference to <FIG>, a portable power unit <NUM> includes a frame or backpack <NUM> (<FIG>), a battery receptacle unit <NUM>, a battery pack <NUM> attached to the battery receptacle unit <NUM>, a handle <NUM> to facilitate hand-carrying the unit <NUM>, and a motor control unit <NUM>. The portable power unit <NUM> may be similar to the other portable power units described herein, except for certain aspects. For example, the motor control unit <NUM> is integrated into the battery receptacle unit <NUM>. In other words, the motor control unit <NUM> and the battery receptacle unit <NUM> share a common contiguous housing <NUM>. In other words, the common contiguous housing <NUM> may house both power electronics as well as control electronics, which are used for powering and controlling, for example, the vibrating head <NUM>. Other than being integrated into the battery receptacle unit <NUM>, the motor control unit <NUM> may be similar to the other motor control units described herein. For example, the motor control unit <NUM> includes a control panel <NUM>, an on/off switch <NUM>, and a first electrical connection <NUM> configured to selectively attach a first end of a cable <NUM> (shown in <FIG>) to the motor control unit <NUM>. The common contiguous housing <NUM> includes bump guards 454a, 454b on bottom and front edges of the motor control unit <NUM> to protect the motor control unit <NUM> from contact with other objects (<FIG>). In operation, the power unit <NUM> may be used to power a high-cycle concrete vibrator.

The motor control unit <NUM> includes a docking port <NUM> on a side of the motor control unit <NUM> to dock a remote control <NUM>. The docking port <NUM> may be located, for example, generally below the battery receptacle unit <NUM> and, accordingly, generally below the battery pack <NUM> when the battery pack <NUM> is mounted to the battery receptacle unit <NUM>. In other embodiments, the docking port <NUM> may be mounted to the battery receptacle unit <NUM> or in another location. The remote control <NUM> may be mounted to the docking port <NUM> in a variety of different manners. For example, the remote control <NUM> may be mounted to the docking port <NUM> by a clip, such as a spring clip. The spring clip may be attached to the remote control <NUM> such that when the user slides the remote control <NUM> into the docking position, the spring clip engages the docking port <NUM>, and in some embodiments, engages with a recess in the docking port <NUM> to frictionally retain the remote control <NUM> in the docking position until the user overcomes the frictional force applied by the spring clip to remove the remote control <NUM> from the docking port <NUM>. The remote control <NUM> may be used to communicate with the motor control unit <NUM> and prompt the motor control unit <NUM> to transmit a motor control signal to a motor such as, for example, one of the motors <NUM>, <NUM>. In addition to the remote control, the portable power unit <NUM> may include a user interface (e.g., the control panel <NUM>) on a housing such as the common contiguous housing <NUM>, and the user may operate the user interface to prompt the motor control unit <NUM> to transmit the motor control signal to the motor. In some embodiments, one or both of the remote control <NUM> or the user interface may be operable to prompt the motor control unit <NUM> to vary a rotational speed of the motor.

With reference to <FIG>, the portable power unit <NUM>, and specifically the motor control unit <NUM>, may include a power and/or control PCB <NUM>, which may be referred to simply as a power PCB <NUM> or as a control PCB <NUM>, for controlling a flow of electrical current from the battery pack <NUM> to, among other things, a power tool such as the vibrator <NUM> (<FIG>). The power PCB <NUM> may be positioned below the battery receptacle unit <NUM> and, therefore, below the battery pack <NUM> when the battery pack <NUM> is mounted to the battery receptacle unit <NUM>. The portable power unit <NUM>, and specifically the motor control unit <NUM>, may further include a user interface PCB <NUM> located, for example, below the battery receptacle unit <NUM> and, therefore, below the battery pack <NUM> when the battery pack <NUM> is mounted to the battery receptacle unit <NUM>. The power PCB <NUM> may include electronic switches (e.g., field effect transistors) to commutate a motor such as one of the motors <NUM>, <NUM>. The power PCB <NUM> may include microprocessors for receiving sensor inputs and/or user inputs from the control panel <NUM> and/or from the user interface PCB <NUM>. In some embodiments, the functions of the power PCB <NUM> and the user interface PCB <NUM> are combined and performed by, for example, a single PCB. In some embodiments, the functions of the power PCB <NUM> and the user interface PCB <NUM> are divided and performed by three or more PCBs.

