CN201263101Y - 具有双换向器条组及可选串联并联连接线圈的直流电动机 - Google Patents

具有双换向器条组及可选串联并联连接线圈的直流电动机 Download PDF

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CN201263101Y
CN201263101Y CNU2007900000274U CN200790000027U CN201263101Y CN 201263101 Y CN201263101 Y CN 201263101Y CN U2007900000274 U CNU2007900000274 U CN U2007900000274U CN 200790000027 U CN200790000027 U CN 200790000027U CN 201263101 Y CN201263101 Y CN 201263101Y
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armature
group
electric tool
coil
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乔舒亚·D·韦斯特
尤戴·S·德施潘德
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    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K23/00DC commutator motors or generators having mechanical commutator; Universal AC/DC commutator motors
    • H02K23/26DC commutator motors or generators having mechanical commutator; Universal AC/DC commutator motors characterised by the armature windings
    • H02K23/36DC commutator motors or generators having mechanical commutator; Universal AC/DC commutator motors characterised by the armature windings having two or more windings; having two or more commutators; having two or more stators
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K23/00DC commutator motors or generators having mechanical commutator; Universal AC/DC commutator motors
    • H02K23/02DC commutator motors or generators having mechanical commutator; Universal AC/DC commutator motors characterised by arrangement for exciting
    • H02K23/04DC commutator motors or generators having mechanical commutator; Universal AC/DC commutator motors characterised by arrangement for exciting having permanent magnet excitation
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K7/00Arrangements for handling mechanical energy structurally associated with dynamo-electric machines, e.g. structural association with mechanical driving motors or auxiliary dynamo-electric machines
    • H02K7/14Structural association with mechanical loads, e.g. with hand-held machine tools or fans
