CN105473287B - 电动工具 - Google Patents
电动工具 Download PDFInfo
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- CN105473287B CN105473287B CN201480046017.9A CN201480046017A CN105473287B CN 105473287 B CN105473287 B CN 105473287B CN 201480046017 A CN201480046017 A CN 201480046017A CN 105473287 B CN105473287 B CN 105473287B
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23D—PLANING; SLOTTING; SHEARING; BROACHING; SAWING; FILING; SCRAPING; LIKE OPERATIONS FOR WORKING METAL BY REMOVING MATERIAL, NOT OTHERWISE PROVIDED FOR
- B23D59/00—Accessories specially designed for sawing machines or sawing devices
- B23D59/001—Measuring or control devices, e.g. for automatic control of work feed pressure on band saw blade
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23D—PLANING; SLOTTING; SHEARING; BROACHING; SAWING; FILING; SCRAPING; LIKE OPERATIONS FOR WORKING METAL BY REMOVING MATERIAL, NOT OTHERWISE PROVIDED FOR
- B23D47/00—Sawing machines or sawing devices working with circular saw blades, characterised only by constructional features of particular parts
- B23D47/12—Sawing machines or sawing devices working with circular saw blades, characterised only by constructional features of particular parts of drives for circular saw blades
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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
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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
- B25F5/001—Gearings, speed selectors, clutches or the like specially adapted for rotary tools
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- Mechanical Engineering (AREA)
- Control Of Motors That Do Not Use Commutators (AREA)
- Sawing (AREA)
- Portable Power Tools In General (AREA)
Abstract