With returning reference to <FIG> and <FIG>, the portable power unit <NUM> includes a mode selector switch <NUM> that may include, for example, three positions: "on," "off," and "remote. " To shut off power to the motor control unit <NUM> and/or to shut off power to a power tool such as a high cycle concrete vibrator that is connected to the motor control unit <NUM>, the user may toggle the mode selector switch <NUM> to the "off" position. To allow the motor control unit <NUM> to be controlled by the remote control <NUM>, the user may toggle the mode selector switch <NUM> to the "remote" position, thereby allowing the remote control <NUM> to control whether the motor control unit <NUM> is on or off (e.g., whether the motor control unit <NUM> is armed) and whether the power tool, such as, for example, the vibrator <NUM> (<FIG>), is activated.

With continued reference to <FIG> and <FIG>, to arm the motor control unit <NUM> without using the remote control <NUM>, the user may toggle the mode selector switch <NUM> to an "on" state in which electrical current from the battery pack <NUM> is supplied to the power PCB <NUM> and/or to the user interface PCB <NUM>, thereby waking the power PCB <NUM> and/or the user interface PCB <NUM> and readying the power PCB <NUM> and/or the user interface PCB <NUM> to accept an input from the control panel <NUM>. Then, using the control panel <NUM>, the user could activate a tool such as the vibrator <NUM> (<FIG>) by pressing a button on the control panel <NUM> to selectively activate the tool or to allow the tool to be selectively activated by actuating another switch. Activating the tool and/or the motor <NUM> (<FIG>) may allow the motor <NUM> to rotate at a predefined rotational speed coinciding with a pre-set vibrational frequency. In some embodiments, the motor control unit <NUM> may be configured such that the user may arm a tool such as the vibrator <NUM> and activate the tool such as the vibrator <NUM> in a single step (e.g., by pressing a single button on the control panel <NUM> or by pressing a single button on the remote control <NUM>). In some embodiments, the motor control unit <NUM> may be configured such that the user may arm the motor control unit <NUM> and activate a tool such as the vibrator <NUM> in a single step (e.g., by pressing a single button or actuating a single switch such as the mode selector switch <NUM>). 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 control <NUM> with the motor control unit <NUM>, the user may press a remote pairing button <NUM> (<FIG>) on the control panel <NUM>, thereby allowing wireless communication between the remote control <NUM> and the motor control unit <NUM>. Output of the rotational speed-sensing PCB <NUM> (<FIG>; see also the Hall-effect board <NUM> of <FIG>) is transmitted through the whip <NUM> (see also the whip <NUM> of <FIG>) to the motor control unit <NUM>, which, based on the feedback from the PCB <NUM>, may adjust the rotational speed of the motor <NUM> as necessary to ensure that the vibration frequency of the vibrator <NUM> remains consistent as the vibrating head <NUM> is plunged into wet concrete.

With reference to <FIG>, the remote control <NUM> is capable of wirelessly transmitting a signal to the power PCB <NUM> and/or to the user interface PCB <NUM> in response to a user depressing a button on the remote control <NUM> such as a power button <NUM>. The signal is wirelessly transmitted to the motor control unit <NUM> to activate and deactivate a motor such as the motor <NUM> in the vibrating head <NUM> (<FIG>). In some embodiments, the motor control unit <NUM>, and more specifically the power PCB <NUM> and/or the user interface PCB <NUM>, may include feedback control capable of detecting physical properties of wet concrete in which a vibrating head such as the vibrating head <NUM> is submerged and then adjusting the speed of the motor <NUM> to optimize a frequency of vibration of the vibrating head <NUM>. Such feedback control may be continuously active as long as the motor <NUM> remains activated, allowing the frequency of vibration of the vibrating head <NUM> to be adjusted contemporaneously with movement of the vibrating head <NUM> throughout the wet concrete.

