CN100442622C - 电动工具中电池过电流的保护的安培数控制 - Google Patents
电动工具中电池过电流的保护的安培数控制 Download PDFInfo
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
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Abstract
本发明涉及用于延长电动工具中电池寿命的方法和装置。通过来自电源的电流的脉宽调制提供电动工具电动机的安培数控制。该脉宽调制可依照测定的电动机电流和测得的电源电压被改变。该电源优选包含一个电池，诸如锂离子电池或镍镉电池。本发明不但保护电池，而且也使电动工具能够在位势电流超过电池的最大可允许电流的场合使用电池。
Description
技术领域
本发明总体涉及电动工具的电源管理领域，特别是用于延长电动工具中电池寿命的方法和装置。
背景技术
在电动工具行业，电池寿命的最大化及防止损坏电池被人们所关注。典型的无绳电动工具使用镍镉(NiCd)或锂离子电池，并且在重负载时吸引30至35安培或更多安培电流。镍镉电池寿命的严重降低发生在50安培或50以上安培电流时。当在重负载时、接近堵转或者当电池接近耗尽时，电动工具可能吸引超过50安培的电流。其它类型电池对高电流具有不同的耐受值。例如，超过15安培时，与温度相关的损坏可能发生于锂离子电池。
因此，值得提供一种电路以限制从电池至电动工具电动机的电流。
发明内容
因此，本发明的目的是提供一种方法和电路以限制至电动工具电动机的电流。
本发明的第一方面提出一种延长电池的寿命的方法，该电池提供电力给电动工具中诸如永磁直流电机的电动机。该延长电池寿命的方法可利用一个脉宽调制控制器提供初始宽度的电压脉冲至永磁直流电动机。如果与电压相关的电流变化超过一个阈值，则脉冲宽度可由初始宽度改变至第一宽度。
在本发明的第二方面，本发明的电动工具可以包括一个电源、一个电动机以提供扭矩给电动工具、以及一个脉宽调制控制器以确定由电源供给电动机的电流的数量。
本发明不但保护电池，而且也使电动工具能够在位势电流超过电池的最大可允许电流的场合使用电池。
可以理解，前面的概述以及随后的详细描述都是示例性和解释性的，并不对本发明的权利要求构成限制。作为说明书一部分的附图举例说明了本发明的实施例，并与前面的概述一起用来解释本发明的原理。
附图说明
通过参考附图，本发明的诸多优点可以更好地被本领域的技术人员理解，其中：
图1表示本发明的方法的实施例；
图2表示本发明的方法实施例的基本框图；
图3表示本发明实施例的原理框图；
图4表示本发明的典型电路的实施例；
图5表示图4的模拟至数字转换框图的实施例；
图6表示本发明另一实施例的原理框图；
图7表示本发明又一实施例的原理框图；
图8表示本发明例证性的脉宽调制波形；
图9表示脉宽调制发生电路的典型实施例；
图10表示本发明锂离子电池电源的电压-电流曲线图；及
图11表示用于本发明的功率、扭矩、效率及转速(转数/分)的曲线图。
具体实施方式
现在详细参考本发明的优选实施例，它们的一些实例在附图中示出。
本发明涉及用于控制供给电动工具，尤其是诸如钻孔机的手持电动工具的电动机的电流的方法及装置。本方法可以依靠脉宽调制来控制供给电动机，尤其是永磁直流电动机的电流。在一个实施例中，本发明的电路可以以确定的取样速度测定电动机电流和电池电压。该测量值可被提供给微处理器或其它电路，脉宽调制提供给电动工具驱动电动机的电流。在另一实施例中，模拟电路根据提供给电动机的电流的数量把电力转到电动机。
图1表示本发明方法的实施例。为了防止损坏电动工具的电池，当设定的电流值被超过时，电流反馈被用来减少电压(图1中步骤20)，而当产生的电流少于所设定值时增加电压至额定值(图1中步骤25)。(图1中步骤40)电压被减少至由控制器所设定的限度，该限度由电池组和电动机的内电阻决定。脉宽调制(PWM)控制器减少了平均电压，所以电动机的失速电流将不超过电池的限度。接着，当负载从电动机离开时，只要电流处于限度以下，该脉宽调制(PWM)控制器就增加电压，直到电压达到额定峰值电压。在本发明的一个实施例中，电压的增加和减少指总平均电压的电压值。
