JP2014069252A - 電動工具 - Google Patents
電動工具 Download PDFInfo
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- JP2014069252A JP2014069252A JP2012215521A JP2012215521A JP2014069252A JP 2014069252 A JP2014069252 A JP 2014069252A JP 2012215521 A JP2012215521 A JP 2012215521A JP 2012215521 A JP2012215521 A JP 2012215521A JP 2014069252 A JP2014069252 A JP 2014069252A
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02P—CONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
- H02P7/00—Arrangements for regulating or controlling the speed or torque of electric DC motors
- H02P7/06—Arrangements for regulating or controlling the speed or torque of electric DC motors for regulating or controlling an individual dc dynamo-electric motor by varying field or armature current
- H02P7/18—Arrangements for regulating or controlling the speed or torque of electric DC motors for regulating or controlling an individual dc dynamo-electric motor by varying field or armature current by master control with auxiliary power
- H02P7/24—Arrangements for regulating or controlling the speed or torque of electric DC motors for regulating or controlling an individual dc dynamo-electric motor by varying field or armature current by master control with auxiliary power using discharge tubes or semiconductor devices
- H02P7/28—Arrangements for regulating or controlling the speed or torque of electric DC motors for regulating or controlling an individual dc dynamo-electric motor by varying field or armature current by master control with auxiliary power using discharge tubes or semiconductor devices using semiconductor devices
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02P—CONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
- H02P27/00—Arrangements or methods for the control of AC motors characterised by the kind of supply voltage
- H02P27/04—Arrangements or methods for the control of AC motors characterised by the kind of supply voltage using variable-frequency supply voltage, e.g. inverter or converter supply voltage
- H02P27/06—Arrangements or methods for the control of AC motors characterised by the kind of supply voltage using variable-frequency supply voltage, e.g. inverter or converter supply voltage using dc to ac converters or inverters
- H02P27/08—Arrangements or methods for the control of AC motors characterised by the kind of supply voltage using variable-frequency supply voltage, e.g. inverter or converter supply voltage using dc to ac converters or inverters with pulse width modulation
- H02P27/085—Arrangements or methods for the control of AC motors characterised by the kind of supply voltage using variable-frequency supply voltage, e.g. inverter or converter supply voltage using dc to ac converters or inverters with pulse width modulation wherein the PWM mode is adapted on the running conditions of the motor, e.g. the switching frequency