一种电动工具,包括:无刷电机;控制单元,其被构造为控制对所述无刷电机的电力供应;旋转工具,其被构造为通过所述无刷电机而旋转;旋转速度检测单元,其被构造为检测所述无刷电机的旋转速度;主开关,其被构造为向所述控制单元发送用于在驱动和停止所述无刷电机之间进行切换的ON/OFF信号;以及模式切换单元,其被构造为向所述控制单元发送用于在对所述无刷电机进行旋转控制的多种模式之间进行切换的模式切换信号,其中所述控制单元被构造为以至少包括高速模式和低速模式的多种模式中的任何一种模式对无刷电机执行旋转控制。
Description
技术领域
本发明涉及诸如圆锯之类的电动工具。
背景技术
在圆锯中,例如,为了提高切割效率,需要增大切割期间锯片的旋转速度。为此,需要增大空载期间的旋转速度。甚至是在市场上,为了强调平滑切割性能,厂商也趋于迎合空载期间的高速旋转的需求。
在空载期间旋转速度增大的情况下,存在振动和噪声增加以及功耗不必要地增加的问题。这些问题不只限于圆锯,对于其他电动工具(比如研磨机)也很普遍。
发明内容
鉴于上述情况而做出本发明,本发明的一个方面提供了一种电动工具,其可以在多个旋转速度上控制无刷电机并且工作效率优异。
根据本发明的说明性实施例,提供了一种电动工具,包括:无刷电机;控制单元,其被构造为控制对无刷电机的电力供应;旋转工具,其被构造为通过无刷电机而旋转;旋转速度检测单元,其被构造为检测无刷电机的旋转速度;主开关,其被构造为向控制单元发送用于在驱动和停止无刷电机之间进行切换的ON/OFF信号;以及模式切换单元,其被构造为向控制单元发送用于在对无刷电机进行旋转控制的多种模式之间进行切换的模式切换信号,其中控制单元被构造为以多种模式中的任何一种对无刷电机执行旋转控制,该多种模式至少包括高速模式和低速模式。
在上述电动工具中,在低速模式中,控制单元可以被构造为通过占空比控制来控制无刷电机在预定负荷范围中以预定的第一旋转速度旋转。
在上述电动工具中,在高速模式中,控制单元可以被构造为通过占空比控制来控制无刷电机在预定负荷范围中以比所述预定的第一旋转速度更高的预定的第二旋转速度旋转。
上述电动工具还可以包括电池组,其被可拆卸地附接并且被构造为向无刷电机和控制单元供应电力。
在上述电动工具中,在低速模式中,当检测到等于或大于第一预定值的负荷时,控制单元可以被构造为切换至预定的占空比控制,该预定的占空比控制与无刷电机的旋转速度无关。
在上述电动工具中,可以基于电流、电压和占空比中的预定一个或其组合来执行等于或大于第一预定值的负荷的检测。
在上述电动工具中,预定的占空比控制可以包括用于逐渐地将占空比增加至预定的占空比并随后用该预定的占空比驱动无刷电机的控制。
在上述电动工具中,当在执行预定的占空比控制的状态下检测到等于或小于比用于向预定的占空比控制进行切换的第一预定值更小的第二预定值的负荷时,控制单元可以被构造为逐渐地减小占空比并随后控制无刷电机以预定的第一旋转速度旋转。
在上述电动工具中,旋转工具可以是通过减速机构与无刷电机的输出轴相连接的锯片,并且在预定的负荷范围中,控制单元可以被构造为在低速模式中控制无刷电机以使得锯片的旋转速度变得恒定在2500rpm至3500rpm的范围内,并且可以被构造为在高速模式中控制无刷电机以使得锯片的旋转速度变得恒定在4500rpm至5500rpm的范围内。
在上述电动工具中,控制单元可以被构造为执行软启动控制,以在无刷电机启动时逐渐地供应电流。
根据本发明的另一说明性实施例,提供了一种电动工具,包括:无刷电机;控制单元,其被构造为控制无刷电机的电力供应;旋转工具,其被构造为通过无刷电机而旋转;旋转速度检测单元,其被构造为检测无刷电机的旋转速度;以及主开关,其被构造为向控制单元发送用于在驱动和停止无刷电机之间进行切换的ON/OFF信号,其中在利用小于100%的占空比对无刷电机执行恒定速度控制的状态下,当检测到等于或大于第一预定值的负荷时,控制单元被构造为执行从恒定速度控制到预定的占空比控制的切换,所述预定的占空比控制与无刷电机的旋转速度无关,并且其中所述预定的占空比控制是用于将占空比逐渐地增加至预定的占空比并随后利用该预定的占空比驱动无刷电机的控制。
