CN101911468B - 电动机控制装置及使用该电动机控制装置的电动工具 - Google Patents
电动机控制装置及使用该电动机控制装置的电动工具 Download PDFInfo
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Abstract
一种电动机控制装置及使用该电动机控制装置的电动工具，电动机控制装置具备：处理电路，其向上臂侧开关元件以及下臂侧开关元件选择性地输出接通信号；栅极驱动电路，其对处理电路输出的接通信号进行电平移动，向开关元件的栅极施加驱动电压；以及自举电容器，其在上臂侧开关元件断开时被充电，在上臂侧开关元件接通时作为所述栅极驱动电路的电压源发挥作用。处理电路在将占空比设定在规定值(例如80％)以上的状态下，在电动机的旋转位置经过第一规定时间没有变化的情况下，使占空比的设定值降低。根据该电动机控制装置，即使在电动机锁定的情况下，也能防止开关元件的烧损。
Description
技术领域
本发明涉及电动机的控制装置。尤其涉及通过自举式的驱动电路来驱动用来导通/关断无刷电动机和直流电源的开关元件的控制装置。
背景技术
本申请主张基于2008年1月8日提出的日本国专利申请第2008-000977号的优先权。该申请的全部内容被加入到本申请说明书中用于参考。
在日本特开2004-201453.号公报中公开了无刷电动机的控制装置。该控制装置具备：位置检测传感器，其检测电动机的旋转位置；栅极驱动型的上臂侧开关元件，其将电动机的各端子与直流电源的正极导通/关断；栅极驱动型的下臂侧开关元件，其将电动机的各端子与直流电源的负极导通/关断；处理电路，其向上臂侧开关元件和下臂侧开关元件选择性地输出接通信号；上臂侧栅极驱动电路，其对处理电路输出的针对上臂侧开关元件的接通信号进行电平移动，向所述上臂侧开关元件的栅极施加驱动电压；下臂侧栅极驱动电路，其对处理电路输出的针对下臂侧开关元件的接通信号进行电平移动，向所述下臂侧开关元件的栅极施加驱动电压；以及自举电容器，其在上臂侧开关元件断开时被充电，在上臂侧开关元件接通时作为上臂侧栅极驱动电路的电压源发挥作用。另外，所述的处理电路具备根据指示的电动机的目标旋转速度设定占空比的处理部和根据设定的占空比对输出的接通信号进行脉宽调制的处理部，来调节电动机的旋转速度。
在上述的电动机的控制装置中，在电动机因机械式锁定或过负载等而锁定的情况下，上臂侧开关元件持续接通，所以自举电容器的放电继续下去导致其电压降低。若自举电容器的电压降低，则不能对上臂侧开关元件施加足够的驱动电压。该情况下，上臂侧开关元件的接通电阻急剧上升，存在上臂侧开关元件因自身的发热而导致烧损的情况。
发明内容
本发明鉴于上述问题，提供一种即使在电动机锁定的情况下也可防止开关元件的烧损的电动机控制装置。
通过本发明而具体化的电动机控制装置，具备：位置检测传感器，其检测电动机的旋转位置；栅极驱动型的上臂侧开关元件，其将电动机的各端子与直流电源的正极导通/关断；栅极驱动型的下臂侧开关元件，其将电动机的各端子与直流电源的负极导通/关断；处理电路，其根据由所述位置检测传感器检测出的电动机的旋转位置，向所述上臂侧开关元件以及所述下臂侧开关元件选择性地输出接通信号；上臂侧栅极驱动电路，其对所述处理电路输出的针对上臂侧开关元件的接通信号进行电平移动，向所述上臂侧开关元件的栅极施加驱动电压；下臂侧栅极驱动电路，其对所述处理电路输出的针对下臂侧开关元件的接通信号进行电平移动，向所述下臂侧开关元件的栅极施加驱动电压；以及自举电容器，其在所述上臂侧开关元件断开时被充电，在所述上臂侧开关元件接通时作为所述上臂侧栅极驱动电路的电压源发挥作用。
处理电路具有：设定处理部，其根据指示的电动机的目标旋转速度来设定占空比；PWM处理部，其根据设定的占空比对所述接通信号进行脉宽调制；以及计时处理部，其对位置检测传感器的对检测位置进行更新的更新时间进行计时。设定处理部在占空比的设定值在规定值(例如80％)以上、计时处理部的计时时间超过第一规定时间时，执行使该占空比的设定值降低的处理。
