POWER TOOL HAVING A BRUSHLESS MOTOR AND A CONTROL UNIT FOR CONTROLLING THE BRUSHLESS MOTOR

• US 20140210379A1
• Filed: 01/28/2014
• Published: 07/31/2014
• Est. Priority Date: 01/28/2013
• Status: Active Grant

• Current Assignee: Makita Corporation
• Original Assignee: Makita Corporation
• Inventors: OMURA, Motohiro, Kato, Itsuku
• Granted Patent: US 9,276,509 B2
• Time in Patent Office: Days
• US Class Current: 318/139
• CPC Class Codes: H02P 6/15 Controlling commutation time
• CPC Class Codes: H02P 6/153 wherein the commutation is advanced from position signals phase in function of the speed

Abstract

A power tool according to one aspect of one embodiment described in the disclosure includes a brushless motor, a battery voltage detection unit configured to detect a voltage of a battery that provides energy for driving the brushless motor, a rotational position detection unit configured to detect a rotational position of the brushless motor, and a control unit configured to control a drive output supplied to the brushless motor based at least in part on a signal from the rotational position detection unit. The control unit controls a current conduction angle and/or an advance angle supplied to the brushless motor so that, during control of the drive output to the brushless motor, a rotational speed or a conducting current of the brushless motor approaches or reaches a target value, the target value being based at least in part on a battery voltage detected by the battery voltage detection unit.

Claims

1. A power tool, comprising:

a brushless motor;

a battery voltage detection unit configured to detect a voltage of a battery that provides energy for driving the brushless motor;

a rotational position detection unit configured to detect a rotational position of the brushless motor; and

a control unit configured to control a drive output supplied to the brushless motor based at least in part on a signal from the rotational position detection unit;

wherein,

the control unit is configured to control a current conduction angle and/or an advance angle supplied to the brushless motor such that, during control of the drive output to the brushless motor, a rotational speed or a conducting current of the brushless motor reaches a target value based at least in part on a battery voltage detected by the battery voltage detection unit.

2. The power tool according to claim 1, wherein the control unit is configured to:

increase the rotational speed of the brushless motor by widening the current conduction angle and/or advancing the advance angle if the rotational speed of the brushless motor is lower than a target rotational speed, the target rotational speed being based at least in part on the battery voltage; and

decrease the rotational speed of the brushless motor by narrowing the current conduction angle and/or retarding the advance angle if the rotational speed of the brushless motor is higher than the target rotational speed.

3. The power tool according to claim 1, wherein the control unit is configured to:

increase the conducting current of the brushless motor by widening the current conduction angle and/or advancing the advance angle if the conducting current of the brushless motor is smaller than a target current, the target current being based at least in part on the battery voltage; and

decrease the conducting current of the brushless motor by narrowing the current conduction angle and/or retarding the advance angle if the conducting current of the brushless motor is larger than the target current.

4. The power tool according to claim 1, wherein the control unit is configured such that:

if the rotational speed or the conducting current of the brushless motor converges to within a predetermined range encompassing the target value, the control unit terminates control of the current conduction angle and/or the advance angle by fixing the current conduction angle and/or the advance angle.

5. The power tool according to claim 4, wherein the control unit is configured such that:

if the rotational speed or the conducting current of the brushless motor is within the predetermined range for a prescribed time or longer, then the control unit terminates control of the current conduction angle and/or the advance angle by fixing the current conduction angle and/or the advance angle.

6. The power tool according to claim 1, wherein the control unit is configured such that:

prior to starting the drive of the brushless motor, the control unit detects the battery voltage via the battery voltage detection unit and sets the target value based at least in part on the detected battery voltage.

7. The power tool according to claim 5, wherein the control unit is configured such that:

prior to starting the drive of the brushless motor, the control unit detects the battery voltage via the battery voltage detection unit and sets the target value based at least in part on the detected battery voltage.

8. The power tool according to claim 7, wherein the control unit is configured to:

increase the rotational speed of the brushless motor by widening the current conduction angle and/or advancing the advance angle if the rotational speed of the brushless motor is lower than a target rotational speed, the target rotational speed being based at least in part on the battery voltage; and

decrease the rotational speed of the brushless motor by narrowing the current conduction angle and/or retarding the advance angle if the rotational speed of the brushless motor is higher than the target rotational speed.

9. A power tool according to claim 8, wherein the control unit is configured to:

increase the conducting current of the brushless motor by widening the current conduction angle and/or advancing the advance angle if the conducting current of the brushless motor is smaller than a target current, the target current being based at least in part on the battery voltage; and

decrease the conducting current of the brushless motor by narrowing the current conduction angle and/or retarding the advance angle if the conducting current of the brushless motor is larger than the target current.

10. A power tool, comprising:

a brushless motor having a rotor and having an input for receiving a control signal;

a battery voltage detection unit configured to detect a voltage of a battery electrically connected to the brushless motor;

a rotational position detection unit configured to detect a rotational position of the rotor of the brushless motor; and

a control unit configured to send a control signal to the input of the brushless motor for controlling a current conduction angle or an advance angle or both a current conduction angle and an advance angle of the brushless motor,

wherein,

the control unit is configured to control the current conduction angle or the advance angle or both the current conduction angle and the advance angle such that a rotational speed or a conducting current of the brushless motor reaches a target value, wherein the target value is based at least in part on a battery voltage detected by the battery voltage detection unit.

11. The power tool according to claim 10, wherein the control unit is configured such that:

if the rotational speed reaches an acceptable speed level within a predetermined range of acceptable speeds or if the conducting current reaches an acceptable current level within a predetermined range of current levels, the control unit stops changing the current conduction angle or stops changing the advance angle or stops changing both the current conduction angle and the advance angle.

12. A method of controlling a power tool having a brushless motor and a battery for powering the brushless motor, the method comprising:

detecting a voltage of the battery;

detecting a rotational position of a rotor of the brushless motor;

determining a target rotational speed or a target conducting current for the brushless motor based at least in part on the detected voltage of the battery; and

controlling a current conduction angle and/or an advance angle of the brushless motor to cause a rotational speed of the brushless motor to reach the target rotational speed or to cause a conducting current of the brushless motor to reach the target conducting current.

13. The method according to claim 12, further comprising:

increasing the rotational speed of the brushless motor by widening the current conduction angle and/or advancing the advance angle, or

decreasing the rotational speed of the brushless motor by narrowing the current conduction angle and/or retarding the advance angle.

14. The method according to claim 12, further comprising:

increasing the conducting current of the brushless motor by widening the current conduction angle and/or advancing the advance angle;

or

decreasing the conducting current of the brushless motor by narrowing the current conduction angle and/or retarding the advance angle.

15. The method according to claim 12, further comprising:

determining whether the rotational speed of the brushless motor is within a predetermined range encompassing the target rotational speed, and

if so, terminating control of the current conduction angle and/or the advance angle by holding constant the current conduction angle and/or the advance angle.

16. The method according to claim 12, further comprising:

determining whether the conducting current of the brushless motor is within a predetermined range encompassing the target conducting current, and

if so, terminating control of the current conduction angle and/or the advance angle by holding constant the current conduction angle and/or the advance angle.