在上述电动工具中,恒定速度控制被切换到预定的占空比控制时的负荷可以被设为这样的阈值:如果负荷超过该阈值,则预定的占空比控制的效率变得高于恒定速度控制的效率,或者可以被设为在该阈值附近的值。
在上述电动工具中,当在执行预定的占空比控制的状态下检测到等于或小于第二预定值的负荷时,控制单元可以被构造为逐渐地减小占空比以使得无刷电机的旋转速度变为预定的旋转速度,并随后以预定的旋转速度对无刷电机执行恒定速度控制。
在上述电动工具中,使得占空比减小以使从预定的占空比控制向恒定速度控制改变的第二预定值小于使得恒定速度控制改变为预定的占空比控制的第一预定值。
此外,上述部件的任意组合以及通过在方法和系统之间转换本发明的实施例而获得的修改有效作为本发明的实施例。
根据上述构造,可以提供能够以多个旋转速度控制无刷电机并且工作效率优异的电动工具。
附图说明
在附图中:
图1是示出根据本发明的实施例的无绳圆锯的俯视图;
图2是该无绳圆锯的侧视图;
图3是该无绳圆锯的后视图;
图4是该无绳圆锯的正视图;
图5是该无绳圆锯的第一俯视图,其中其一部分被示出为截面;
图6是该无绳圆锯的第二俯视图,其中另一部分被示出为截面;
图7是沿图1的A-A线截取的截面图;
图8是示出图1所示的无绳圆锯的功能块的示图;
图9是示出当实施例的无绳圆锯处于普通模式和第一经济模式时圆锯片8相对于负荷电流的旋转速度与效率的特性图;
图10是示出当实施例的无绳圆锯处于第二经济模式时圆锯片8相对于负荷电流的旋转速度与效率的特性图;
图11是示出当实施例的无绳圆锯处于第二经济模式时根据负荷电流的变化的占空比控制的说明图;
图12是示出当实施例的无绳圆锯处于第二经济模式时的控制流程的流程图;
图13是示出在软启动实施例的无刷电机9期间圆锯片8的旋转速度的时间变化以及用于无刷电机9的供应电流的时间变化的说明图;
图14是示出在不仅执行了占空比控制而且执行了提前角控制的实施例中每种模式下旋转速度和负荷电流之间的关系的特性图;
图15是示出根据本发明的另一实施例的无绳圆锯的侧视图,其中模式改变开关16设置在手柄部4的主触发开关18附近;
图16是示出根据本发明的另一实施例的研磨机的透视图;和
图17是示出根据本发明的另一实施例的电刨的透视图。
具体实施方式
下文中,将参照附图描述本发明的实施例。附图中示出的彼此相同或等同的部件、构件等用相同的附图标记表示并且可能不对其进行重复描述。实施例不限制本发明并且是说明性的,并且在实施例中描述的所有特征及其组合可以不是本发明的必要特征。
图1至图4分别是示出根据本发明的实施例的无绳圆锯的俯视图、侧视图、后视图和正视图。图5是该无绳圆锯的第一俯视图,其中其一部分示出为截面。图6是该无绳圆锯的第二俯视图,其中其另一部分示出为截面。图7是沿图1的A-A线截取的截面图。
本实施例的无绳圆锯包括底座1和主体2。底座1是诸如铝之类的金属制成的大致为矩形形状的板材。底座1的纵向方向与切割方向相一致。底座构件的底面是在工件上滑动的表面。主体2在前后方向上的两个位置处与底座1相接,使得主体可以旋转并相对于底座1向左或向右倾斜。主体2包括电机壳体3、手柄部4、齿轮罩5、锯罩6、保护罩7和圆锯片8(旋转工具)。电机壳体3由例如树脂制成并容纳无刷电机9(图5和图6)。无刷电机9使圆锯片8旋转。手柄部4由与电机壳体3的材料相同的材料制成,并且在电机壳体3上的前后方向上延伸。手柄部4包括主触发开关18(主开关),该主触发开关18作为用于允许用户在驱动和停止无刷电机9之间执行切换的操作单元。如图3和图4所示,手柄部4由左部件和右部件构成,左部件与电机壳体3一体设置,右部件介于电机壳体3和齿轮罩5之间,并且左部件和右部件组合构成电池组附接部4a(下文将描述),并且控制电路板容纳部4b(下文将描述)设置在位于圆锯片8一侧的手柄部4的右部件处。手柄部4的左部件和右部件之间的边界是图1、图3、图4等中手柄部4的中央处示出的线条。