    • H02K7/145Hand-held machine tool

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  • Power Engineering (AREA)
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Abstract

一种永磁体直流电动机,特别适合于在电动工具,尤其是手持的、电池供电的电动工具中使用。所述电动机包括两组电枢线圈,每组线圈连接到电枢上的单个换向器条组。分别的电刷对被用于与两组换向器条接合。切换子系统或者通过使用者可接合开关人工控制或者由控制器自动控制以将所述两组线圈串联或者并联配置。所述串联连接比并联连接提供所述电动机更高的效率,但是较低的功率输出。因此,所述工具的运行特性可以被调节为更好满足工作任务的需要,并且以最高效的方式利用可用的电池电量。

Description

具有双换向器条组及可选串联并联连接线圈的直流电动机
技术领域
本申请涉及直流电动机,更具体地说,涉及一种直流电动机,其具有包括一对换向器条组的电枢和其上具有两组绕组的电枢叠片组,以及用于使得所述两组绕组可控制的串联连接或者并联连接以为该电动机提供若干不同操作模式的切换系统。
背景技术
永磁体直流电动机在很多场合广泛使用,特别是与电动工具,例如钻、锯、沙磨机等等一起使用。这些电动机与由可充电直流电源供电的无缆电动工具一起使用。利用无缆电动工具时,经常需要完成多种需要不同电动机性能特征的任务以最好地完成工作任务。例如,当在一片软木上用无缆式钻钻孔时,所需要的扭矩,以及因此的电动机所需的功率输出可能仅仅是钻穿硬木或者经压力处理的木材所需的一小部分。然而,从功率观点,如果经常使用同一个钻用于仅仅需要轻负载钻削的任务,这时对于该工作任务仅仅需要较低的扭矩,对于高功率场合设计电动机是效率不高的。
在永磁直流电动机中,所述电动机的运行特性可以通过改变导线尺寸和每个线圈缠绕到电枢叠片组的绕组匝数而显著改变。对于永磁体直流的给定电动机,加倍构成每个线圈的绕组的匝数将把所述电动机的空载速度大约减小一半,并且该电机的堵转扭矩显著增大。实际堵转扭矩将受到电源阻抗的很大影响。例如,典型的电池/电动工具组合可能导致电动机的堵转扭矩增大50%。另外,电动机效率将增大,但是同时电动机的最大输出功率将减小。因此,仅仅加倍线圈绕组的匝数,同时提供显著增大的堵转扭矩并在低功率时提供更高的效率,将以一种方式改变所述电动机的运行特性,即使得该电动机更不适合于需要更大输出功率的工作任务。然而,设计一种永磁体电动机以提供更高的恒定功率输出将导致所述电动机汲取另外的电池电流,这对于很多钻削任务来说(比如,轻负载钻削任务)来说并不需要。对于特定的电动机,与可以用于更低的最大功率输出而设计的电动机能够实现的相比,这将减小为工具供电的电池运行时间。
因此,本实用新型的目的就是提供一种具有提供变化的速度、扭矩、以及功率输出等级的多种明显不同运行模式的直流电动机,以便更好的与特定的工作任务相匹配。例如,如果电动机和相关的控制系统设置为可以自动检测执行特定任务需要额外的电动机功率的时刻,并且所述电动机自动从特定运行模式转换到增大或者减小扭矩和/或运行速度将是很有利的。或者,电动机的不同运行模式可以由使用者通过电动工具上的控制机构选择是理想的。这将使得使用者可以控制不同的可选运行模式的执行。考虑将执行的工作任务,对于给定工作任务最优化所述电动机性能也将有助于最高效的使用可用的电池电源。对于特定直流电动机,在特定的电量,这反过来可以用于显著延长电池的运行时间。
实用新型内容
为了实现本实用新型的目的,提供了一种电动机,特别是很好地适合于与多种电动工具一起使用的电动机,但是不限于涉及电动工具应用的场合。在一个实施例中,所述电动机包括具有定子和支撑以在定子中旋转运动的电枢的直流电动机。所述电枢包括叠片组,和同轴延伸穿过所述叠片组的电枢轴。所述电枢轴包括两组支撑在该电枢轴上的换向器条,两组缠绕在所述叠片组上的线圈绕组,以及两对电刷。第一对电刷与换向器条组中的一个相关联而第二对电刷与所述换向器条组的第二个相关联。切换系统将两对电刷互相连接以使得两个线圈连接以形成串联电路或者并联电路。当以串联配置连接时,所述电动机的空载运行速度基本是两个线圈组并联连接时的空载运行速度的一半,并且堵转扭矩显著增大而在低功率输出时效率更高。当所述两个线圈组并联配置连接时,所述电动机提供比串联配置更大的最大功率输出,并且空载速度为串联配置时的大约两倍。然而,当所述线圈组被布置为并联配置时,所述电动机的效率更低。