With continued reference to <FIG>, additionally or alternatively, the remote control <NUM> is capable of controlling the speed of the motor <NUM> with a joystick <NUM> on the remote control <NUM>. Input from the joystick <NUM> may be transmitted wirelessly to the motor control unit <NUM> to adjust the speed of the motor <NUM>. In some embodiments, the joystick <NUM> may be toggled in a first direction (e.g., toward the right from the frame of reference of <FIG>) to increase the speed of the motor <NUM>, and toggling the joystick <NUM> in an opposite, second direction (e.g., toward the left from the frame of reference of <FIG>) may decrease the speed of the motor <NUM>. Similarly, the joystick <NUM> may be toggled in a vertical direction (i.e., up or down from the frame of reference of <FIG>) to adjust the motor <NUM> between a forward rotational direction and a reverse rotational direction, respectively. Also, in some embodiments, depressing or clicking the joystick <NUM> (i.e., into the page from the frame of reference of <FIG>) may adjust the motor <NUM> between 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 control <NUM> may utilize a dial potentiometer (not shown) to set or adjust the speed of the motor <NUM>. In the illustrated embodiment, the forward/reverse control and speed control of the motor <NUM> is integrated using the single joystick <NUM>. However, in alternate embodiments, the forward/reverse control and speed control of the motor <NUM> may be performed by separate switches or buttons. The remote control <NUM> is configured to receive user input and transmit the user input to the power PCB <NUM> and/or the user interface PCB <NUM>. At least one of the power PCB <NUM> or the user interface PCB <NUM> may be configured to receive the user input and adjust the operation of the motor based on the user input.

With reference to <FIG>, the portable power unit <NUM> and/or a whip such as the whip <NUM> and/or a vibrating head such as the vibrating head <NUM> may be provided with a work light <NUM> to illuminate an area of wet concrete in which the vibrating head <NUM> is immersed. The light <NUM> may be capable of changing between a spot illumination mode, in which the light generated by the component on which the light <NUM> are mounted, which may be the portable power unit <NUM>, is cast about a relatively small area, and a flood illumination mode, in which the light generated by the component on which the light <NUM> are mounted is cast about a relatively large area. The work light <NUM> may also be deactivated if not needed. In the illustrated embodiment, the remote control <NUM> includes a light mode selection button <NUM> that 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 light <NUM> may be coupled to one of the portable power unit <NUM> or the vibrating head <NUM>, and the remote control <NUM> may be configured to selectively activate the work light <NUM>. The remote control <NUM> also includes a brightness control button <NUM> that allows a user to adjust the brightness of the work light <NUM> between multiple different levels. For example, the brightness control button <NUM> may be depressed by a user to sequentially adjust the work light <NUM> between two or more brightness levels.

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

With continued reference to <FIG>, the remote control <NUM> may communicate with the portable power unit <NUM> with a wireless communication protocol, such as Bluetooth Low Energy ("BTLE"), standard Bluetooth, radio frequency communication such as <NUM>, Wi-Fi, infrared, or standard cellular communication frequencies (<NUM>, <NUM>, <NUM>, <NUM>, or LTE services). The remote control <NUM> may include a transmitter <NUM> configured to send messages to a receiver <NUM> on the portable power unit <NUM>. A communications link between the transmitter <NUM> of the remote control <NUM> and the receiver <NUM> of the portable power unit <NUM> may 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 unit <NUM> or remote control <NUM> activates a physical switch on the other of the portable power unit <NUM> and the remote control <NUM>. In other embodiments, the remote control <NUM> may be a wired communication device receiving power and communicating through a wired connection with the portable power unit <NUM>.

Additionally or alternatively, a signal may be generated by the power PCB <NUM> and/or the user interface PCB <NUM> of the portable power unit <NUM> to indicate the running state (for example, on/off status, direction, and/or speed) of the motor <NUM>. This signal may be sent by a transmitter <NUM> of the portable power unit <NUM> and may be received by a receiver <NUM> of the remote control <NUM> for communicating the signal to the user via an indicator <NUM> on the remote control <NUM>. Thus, the indicator <NUM> may communicate to a user of the portable power unit <NUM> the running state of a concrete vibrator motor such as the motor <NUM> (<FIG>). In the illustrated embodiment, the indicator <NUM> is an LED configured to illuminate, for example, when the motor <NUM> is activated. Alternatively or additionally, the indicator <NUM> may provide an audible or tactile signal to the user.