在手柄部4的后端下部处,一体设置电池组附接部4a(电池附接部)和控制电路板容纳部4b。电池组20(可充电电池)从后侧滑入电池组附接部4a,从而被可拆卸地附接。在手柄部4的下侧的电池组附接部4a的上表面上,设置有模式改变开关16(例如,轻触开关)和用作对模式进行显示的显示单元的LED 29。例如,用户可以通过模式改变开关16选择普通模式和经济模式中的任一个。模式改变开关16和LED 29被设置在同一板上,并且当通过操作模式改变开关16设置了经济模式时,LED 29点亮。由于模式改变开关16设置在手柄部4的下侧,因此防止了由于诸如某物碰撞到模式改变开关16之类的因素导致不期望地执行模式切换。电池组20向无刷电机9供应驱动电力。如图1所示,附接至电池组附接部4a的电池组20的左表面与电机壳体3的左表面大致处于同一平面。即,电机壳体3的左表面距圆锯片8的距离与电池组20的左表面距圆锯片8的距离大致相同。因此,可以将无绳圆锯放置为电池组20的左表面和电机壳体3的左表面向下,从而容易进行更换圆锯片8的工作。控制电路板容纳部4b设置在电池组20的右侧。在控制板容纳部4b中,存放和保持控制电路板21。控制电路板21上安装有用于控制无刷电机9的操作的控制单元(控制器)。控制电路板21与无刷电机9的旋转轴(圆锯片8的旋转轴)大致垂直。控制电路板21,更具体地,控制电路板21的左侧与电池组20被控制器罩22(例如由树脂制成)隔开。
齿轮罩5设置在手柄部4的右侧。齿轮罩5由例如金属制成,并且容纳用于在无刷电机9与圆锯片8之间传输旋转的机构。旋转传输机构由已知的减速结构构成。锯罩6附接至齿轮罩5,并与齿轮罩5一起覆盖圆锯片8的上半部分。锯罩6可以用与齿轮罩5的材料相同的材料和齿轮罩5一体形成。齿轮罩5的前端部分和锯罩6的前端部分通过旋转支撑单元14可旋转地连接。保护罩7由例如树脂制成,并且沿齿轮罩5和锯罩6的外边缘可旋转地设置在齿轮罩5的后侧。在齿轮罩5和保护罩7之间,插入有弹簧(未示出)。该弹簧使保护罩7在一个方向(图2中的逆时针方向)上偏向齿轮罩5,以在齿轮罩5和锯罩6的圆周方向上覆盖圆锯片8的下半部分。因此,在未执行切割工作的状态下,保护罩7覆盖圆锯片8的下半部分(从底座1的底部突出的部分),不包括前侧部分。
在底座1的前侧,设置直立的斜板12。斜板12在与切割方向大致垂直的短长度方向上直立。斜板12具有长孔13。长孔13具有弧形形状,该弧形形状具有作为中心的在切割方向上延伸的第一倾斜轴部15a并且与第一倾斜轴部15a垂直。旋转支撑单元14被支撑为能够在第一倾斜轴部15a上相对于底座1向左或向右倾斜。在倾斜角度调整杆11松弛的状态下调整旋转支撑单元14的倾斜位置,并且通过扣紧倾斜角度调整杆11来固定旋转支撑单元14的倾斜位置。旋转支撑单元14可旋转地将锯罩6的前端部分支撑在与无刷电机9的旋转轴(圆锯片8的旋转轴)平行的轴上。将在下文描述调整和固定锯罩6的旋转位置。
在底座1的后侧,沿齿轮罩5的左表面设置连接件10,其可与第一倾斜轴部15a同心地围绕倾斜轴部15b旋转。连接件10由诸如铝之类的金属制成。在切割深度调整杆19松弛的状态下,连接件10和齿轮罩5相对彼此可滑动,由此可以相对于底座1调整锯罩6的旋转位置,即,切割深度。此外,可以通过扣紧切割深度调整杆19来固定齿轮罩5的旋转位置。
如图6所示,无刷电机9具有围绕输出轴9a的转子芯9b。输出轴9a与圆锯片8的旋转轴平行。转子芯9b与输出轴9a一体地旋转。转子磁体9c插入并支撑在转子芯9b中。定子芯9d设置为围绕转子芯9b的外圆周表面。在定子芯9d上,设置有定子线圈9f,并且绝缘体9e介于它们之间。在定子芯9d的左端侧,固定有开关板23。开关板23与输出轴9a大致垂直。如图7所示,6个开关器件23a(诸如FET之类)以它们的主体部分平躺的方式安装在开关板23上。开关器件23a切换来自电池组20的供应电压。如图5所示,电池组20的端子部20a和开关板23通过线路24彼此电连接。线路25将电池组20的端子部20a与控制电路板21彼此电连接。线路26将控制电路板21与开关板23彼此电连接。通过线路26从控制电路板21的控制器向安装在开关板23上的开关器件23a的控制端子(栅极)施加控制信号,从而控制开关器件23a的ON/OFF。冷却风扇33附接至无刷电机9的输出轴9a,并且与输出轴9a一起旋转。冷却风扇33产生冷却无刷电机9和开关器件23a的气流。
