CN204652140U

CN204652140U - Power tool

Info

Publication number: CN204652140U
Application number: CN201420680164.9U
Authority: CN
Inventors: A·T·拜尔
Original assignee: AC Macao Commercial Offshore Ltd
Current assignee: AC Macao Commercial Offshore Ltd
Priority date: 2014-11-07
Filing date: 2014-11-07
Publication date: 2015-09-16
Anticipated expiration: 2024-11-07

Abstract

The utility model discloses a kind of power tool, this power tool has the PCB of combination, and the PCB of this combination has annular shape and locates coaxially with motor shaft.The PCB of described combination is fixed on radiator on described motor one end and metal end sheet is positioned at relative one end of described motor.Described metal end cover plate and radiator are provided by securing member and are rigidly connected to be fixed to one another.Outstanding end flaps to be arranged between described radiator and described motor stator and by described securing member fix in position.Described outstanding end flaps comprises the line supporting bracket for motor coil lead-in wire provides strain to alleviate.Described supporting bracket axially extends from the circumferential position of described outstanding end flaps and comprises the passage of described motor coil wires guides to the welding contact point the PCB of described combination.

Description

Power tool

Related application

This application claims the preference of the U.S. Provisional Patent Application number 61/832,012 submitted on June 6th, 2013, its full content is incorporated herein by reference.

Technical field

The utility model relates to brushless electric machine power tool.

Background technology

The motor of power tool can be divided into two classes substantially: brush motor and brushless electric machine.In brush motor, the rotation formation of motor brush due to rotor and the electrical connection of disconnection and motor.In the power tool 100 of brushless electric machine power tool such as shown in Fig. 1, switch element is optionally activated by the control signal carrying out self-controller and disabled, optionally to apply power from power source to drive this brushless electric machine.Power tool 100 is the brushless hammer drills with the housing 102 comprising handle portion 104 and motor casing body 106.Power tool 100 also comprises output unit 107, torque setting dish 108, forward/backward selector 110, trigger 112, battery interface 114 and lamp 116.

Fig. 2 shows the simplified block diagram 120 of power tool 100, it comprises power source 122 (such as, battery pack), field-effect transistor (FET) 124, motor 126, Hall element 128, motor control unit 130, user input 132 and other parts 133 (battery pack fuel gauge, work light (LED), current/voltage sensor).Hall element 128 provides motor information feed back, such as motor rotary position information, and these information can be utilized to determine the position of motor, voltage and/or acceleration by motor control unit 130.Motor control unit 130 receives the user inputting 132 from user and controls, such as, by by trigger squeeze 112 or change forward/backward selector 110.Control in response to motor information feed back and user, motor control unit 130 transmission of control signals with accurately control FET 124 with drive motors 126.By optionally activating and forbid FET 124, the power from power source 122 is optionally applied to motor 126 to cause the rotation of rotor.Although not display, being connected to power source 122 can provide power to them to make power source 122 other parts information model of motor control unit 130 and power tool 100.

Utility model content

The utility model is because herein is provided a kind of new power tool to overcome the technical problem existed in prior art, particularly need network complexity and the assembly complexity of improving power tool inside, and how to make internal structure compacter and effective, more there is flexibility ratio to make its design.

In one embodiment, the utility model provides a kind of power tool, and this power tool comprises: housing and brshless DC motor, and this brshless DC motor is in described housing.Described brshless DC motor comprises rotor and stator, and wherein said rotor is connected to motor shaft and exports to produce to rotate.Described power tool comprises endless metal end flaps, radiator and printing board PCB further.Described endless metal end flaps is positioned at the first end of described brshless DC motor, described radiator at second end relative with described first end of described brshless DC motor to make described brshless DC motor between described radiator and described endless metal end flaps.Described radiator and described endless metal end flaps are fixed together to clamp described brshless DC motor, thus described radiator is rigidly connected to described brshless DC motor.Described printing board PCB is positioned at the second end of described brshless DC motor and is fixed on described radiator.

In another embodiment, the utility model provides a kind of power tool, and this power tool comprises: housing and brshless DC motor, and this brshless DC motor is in described housing.Described brshless DC motor comprises rotor and stator, and wherein said rotor is connected to motor shaft and exports to produce to rotate.Described power tool comprises endless metal end flaps, radiator, threaded fastener and printing board PCB further.Described endless metal end flaps is positioned at the first end of described brshless DC motor, and described radiator is positioned at second end relative with described first end of described brshless DC motor.Described brshless DC motor is between described radiator and described endless metal end flaps and have axial length.Described threaded fastener extends the axial length of described brshless DC motor and described radiator is fixed on described endless metal end flaps.Described printing board PCB is positioned at the second end of described brshless DC motor and is fixed on described radiator.Described printing board PCB comprises the through hole that Hall element, power switch component (such as field-effect transistor) and described motor shaft extend through.