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
- B25F—COMBINATION OR MULTI-PURPOSE TOOLS NOT OTHERWISE PROVIDED FOR; DETAILS OR COMPONENTS OF PORTABLE POWER-DRIVEN TOOLS NOT PARTICULARLY RELATED TO THE OPERATIONS PERFORMED AND NOT OTHERWISE PROVIDED FOR
- B25F5/00—Details or components of portable power-driven tools not particularly related to the operations performed and not otherwise provided for
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02P—CONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
- H02P7/00—Arrangements for regulating or controlling the speed or torque of electric DC motors
- H02P7/06—Arrangements for regulating or controlling the speed or torque of electric DC motors for regulating or controlling an individual dc dynamo-electric motor by varying field or armature current
- H02P7/18—Arrangements for regulating or controlling the speed or torque of electric DC motors for regulating or controlling an individual dc dynamo-electric motor by varying field or armature current by master control with auxiliary power
- H02P7/24—Arrangements for regulating or controlling the speed or torque of electric DC motors for regulating or controlling an individual dc dynamo-electric motor by varying field or armature current by master control with auxiliary power using discharge tubes or semiconductor devices
- H02P7/28—Arrangements for regulating or controlling the speed or torque of electric DC motors for regulating or controlling an individual dc dynamo-electric motor by varying field or armature current by master control with auxiliary power using discharge tubes or semiconductor devices using semiconductor devices
- H02P7/285—Arrangements for regulating or controlling the speed or torque of electric DC motors for regulating or controlling an individual dc dynamo-electric motor by varying field or armature current by master control with auxiliary power using discharge tubes or semiconductor devices using semiconductor devices controlling armature supply only
- H02P7/29—Arrangements for regulating or controlling the speed or torque of electric DC motors for regulating or controlling an individual dc dynamo-electric motor by varying field or armature current by master control with auxiliary power using discharge tubes or semiconductor devices using semiconductor devices controlling armature supply only using pulse modulation
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02P—CONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
- H02P31/00—Arrangements for regulating or controlling electric motors not provided for in groups H02P1/00 - H02P5/00, H02P7/00 or H02P21/00 - H02P29/00