图2中表示本发明的装置的实施例的基本原理框图。本发明优选使用具有一个闭合电流反馈回路的脉宽调制电路220、一个永磁直流(PMDC)电动机230以及一个电源210。本发明的电源210优选是一个电池或一系列电池。对于提供低电流情形，优选用锂离子电池。对于锂离子电池，最大的安全电流可能是大约15安培。当被电流负载驱动时，电池温度影响电流限度。也可使用其它电池，诸如氢离子电池、镍镉电池等等。电池优选为可再充电电池。
永磁直流(PMDC)电动机是耐久电动机，它的永磁场能够运转数千小时，并且在长占空度应用下运行。永磁直流(PMDC)电动机也具有长的保存寿命及高失速扭矩。永磁直流(PMDC)电动机在零转速(转数/分)时产生最大扭矩，在最大转速(转数/分)时产生零扭矩，以及在最大转速(RPMs)值50％的转速时产生最大扭矩50％的扭矩。在最大转速(转数/分)值的50％的转速时，永磁直流(PMDC)电动机产生最大马力，并且具有最大效率。在任何给定电压，永磁直流(PMDC)电动机消耗与所需扭矩成比例的电流。对于镍镉电池，在电动工具应用中的永磁直流(PMDC)电动机实际的失速电流被电池组的阻抗限定至大约85安培，而不管电动机设计的失速电流。在本发明中，可以使用其它组合的电动机、电池及控制器。
图3表示电流反馈回路的典型实施例。由电源提供的电流310被向上或向下调整。得到的电流被应用至电动机335，并通过电流测量电路测量电流值320。测得的电流被提供给微处理器325，该微处理器确定电流增加或减少330。
图4表示本发明的典型实施例的电路。对于低电流应用，电源410可以使用锂离子电池；对于更低电流应用可以使用氢离子电池；当需要更稳定的电流运行时使用镍氢(NiH6)电池；或者电源410也可使用其它类型电池。电源优选是总保持串联的两个或多个电池，这样每一电池用作多组件电源中的一个组件。电池被排列成以使不与任何电池连接的正极端用作电源的正极端，而不与任何电池连接的负极端用作电源的负极端。优选地，电池是可再充电电池。本发明也可以预想到其它的电源排列。
一个手动开关SW1被优选用于导电连接电源410与电路。一旦通过合上开关SW1激活电路，则电源电压被连续地监测。一个与电源410平行的分压器允许随时测量电压，以监测电源410的电力水平。通过模拟至数字转换框420测得的电压由分压器决定，该分压器由电阻R1和R2组成。对于大约40伏特的电池电压，电阻R1值可被设置成大于电阻R2值的7倍，以提供最大约为5伏特电压至模拟至数字(A/D)转换框420。这些电阻可被选择以使通过分压器的电流最小。例如，R1可以是100kΩ，而R2可以是14.3kΩ。优选地，分压器中使用的这些电阻是温度不敏感的，并且是精密电阻。
脉宽调制控制器决定提供给电动机470的电流。所提供电流的数量可以通过一个诸如功率晶体管430的开关确定。由微处理器440提供给功率晶体管基极(对于双极结晶体管)或者栅(对于金属氧化物半导体场效应晶体管)一个信号。该信号可以被设定在高电压水平以打开功率晶体管430，也可以被设定在低电压水平以关闭功率晶体管430；换而言之，以二元方式。可以选择地，也可以利用低电压水平打开功率晶体管430的相反安排。为了确保足够的电压被发送至功率晶体管430，增压电路490可以增加电压，或者提供足够驱动能力以开关功率晶体管。该增压电路可以是一个操作放大器、晶体管等等。通过检测电池电压和电动机电流，微处理器决定该信号被提供。该功率晶体管可以包含两个或更多个平行的功率晶体管，也可以包含二极管以增强可靠性。使用功率晶体管的一个好处是功率晶体管浪费最小的功率。电动机单独的电感可足以使电动机速度减慢。脉宽调制功率晶体管430可以打开一段时间以允许电流流动，以便在关闭以前不超过峰值电流。脉宽调制的占空度依照微处理器的可执行代码中提供的算法来改变。为了在电切断过程中提供电流通道并限制电压电位穿过电动机接线端，可以使用一个反馈二极管。当该功率晶体管被打开较时间时，被提供给电动机的电流增加，因而增加电动机速度。脉冲发生的速率可以被改变，以确保精确而充分的电流流向电动机。在另一个实施例中，功率晶体管可以被放置在电动机与地面之间。
如图4所示，在功率晶体管430的输出端可以提供一个滤波器。此处，电感线圈L1衰减电流峰值，电容器C1使至电动机的电压平滑。许多不同的滤波器可被用来使脉冲电压波形平滑。晶体管430是一个选择，因为功率晶体管可以常常被充分脉冲以至电动机的电感补偿穿过电动机的任何的突然电压变化。