根据该控制装置，例如在电动机因机械式锁定或过负载等锁定了的情况下，即使在目标旋转速度被设定为最大的情况下，也断续地使上臂侧开关元件断开。通过断续地使上臂侧开关元件断开，从而可防止自举电容器因放电引起的电压降低，对上臂侧开关元件持续施加足够的驱动电压。由此，防止上臂侧开关元件的烧损。
处理电路的设定处理部优选在所述的使占空比的设定值降低的处理中，使占空比的设定值降低10％到50％的幅度。
由此，不用无用地过度降低电动机的输出，能防止自举电容器因放电引起的电压降低。
处理电路的设定处理部优选在执行所述的使占空比的设定值降低的处理后，在计时处理部的计时时间小于第一规定时间时，根据指示的电动机的目标旋转速度再次设定占空比。
根据该电动机控制装置，在除去了机械式的锁定或过负载等电动机再次开始旋转的情况下，可以使电动机的旋转速度快速恢复到目标旋转速度。
处理电路的设定处理部优选在执行使占空比的设定值降低的处理后，在计时处理部的计时时间超过比第一规定时间长的第二规定时间时，将占空比的设定值设为0％。
由此，能够避免对因机械式锁定或过负载等而不能旋转的电动机，持续无用地供给电力。
发明效果
根据本发明，实现了一种即使在电动机锁定的情况下，也能防止开关元件的烧损的电动机控制装置。
附图说明
图1是电动改锥的侧截面图。
图2是表示电动改锥的电结构的图。
图3是表示微型计算机的功能结构的框图。
图4是表示霍尔信号(hall signal)和接通信号之间的关系的时间表(占空比100％)。
图5是表示霍尔信号和接通信号之间的关系的时间表(占空比50％)。
图6是表示设定占空比的处理的流程图。
图7是表示在时刻P2使占空比降低，在时刻P3使电动机停止时的接通信号的时间图。
图8是表示在时刻P2使占空比降低，在时刻P4再次设定占空比时的接通信号的时间图。
具体实施方式
首先，列举本发明的优选实施方式。
(方式1)作为控制对象的电动机优选是DC三相无刷电动机。
(方式2)开关元件优选采用n沟道型的绝缘栅极型场效应晶体管(n-MOSFET)或绝缘栅极型双极型晶体管(IGBT)。
(方式3)电动机控制装置中优选设置有设定目标旋转速度的机构。
实施例
参照附图对实施了本发明的电动改锥10进行说明。电动改锥10是电动工具的一种，用于螺钉类的紧固作业。本实施例的电动改锥10是冲击方式的电动改锥(电动冲击改锥)。
图1是表示电动改锥10的结构的侧截面图。如图1所示，电动改锥10具备主体12和可拆装地安装于主体12的电池组件50。主体12大致包括近似圆柱形的机体部14和向机体部14的侧方伸出的把手部16。电池组件50安装在把手部16的前端。
在主体12的机体部14，内置有能旋转地被支承的工具卡盘22、与工具卡盘22连接的冲击机构24、与冲击机构24连接的减速机26和与减速机26连接的电动机32。工具卡盘22从机体部14的一端(图1中的右侧)突出，能拆装改锥刀头(省略图示)。电动机32经由减速机26和冲击机构24与工具卡盘22连接，使安装有改锥刀头的工具卡盘22旋转。此时，电动机32的旋转转矩通过减速机26放大。电动机32是DC三相无刷电动机。
在主体12的机体部14，设置有检测电动机32的旋转位置的位置检测传感器34。位置检测传感器34具备：固定于电动机32的多个磁体34a；和固定于主体12侧的传感器基板34b。在传感器基板34b，设有检测磁体34a的接近/离开的多个霍尔元件。随着电动机32旋转，磁体34a反复与传感器基板34b的各霍尔元件接近/离开。每当电动机32旋转规定的旋转角，位置传感器34更新并输出表示电动机32的旋转位置的检测信号(以下称为霍尔信号HS)。
在主体12的把手部16设有：利用者操作所用的触发开关28；和根据施加到触发开关28的操作来控制电动机32的动作的控制装置100。触发开关28是用于起动/停止电动机32的操作部，并且也是用于调节电动机32的旋转速度的操作部。若利用者操作了触发开关28的触发部件28a，电动机32开始旋转，若利用者使触发部件28a返回，电动机32的旋转被中止。另外，若利用者大幅度操作触发部件28a，电动机32则以高速旋转，若利用者小幅操作触发部件28a，电动机32则以低速旋转。
图2是表示电动改锥10的电结构。如图2所示，在电动改锥10中，经由控制装置100连接电动机32和电池组件50。