因此,控制两组电枢线圈在串联和并联配置之间连接为电动机提供了具有不同运行特性的两个不同运行模式。这使得可以实现“最大功率”模式,这里所述电动机被配置为其两个线圈组为并联。这对于需要电动机更大功率输出的任务,为电动机提供了更高的空载速度和最大功率输出。如果所述电动机被用在钻中,这样重载任务可能涉及驱动螺丝进入硬木中或者钻入潮湿的压力处理过的木材中。对于轻载任务,通过使用线圈的串联配置,同一个钻的使用可以最优化,所述串联配置提供了较小功率输出时更高的电动机效率,使得所述电动机更适合于轻载钻削任务。这样的轻载任务可能包括钻孔或者在例如松木的软木中驱动螺丝。
在一个实施例中,控制器与电动机速度检测器和电动机电流检测器一起使用以自动在串联和并联配置之间切换线圈组。所述控制器在串联和并联绕组配置之间选择以配置所述电动机以便将电动机的运行参数与当前工作任务最好的匹配。在另一个实施例中,电动工具包括使用者用来选择最大功率模式或者最大效率模式的控制机构。在另一个实施例中,可选的LED显示器通知使用者电动工具运行在哪个模式。
本实用新型可应用的其他领域将根据此后提供的详细描述而变得明显。应当理解,所述详细描述和特定的例子,虽然表示了本实用新型不同的优选实施例,仅仅是用于说明的目的,并不是为了限制本实用新型的范围。
附图说明
根据下面的详细描述和附图,本实用新型将能被更充分的理解,其中:
图1是示例性电动工具的侧视图,在这个示例中,具有根据本实用新型的优选实施例的永磁体直流电动机的无缆钻在短划线中表示;
图2是图1的电动工具的内部组件的简化的示意性框图;
图3A和3B示出了图2的电动机的电枢的简化的框图,其还示出了两组换向器条、两组线圈、两对换向器条、用于选择性的将所述两个线圈组以串联或者并联配置的电开关,以及用于检测所述电动机经历的运行状态并在串联(图3A)和并联(图3B)连接之间选择的各种其他组件;
图4是简化的电路原理图,其示出了当所述线圈组串联连接时两个线圈组的连接;以及
图5示出了图4中的两个线圈组的并联配置;
图6示出了两个性能曲线,一个示出了当电动机电枢线圈串联连接时该电动机的速度/扭矩关系,另一个示出了当其电枢线圈并联连接时的速度/扭矩关系;
图7示出了两个性能曲线,一个示出了当电动机电枢线圈串联连接时该电动机的效率/功率关系,另一个示出了当其电枢线圈并联连接时的效率/功率关系;
图8示出了两个性能曲线,一个示出了当电动机电枢线圈串联连接时该电动机的功率/扭矩关系,另一个示出了当其电枢线圈并联连接时的功率/扭矩关系;
图9示出了两个性能曲线,一个示出了当电动机电枢线圈串联连接时该电动机的电流/扭矩关系,另一个示出了当其电枢线圈并联连接时的电流/扭矩关系;
图10是示出了电动机每个串联和并联连接线圈组所汲取的电流和功率之间的关系的曲线图;
图11是示出了电动机效率与轻、中、重钻削场合的电动机可用扭矩输出的关系的曲线图;
图12是示出了电动机速度与轻、中、重钻削场合的电动机扭矩的关系的曲线图;
图13是示出了可以实际上瞬时改变电动机性能特征的线圈组连接的曲线图;
图14是一个曲线图,其示出了表示串联和并联线圈连接的一对速度/扭矩性能曲线,并进一步示出了使用串联和并联连接线圈的电动机的最大功率范围,最大扭矩范围和最大效率范围;
图15是一个曲线图,其示出了三个电动机性能曲线以显示速度控制的使用如何被实现以产生速度/扭矩性能曲线的,该曲线是对由并联和串联连接的线圈产生的曲线的改进;
图16-21示出了电动机和齿轮减速单元以及如何利用串联或并联线圈结合用所述齿轮减速单元不同的内部级获得若干不同的输出的简化示意图;
图22电动机的常规速度/扭矩曲线和典型的齿轮箱的速度/扭矩性能曲线,其示出了需要设计到所述齿轮箱中的典型速度/扭矩“上裕量”;
图23是一个曲线图,其示出了此处所描述的新型电动机的速度/扭矩性能如何由该电动机系统的控制器控制,以便基本匹配而不超过齿轮减速单元的速度-扭矩能力;
图24是一个曲线图,其示出了该新型电动机的速度/扭矩性能如何由该电动机系统的控制器控制,以便基本匹配,并周期地在短时间段超过齿轮减速单元的速度-扭矩性能能力;以及
图25-28是图1的电动工具的顶视图,其示出了选择器开关和用于显示工具运行模式和电池充电水平的显示系统。
具体实施方式
下面多个优选实施例的描述本质上仅仅为了示例而决不是为了限制本实用新型,其应用场合,或使用。
参照图1,其示出了根据本实用新型一个优选实施例的包括电动机系统10的、钻12形式的电动工具。可以直接理解,当电动工具被以手持钻12示出时,所述电动机系统10可以以多种其他电动工具,例如锯、沙磨机、刳刨机、钻床以及几乎任何其他形式的直流供电的工具或设备实现。然而,所述电动机系统10预期在手动无缆电动工具中特别有用。