另一个分压器可以被跨过电动机接线端放置，以通过跨过电动机470的接线端的电压测量确定电流。该分压器可以由两个依比例决定以允许合适电压范围被输入A/D变换框450的精密电阻R3和R4组成。例如，R3可以是100kΩ，而R4可以是14.3kΩ。回扫二极管460和/或电容器可以被布置跨过电动机的接线端，以电流变化平滑，以便抑制电压峰值，并当电源被切断时提供电流通道。电容器可以是适当类型和数值，诸如0.1μFd陶瓷电容器。二极管460可以是单二极管或者复式二极管。
通过位于电动工具机壳外面的操作者可外部接触的旋钮，可以手动设定电动机速度。例如，该旋钮可以被连接至电位计R6，电位计R6与另一电阻R5控制分压器中电阻的值。跨过电位计R6的电压通过模拟至数字(A/D)转换框480被数字化。接着数字化的电压值被微处理器读取，以决定电动机速度设定。
在脉宽调制速度控制器中，微处理器440提供分析和控制。该微处理器可具有相关的只读存储器(ROM)和相关的随机存储器(RAM)。在图4的实施例中，微处理器440控制电动机470的脉宽调制。微处理器440被加载来自只读存储器(ROM)的可执行代码。该可执行代码为测量电池电压、电动机电压以及速度控制电位计电压作准备。该可执行代码可被编写以允许电源410中不同种类的电池。可以提供一个位于电动工具主体上的开关，以便允许使用者选择具体类型的电池。微处理器将读出该开关值以确定用于运行具体电池类型的可执行代码部分。电源外壳也可包含能够探测置于其内的电池类型的执行器。通过以下伪码提供由微处理器440执行处理的例子：
Measure battery voltage；
Address battery voltage storage；
Read battery voltage value；
Store battery voltage；
End battery voltage；
Measure motor current；
Address motor voltage storage；
Read motor voltage；
Calculate motor current；
Store motor current；
End motor current；
Measure speed control potentiometer voltage；
Address speed control potentiometer voltage storage；
Read speed control potentiometer voltage；
Store speed control potentiometer voltage；
End speed control potentiometer voltage；
Adjust pulse width；
Case(motor current＞maximum tolerable current)then pulse width＝0
and shut off power to the motor；
Case(motor current＞upper current level 1 and motor current≤
maximum tolerable current)then pulse width＝1；
Case(motor current＞upper current level 2 and motor current≤upper
current level 1)then pulse width＝2；
And so forth；
Case(motor current＞upper current level n and motor current≤upper
current level n-1)then pulse width＝n；
Case(motor c urrent＞m inimum t olerable current and m otor current≤
lower current level 1)then pulse width＝m；
Case(motor current＞lower current level 1 and motor current≤lower