控制装置100具备电连接电动机32和电池组件50的电动机驱动电路110。电动机驱动电路110具备：第一开关元件111，其导通/关断电动机32的U相端子32u和电池组件50的正极50a；第二开关元件112，其导通/关断电动机32的V相端子32v和电池组件50的正极50a；第三开关元件113，其导通/关断电动机32的W相端子32w和电池组件50的正极50a；第四开关元件114，其导通/关断电动机32的U相端子32u和电池组件50的负极50b；第五开关元件115，其导通/关断电动机32的V相端子32v和电池组件50的负极50b；以及第六开关元件116，其导通/关断电动机32的W相端子32w和电池组件50的负极50b。这些开关元件111-116是n沟道型的绝缘栅极型场效应晶体管(MOSFET)。其中，开关元件111-116例如也可以使用绝缘栅极型双极型晶体管(IGBT)等其他的栅极驱动型的半导体开关元件。
在本说明书中，将导通/关断电动机32的各端子32u、32v、32w和电池组件50的正极的第一开关元件111、第二开关元件112以及第三开关元件113统称为上臂侧开关元件111-113，将导通/关断电动机32的各端子32u、32v、32w和电池组件50的负极的第四开关元件114、第五开关元件115以及第六开关元件116统称为下臂侧开关元件114-116。
控制装置100具备微型计算机150。在微型计算机150上连接有触发开关28和位置检测传感器34，使得从触发开关28输入触发信号TG，从位置检测传感器34输入霍尔信号HS。这里，触发信号TG是指从触发开关28输出的电压信号，根据触发部件28a的操作量而变动。即，触发信号TG表示利用者所希望的电动机32的目标旋转速度。微型计算机150根据触发信号TG以及霍尔信号HS，选择性地输出针对开关元件111-116的接通信号UH、VH、WH、UL、VL、WL。关于微型计算机150将在后面详细说明。
控制装置100具备分别对电动机驱动电路110的开关元件111-116进行驱动的六个栅极驱动电路121-126。栅极驱动电路121-126分别对微型计算机150输出的针对开关元件111-116的接通信号UH、VH、WH、UL、VL、WL进行电平移动，向开关元件111-116的栅极施加驱动电压。所述这些六个栅极驱动电路121-126是具有相同构造的电平移动电路。例如，第一开关元件111用的栅极驱动电路121从信号输入端子121c输入二值的电压信号，从信号输出端子121d输出以第一电压输入端子121a和第二电压输入端子121b之间的电压变动的二值的电压信号。如图2所示，第一电压输入端子121a与电池组件50的正极50a连接，第二电压输入端子121b与第一开关元件111的源极连接。其他的栅极驱动电路122-126也具有同样的结构和功能，同样地针对各开关元件112-126设置。
如图2所示，在上臂侧开关元件111-113用的栅极驱动电路121-123分别设有自举电路131-133。自举电路131-133分别具有自举电容器131a-133a和二极管131b-133b。自举电容器131a-133a分别连接于栅极驱动电路121-123的第一电压输入端子121a-123a和第二电压输入端子121b-123b之间。另外，二极管131b-133b分别介于自举电容器131a-133a和电池组件50的正极50a之间。另外，二极管131b-133b设置在不介于自举电容器131a-133a和栅极驱动电路121-123的第一电压输入端子121a-123a之间。各自举电容器131a-133a在对应的上臂侧开关元件111-113断开时被充电，在对应的上臂侧开关元件111-113接通时，作为所述栅极驱动电路121-123的电压源发挥作用。即，在上臂侧开关元件111-113接通时，所述栅极驱动电路121-123的第一电压输入端子121a-123a的电压升压为比电池组件50的正极50a高。由此，即使在上臂侧开关元件111-113接通时，也向上臂侧开关元件111-113的栅极施加足够的驱动电压。
接着，对微型计算机150进行说明。图3是表示微型计算机150的功能构成的框图。如图3所示，微型计算机150功能性地具备接通信号生成部152、占空比设定部154和计时器156。