进一步参照图1,所述示例性钻12典型地包括连接到齿轮减速单元16的输出端的卡盘14。所述齿轮减速单元16的输入端连接到电动机10a的输出轴。扳机20用于打开和关闭所述电动机10a并且可能也被用于根据该扳机的接合程度控制所述电动机的速度。可充电电池22被可拆卸的固定在,或者可拆卸的连接到钻12的外壳26的把手部分24中。控制器28也设置在所述把手部分24中,但是也可以位于钻12中的其他位置。所述控制器28与扳机20和电动机10a通信。所述控制器28被用于控制电动机10a并马上将被详细描述。
使用者可接合的选择器开关30也与所述控制器28通信。该选择器开关30也可以是线性滑动开关、多位置旋转开关、或者甚至是多个按钮开关。所述选择器开关30允许使用者从电动机10a的若干操作模式中选择一个,以使得将所述电动机10a的运行特性变得更好处理特定的任务。例如,如将在下面的段落中将详细描述的那样,如果工作任务涉及将螺栓旋入软木,使用者可以用选择器开关30选择高速、低功率输出。如果工作任务涉及钻入硬木、钻入潮湿的压力处理的木材、或者钻入其它需要更大电动机功率的材料,使用者可以为电动机10a选择高工率输出模式。可以加入显示器32以显示电动机10a的各种运行模式。显示器32可以包括LCD、LED或者其它具有低功率吸取的显示装置的任何适合形式。
参照图2,其示出了钻12的内部组件的高度简化的框图。使用常规电压调节器34以为控制器28和所述钻12中使用的其它电子组件提供调节的直流电压。所述控制器28可以是8位、16位或者更大能力的控制器,例如数字信号处理器(DSP)。在一个实施例中,用于电连接电动机10a的电枢线圈为串连和并联配置的系统包括MOSFET连接子系统36。电动机速度检测器38可以被用于检测所述电动机10a的速度并对该电动机10a施加表示电动机速度的控制信号。电流检测电路40可以被用于检测流过电动机10a的电流并根据所检测的流过电动机10a的电枢线圈的电流施加控制信号到控制器28。组件28、30、32、34、38和40是所述钻12的“控制”部分。所述电动机系统10可以被看作包括电动机10a、连接子系统36、速度检测器38、电流检测电流40、控制器28、使用者选择控制器30和扳机开关20。
参照图3A,其示出了电动机10a的电枢42。如在下面的段落中详细描述的那样,所述电动机10a包括第一组电枢线圈,其通过附图标记44以高度简略的形式示出,缠绕在所述电枢42的叠片组46上。第一组线圈44连接到第一组换向器条48。第一组换向器条被支撑在电枢轴50上。所述电枢轴50延伸穿过叠片组46的同轴中心并包括一对在相对端相邻的轴承52以支撑电枢轴50在所述钻12的外壳中旋转运动。齿杆54用于与齿轮减速单元16接合。第一对电刷56a、56b设置为接触第一组换向器条48。
所述电枢42也包括缠绕在所述叠片组46的槽中的第二组电枢线圈58。所述第二组线圈58连接到安装在所述电枢轴50上的第二组换向器条60。第二对电刷62a、62b设置为与第二组换向器条60接触。
所述两对电刷56a、56b和62a、62b通过开关64、66和68连接电池22的末端。开关64、66和68共同表示图2中的开关连接系统36。开关64、66和68使得电刷连接以便所述两组电枢线圈54、58串连或并联连接。串连连接所述电枢线圈44、58提供电动机10a具有较低最大功率输出,以及较低空载速度,但是效率较高的第一运行模式。并联连接所述电枢线圈44、58提供第二运行模式。在该第二运行模式中,所述电动机10a与串连布置提供的相比具有较高的空载速度和较高的最大功率输出,但是当该电动机以较低功率输出时,以电动机效率更低为代价。因此,通过控制所述两个电枢线圈组44、58,单个电动机可以提供显著不同的运行特性。这通过允许其运行特性更好的适用于即将到来的特定工作任务(即,需要更高电动机功率或者更低电动机功率的任务)增加了所述电动机10a的应用。通过为那些需要更低程度电动机功率的任务选择第一运行模式,所述电动机10a流过的电流减小,因此与如果所述钻在第二运行模式下持续运行实现的运行时间相比在给定电量延长所述钻12的运行时间。然而,对于需要更大程度电动机输出功率的工作任务,所述第二运行模式很容易获得。
图3A示出了通过开关64、66和68连接以便两个线圈组44、58串连连接的两组电刷56a、56b和62a、62b。在这个模式中,开关64和66打开,同时开关68关闭。箭头表示当所述电动机10a在第一运行模式,两个线圈组44、58串连连接时流过电刷56a、56b、62a、62b和开关64、66、68的电流方向。在电刷56a、第一线圈组44、电刷56b、开关68、电刷62a、第二线圈组、和电刷62b之间形成完全串连通路。