When using the remote control <NUM>, a first user carrying the portable power unit <NUM> may be responsible for submerging and moving a vibrating head such as, for example, the vibrating head <NUM> throughout a region of wet concrete, while a second user may hold the remote control <NUM> and be responsible for adjusting the frequency of vibration of the vibrating head <NUM> to account for variations in the consistency of the wet concrete, or to adjust the vibrating head <NUM> for use with wet concrete in different stages of dryness. In this manner, the user carrying the portable power unit <NUM> needs only to concentrate on placement of the vibrating head <NUM> within the wet concrete. Alternatively, the same user responsible for submerging and moving the vibrating head <NUM> may also hold the remote control <NUM> and be responsible for adjusting the frequency of the vibrating head <NUM>. This allows a single user to adjust the frequency of vibration of the vibrating head <NUM> based on tactile feedback from the vibrating head <NUM> due to the consistency of the wet concrete. Additionally or alternatively, a single user can operate the portable power unit <NUM> by submerging the vibrating head <NUM> in wet concrete and controlling the frequency of vibration of the vibrating head <NUM> using the remote control <NUM>, all while carrying the portable power unit <NUM> with, for example, the rigging <NUM> (<FIG>).

With reference to <FIG>, another vibrating head <NUM> is shown that may be interchangeable with any of the previously described vibrating heads for use with the portable power unit <NUM>, <NUM>. For example, the vibrating head <NUM> may be used as a high cycle concrete vibrator with the portable power unit <NUM> and controlled by the motor control unit <NUM> and further may be controllable via instructions transmitted to and/or from the remote control <NUM>. The vibrating head <NUM> includes an onboard electric motor <NUM> that may be a brushless DC motor. The motor <NUM> may include a rotor shaft <NUM> that is coupled for corotation with an eccentric mass <NUM> such that a rotation of the motor <NUM> induces a vibration in the vibrating head <NUM>, thereby allowing the vibrating head <NUM> to function as a concrete vibrator. The vibrating head <NUM> may include a rotational speed sensor <NUM>, such as a Hall-effect sensor or Hall-effect sensor array located on a Hall-effect circuit board <NUM>, for sensing a rotational speed of the rotor shaft <NUM>, and therefore a rotational speed of the motor <NUM>, and transmitting a signal representing the rotational speed of the rotor shaft <NUM> to the motor control unit <NUM>. The rotor shaft <NUM> is rotatably supported at or near an end of the rotor shaft <NUM> by a rotor bearing <NUM>. The bearing <NUM> may be partially or entirely surrounded and supported by a bearing retainer <NUM>.

With continued reference to <FIG>, the vibrating head <NUM> is connectable to an electrical cable <NUM>, which may be called a whip <NUM>, at an electrical connection <NUM>. The whip <NUM> may transmit electrical current to the motor <NUM> and may also transmit control signals. The whip <NUM> may include a bundle of wires (not shown) that are electrically connected to a first electrical connector (i.e., a whip electrical connector <NUM>) that is mounted to the whip <NUM>. The vibrating head <NUM> includes a second electrical connector (i.e., a vibrating head electrical connector <NUM>) that is selectively electrically connectable to the whip electrical connector <NUM>. The whip electrical connector <NUM> is electrically connected to the vibrating head electrical connector <NUM> when the vibrating head <NUM> is connected to the whip <NUM>. When the vibrating head <NUM> is disconnected from the whip <NUM>, the electrical connectors <NUM>, <NUM> are disconnected. The bearing retainer <NUM> supports the vibrating head electrical connector <NUM> within the vibrating head <NUM>. In some embodiments, the bearing retainer <NUM> may function as a stator mount. The bearing retainer <NUM> may be positioned within the vibrating head <NUM> between the rotor shaft <NUM> and the vibrating head electrical connector <NUM>. One of the whip electrical connector <NUM> or the vibrating head electrical connector <NUM> may include a male connector, and the other of the whip electrical connector <NUM> or the vibrating head electrical connector <NUM> may include a female connector. In some embodiments, each electrical connector <NUM>, <NUM> may include at least one male and at least one female component. The vibrating head electrical connector <NUM> may be positioned such that the circuit board <NUM> is supported at an end of the motor <NUM> that is proximate the vibrating head electrical connector <NUM>. One or more electrical wires (e.g., one wire, a plurality of wires, or a single multi-conductor cable) such as the electrical wire <NUM> interconnects the circuit board <NUM> and the vibrating head electrical connector <NUM>. An output of the sensor <NUM> may be transmitted through the electrical wire <NUM> to the second electrical connector <NUM>. One or more commutation wires 549a, 549b, 549c may electrically connect the motor <NUM> and the vibrating head electrical connector <NUM>, and the commutation wires 549a, 549b, 549c may be routed adjacent to or in a multi-conductor cable with the electrical wire <NUM>. In the illustrated embodiment, three commutation wires 549a, 549b, 549c are provided.