Abstract
【課題】電圧変換回路を備え、負荷の大きさによらずモータへの印加電圧を一定にする場合と比較して重負荷時のトルクを大きくすることの可能な電動工具を提供する。
【解決手段】制御部5は、モータ3に流れる電流を監視しており、電流(負荷)が大きくなるにつれてモータ3への印加電圧を低下させる(電圧変換回路2の昇圧率を低下させる)。電流(負荷)の増大に伴って電圧変換回路2の昇圧率を低下させることにより、軽負荷時にはモータ3を高速回転させながら重負荷時にはモータ3のトルクを大きくすることが可能となる。
【選択図】図1
【解決手段】制御部5は、モータ3に流れる電流を監視しており、電流(負荷)が大きくなるにつれてモータ3への印加電圧を低下させる(電圧変換回路2の昇圧率を低下させる)。電流(負荷)の増大に伴って電圧変換回路2の昇圧率を低下させることにより、軽負荷時にはモータ3を高速回転させながら重負荷時にはモータ3のトルクを大きくすることが可能となる。
【選択図】図1
Description
本発明は、DC−DCコンバータ等の電圧変換回路を備える電動工具に関する。
ドライバドリル等の電動工具においては、下記特許文献1に示されるように、使用者によるトリガの引き量に応じてマイコン等の制御部がモータを制御するのが一般的である。下記特許文献2は、電池電圧で動作する電動刈払機において、昇圧回路を用いることにより、容量の小さい電池でも十分に高い回転数で作業を行うことを可能としている。電池電圧で動作する電動工具でネジ締め等を行う場合、電池電圧を昇圧することでモータを高速回転させることができ、締付スピードを速くすることができる。
ネジ締めの最終段階では、モータのトルクが高くなり回転数が低下する。電源の出力電力には限界があるため、電源電圧を昇圧すると、モータに供給可能な電流が小さくなり、最終的な締付トルクが小さくなる。
本発明はこうした状況を認識してなされたものであり、その目的は、電圧変換回路を備え、負荷の大きさによらずモータへの印加電圧を一定にする場合と比較して重負荷時のトルクを大きくすることの可能な電動工具を提供することにある。
本発明のある態様は、電動工具である。この電動工具は、電圧変換回路を備え、負荷の大きさに応じて前記モータへの印加電圧の大きさを制御する。
負荷が大きいときは前記モータへの印加電圧を低くし、負荷が小さいときは前記モータへの印加電圧を高くしてもよい。
前記モータへの印加電圧のレベルを切り替える境界となる負荷の大きさが複数存在してもよい。
入力部の操作量に応じて前記モータへの印加電圧を制御してもよい。
前記操作量が大きいときは前記モータへの印加電圧を高くし、前記操作量が小さいときは前記モータへの印加電圧を低くしてもよい。
前記操作量によらずデューティ比100%で前記モータに電圧を印加してもよい。
なお、以上の構成要素の任意の組合せ、本発明の表現を方法やシステムなどの間で変換したものもまた、本発明の態様として有効である。
本発明によれば、電圧変換回路を備え、負荷の大きさによらずモータへの印加電圧を一定にする場合と比較して重負荷時のトルクを大きくすることの可能な電動工具を実現できる。
以下、図面を参照しながら本発明の好適な実施の形態を詳述する。なお、各図面に示される同一または同等の構成要素、部材等には同一の符号を付し、適宜重複した説明は省略する。また、実施の形態は発明を限定するものではなく例示であり、実施の形態に記述されるすべての特徴やその組み合わせは必ずしも発明の本質的なものであるとは限らない。
図1は、本発明の実施の形態1に係る電動工具のブロック図である。電動工具の種類はネジ締めを行う例えば電動ドライバが好適であるが、特に限定されない。また、電動工具の機械的構成は周知のものでよいためここでは説明を省略する。図1に示すように、電動工具は、電池1を電源とし、電池1の電圧を電圧変換回路2で昇圧してモータ3に供給する。
電圧変換回路2は、例えば図2に示すようなチョッパ方式のDC−DCコンバータ(ブーストコンバータ)すなわち昇圧回路であり、スイッチング素子Mのスイッチング制御により、チョークコイルLに溜めたエネルギーを電池1の電圧に加算して出力する。スイッチング素子Mのスイッチング制御は、制御部5が、電圧変換回路2の出力電圧を監視しながら昇圧率(昇圧目標電圧)に応じて実施する。ダイオードDは電流の逆流を防止し、平滑コンデンサCは出力電圧の変動を抑える。
モータ3は本実施の形態ではブラシ付きモータである。モータ3と直列にスイッチング素子Q及び抵抗Rが設けられる。スイッチング素子Qは制御部5によりオンオフ制御される。抵抗Rはモータ3に流れる電流を電圧に変換するために設けられる。トリガスイッチ4は、入力部の例示であり使用者に操作される。制御部5はモータ3の動作を制御する。制御の詳細は後述する。
制御部5において、モータ電流検出回路6は、抵抗Rの端子電圧に基づきモータ3に流れる電流を検出して演算部11に送信する。昇圧電圧検出回路7は、電圧変換回路2の出力電圧を検出して演算部11に送信する。電池電圧検出回路8は、電池1の出力電圧を検出して演算部11に送信する。スイッチ操作検出回路9は、トリガスイッチ4の操作を検出して制御部5を起動する。印加電圧設定回路10は、トリガスイッチ4の操作量を検出して演算部11に送信する。演算部11は、モータ3の制御に必要な各種の演算を行う。演算部11はハードウエアとソフトウエアの組合せにより実現される。
図3(A)は、モータ3のトルクと電流の関係を示す特性図である。本図に示すようにモータ3のトルクと電流は比例関係にある。図3(B)は、実施の形態の制御を適用した場合の、モータ3への印加電圧(電圧変換回路2の出力電圧)とモータ3に流れる電流との関係を示す特性図(その1)である。図3(C)は、図3(B)の制御を適用した場合の、モータ3の回転数とモータ3に流れる電流との関係を示す特性図である。図3(B)及び図3(C)において、トリガスイッチ4の操作量は一定であり、スイッチング素子Qのゲート(制御端子)への印加電圧のデューティ比は一定(例えば100%)とする。