图3B表示流过相同组件的电流方向,但是开关62、64、66布置成并联连接电刷对56a、56b。在这个模式中,开关64和66关闭而开关68打开。电流从所述电池的正端子同时流过电刷56a和62a,同时流过线圈组44和58并流回该电池的负端子。流过所述第一线圈组44的电流在其流回电池22的负端子时流过开关66。
所述开关64、66和68可以包括全部位于公用、独立电路板组件上的MOSFET开关,或者它们可以位于具有控制器28的印刷电路板组件上。也可以利用除了MOSFET的任何其它电控开关,只要该开关能够处理当在其最大功率模式运行时将由电动机10a汲取的最大电流。
参照图4和5,其示出了线圈组44和58的简化电路示意图以进一步示出两个线圈组44和58到它们各自换向器条组48和60的互相连接的例子。在这个示例中,所述电枢42缠绕有构成第一线圈组44的第一组十个线圈,和构成第二线圈组58的另外组十个线圈。
电动机运行性能的比较
提供能够进行上述运行模式的电动机需要考虑其基本运行特性。例如,设计为用于更高功率的电动机在低扭距和高速度场合效率较低,例如,当钻入小螺钉或者在软木中钻小孔。主要原因是由于具有较高的空载速度和较少的线圈匝数,设计为用于大功率的电动机具有较低的扭矩每安培比。基本上,当两个线圈组44、58串连连接时,与线圈组44、58并联连接时所获得的相比,所述电动机10a将产生一半功率并且将在空载速度的一半运行。然而,将线圈组44,58串连连接与线圈组44、58的并联连接相比将基本上产生两倍的扭矩每安培比率。因此,线圈组44、58串连连接,对于相同的低扭矩、高速度应用场合,所述电动机10a将仅仅汲取大约一半的电流。因此将所述线圈组44、58串连连接将在以给定的电量为给定的电动机供电时增长电池22的运行时间。
现在参照图6-10,其示出了当在两个运行模式下运行时电动机10a的性能的比较。在图6中,速度/扭矩关系由曲线70和72示出,曲线70表示两个线圈组44、58串联连接(运行模式1),而曲线72表示两个线圈组并联连接(运行模式2)。曲线72表示当所述电动机10a被布置成其电枢线圈组44、58并联连接时空载速度相当的高(在此例中约为27000转)。
图7示出了当所述电动机电枢线圈组44、58串联连接和并联配置连接时效率和功率之间的关系。曲线74表示串连连接而曲线76表示并联连接。当所述电动机10a输出功率小于大约300瓦时,可以看到串连连接电动机效率更高,当电动机功率输出小于大约100瓦时仍然非常高。因此,对于轻载工作任务,所述线圈组44、58串联连接(运行模式1)使得电动机10a能够以高效的方式运行,该方式可以在给定的电量下延长所述钻12的运行时间,其超过如果所述电动机10a被配置成提供恒定的最大功率输出的运行时间。
图8示出了当所述电动机10a以两个运行模式中的每一个连接时电动机功率和电动机扭矩之间的关系。曲线78表示当所述电动机10a的两个线圈组44、58串连连接时功率/扭矩关系。曲线80表示当两个线圈组44、58并联连接时的功率/扭矩关系。对于给定的电动机扭矩,可以看出,由曲线80示出的线圈组44、58的并联连接电动机使用的功率与所述线圈组44、58串连布置时相比更多。例如,在40英寸/盎司的扭矩,电动机10a的线圈组44、58并联连接,电动机10a使用了几乎超过当线圈组44、58串连连接时所述电动机10a消耗的电能200瓦的额外功率。
图9示出了串连连接和并联连接的线圈组44、58的电动机电流和电动机扭矩之间的关系。性能曲线82表示当其线圈组44、58串连连接时所述电动机10a的电流/扭矩关系。曲线84表示线圈组44、58并联连接。当所述线圈组44、58并联连接时,产生给定的扭矩,所述电动机10a汲取更多电流。例如,在50英寸/盎司的电动机扭矩,所述电动机10a线圈组44、58并联几乎比该所述线圈组串连多汲取了30毫安的电流。因此,对于需要电动机低扭矩(以及因此的电动机低功率输出)的轻载应用,利用线圈组44、58的串连连接允许当提供给定扭矩时电动机10a汲取非常小的电流。图10示出了每个串连和并联连接方案的电动机10a的电流和功率之间的关系。
参照图11和12,其示出了表示电动机10a在不同运行模式中所产生的不同效率和扭矩曲线。在图11中,以最大效率模式运行所述电动机10a,例如模式“1”,产生由曲线100表示的效率/扭矩曲线。以最大“功率”模式运行所述电动机10a产生由曲线102表示的效率/扭矩曲线。图12说明所述电动机10a的速度可以被控制为适合于需要不同扭程度矩输出的轻、中或者中载应用。曲线104和曲线106说明使用电动机高速(即曲线106)以实现用于重载应用的最大扭矩。