图8是示出根据本发明的实施例的无绳圆锯的功能块的示图。控制单元27安装在图6示出的控制电路板21上。逆变器单元28是以桥接形式将图6和图7示出的开关器件23a连接而获得的电路。剩余电量显示单元30显示电池组20的剩余电量。温度传感器31包括温度检测器件,诸如设置在逆变器单元28的开关器件23a附近的热敏电阻,以检测开关器件23a的温度。检测电阻32设置在无刷电机9的驱动电流的路径上。控制单元27可以通过检测电阻32的端电压来检测驱动电流(负荷电流),即负荷。附带提及,负荷不限于电流,可以通过电压、或占空比、或它们的组合来检测负荷。旋转传感器34是例如磁传感器,诸如3个霍尔(Hall)器件。控制单元27通过旋转传感器34的输出信号检测无刷电机9的旋转速度。当主触发开关18导通时,控制单元27根据由模式改变开关16设定的模式(例如,普通模式和经济模式中的任一个)来向逆变器单元28的每个开关器件23a施加PWM信号,从而控制对无刷电机9的驱动。在普通模式中,控制单元27控制要施加至每个开关器件23a的PWM信号的占空比,以使得占空比变为100%,而在经济模式中,控制单元27控制占空比以使得圆锯片8以预定的旋转速度(例如,3000rpm)旋转。在驱动无刷电机9的情况下,在每个模式中,控制单元27执行软启动控制以逐渐增加占空比,使得在普通模式中,当经过约0.6秒时占空比变为100%,而在经济模式中,在空载状态下圆锯片8在经过约0.4秒时以预定的旋转速度旋转。
图9是示出当实施例的无绳圆锯处于普通模式和第一经济模式时圆锯片8相对于负荷电流的旋转速度与效率的特性图。在普通模式(高速模式的示例)中,占空比始终处于最大值(例如,100%),并且随着负荷电流从空载状态增加,圆锯片8的旋转速度降低。第一经济模式(低速模式的示例)不同于普通模式之处在于当负荷电流等于或小于预定值(图9的示例中的约35A)时,对旋转速度执行控制(恒定速度控制)以使得旋转速度变得恒定(图9的示例中的3000rpm),但是当负荷电流超过预定值时与普通模式是相同的。即,在第一经济模式中,如果负荷增加,则占空比增加,而如果负荷超过预定值,则占空比变为最大值(例如,100%)。因此,当施加了超过预定值的负荷时,即使是在第一经济模式中,也执行与普通模式中的控制相同的控制。附带提及,在恒定速度控制期间可以存在旋转速度不同的多个经济模式。例如,可以选择一个经济模式(低速模式的示例),其中在恒定速度控制期间的旋转速度处于2500rpm至3500rpm的范围中,以及可以选择一个经济模式(高速模式的示例),其中在恒定速度控制期间的旋转速度处于4500rpm至5500rpm的范围中。
如图9所示,当负荷电流等于或小于预定值(图9的示例中的约17A)时,第一经济模式的效率(输出与输入功率之比)高于普通模式的效率。同时,当负荷电流超过预定值时,在直到占空比变为最大值(与普通模式中相同)时的负荷电流值(图9的示例中的约35A)的范围中,普通模式的效率高于第一经济模式的效率。即,在特定负荷电流值处,普通模式的效率和第一经济模式的效率颠倒。因此,为了有效利用输入功率,存在对第一经济模式进行改进的余地。
图10是示出当实施例的无绳圆锯处于第二经济模式时圆锯片8相对于负荷电流的旋转速度与效率的特性图。图10示出了图9示出的普通模式和第一经济模式的特性以及第二经济模式的特性(用粗线示出)。图11是示出当实施例的无绳圆锯处于第二经济模式时根据负荷电流的变化的占空比控制的说明图。在图11中,第一经济模式中的占空比的改变用虚线示出。
