Control device for an electric motor

• US 7,359,628 B2
• Filed: 03/22/2002
• Issued: 04/15/2008
• Est. Priority Date: 03/24/2001
• Status: Expired due to Term

• Current Assignee: Chiron Corporation (Bayer AG), Marquardt GmbH (J U J Marquardt KG)
• Original Assignee: Marquardt GmbH (J U J Marquardt KG)
• Inventors: Broghammer, Peter, Hafen, Daniel
• Primary Examiner(s): IP, SHIK LUEN PAUL
• Application Number:
  US10/472,691
• Publication Number:
  US 20040112616A1
• Time in Patent Office: 2,216 Days
• Field of Search: 318/138, 318/254, 318432-434, 318/439, 318/700, 173/2, 173/20, 173/171, 173/216, 173/217, 388/819, 388/820, 388/937, 200/6.BB, 200/522
• US Class Current: 388/819
• CPC Class Codes: B25F 5/008 Cooling means
• CPC Class Codes: B25F 5/02 Construction of casings, bodies or handles B25F5/006, B25F5/008 take precedence
• CPC Class Codes: Y10S 388/937 Hand tool

Abstract

The invention relates to a drive device for an electric motor, in particular for a brushless DC motor in an electrical tool, which is powered by a rechargeable battery. The drive device has at least one power semiconductor, in particular for controllable application of an electrical voltage to the electric motor, a control circuit for controlling the power semiconductor, and a mounting plate which, for example, is in the form of a printed circuit board. At least one portion of the control circuit, in particular electrical and/or electronic components as well as the conductor tracks (which connect the electrical and/or electronic components) of the control circuit, is arranged on the mounting plate. The power semiconductor is arranged on the mounting plate and/or on a mount element, which is mounted on the mounting plate.

Claims

1. An electrical tool comprising:

a handle shell,

a device for driving an electric motor, the device being arranged within the handle shell of the electrical tool and comprising;

at least one power semiconductor for controlling an electrical voltage applied to the electric motor;

a control circuit for controlling the at least one power semiconductor, the control circuit comprising electrical components and conductor tracks for connecting the electrical components;

a mounting plate in the form of a printed circuit board, at least a portion of the control circuit being mounted on the mounting plate; and

a mount element mounted on the mounting plate and having at least one surface projecting approximately perpendicularly from the mounting plate, the at least one power semiconductor being arranged on the at least one surface of the mount element, wherein the device reduces wiring complexity within the electrical tool.

2. The electrical tool as claimed in claim 1, wherein the electric motor is a brushless DC motor powered by a rechargeable battery.

3. The electrical tool as claimed in claim 1, wherein the at least one power semiconductor comprises at least two power semiconductors, each of the at least two power semiconductors being arranged on one of the at least one surface of the mount element and the mounting plate.

4. The electrical tool as claimed in claim 1, wherein the mount element is coupled to the mounting plate by at least one of pressing and soldering and constitutes a heat sink for the at least one power semiconductor.

5. The electrical tool as claimed in claim 1, further comprising a rechargeable battery for supplying voltage to the electric motor, and wherein the mounting plate is arranged in the vicinity of the rechargeable battery such that at least one of (1) the at least one power semiconductor and (2) the mount element, faces the rechargeable battery.

6. The electrical tool as claimed in claim 5, the device further comprising plug contacts in the form of contact brackets arranged on the mounting plate to make plug in contact with the rechargeable battery, the plug contacts being plugged and/or latched onto the mounting plate by means of an adapter.

7. The electrical tool as claimed in claim 6, wherein at least one of the at least one power semiconductor and the mount element is arranged directly on an edge of the mounting plate which faces the rechargeable battery, at least one of the at least one power semiconductor and the mount element making direct electrical contact with the plug contacts for the rechargeable battery, the plug contacts being integral with at least one of the mounting plate and the mount element and having capacitors of the control circuit soldered directly thereto.

9. The electrical tool as claimed in claim 1, the device further comprising

a sensor element in the form of at least one of a potentiometer, a Hall element, and a magnetoresistive element, the sensor element being located on the mounting plate and adapted to produce a nominal value supplied to the control circuit to set an associated rotation speed for the electric motor, the sensor element being arranged in a housing of an electrical switch;

and

an operating member for the sensor element, the operating member being in the form of a push button and being arranged on the housing of the switch.

10. The electrical tool as claimed in claim 9, the device further comprising a contact system for switching the voltage supply for at least one of the electric motor and the control circuit, the contact system being arranged in the electrical switch, the contact system being capable of operating by means of the operating member.

11. The electrical tool as claimed in claim 9, the device further comprising

a further electrical switch in the form of at least one of a micro switch and a snap action switch, the further electrical switch being arranged on the mounting plate;

and

an operating element in the form of a slide for switching the electric motor between clockwise running and counterclockwise running, the operating element acting on the further switch.

12. The electrical tool according to claim 9,

wherein the device is arranged in the handle shell such that the operating member projects out of the handle shell for manual operation.

13. An electrical tool according to claim 9,

wherein the device is arranged in a rechargeable battery such that, when the rechargeable battery is inserted into the handle shell of the electrical tool, the an operating member projects out of the handle shell for manual operation.