接通信号生成部152根据来自位置检测传感器34的霍尔信号HS，生成向开关元件111-116输出的接通信号UH、VH、WH、UL、VL、WL。在图4中，例示了位置检测传感器34更新霍尔信号HS的定时、和接通信号生成部152生成的接通信号UH、VH、WH、UL、VL、WL之间的关系。另外，如图5所示，接通信号生成部152根据由占空比设定部154设定的占空比，可以对向上臂侧开关元件111-113输出的接通信号UH、VH、WH进行脉宽调制。由此，调节电动机32的旋转速度。
占空比设定部154根据来自触发开关28的触发信号TG，来设定所述的占空比。另外，根据计时器156的计时时间，对设定的占空比进行增减调整。这里，计时器156输入从位置检测传感器34输出的霍尔信号HS，对更新霍尔信号HS的时间间隔进行计时。电动机32的旋转速度越慢，计时器156的计时时间越长。另外，在计时器156的计时时间非常长的情况下，可以推定为电动机32因机械式锁定或过负载等而锁定。
图6是表示占空比设定部154设定占空比的处理流程的流程图。占空比设定部154在利用者操作触发开关28的期间，执行图6所示的处理流程。
首先，在步骤S10中，占空比设定部154从触发开关28输入触发信号TG。
接着，在步骤S20中，占空比设定部154根据输入的触发信号TG设定占空比。
接着，在步骤S30中，若占空比设定部154设定的占空比在80％以上，则进入步骤S40的处理，若设定的占空比没有在80％以上，则返回步骤S10的处理。即，若设定的占空比没有在80％以上，则根据从触发开关28输入的触发信号TG反复执行占空比的设定。这里，与80％以上的占空比相关的判定基准，作为能引起上臂侧开关元件111-113的烧损的占空比的范围，预先存储于占空比设定部154中。与占空比相关的判定基准，并非限定于本实施例那样的80％以上，可以根据电动工具10的结构适当设定。是作为阈值预先存储于占空比设定部154中的值。
另一方面，在进入了步骤S40的处理的情况下，占空比设定部154确认计时器156的计时时间。然后，若计时器156的计时时间在第一规定时间T1以上，则进入步骤S50的处理，若没有超过第一规定时间T1，则返回步骤S10的处理。这里，在第一规定时间T1以上的判定基准，作为推定为电动机32停止的时间，预先存储于占空比设定部154中。第一规定时间T1例如可以设定为数十微秒左右。即，在该步骤S40中，通过占空比设定部154，判断电动机是否停止。然后，在判断为电动机32停止的情况下，进入步骤S50的处理。
在进入了步骤S50的处理的情况下，占空比设定部154将设定为80％以上的占空比降低到70％。由此，如图7所示，针对上臂侧开关元件111-113的接通信号UH、VH、WH通过脉宽调制被变更为脉冲信号列。这里，图7中的时刻P1表示霍尔信号HS最后被更新的时刻，时刻P2表示从时刻P1经过了第一规定时间T1后的时刻。
这里，在步骤S50的处理中使占空比降低的幅度不限定于10％。只要不将电动机的输出无用地过度降低，在能防止自举电容器因放电引起的电压降低的范围即可，具体而言，设定在10％到50％的范围为好。
另外，在电动改锥10这样的电动工具中，利用者立刻能感受到电动机的输出降低了。由此，通过在步骤S50的处理中使占空比降低，从而可以向利用者通报对电动机32的负载过大。但是，若使占空比过大降低，由于来自电动改锥10的反力急剧降低，所以也能引起利用者失去平衡的情况。从这些观点出发，使占空比降低的幅度优选在10％-50％的范围。
如图7所示，例如在100％的占空比下进行运转中因机械式锁定等使得电动机32锁定的话，在上臂侧开关元件111-113(图7的情况下为两个上臂侧开关元件111、112)长时间持续接通。若该状态持续，自举电容器131a-133a会持续放电，自举电容器131a-133a的电压降低。这样的放电引起的自举电容器131a-133a的电压降低并不限于占空比被设定为100％的情况，在占空比被设定为80％以上比较高的值的情况下也能引起上述电压降低。若自举电容器131a-133a的电压降低，则不能向上臂侧开关元件111-113施加足够的驱动电压。在该情况下，会导致在上臂侧开关元件111-113的接通电阻急剧上升，上臂侧开关元件111-113因自身的发热而烧损。对此，若在判断为电动机32停止的时刻(P2)使占空比降低，使上臂侧开关元件111-113断续地断开，则自举电容器131a-133a被充电，维持其电压。由此，可以防止上臂侧开关元件111-113的烧损。