制御部5は、モータ3に流れる電流を監視しており、図3(B)に示すように、電流(負荷)が大きくなるにつれてモータ3への印加電圧を低下させる(電圧変換回路2の昇圧率を低下させる)。なお、図3(B)では電圧変換回路2の出力電圧のレベル切替え(昇圧率切替え)の境界となる電流値を2つ(I1とI3)としているが、境界となる電流値は1つ又は3つ以上であってもよい。
図3(C)から明らかなように、電流(負荷)の増大に伴って電圧変換回路2の昇圧率を低下させることにより、モータ3への供給可能最大電流が大きくなり(I5>I4>I3)、トルクを大きくできる。これはネジ締めであれば最終的な締め付けトルクを大きくできることを意味する。また、モータ3の電流がI1〜I3(I1<I3)の区間では、昇圧率が中の場合のほうが大の場合よりもモータ3を高速回転できる。同様にモータ3の電流がI3〜I5(I3<I5)の区間では、昇圧率が小の場合のほうが中の場合よりもモータ3を高速回転できる。したがって、図3(B)の制御を適用することで、すなわちモータ3の電流がI1までは昇圧率を大、I1〜I3では昇圧率を中、I3〜I5では昇圧率を小(昇圧なし)とすることで、軽負荷時にはモータ3を高速回転させながら重負荷時にはモータ3のトルクを大きくすることが可能となる。
図3(B)の制御において、トリガスイッチ4の操作量は、昇圧率を変更する(操作量が大きいほど昇圧率を大きくする)ことにより反映することができる。このとき、昇圧率切替えの境界となる電流値もトリガスイッチ4の操作量に応じて変更するとよい。なお、トリガスイッチ4の操作量に応じてスイッチング素子Qのゲート(制御端子)への印加電圧のデューティ比を併せて制御してもよいが、トリガスイッチ4の操作量によらずスイッチング素子Qのデューティ比を100%に固定することで、スイッチング素子QのPWM制御を不要にして回路の簡素化を図ることができる。
図4(A)は、モータ3のトルクと電流の関係を示す特性図である。本図は図3(A)と同じである。図4(B)は、実施の形態の制御を適用した場合の、モータ3への印加電圧(電圧変換回路2の出力電圧)とモータ3に流れる電流との関係を示す特性図(その2)である。図4(C)は、図4(B)の制御を適用した場合の、モータ3の回転数とモータ3に流れる電流との関係を示す特性図である。図4(B)の制御では、制御部5は、トリガスイッチ4の操作量が大きいときは、モータ3に流れる電流がI6までは電圧変換回路2を動作させて昇圧した電圧をモータ3に印加し、電流がI6を超えると電圧変換回路2による昇圧を行わずに電池1の電圧をモータ3に印加する。一方、制御部5は、トリガスイッチ4の操作量が小さいときは、モータ3に流れる電流に関わらず電圧変換回路2による昇圧を行わずに電池1の電圧をモータ3に印加する。こうした制御によれば、トリガスイッチ4の操作量に関係なく常に電圧変換回路2を動作させる場合と比較して、回転数の調整が容易で回転数の急変動を防止することができる。トリガスイッチ4の操作量が中の場合は、大の場合よりも昇圧電圧を小さくすればよい。なお、図4(C)の特性は、トリガスイッチ4の操作量に応じてスイッチング素子Qのデューティ比も変化させた場合を示している(トリガスイッチ4の操作量が小のときはデューティ比も小)。
本実施の形態によれば、下記の効果を奏することができる。
(1) モータ3の電流(負荷)の増大に伴って電圧変換回路2の昇圧率を低下させる(モータ3への印加電圧を低下させる)ため、重負荷時にモータ3に供給可能な電流を大きくすることができる。このため、モータ3の電流の大きさによらず電圧変換回路2の昇圧率を一定にする場合と比較して、重負荷時のトルクを大きくすることが可能となる。
(2) トリガスイッチ4の操作量が小さいときは電圧変換回路2による昇圧を行わないため、トリガスイッチ4の操作量に関係なく常に電圧変換回路2を動作させる場合と比較して、回転数の調整が容易で回転数の急変動を防止することができる。
(3) トリガスイッチ4の操作量に応じて電圧変換回路2の昇圧率を可変とすることで、スイッチング素子Qのデューティ比はトリガスイッチ4の操作量によらず100%で一定とすることもでき、そうすることでスイッチング素子QのPWM制御を不要として回路構成を簡素化できる。
図5は、本発明の実施の形態2に係る電動工具のブロック図である。図6は、同電動工具の全体構造図である。この電動工具は、図1に示した実施の形態1のものと異なり、モータ3がブラシレスモータである。回転子位置検出素子12は、例えばホール素子などの磁気検出素子である。制御部5において、回転子位置検出回路13は、回転子位置検出素子12の出力信号に基づいてモータ3の回転位置を検出し、演算部11及び回転数検出回路14に送信する。回転数検出回路14は、回転子位置検出回路13の出力信号によりモータ3の回転数を検出し、演算部11に送信する。演算部11は、回転子位置検出回路13からの位置信号に基づいて、インバータ回路16のスイッチング素子Q1〜Q6に印加するスイッチング素子駆動信号H1〜H6を生成し、それらを制御信号出力回路15からスイッチング素子Q1〜Q6のゲート(制御端子)に入力する。インバータ回路16は、スイッチング素子駆動信号H1〜H6によって制御されて、電圧変換回路2の出力する直流電圧を交流電圧に変換してモータ3に供給する。スイッチング素子駆動信号H1〜H6は、トリガスイッチ4の操作量に応じたデューティ比のPWM信号であってもよいが、実施の形態1と同様にトリガスイッチ4の操作量に応じて電圧変換回路2の昇圧率を可変とすることでスイッチング素子Qのデューティ比はトリガスイッチ4の操作量によらず100%で一定にすることもできる。本実施の形態のその他の点は実施の形態1と同様である。本実施の形態も、実施の形態1と同様の効果を奏することができる。
以上、実施の形態を例に本発明を説明したが、実施の形態の各構成要素や各処理プロセスには請求項に記載の範囲で種々の変形が可能であることは当業者に理解されるところである。以下、変形例について触れる。
電動工具はDC工具に限定されずAC工具であってもよい。電圧変換回路2は、実施の形態で例示した昇圧型(ブーストコンバータ)に限らず、降圧型(バックコンバータ)あるいは昇圧と降圧の双方が可能なタイプ(バックブーストコンバータ)であってもよく、また、AC電源からの電圧を昇圧又は降圧する変圧器であってもよい。いずれにしても、モータ3の電流(負荷)の増大に伴ってモータ3への印加電圧を低下させることで、重負荷時にモータ3に供給可能な電流を大きくすることができる。また、複数のコンプレッサやAC工具などを商用電源に接続した場合にはブレーカーが落ちやすくなるが、重負荷時にモータへの印加電圧を低下させることでブレーカーが落ちるのを防ぐことができる。