如图10所示,在第二经济模式(低速模式的示例)中,当负荷电流等于或小于普通模式的效率与第一经济模式的效率颠倒时的预定值(例如,约17A)时,执行与第一经济模式中的恒定速度控制相同的恒定速度控制;但是,如果负荷电流超过预定值,则执行增加旋转速度的控制。具体地,在第二经济模式中,如果负荷电流超过17A,则与旋转速度无关(独立于旋转速度)地将占空比逐渐增加至100%,随后,占空比保持为100%。该控制将圆锯片8的旋转速度从恒定速度控制期间的3000rpm增加至约3800rpm(在图10中,执行从操作点“A”至操作点“B”的转变)。操作点“B”在普通模式的特性曲线上。在负荷电流超过17A并且占空比变为100%之后,第二经济模式的效率变得与普通模式的效率相同。因此,在第二经济模式中,在从17A至35A的范围中,与第一经济模式相比,可以更有效地利用输入功率。在第二经济模式中,在负荷电流超过17A并且占空比变为100%之后(在转变到操作点“B”之后),执行与普通模式相同的控制,直到负荷电流变为小于14A为止。如果负荷电流变为小于14A,则占空比逐渐减小使得圆锯片8的旋转速度降低至3000rpm,并且随后执行与第一经济模式中的恒定速度控制相同的恒定速度控制。
图12是示出当实施例的无绳圆锯处于第二经济模式时的控制流程的流程图。如果用户使主触发开关18导通,则控制流程开始。如果主触发开关18导通,则在步骤S1,控制单元27以软启动方式启动无刷电机9。在软启动期间圆锯片8的旋转速度的时间变化以及用于无刷电机9的供应电流(负荷电流)的时间变化如图13所示,并且该电流供应使得圆锯片8的旋转速度平滑增加。如果圆锯片8的旋转速度变为3000rpm,则在步骤S2,控制单元27以该旋转速度执行恒定速度控制。具体地,在通过来自旋转传感器34的信号对无刷电机9的旋转速度进行监控的同时,控制单元27控制要施加至开关器件23a的PWM信号的占空比,以使得圆锯片8的旋转速度恒定为3000rpm。继续进行与第一经济模式中的恒定速度控制相同的恒定速度控制直到负荷电流超过17A为止(步骤S3中的“否”)。如果在执行恒定速度控制期间负荷电流超过17A(步骤S3中的“是”),则在步骤S4,控制单元27将占空比平滑地增加至100%而不管无刷电机9的旋转速度(独立于无刷电机9的旋转速度)如何。如果占空比变为100%,则在步骤S5,控制单元27利用100%的占空比来驱动无刷电机9。继续进行与普通模式相同的利用100%的占空比的控制直到负荷电流变为小于14A为止(步骤S6中的“否”)。如果负荷电流变为小于14A(步骤S6中的“是”),则在步骤S7中,在通过来自旋转传感器34的信号对无刷电机9的旋转速度进行监控的同时,控制单元27平滑地减小占空比直到圆锯片8的旋转速度变为3000rpm为止。随后,控制流程返回至步骤S2的恒定速度控制。
根据上述实施例,可以实现以下效果。
(1)在第一经济模式中,在从0到预定值的负荷范围中,占空比被抑制并且执行恒定速度控制。因此,与普通模式相比,可以降低空载期间的旋转速度。从而,可以降低振动和噪音,并防止功耗不必要地增加。由于降低了功耗,每次充电能执行的工作量增加,因此方便。此外,当负荷等于或大于预定值时,和普通模式一样,占空比变为最大值。因此,改进了工作效率。
(2)在第二经济模式中,在其中普通模式的效率高于第一经济模式的负荷范围中,不执行恒定速度控制而执行与普通模式中的控制相同的控制。因此,与第一经济模式相比,可以更有效地利用输入功率。
(3)在第二经济模式中,当占空比与旋转速度无关地从恒定速度控制增加时,以及当为了恒定速度控制而将占空比从100%减小时,逐渐地改变占空比(平滑地改变圆锯片8的旋转速度)。因此,无绳圆锯具有低的反向作用且易于使用。此外,在每种模式中,在启动无刷电机9期间,执行软启动控制。因此,即使在软启动期间,无绳圆锯也具有低的反向作用且易于使用。
(4)在第二经济模式中,为了恒定速度控制而将占空比从100%减小的情况下的负荷值(例如,14A)被设置为小于在从恒定速度控制与旋转速度无关地增加占空比的情况下的负荷值。因此,可以防止频繁地执行控制切换,使得无绳圆锯变得稳定。
虽然通过参照实施例已经描述了本发明,但是本发明所属领域的技术人员可以理解的是,可以在不脱离权利要求的范围的情况下对实施例的部件和过程应用各种修改。