接着，在步骤S60中，占空比设定部154确认计时器156的计时时间。若计时器156的计时时间在第一规定时间T1以上，则进入步骤S70的处理，若没有超过第一规定时间T1，则返回步骤S10的处理。另外，即使在步骤S70中，占空比设定部154也确认计时器156的计时时间。然后，若计时器156的计时时间在第二规定时间T2以上，则进入步骤S80的处理，若没有超过第一规定时间T1，则返回步骤S60的处理。这里，第二规定时间T2被设定为比第一规定时间T1长。通过该步骤S60、S70的处理，占空比设定部154判断电动机32是否还继续处于停止状态，还是电动机32再次开始旋转。
在计时器156的计时时间在第二规定时间T2以上的情况下(在步骤S70的处理中“是”)，判断为电动机32依然停止。此时，占空比设定部154进入步骤S80的处理，将占空比设定为0％。由此，如图7所示，在从时刻P1经过了第二个的时间T2后的时刻P3，强制终止电动机32的运转。
另一方面，在计时器156的计时时间小于第一规定时间T1的情况下(在步骤S60的处理中“是”)，判断为电动机32再次开始旋转。此时，占空比设定部返回到步骤S10的处理。由此，如图8所示，在时刻P3以前的时刻P4，再次设定与触发信号TG对应的占空比。例如，若利用者将触发开关28持续操作为最大，则占空比再次被设定为100％。若因过负载等临时使电动机32锁定，则利用者不用重新操作触发开关28，可以继续作业。
以上，根据本实施例的电动改锥10，例如在电动机32因机械式锁定或过负载等而锁定的情况下，即使在触发开关28被最大操作的情况下，上臂侧开关元件111-113也被断续地断开。通过使上臂侧开关元件111-113断续地断开，可以防止自举电容器131a-133a的放电引起的电压降低，对上臂侧开关元件111-113持续施加足够的驱动电压。由此，可防止上臂侧开关元件111-113的烧损。
以上，对本发明的实施方式进行了说明，但这些只不过是例示，不会对权利要求书造成限定。在权利要求书记载的技术中，包括对以上例示的具体例子进行了各种变形、变更后的技术。
在本说明书或附图中说明的技术要素根据单独或各种组合而发挥技术上的有用性，并不限定于申请时的权利要求中记载的组合。在本说明书或附图例示的技术能同时达到多个目的，对于达到其中一个目的自身也具有技术上的有用性。
Claims (9)
1.一种电动机控制装置，具备：
位置检测传感器，其检测电动机的旋转位置；
栅极驱动型的上臂侧开关元件，其将电动机的各端子与直流电源的正极导通/关断；
栅极驱动型的下臂侧开关元件，其将电动机的各端子与直流电源的负极导通/关断；
处理电路，其根据由所述位置检测传感器检测出的电动机的旋转位置，向所述上臂侧开关元件以及所述下臂侧开关元件选择性地输出接通信号；
上臂侧栅极驱动电路，其对所述处理电路输出的针对上臂侧开关元件的接通信号进行电平移动，向所述上臂侧开关元件的栅极施加驱动电压；
下臂侧栅极驱动电路，其对所述处理电路输出的针对下臂侧开关元件的接通信号进行电平移动，向所述下臂侧开关元件的栅极施加驱动电压；以及
自举电容器，其在所述上臂侧开关元件断开时被充电，在所述上臂侧开关元件接通时作为所述上臂侧栅极驱动电路的电压源发挥作用，
所述处理电路具有：设定处理部，其根据指示的电动机的目标旋转速度来设定占空比；PWM处理部，其根据该占空比的设定值对所述接通信号进行脉宽调制；以及计时处理部，其对由所述位置检测传感器检测的位置被更新的时间间隔进行计时，
在占空比的设定值在规定值以上、所述计时处理部的计时间隔超过第一规定时间时，所述设定处理部执行使该占空比的设定值降低的处理。
2.如权利要求1所述的电动机控制装置，其特征在于，
所述设定处理部在占空比的设定值在80％以上、所述计时处理部的计时间隔超过第一规定时间时，使该占空比的设定值降低。
3.如权利要求1或2所述的电动机控制装置，其特征在于，
所述设定处理部在所述的使占空比的设定值降低的处理中，使占空比的设定值降低10％到50％的幅度。
4.如权利要求1所述的电动机控制装置，其特征在于，