With reference to <FIG>, the bearing retainer <NUM> includes a first wall <NUM> defining a first pocket (i.e., a bearing pocket <NUM>) and a second wall <NUM> opposite from the bearing pocket <NUM> and defining a second pocket (i.e., a connector pocket <NUM>). The first wall <NUM> supports the bearing <NUM> (<FIG>), and the second wall <NUM> supports the vibrating head electrical connector <NUM>. The first wall <NUM> and/or the bearing pocket <NUM> may be referred to as a rotor bearing retention portion, and the second wall <NUM> and/or the connector pocket <NUM> may be referred to as a connector retention portion. Inwardly extending protrusions <NUM> within the first wall <NUM> provide a press-fit connection with an outside diameter of the bearing <NUM>. The flange <NUM> may include one or more, and in the illustrated embodiment includes four, openings 568a, 568b, 568c, 568d through which the electrical wire <NUM> and/or the commutation wires 549a, 549b, 549c may be routed to electrically connect the circuit board <NUM> and the vibrating head electrical connector <NUM> and/or to electrically connect the motor <NUM> and the vibrating head electrical connector <NUM>. More specifically, the commutation wires 549a, 549b, 549c may electrically connect windings of the motor <NUM> and the vibrating head electrical connector <NUM>. In some embodiments, the electrical wire <NUM> and the one or more commutation wires 549a, 549b, 549c are routed through the same opening 568a, 568b, 568c, 568d, and in other embodiments, the electrical wire <NUM> and the one or more commutation wires 549a, 549b, 549c are routed through different openings 568a, 568b, 568c, 568d. Further, the bearing retainer <NUM> includes three positioning fingers 570a, 570b, 570c that rotationally constrain the bearing retainer <NUM> within the vibrating head <NUM>. The positioning fingers 570a, 570b, 570c may engage with a housing of the vibrating head <NUM> (see, e.g., the housing <NUM> of <FIG>) to support the bearing retainer <NUM> within the housing. In other embodiments, more or fewer positioning fingers 570a, 570b, 570c may be used. The positioning fingers 570a, 570b, 570c may be equidistantly spaced apart about a flange <NUM> and may axially extend from the flange <NUM>. The flange <NUM> may extend radially outward from the bearing pocket <NUM>.

With reference to <FIG>, one of the positioning fingers 570a may be shorter than the other of the positioning fingers 570b, 570c. Further, one of the positioning fingers 570a, 570b, 570c, and in the illustrated embodiment, the positioning finger 570a, may include a through hole <NUM> (<FIG>). The through hole <NUM> may have an axis that is parallel to a rotational axis of the rotor shaft <NUM>. Certain positioning fingers 570a, 570b, 570c, and in the illustrated embodiment the positioning fingers 570b, 570c, may include blind holes <NUM> that are parallel or substantially parallel to the axis of the through hole <NUM>.