图14是示出在不仅执行了占空比控制而且执行了提前角控制的实施例中每种模式下旋转速度和负荷电流之间的关系的特性图。在第一模式中,在从0至预定值的负荷电流范围中,利用例如100%的占空比和90度的提前角来控制无刷电机9,并且如果负荷电流超过预定值,则利用例如100%的占空比和15度的提前角来控制无刷电机9。在第一模式中,用于将提前角从15度改变为90度的负荷电流值被设置为小于用于将提前角从90度改变为15度的负荷电流值,从而防止频繁切换。在图14所示的第一模式中,在低负荷期间,采用大提前角。因此,可以增加空载期间的旋转速度,并且在提升其空载期间高速旋转性能的情况下,这是有效的。在第二模式中,在包括空载在内的低负荷范围中,执行45度提前角的基于占空比控制的恒定速度控制,并且如果负荷电流超过占空比通过恒定速度控制变为100%时的负荷电流值,则利用例如100%的占空比和45度的提前角来控制无刷电机9,直到负荷电流变为预定值为止,并且如果负荷电流超过预定值,则利用例如100%的占空比和15度的提前角控制无刷电机9。在第二模式中,用于将提前角从15度改变为45度的负荷电流值被设置为小于用于将提前角从45度改变为15度的负荷电流值,从而防止频繁切换。在第三模式中,提前角固定在15度,并且在包括空载在内的低负荷范围中,执行基于占空比控制的恒定速度控制,并且如果负荷电流超过占空比通过恒定速度控制变为100%时的值,则利用100%的占空比控制无刷电机9。由于如上所述地增加了提前角控制,因此可以设置各种模式。
图15是示出根据本发明的实施例的无绳圆锯的侧视图,其中模式改变开关16设置在手柄部4的主触发开关18附近。根据图15的构造,由于可以用握住手柄部4的手来操作主触发开关18和模式改变开关16两者,因此该无绳圆锯易于使用。具体地,在用右手握住手柄部4的情况下,可以用右手的拇指操作模式改变开关16,并且在用左手握住手柄部4的情况下,可以用左手的食指或中指操作模式改变开关16。因此,可以在工作中容易地执行模式切换,可操作性佳。
所述电动工具不限于如上述实施例说明的无绳圆锯,并且可以是任意其他电动工具,比如研磨机或电刨。图16是示出根据另一实施例的研磨机的透视图。当主触发开关18导通时,由此通过电机使研磨石8a旋转,研磨机执行抛光或研磨。图17是示出根据另一实施例的电刨的透视图。当主触发开关18导通时,由此通过电机使刀盘旋转,电刨刨工件表面。不仅在图16所示的研磨机的情况下,而且也在图17所示的电刨的情况下,功能框图与图8相同,并且控制流程图与图10相同,并且在满足预定条件的情况下,即使主触发开关18导通,也可以通过推动模式改变开关16来在各操作模式之间执行切换。此外,由于模式改变开关16设置在手柄部4的主触发开关18附近,因此可以用握住手柄部4的手来操作主触发开关18和模式改变开关16两者。此外,本发明对于诸如研磨机或电刨之类的电动工具是优选的,其可以对无刷电机9执行旋转控制而与主触发开关18的操作量(拉动量)无关。
在上述实施例中,可以选择占空比始终为100%的普通模式和执行恒定速度控制使得占空比在高负荷状态中变为100%的经济模式(第一或第二经济模式)。根据该构造,如上所述,无需根据负荷状态执行从经济模式到普通模式的切换。因此,具有无需在工作期间频繁地执行模式切换的效果,并且可操作性佳。但是,可以选择占空比始终为100%的普通模式和例如占空比始终为80%的经济模式(第三模式)。此外,普通模式中的占空比(以及每种模式中的占空比的最大值)可以例如为小于100%的95%。此外,可以只有实施例中描述的第二经济模式作为操作模式存在。无刷电机9可以以无传感器方式被驱动,其中不使用任何旋转传感器(位置传感器)。在这种情况下,可以不使用旋转传感器来检测旋转速度。该实施例中,使用无刷电机作为驱动源。但是,可以使用有刷的电机作为驱动源。诸如占空比、旋转速度和负荷电流值之类的参数不限于实施例中例示的具体数值,而是可以任意地设置。
本申请要求于2013年8月19日提交的日本专利申请No.2013-169596的优先权,其全部内容通过引用合并于此。
Claims (12)
1.一种电动工具,包括:
无刷电机;
控制单元,其被构造为控制对所述无刷电机的电力供应;
旋转工具,其被构造为通过所述无刷电机而旋转;
旋转速度检测单元,其被构造为检测所述无刷电机的旋转速度;
主开关,其被构造为用于允许用户在驱动和停止所述无刷电机之间进行切换,
其中所述控制单元被构造为以至少包括高速模式和低速模式的多种模式中的任何一种模式对所述无刷电机执行旋转控制,