8. The electrical tool as claimed in 7, wherein the capacitors of the control circuit are arranged on the mounting plate, the capacitors being located between at least one of (a) the at least one power semiconductor and the plug contacts and (b) the mount element and the plug contacts.

14. An electrical tool comprising:

a handle shell;

a device for driving an electric motor, the device being arranged within the handle shell of the electrical tool and comprising;

at least one power semiconductor for controlling an electrical voltage applied to the electric motor;

a control circuit for controlling the at least one power semiconductor, the control circuit comprising electrical components and conductor tracks for connecting the electrical components;

a mounting plate comprising a metal part with a surface facing the electrical components and the conductor tracks, at least a portion of the control circuit being mounted on the mounting plate; and

an insulating coating provided on the surface of the metal part, wherein the electrical components and the conductor tracks are located on the coating and the metal part constitutes a heat sink; and

a mount element mounted on the mounting plate, wherein a surface of the mount element projects approximately perpendicularly from the mounting plate and the at least one power semiconductor is arranged on the surface of the mount element, wherein the device reduces wiring complexity within the electrical tool.

15. The electrical tool as claimed in claim 14, wherein the electric motor is a brushless DC motor powered by a rechargeable battery.

16. The electrical tool as claimed in claim 14, wherein the at least one power semiconductor comprises at least two power semiconductors, each of the at least two power semiconductors being arranged on at least one of the mount element and the mounting plate.

17. The electrical tool as claimed in claim 16, wherein at least one of the at least two power semiconductors is arranged on the coating on the metal part.

18. The electrical tool as claimed in claim 16, wherein the coating contains a cutout, and at least one of the at least two power semiconductors is mounted directly on the metal part by a soldering connection.

19. The device for driving an electric motor electrical tool as claimed in claim 14, wherein the mount element constitutes a heat sink for the at least one power semiconductor, the mount element being coupled to the mounting plate by at least one of pressing and soldering.

20. The electrical tool as claimed in claim 14, further comprising a rechargeable battery for supplying voltage to the electric motor, and wherein the mounting plate is arranged in the vicinity of the rechargeable battery such that at least one of (a) the at least one power semiconductor and (b) the mount element, faces the rechargeable battery.

21. The electrical tool as claimed in claim 20, the device further comprising plug contacts in the form of contact brackets arranged on the mounting plate to make plug in contact with the rechargeable battery, the plug contacts being plugged and/or latched onto the mounting plate by means of an adapter.

22. The electrical tool as claimed in claim 21, wherein at least one of the at least one power semiconductor and the mount element is arranged directly on an edge of the mounting plate which faces the rechargeable battery, at least one of the at least one power semiconductor and the mount element making direct electrical contact with the plug contacts for the rechargeable battery, the plug contacts being integral with at least one of the mounting plate and the mount element and having capacitors of the control circuit soldered directly thereto.

24. The electrical tool as claimed in claim 14, the device further comprising

a sensor element in the form of at least one of a potentiometer, a Hall element, and a magnetoresistive element, the sensor element being located on the mounting plate and adapted to produce a nominal value supplied to the control circuit to set an associated rotation speed for the electric motor, the sensor element being arranged in a housing of an electrical switch;

and

an operating member for the sensor element, the operating member being in the form of a push button and being arranged on the housing of the switch.

25. The electrical tool as claimed in claim 24, the device further comprising

a further electrical switch in the form of at least one of a micro switch and a snap action switch, the further electrical switch being arranged on the mounting plate;

and

an operating element in the form of a slide for switching the electric motor between clockwise running and counterclockwise running, the operating element acting on the further switch.

26. The electrical tool according to claim 24,

wherein the device is arranged in the handle shell such that the operating member projects out of the handle shell for manual operation.

27. The electrical tool according to claim 24,

wherein the device is arranged in a rechargeable battery such that, when the rechargeable battery is inserted into the handle shell of the electrical tool, the operating member projects out of the handle shell.

23. The electrical tool as claimed in 22, wherein the capacitors of the control circuit are arranged on the mounting plate, the capacitors being located between at least one of (a) the at least one power semiconductor and the plug contacts and (b) the mount element and the plug contacts.

28. A device for driving an electric motor, comprising:

at least one power semiconductor for controlling an electrical voltage applied to the electric motor;

a control circuit for controlling the at least one power semiconductor, the control circuit comprising electrical components and conductor tracks for connecting the electrical components;

a mounting plate comprising a metal part with a surface facing the electrical components and the conductor tracks, at least a portion of the control circuit being mounted on the mounting plate;

an insulating coating provided on the surface of the metal part, wherein the electrical components and the conductor tracks are located on the coating and the metal part constitutes a heat sink;

a sensor element in the form of at least one of a potentiometer, a Hall element, and a magnetoresistive element, the sensor element being located on the mounting plate and adapted to produce a nominal value supplied to the control circuit to set an associated rotation speed for the electric motor, the sensor element being arranged in a housing of an electrical switch;

an operating member for the sensor element, the operating member being in the form of a push button and being arranged on the housing of the switch; and

a contact system for switching the voltage supply for at least one of the electric motor and the control circuit, the contact system being arranged in the electrical switch, the contact system being capable of operating by means of the operating member.