With reference to <FIG> and <FIG>, the bearing retainer <NUM> includes a longitudinal axis A1. The longitudinal axis A1 may pass through a center of the bearing pocket <NUM>, and the longitudinal axis A1 may pass through a center of the connector pocket <NUM>. In the illustrated embodiment, the longitudinal axis A1 passes through both the center of the bearing pocket <NUM> as well as the center of the connector pocket <NUM>. Further, the longitudinal axis A1 may be parallel to and/or collinear with the longitudinal axis of the rotor shaft <NUM> when the bearing retainer <NUM> is installed within the vibrating head <NUM>. In the illustrated embodiment, the second wall <NUM> is supported in an axial direction of the longitudinal axis A1 away from the flange <NUM> by four axial supports <NUM>. In other embodiments, the number of axial supports may be zero, one, two, three, five, or another number. In the illustrated embodiment, the bearing retainer <NUM> is configured to support the bearing <NUM> and the vibrating head electrical connector <NUM> in an electrical assembly pertaining to a concrete vibrator. In other embodiments, a bearing retainer such as the illustrated bearing retainer <NUM> may 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 to <FIG>, the Hall-effect board <NUM> may be fastened to an inside of the vibrating head <NUM> by means of fasteners <NUM>. The Hall-effect board <NUM> may be a rotational speed-sensing PCB <NUM>. The Hall-effect board <NUM> may include notches 588a, 588b, 588c that are spaced, and in some embodiments equidistantly spaced, about a periphery of the Hall-effect board <NUM>. Each notch 588a, 588b, 588c may be configured to respectively receive one of the three positioning fingers 570a, 570b, 570c (<FIG>). A temperature sensor such as a thermistor <NUM> may be located on the Hall-effect board <NUM>. The thermistor <NUM> measures an air temperature within the vibrating head <NUM>. The thermistor <NUM> sends a signal that is representative of the air temperature within the vibrating head <NUM> to at least one of the power PCB <NUM> and/or the user interface PCB <NUM> in the motor control unit <NUM>. The power PCB <NUM> and/or the user interface PCB <NUM> may operate to compare the air temperature as measured by the thermistor <NUM> to a desired air temperature or range of air temperatures. Further, the power PCB <NUM> and/or the user interface PCB <NUM> may correlate the air temperature as measured by the thermistor <NUM> to a core or coil temperature of the motor <NUM>. In other words, the thermistor <NUM> may detect a temperature of the motor <NUM>. In some embodiments, a desired core or coil temperature of the motor <NUM> may be below <NUM> degrees Celsius, for example. In other embodiments, for example, a desired core or coil temperature of the motor <NUM> may be below <NUM> degrees Celsius, below <NUM> degrees Celsius, below <NUM> degrees Celsius, or below <NUM> degrees Celsius. Further, a desired core or coil temperature of the motor <NUM> may be above, for example, <NUM> degrees Celsius, -<NUM> degrees Celsius, etc..

With reference to <FIG>, a thermistor <NUM> may be located on a part of the cable <NUM> or whip <NUM>. In some embodiments, a thermistor such as one of the thermistors <NUM>, <NUM> may be located on the motor. For example, the thermistor <NUM> may be located, in some embodiments, on an end of the whip <NUM> such as on the whip electrical connector <NUM>. The thermistor <NUM> may function similarly to the thermistor <NUM> to communicate signals that represent an air temperature to the power PCB <NUM> and/or the user interface PCB <NUM>. The power PCB <NUM> and/or the user interface PCB <NUM> may evaluate the signal delivered by the thermistor <NUM> alone or in combination with the signal from the thermistor <NUM>. 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 head <NUM> and/or on the whip <NUM>. In response to the temperature signals from the thermistors <NUM>, <NUM>, the power PCB <NUM> and/or the user interface PCB <NUM> may control the motor <NUM> to cease or to otherwise alter the operation of the motor <NUM> in response to the temperature signals provided by the thermistors <NUM>, <NUM>. In other words, the power PCB <NUM> and/or the user interface PCB <NUM> may cause the motor <NUM> to shut off if a temperature measured by the thermistor <NUM> and/or the thermistor <NUM> is outside of a desired temperature range. In some embodiments, the power PCB <NUM> and/or the user interface PCB <NUM> may cause the motor <NUM> to shut off if a temperature measured by the thermistor <NUM> and/or the thermistor <NUM> is outside of a desired temperature range for a certain (for example, a predetermined) period of time. In another aspect, the portable power unit <NUM> may be configured to deactivate the motor <NUM> in response to the temperature of the motor <NUM> exceeding a threshold temperature and/or in response to the temperature of the motor <NUM> being below a threshold temperature.