其中在所述低速模式中,所述控制单元被构造为通过占空比控制来控制无刷电机以恒定的旋转速度旋转,
其中在所述高速模式中,所述控制单元被构造为通过预定的占空比控制来控制无刷电机旋转,
其中在所述低速模式中,当检测到等于或大于第一预定值的负荷时,所述控制单元被构造为执行从所述低速模式到所述高速模式的切换,并执行所述无刷电机的旋转速度的增加。
2.根据权利要求1所述的电动工具,还包括:
电池组,其被可拆卸地附接并且被构造为向所述无刷电机和所述控制单元供应电力。
3.根据权利要求1所述的电动工具,
其中基于电流、电压和占空比中的预定一个或其组合来执行等于或大于所述第一预定值的负荷的检测。
4.根据权利要求1所述的电动工具,
其中所述预定的占空比控制包括用于逐渐地将占空比增加至预定的占空比并随后用该预定的占空比驱动无刷电机的控制。
5.根据权利要求1所述的电动工具,
其中当在执行所述预定的占空比控制的状态下检测到等于或小于比用于切换至所述预定的占空比控制的第一预定值更小的第二预定值的负荷时,所述控制单元被构造为逐渐地减小占空比并随后控制无刷电机以预定的第一旋转速度旋转。
6.根据权利要求1所述的电动工具,
其中所述旋转工具通过减速机构与所述无刷电机的输出轴相连接,并且
其中在预定的负荷范围中,所述控制单元被构造为在所述低速模式中控制所述无刷电机以使得所述旋转工具的旋转速度变得恒定在2500rpm至3500rpm的范围内,并且所述控制单元被构造为在高速模式中控制所述无刷电机以使得所述旋转工具的旋转速度变得恒定在4500rpm至5500rpm的范围内。
7.根据权利要求1所述的电动工具,其中所述控制单元被构造为执行软启动控制,以在无刷电机的启动时逐渐地供应电流。
8.根据权利要求1所述的电动工具,还包括模式切换单元,其被构造为向所述控制单元发送用于在对所述无刷电机进行旋转控制的多种模式之间进行切换的模式切换信号。
9.一种电动工具,包括:
无刷电机;
控制单元,其被构造为控制所述无刷电机的电力供应;
旋转工具,其被构造为通过所述无刷电机而旋转;
旋转速度检测单元,其被构造为检测所述无刷电机的旋转速度;以及
主开关,其被构造为向所述控制单元发送用于在驱动和停止所述无刷电机之间进行切换的ON/OFF信号,
其中所述控制单元被构造为以至少包括恒定速度控制模式和预定占空比控制模式的多种模式中的任何一种模式对所述无刷电机执行旋转控制,
其中在所述恒定速度控制模式下,所述控制单元构造为利用小于100%的占空比控制所述无刷电机以恒定旋转速度旋转,
其中在所述预定占空比控制模式下,所述控制单元构造为通过所述预定占空比控制所述无刷电机旋转,
其中在所述恒定速度控制模式下,当检测到等于或大于第一预定值的负荷时,所述控制单元被构造为执行从所述恒定速度控制模式到所述预定占空比控制模式的切换,并且
其中至少在所述预定占空比控制模式下的负荷范围的部分中,所述控制单元构造为能够以超过所述恒定旋转速度的速度驱动所述无刷电机。
10.根据权利要求9所述的电动工具,
其中所述恒定速度控制模式被切换到所述预定占空比控制模式时的负荷被设为这样的阈值:如果负荷超过该阈值,则所述预定占空比控制模式的效率变得高于所述恒定速度控制模式的效率,或者被设为在该阈值附近的值。
11.根据权利要求9所述的电动工具,
其中当在所述预定占空比控制模式下检测到等于或小于第二预定值的负荷时,所述控制单元被构造为逐渐地减小占空比以使得所述无刷电机的旋转速度变为预定的旋转速度,并随后以该预定的旋转速度对所述无刷电机执行所述恒定速度控制模式下的控制。
12.根据权利要求11所述的电动工具,
其中使得占空比减小以使从所述预定占空比控制模式向所述恒定速度控制模式改变的第二预定值小于使得所述恒定速度控制模式向所述预定占空比控制模式改变的第一预定值。
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CN105473287A (zh) | 2016-04-06 |
US10099303B2 (en) | 2018-10-16 |
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