图13说明了当操作工具12实际上立刻改变运行性能时线圈组44、58如何转换。从串连连接到并联连接的转换(反之亦然)可以是“硬”转换,电连接不经过任何过渡的电“平滑”。这样的转换由图13中的曲线108表示。一旦所述电动机10a的速度下降到大约11000rpm,所述串连连接的线圈组44、58将并联连接,因此从所述电动机10a提供更大的功率输出。这提供的优点是包括所述电动机10a的工具对于给定的电动机和电池电量,在轻载工作任务时,与用并联连接的线圈可以实现的运行时间相比将增大。然而,并联连接所述线圈组44、58使得所述电动机10a的最大功率输出增大到超过所述线圈组44、58串联连接可能达到的功率。这使得当执行重载工作任务时,相同的电动机10可提供的功率更大。
对于所述钻12,线圈组44、58在串联和并联配置之间切换使得该电动机10a的输出特性实时变化。参照图14,所述串联连接提供来了最大效率和最大扭矩。而所述并联连接提供了最大运行速度和最大功率。
图15示出了所述电动机的输出特性如何通过串联/并联转换而改变并利用齿轮减速单元16进一步改变输出速度。在电动锯的应用场合,这对于改变锯片的速度以当切割不同类型的材料(例如,软木与硬木)时最优化该锯的性能将特别有用。
通过控制电动机和齿轮减速单元获得增加数量的电动机性能输出曲线
所述电动机10a和齿轮减速单元16可以通过控制器28控制以提供超过仅仅由控制齿轮减速单元16实现的不同速度数量的多个单元16的输出速度。例如,参照图16-21,示出了若干简化示图,其说明了齿轮减速单元16的一个实施例,在这个示例中,其包括二级齿轮减速单元。通过仅仅选择二级齿轮减速单元的不同级,可以从电动机/齿轮减速单元的结合获得三个不同的输出速度,如图16-18所示。但是,所述电动机10a的线圈组44、58串联或者并联的能力使得从所述二级齿轮减速单元16可以获得总共六个不同的输出速度。这使得可以利用比没有串联/并联能力用成本更低、更小和更轻的齿轮减速单元以提供给定数目的不同输出曲线。手持电动工具中更小,更轻的齿轮减速单元的使用特别有利,这样所述工具的重量和尺寸是设计时重要的考虑因素。
将所述电动机线圈组44、58连接布置(串联或者并联),以及所述齿轮减速单元16的电子控制结合的能力使得可以获得具有多个性能曲线的宽范围的输出。例如,对于相同的电动机,在给定的低功率输出下串联连接所述线圈组44、58将比并联连接提供更高的效率。因此,所述线圈组44、58的串联配置可以与所述齿轮减速单元16的高速齿数比一起使用以最优化钻12以便拧入小螺钉或用小直径钻头钻削,这时需要电动机速度较高。相反的,所述线圈组44、58的并联连接(其提供较高的最大功率输出)可以与较低的齿数比结合使用。这个结合将为重载工作任务提供最大的应用速度和热稳定性。因此,可以理解,具有多个速度/扭矩/功率/效率特性的宽范围电动机输出可以通过所述线圈组44、58的选择性连接和所述齿轮减速单元16的控制实现。
利用控制器以将电动机速度-扭矩曲线与齿轮减速单元的速度-扭矩能力 相匹配
所述控制器28也可以用于将所述电动机10a的速度-扭矩曲线与齿轮减速单元16的速度-扭矩能力相匹配。这免去了在充足量的速度-扭矩“上裕量”设计入所述齿轮减速单元16中的需要以确保在钻12的运行过程中所述电动机10a不损坏或者所述齿轮减速单元16产生过度应力。简要参照图22-24,这个特点可以得到进一步解释。图22说明了需要设计到齿轮减速系统(通常简称为“齿轮箱”)以确保其使用的电动机将不破坏或所述齿轮系统产生过度应力的典型“上裕量”的示例程度。曲线110代表直流电动机的示例性速度-扭矩性能曲线,而曲线112表示常规齿轮箱的速度-扭矩性能曲线。设计到所述齿轮箱中的速度-扭矩“上裕量”由两个曲线110和112之间的区域114表示。区域114基本上设计到所述齿轮箱中的,超过所述电动机所能够产生的速度-扭矩处理能力增加程度。这个上裕量确保所述电动机不能使产生过度应力所述或者损坏所述齿轮箱。
图23说明了控制所述电动机10a速度-扭矩特性以基本将电动机的速度-扭矩曲线向上“推”以与所述齿轮减速单元16的最大速度-扭矩性能容量相匹配。在这个例子中,曲线116表示所述控制器28为电动机10a所实现的电动机10a的速度-扭矩性能曲线。曲线118表示设计到所述齿轮减速单元16中的速度-扭矩性能曲线。所述控制器28控制电动机10a“推”或者增大所述电动机10a的速度-扭矩曲线到基本与齿轮减速单元16的速度-扭矩曲线相匹配。这通过消除所述通常将设计入所述齿轮减速单元16中的上裕量区域114而提供了所述齿轮减速单元16的速度-扭矩能力的最有效的使用。通过监控重要的电动机运行参数,比如电动机速度和电动机电流,所述控制器28确保该电动机10a的运行在任何时刻都不超过所述齿轮减速单元16的速度-扭矩性能容量。相反的,通过使用所述控制器28监控并严格的控制所述电动机10a的速度-扭距性能容量,对于给定的电动机可以实现更廉价的齿轮减速单元。