current level 2)then pulse width＝m-1；
And so forth：
Case(motor current＞lower current level m-1 and motor current≤
lower current level m)then pulse width＝1；
End Adjust Pulse Width；
Main
Begin_loop；
Measure battery voltage；
Measure motor current；
Measure speed control potentiometer voltage；
Scale factor＝speed control potentiometer voltage/C；
Case(motor current＞threshold 1)then adjust pulse width；
Case(motor current＜threshold 2)then adjust pulse width；
Case(battery voltage＜threshold 3/Scale factor)then issue alert and
shut off power to the motor；
Case(battery voltage＞threshold 4/Scale factor)then issue alert and
shut off power to the motor；
End_loop；
End Main；
用于微处理器、A/D转换器以及增压电路的电源可由电源410或诸如分离的电池的另外电源提供。监测电路可以独立地测量电源410的强度，或者可以接受来自微处理器410的信号以确定该值。如果该监测电路确定电源410已经被过度放电，则微处理器和相关电路可以被转换至备用电池以继续运行。此外，一个诸如发光二极管的指示灯可以在电动工具机壳上变亮。可以选择地，一个位于机壳的显示器可以提供电动工具电路系统的电源状态的精确读数。
图5表示图4的A/D转换框420、450和480的典型实施例。A/D转换器510通过操作放大器接收直接来自诸如分压器等的电压测量点的模拟电压输入。A/D转换器510提供数字化的值至三态锁存器520。对每一取样的时钟脉冲，来自A/D转换器510的数字化的值被存储在锁存器520中。该取样的时钟可通过微处理器由振荡器电路提供，或通过其它电路系统提供。当微处理器440执行需要电流数字化值的代码时，微处理器提供用于锁存器存储该值的地址。在其它实施例中，地址位的数量可以改变，诸如，具有3个地址位以寻址5至8个可寻址的锁存器。在本实施例中，一个二位地址总线可足以唯一寻址3个A/D转换框。A/D转换框的寻址逻辑电路使三态锁存器520能实现。一个可读取信号也被提供以读取来自三态锁存器520数据。该可读取信号是可选择的。在一个实施例中，寻址逻辑电路用作使失去取样时钟能力，并且该可读取信号与寻址逻辑电路结合用作允许该锁存的数字化值被从总线读取。
图6表示本发明的电路的另一实施例的原理框图。一个可调整的电阻630被与电源640串联放置，以便更好地控制来自电源的电流和电压。可以通过电压测量电路650测量可调整的电阻630和电源640的电压。一个电流测量电路620也可提供微处理器610电流测量。微处理器610可以发信号给脉宽调制控制器670以使脉冲开始或脉冲停止。在另外的实施例中，脉宽调制控制器控制提供给电动机680的电流和电压。可调整的电阻630可以被用于补偿电源640内电阻的改变。
图7表示本发明的另一个实施例的原理框图。该实施例对于本发明的类似实施特别有用。一个斜坡发生器720被用于提供斜坡电压，诸如锯齿形、三角形、楼梯形或类似波形。一个与穿过电动机的电流相应的电压通过比较器730与斜坡电压进行比较。多种处理运算法则可以被利用来通过电路系统提供电动机电压值至比较器。例如，对于根据图10运转的锂离子电池电源，开关起初可以被无中断地打开，而且，只有当与所测得的电动机电压相应的某一电流值被达到时，该开关把电力由电源脉冲至电动机。脉冲过程中的脉宽还可以通过测定的电动机电流值超过某一电流水平的数量来确定。例如，提供给电动机的电力可以是连续地增加，直到14.2安培的确定的电动机电流，接着，电力可通过以可调整占空度的脉冲被提供给电动机，而且如果某一电动机电流值(例如15安培)被超过时，电源可以被切断，一个增压电路740可以被用来提供足够的电流和电压以开动开关750。