所述设定处理部在执行所述的使占空比的设定值降低的处理后，在所述计时处理部的计时时间小于第一规定时间时，根据指示的电动机的目标旋转速度再次设定占空比。
5.如权利要求1所述的电动机控制装置，其特征在于，
所述设定处理部在执行所述的使占空比的设定值降低的处理后，在所述计时处理的计时时间超过比第一规定时间长的第二规定时间时，将占空比设定为0％。
6.如权利要求1所述的电动机控制装置，其特征在于，
所述设定处理部在占空比的设定值在80％以上、所述计时处理部的计时间隔超过第一规定时间时，使该占空比的设定值降低10％到50％的幅度。
7.如权利要求1所述的电动机控制装置，其特征在于，
所述设定处理部在执行所述的使占空比的设定值降低的处理后，在所述计时处理部的计时时间小于第一规定时间时，根据指示的电动机的目标旋转速度再次设定占空比，在所述计时处理的计时时间超过比第一规定时间长的第二规定时间时，将占空比设定为0％。
8.如权利要求1所述的电动机控制装置，其特征在于，
所述设定处理部，在占空比的设定值在80％以上、所述计时处理部的计时间隔超过第一规定时间时，执行使该占空比的设定值降低10％到50％的幅度的处理，
并且在执行使该占空比的设定值降低10％到50％的幅度的处理后，在所述计时处理部的计时时间小于第一规定时间时，根据指示的电动机的目标旋转速度再次设定占空比，在所述计时处理的计时时间超过比第一规定时间长的第二规定时间时，将占空比设定为0％。
9.一种电动工具，其特征在于，具备：
驱动工具的电动机；以及
控制该电动机的权利要求1～8中的任意一项所述的电动机控制装置。
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| JP2008000977A JP5116490B2 (ja) | 2008-01-08 | 2008-01-08 | モータ制御装置とそれを用いた電動工具 |
| JP2008-000977 | 2008-01-08 | ||
| PCT/JP2008/071779 WO2009087834A1 (ja) | 2008-01-08 | 2008-12-01 | モータ制御装置とそれを用いた電動工具 |
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- 2008-12-01 RU RU2010133155/07A patent/RU2478256C2/ru active
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- 2008-12-01 EP EP08870429A patent/EP2219288A4/en not_active Withdrawn
- 2008-12-01 WO PCT/JP2008/071779 patent/WO2009087834A1/ja active Application Filing
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| JP特开2007-196363A 2007.08.09 |
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|---|---|
| US8294399B2 (en) | 2012-10-23 |
| EP2219288A1 (en) | 2010-08-18 |
| US20100308764A1 (en) | 2010-12-09 |
| JP5116490B2 (ja) | 2013-01-09 |
| RU2478256C2 (ru) | 2013-03-27 |
| RU2010133155A (ru) | 2012-02-20 |
| WO2009087834A1 (ja) | 2009-07-16 |
| CN101911468A (zh) | 2010-12-08 |
| JP2009165280A (ja) | 2009-07-23 |
| EP2219288A4 (en) | 2012-09-12 |
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