参照图24,也可以采用所述控制器28控制所述电动机10a的速度-扭矩性能的替换控制方法以便其仅仅周期性增大较短的持续时间到齿轮减速单元16的水平。曲线120表示由所述控制器28实现的恒定的电动机10a的速度-扭矩曲线。曲线122说明了对于较短的持续时间由所述控制器28增大速度-扭矩曲线120的运行点以周期性“上推”到所述齿轮减速单元16的速度-扭矩曲线124。这样,所述电动机10a可以通过控制器28控制以匹配,甚至较短时间稍微超过所述齿轮减速单元16的速度-扭矩性能容量而没有产生过度应力或者引起损坏所述齿轮减速单元的危险。这也将允许使用更廉价的齿轮减速单元,由于所述齿轮减速单元将不需要设计有充足的上裕量以能够持续容纳所述电动机10a的全部速度-扭矩容量。
使用者选择器控制的运行
现在参照图25-28,将进一步描述使用者选择器30。在一个优选形式中,所述选择器30包括可以由使用者在若干位置之间手动定位以选择若干不同模式中的一个的多位置开关。在目前的例子中,示出了四个运行模式。模式“1”(图25)提供了最大功率模式,而模式“4”(图28)提供了最大效率运行模式。在模式“4”中,例如,在第四开关位置,来自所述电动机10a的功率输出可能由所述控制器28限制到最大,例如300瓦输出。在“1”位置,选择所述最大功率输出为,比如600瓦。所述控制器28也根据所述选择器30的位置在若干预定的速度之间改变电动机10a的速度以最好的满足即将到来的任务(即,或者提供最大功率,最大效率或者它们之间的一些结合)。作为一个例子,开关位置“1”可以包括卡盘14的速度为450rpm,位置“2”(图26)可以包括速度为850rpm,位置“3”(图27)速度为1400rpm而位置“4”速度为2000rpm。或者,所述选择器30可以连接到齿轮减速单元16以便当所述控制器28检测到电动机10a上的载荷时该选择器被自动从一个模式向另一个模式移动。例如,如果检测到电动机的额外载荷,所述控制器28可以用于瞬时从最大效率模式(即模式4)转变到中间模式(即模式2)。所述额外载荷通过电动机10a的电流汲取的增大检测。如果增大载荷的周期减小,则所述控制器28可以再次将运行模式转换回由使用者选择的模式。所述控制器28可以执行为闭环方案或者开环方案以根据一个或者多个检测到的运行参数,比如速度或扭矩串联或者并联连接所述线圈。
显示器32可以包括第一组LED32a用于给使用者显示所述控制器28超越使用者的选择工作模式,并提供有关当前所述电动机10a正在运行的模式的指示。LED组32b可以用于指示所述钻12的电池22的充电水平。
利用控制器以进一步改变电动机运行特性
在上面描述的运行模式中的任一个中,所述控制器28可以执行提前换向和电压控制以提供上面描述的效率/扭矩和速度/扭矩曲线的进一步改变。此外,所述电动机10a的最大电流(即失速电流)可以由控制器28控制。例如,所述控制器28,当检测到由所述电动机汲取电流时,能够在预定的最大电流汲取被超过的时限之后减少该电动机10a的扭矩输出。例如,如果所述失速电流持续产过两秒,所述控制器28可以降低电动机10a的扭矩输出到预定的较低水平以防止电池22输出过大的电流。
所述控制器28也可以被编程为逐渐减小施加到所述电动机10a的电压以模拟一旦电动机被推动到超过安全运行范围同时在最大功率运行模式时模拟功率损失。如果所述钻12在高效模式(即低功率模式)使用时,可以使用最大电流极限。
所述控制器28也可以当所述钻12堵转在给定齿轮级时用于自动将电动机10a从其轻载功率输出模式转换到其高功率输出模式以从电动机10a产生更高的功率输出。所述钻12可以持续在其高功率模式运行的持续时间可以监控并限制以防止所述电动机10a的过度加热。
所述控制器28也可以用于执行一个或多个制动模式以减小所述钻12的多个内部构件上的压力。例如,反馈制动可以通过从所述电动机10a惯性产生电流并将其返回所述电池22实现。
所述控制器28也可以用于执行扭矩控制性能以防锁,并因此执行“电子”离合器的一种形式。例如,检测所述电动机10a汲取的电流瞬时变化率可以被用于控制所述电动机的扭矩输出。这可以为所述钻提供防反冲或防锁定性能。如果需要,所述电动机在每个运行模式的最大汲取电流可以,例如通过软件得到限制。所述控制器28也可以被用于实现电动机10a的反向能力。优选的,所述轻载功率模式是当工具12被切换到反向时的“缺省”模式。当电动机反向运行时,可以为所述电动机10a设定不同的电流极限值。例如,如果当所述钻12运行在反向模式时设定相对较高的电流极限,这将使得所述电动机10a能够产生更高的扭矩,并因此可以螺纹螺栓可以快速从工件上拆下。