图8表示脉宽调制波形。当在软件中执行时，可以设定诸如50％占空度的初始占空度。硬件执行将快速建立必要的占空度。当更多的电流被提供给电动机时，占空度可以被调整至在更高百分数占空度应用电源。相反地，当更少的电流被提供给电动机时，占空度可以被调整至在更少百分数占空度应用电源。
图9表示脉宽调制电路系统的典型实施例。一个斜坡信号被应用至操作放大器的倒相输入端。一个电压信号被应用至操作放大器的非倒相输入端。该电压信号可直接由分压器提供，可以进一步放大或增强，或者由电路系统另外提供。该斜坡信号可以是锯齿形或者三角形波形。一个积分器也可被用来产生斜坡信号。
图10表示用于本发明的锂电池电源的控制器的输入电压1010与输出电压1020的关系。如曲线图所示，输入电源电压1010与控制器输出电压1020以一对一的关系相关联，输入电压和输出控制器电压以渐进线性方式下倾，直到电流值为约14安培。在稍微超过14安培及以上时，输出控制器电压迅速下降。
图11表示电动机效率1140、扭矩1130、消耗功率1110以及电动机的转速(转/分钟)1120的关系。
本发明可预想到其它变化。可以使用光学编码器、箝位电流表、转速计、保护电路、备用电源切断、电流敏感传感器、电压敏感传感器、电流分流器、误差信号放大器、削波电路等等。脉宽调制开关不限于是晶体管，而可以是另外的元件，诸如机械式继电器开关。
可以相信，通过前面的描述，本发明以及其诸多优点将被理解，并且显然，在不脱离本发明的范围和精神或不牺牲本发明的实质优点的情形下，其部件的形成、构造和排列可作各种改变。上文描述只是其解释性实施例，权利要求书概括和包含了此类改变。
Claims (6)
1.一种延长供给电动工具电动机电力的电源的寿命的方法，其特征在于，包括：
利用脉宽调制控制器提供一个初始宽度的电压脉冲至电动机；
将由于所提供的电压脉冲产生的电动机电流与二个不同阈值中的至少一个进行比较；及
基于上述与给定阈值的比较结果，将所述脉冲宽度由初始宽度变成第一可选择的脉冲宽度及第二可选择的脉冲宽度中的一个。
2.一种电动工具，其特征在于，包括：
一个机壳；
一个设置于机壳内的电源，该电源包含多个锂离子电池；
一个设置于机壳内的电动机，该电动机给电动工具提供扭矩；及
一个设置于机壳内的脉宽调制控制器，该脉宽调制控制器用来根据电动机电流与二个不同阈值中的至少一个比较的结果改变提供给所述电动机的电压脉冲的脉冲宽度。
3.如权利要求2所述的电动工具，其特征在于，其中该脉宽调制控制器包含一个开关，在该开关被打开时，提供电流给电动机。
4.如权利要求3所述的电动工具，其特征在于，其中该脉宽调制控制器还包含电压测量电路以确定该开关的打开时间。
5.如权利要求4所述的电动工具，其特征在于，其中该电压测量电路测量电池电压和电动机电压。
6.一种限制电流至负载的装置，其特征在于，包括：
用于提供电力的设备；
用于提供扭矩给负载的设备；
用于可开关地由用于提供电力的设备提供电力给用于提供扭矩的设备的设备，该设备用于可开关地供给依照脉宽调制技术被动作的电力；及
用来根据所述可开关地提供电力的设备中产生的电流与二不同阈值中的至少一个比较的结果控制所述可开关地提供电力的设备的设备。
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Also Published As
| Publication number | Publication date |
|---|---|
| US7276878B2 (en) | 2007-10-02 |
| US7133601B2 (en) | 2006-11-07 |
| CN1523725A (zh) | 2004-08-25 |
| US20070019933A1 (en) | 2007-01-25 |
| US20040179829A1 (en) | 2004-09-16 |
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