作業者によって昇圧レベルを可変として、工具の特性を作業者の使用しやすく調整可能な構成してもよい。この場合、昇圧レベルを可変とするために、工具のハウジングにボタンなどを設けてもよい。
DC−DCコンバータは発熱するため、DC−DCコンバータの例えばスイッチング素子の近傍にサーミスタを装着して、ある一定以上の温度になったら運転を禁止する高温保護機能を付加してもよい。
1 電池、2 電圧変換回路、3 モータ、4 トリガスイッチ、5 制御部、6 モータ電流検出回路、7 昇圧電圧検出回路、8 電池電圧検出回路、9 スイッチ操作検出回路、10 印加電圧設定回路、11 演算部、12 回転子位置検出素子、13 回転子位置検出回路、14 回転数検出回路、15 制御信号出力回路、16 インバータ回路、C 平滑コンデンサ、D ダイオード、L チョークコイル、M スイッチング素子、Q スイッチング素子、Q1〜Q6 スイッチング素子、R 抵抗
Claims (6)
- 電圧変換回路を備え、負荷の大きさに応じて前記モータへの印加電圧の大きさを制御する、電動工具。
- 負荷が大きいときは前記モータへの印加電圧を低くし、負荷が小さいときは前記モータへの印加電圧を高くする、請求項1に記載の電動工具。
- 前記モータへの印加電圧のレベルを切り替える境界となる負荷の大きさが複数存在する請求項2に記載の電動工具。
- 入力部の操作量に応じて前記モータへの印加電圧を制御する請求項1から3のいずれか一項に記載の電動工具。
- 前記操作量が大きいときは前記モータへの印加電圧を高くし、前記操作量が小さいときは前記モータへの印加電圧を低くする、請求項4に記載の電動工具。
- 前記操作量によらずデューティ比100%で前記モータに電圧を印加する請求項4又は5に記載の電動工具。
Priority Applications (5)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP2012215521A JP2014069252A (ja) | 2012-09-28 | 2012-09-28 | 電動工具 |
EP13779939.1A EP2901548A2 (en) | 2012-09-28 | 2013-09-27 | Electric power tool |
CN201380043950.6A CN104885357A (zh) | 2012-09-28 | 2013-09-27 | 电动工具 |
US14/420,353 US20150222212A1 (en) | 2012-09-28 | 2013-09-27 | Electric power tool |
PCT/JP2013/077017 WO2014051167A2 (en) | 2012-09-28 | 2013-09-27 | Electric power tool |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
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JP2012215521A JP2014069252A (ja) | 2012-09-28 | 2012-09-28 | 電動工具 |
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JP2014069252A true JP2014069252A (ja) | 2014-04-21 |
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JP2012215521A Pending JP2014069252A (ja) | 2012-09-28 | 2012-09-28 | 電動工具 |
Country Status (5)
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US (1) | US20150222212A1 (ja) |
EP (1) | EP2901548A2 (ja) |
JP (1) | JP2014069252A (ja) |
CN (1) | CN104885357A (ja) |
WO (1) | WO2014051167A2 (ja) |
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- 2013-09-27 EP EP13779939.1A patent/EP2901548A2/en not_active Withdrawn
- 2013-09-27 CN CN201380043950.6A patent/CN104885357A/zh active Pending
- 2013-09-27 WO PCT/JP2013/077017 patent/WO2014051167A2/en active Application Filing
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JP2011101932A (ja) * | 2009-11-11 | 2011-05-26 | Makita Corp | 電動工具 |
JP2012095459A (ja) * | 2010-10-27 | 2012-05-17 | Hitachi Koki Co Ltd | インバータ装置及びそのインバータ装置を備える電動工具 |
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US20150222212A1 (en) | 2015-08-06 |
CN104885357A (zh) | 2015-09-02 |
EP2901548A2 (en) | 2015-08-05 |
WO2014051167A3 (en) | 2014-09-25 |
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