进一步,所述控制器28可以被配置为利用闭环或开环方法。如果使用闭环方法,该控制器28将利用来自啊电流检测系统40和电动机速度检测器38的反馈以改变所述电动机10的运行模式。如果使用开环方法,所述控制器28可以利用一个或多个储存在内部或外部的具有储存的信息(即,电动机10a的不同电动机速度和/或电流)储存器中的查询表以在给定的工作任务过程中选择最优运行模式。此外,所述控制器28可以集成到电动机10a单个组件中(即“封装”),或者远离所述电动机10a,如图1所示。所述控制器28也可以位于具有切换连接子系统36(图1)的公用印刷电路组件上,或远离所述子系统36。
所述电动机10a,控制器28,以及连接子系统36可以因此被用于由一个单个电动机实现若干不同运行模式。包括轻载运行模式或最大功率运行模式的模式可以通过所述控制器28由使用者选择或者自动实现。当所述工具被用于需要较小电动机功率的应用场合,电动机系统10使得电池的运行时间延长,并很容易的转换,或者手动或者自动转换,如果工作任务需要,可以提供更多电动机功率。对于给定的电池电量,与如果电动机在其最大功率模式在所述电量下运行相比,具有所述电动机系统10的电池电动工具将使得可以实现更长的运行时间。如果工作任务需要,最大功率也将很容易获得,或者自动,或者由使用者仅仅移动控制器,比如开关以手动选择所需要的运行模式。
对于多个实施例的描述本质上仅仅是示例性的,并且因此,不背离本实用新型要点的变化也将在本实用新型的范围之内。
本申请要求2006年2月20日提交的、题目为“电子换向电动机和控制系统”美国临时专利申请60/775407的优先权,所述申请公开的内容因此通过引用并入本申请。

Claims (13)

1.一种电动工具,其特征在于,包括:
电动机;
所述电动机具有电枢,所述电枢包括:
缠绕在叠片组上的第一组电枢线圈;
缠绕在所述叠片组上的第二组电枢线圈;以及
切换系统,其将连接所述两组电枢线圈为串联或者并联配置。
2.如权利要求1所述的电动工具,其特征在于,其中所述切换系统还包括:
第一组换向器条,其选择性的电连接到所述第一组电枢线圈;和
第二组换向器条,其选择性的电连接到所述第二组电枢线圈。
3.如权利要求2所述的电动工具,其特征在于,其中所述开关系统还包括用于与所述第一组换向器条接合的第一组电刷,以及用于与所述第二组换向器条接合的第二组电刷。
4.如权利要求3所述的电动工具,其特征在于,其中所述开关系统还包括:
若干在所述电刷的所选定的电刷之间互相连接的开关;和
控制器,其用于按需要控制所述开关的操作以在串联和并联配置之间切换所述线圈。
5.一种电动工具,其特征在于,包括:
电动机;
所述电动机具有电枢,该电枢包括:
缠绕在叠片组上的第一组电枢线圈;
缠绕在所述叠片组上的第二组电枢线圈;和
切换系统,其将所述两组电枢线圈连接为第一布置以提供最大功率输出,和第二布置以提供最大电动机效率。
6.如权利要求5所述的电动工具,其特征在于,其中所述第一布置包括将所述电枢线圈组连接为并联。
7.如权利要求5所述的电动工具,其特征在于,其中所述第二布置包括将所述电枢线圈组连接为串联。
8.如权利要求5所述的电动工具,其特征在于,其中所述切换系统包括连接到所述电枢线圈中选定的电枢线圈的第一和第二组换向器条。
9.如权利要求8所述的电动工具,其特征在于,其中所述切换系统还包括用于将电源接合到所述若干换向器条的第一和第二对电刷。
10.如权利要求9所述的电动工具,其特征在于,其中所述切换系统包括若干由控制器控制以自动在所述第一和第二布置之间切换所述电枢线圈的开关。
11.如权利要求9所述的电动工具,其特征在于,其中所述切换系统包括若干人工控制以在所述第一和第二布置之间切换所述电枢线圈的开关。
12.如权利要求8所述的电动工具,其特征在于,其中所述第一对电刷定位为接触所述第一组换向器条,并且所述第二对电刷定位为接触所述第二组换向器条。
13.如权利要求9所述的电动工具,其特征在于,其中所述电枢线圈形成具有电枢轴的电枢组件,并且其中所述第一对电刷设置在所述电枢轴的第一端而所述第二对电刷设置在所述电枢轴的第二端。
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US20090033159A1 (en) 2009-02-05
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WO2007098220A2 (en) 2007-08-30

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