With continued reference to <FIG>, the whip electrical connector <NUM> may include a plurality and, in the illustrated embodiment three, commutation terminals 602a, 602b, 602c, each for receiving a pin on another connector such as, for example, the vibrating head electrical connector <NUM>. The commutation terminals 602a, 602b, 602c may be electrically connected with windings of the motor <NUM> by the commutation wires 549a, 549b, 549c. The whip electrical connector <NUM> may further include, for example, nine ports 606a, 606b, 606c, 606d, 606e, 606f, <NUM>, <NUM>, 606i, each for receiving a pin on another connector. One or more of the ports 602a, 602b, 602c, 606a, 606b, 606c, 606d, 606e, 606f, <NUM>, <NUM>, 606i may be configured for transmitting the signals from the thermistors <NUM>, <NUM> to the power PCB <NUM> and/or to the user interface PCB <NUM>. In some embodiments, one or more additional ports 606j may be provided on the whip electrical connector <NUM> in order to transmit the signals from the thermistors <NUM>, <NUM> and/or from the sensor <NUM> to the power PCB <NUM> and/or to the user interface PCB <NUM>. In some embodiments, one or more of the ports 602a, 602b, 602c, 606a, 606b, 606c, 606d, 606e, 606f, <NUM>, <NUM>, 606i may be used to transmit the signals from the thermistors <NUM>, <NUM> and/or from the sensor <NUM> to the power PCB <NUM> and/or to the user interface PCB <NUM>. Other pins and ports may be provided on other connectors for a similar purpose.

With reference to <FIG>, the control panel <NUM> includes the on/off switch <NUM> (<FIG>), the remote pairing button <NUM>, a warning light <NUM>, and an authentication scanner <NUM>. The warning light <NUM> may function as a speed warning light <NUM> and may illuminate in a fashion determined by the power PCB <NUM> and/or the user interface PCB <NUM>. For example, the power PCB <NUM> and/or the user interface PCB <NUM> receives a speed signal from a sensor such as, for example, the Hall-effect board <NUM>. The speed signal may represent a rotational speed of the motor <NUM>. The speed warning light <NUM> may illuminate when the motor <NUM> is operating at a rotational speed that is outside of a desired range. For example, the speed warning light <NUM> may illuminate when the motor <NUM> is operating at a rotational speed of less than, for example, <NUM>,<NUM> RPM. The speed warning light <NUM> may illuminate when the motor <NUM> is operating at a rotational speed of less than another rotational speed that may be predetermined and/or when the motor <NUM> is operating at a rotational speed of greater than another rotational speed that may be predetermined. The warning light <NUM> may 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 light <NUM> may also indicate to the user that the motor <NUM> is operating at a temperature outside of a desired temperature range. Therefore, the warning light <NUM> may be controlled by the power PCB <NUM> and/or the user interface PCB <NUM> based at least in part on temperature signals received from the thermistor <NUM> and/or the thermistor <NUM>. To indicate that the motor <NUM> is operating at a temperature that is too hot or too cold, the warning light <NUM> may flash.

With continued reference to <FIG>, the authentication scanner <NUM> may read an identification device, such as an RFID card, carried by the user. In some embodiments, the portable power unit <NUM> may be configured such that the portable power unit <NUM> is not operable (or is partially inoperable) until the identification device carried by the user is scanned by the authentication scanner <NUM>.

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.

Although the invention has been described in detail with reference to certain preferred embodiments, variations and modifications exist within the scope of the claims.

Claim 1:
A concrete vibrator system (<NUM>) comprising:
a vibrating head (<NUM>, <NUM>, <NUM>) including a shaft (<NUM>) having a center of mass radially offset from a rotational axis of the shaft and an onboard electric motor (<NUM>, <NUM>) configured to provide torque to the shaft (<NUM>), causing the shaft to rotate (<NUM>);
a portable power unit (<NUM>) including a battery pack (<NUM>) configured to provide electrical current to the motor (<NUM>, <NUM>); and
a cable extending between the portable power unit (<NUM>) and the vibrating head (<NUM>), the cable being configured to transmit electrical current from the battery pack (<NUM>) to the motor (<NUM>, <NUM>) and a motor control signal from the portable power unit (<NUM>) to the motor (<NUM>, <NUM>),
wherein the portable power unit includes a motor control unit (<NUM>) configured to transmit the motor control signal to the motor (<NUM>, <NUM>),
characterized in that
the portable power unit includes a battery receptacle unit (<NUM>) to which the battery pack (<NUM>) is removably coupled
and in that the battery receptacle unit (<NUM>) and the motor control unit (<NUM>) are integrated in a common housing (<NUM>).