In another embodiment, the utility model provides a kind of power tool, and this power tool comprises: housing and brshless DC motor, and this brshless DC motor is in described housing.Described brshless DC motor comprises rotor and stator, and wherein said rotor is connected to motor shaft and exports to produce to rotate.Described power tool comprises endless metal end flaps, radiator, threaded fastener and printing board PCB further.Described endless metal end flaps is positioned at the first end of described brshless DC motor.Described radiator at second end relative with described first end of described brshless DC motor to make described brshless DC motor between described radiator and described endless metal end flaps.Described radiator and described endless metal end flaps are fixed together to clamp described brshless DC motor, thus described radiator is rigidly connected to described brshless DC motor.Described brshless DC motor has axial length and described threaded fastener extends described axial length and described radiator is fixed on described endless metal end flaps.Described printing board PCB is positioned at the second end of described brshless DC motor and is fixed on described radiator.Described printing board PCB comprises the through hole that Hall element, power switch component and described motor shaft extend through.

Therefore execution mode disclosed by the utility model makes connection and assembly complexity between the part of power tool inside be reduced, and therefore the layout of these parts is compacter and efficient, makes power tool have greater flexibility at design aspect.In addition, the inner space more simplified is arranged and the thermal management of part is promoted, cooling blast can arrive the assembly of such as field effect transistor better, it can be operated in higher levels of current, and motor also can operate with higher power level and produce higher moment of torsion within the longer time.

By considering that detailed description and the following drawings other aspects of the present utility model will become more obvious.

Accompanying drawing explanation

Fig. 1 shows brushless power instrument.

Fig. 2 shows the block diagram of brushless power instrument.

Fig. 3 A, Fig. 3 B and Fig. 4 provide the extra view of the brushless power instrument of Fig. 1.

Fig. 5 shows Hall element plate.

Fig. 6-Fig. 7 shows the brushless power instrument of the surfboard shape PCB with combination.

Fig. 8 A-Fig. 8 C provides the extra view of the surfboard shape PCB of described combination.

Fig. 9-Figure 11 shows the brushless power instrument that another kind has the surfboard shape PCB of combination.

Figure 12-Figure 14 shows the brushless power instrument that another kind has the surfboard shape PCB of combination.

Figure 15 shows the brushless power instrument of the ring-shaped P CB with combination.

Figure 16 A-Figure 16 B shows the ring-shaped P CB of the combination of the power tool of Figure 15.

Figure 17 A-Figure 17 B shows Hall and the FET PCB of the combination of the power tool of Figure 15.

Figure 18 A-Figure 18 B shows the control PCB of the stacking combination of PCB.

Figure 19 A-Figure 19 G shows process Hall and FET PCB and radiator being connected to brushless electric machine.

Figure 20 shows the winding technique for brushless electric machine.

Figure 21 shows the Hall element and FET PCB that the another kind that uses together with brushless power instrument combines.

Figure 22 A-Figure 22 C shows control PCB position alternative on the brushless power instrument of Figure 15.

Figure 23 A-Figure 23 B shows the configuration of another kind of brushless electric machine.

Figure 24 A-Figure 24 D shows the part of the another kind of brushless electric machine configuration of Figure 23 A-Figure 23 B.

Figure 25 A-Figure 25 B also show the part of the another kind of brushless electric machine configuration of Figure 23 A-Figure 23 B.

Embodiment

Before explaining any execution mode of the present utility model in detail, should be understood that the utility model is not restricted to structure and the layout of the part shown by that following explanation limits or the following drawings in its application.The utility model can be had other execution modes and can be put into practice by different modes and perform.

Fig. 3 A shows the cross section of the power tool 100 of Fig. 1, and Fig. 3 B shows the selected part of power tool 100.Power tool 100 comprises the different printed circuit board (PCB) (PCB) of the different parts for power tool 100.More specifically, power tool 100 comprises control printed circuit board (PCB) (PCB) 136, power P CB 138, forward/backward PCB 140, Hall element PCB 142 and light-emitting diode (LED) PCB 144.Also show in Fig. 3 A for the rotation of motor 126 being exported the driving mechanism 148 that is delivered to output unit 107 and being rotated by motor 126 and provide the cooling fan 149 of cooling-air stream on the part at power tool 100.

As shown in Figure 4, control PCB 136 is on the matrix of power tool 100 and between handle portion 104 and battery interface 114, and battery interface 114 is also referred to as connection terminal portion.Control PCB 136 comprises motor control unit 130, and motor control unit 130 can operate to receive user's input, receive motor information feed back, and control FET 124 is with drive motors 126.Control PCB 136 electrically and be physically connected to lug plate 150.When battery pack (i.e. power source 122) is connected to battery interface 114, the termination of battery pack is contained in and is electrically connected on lug plate 150.The quantity of lug plate can change according to the type of hand-held power tool.But illustratively example, lug plate 150 can comprise battery just (" B+ ") termination, negative (" the B-") termination of battery, sensing or communication termination and identification termination.As shown in Figure 4, lug plate 150 has the fixture block (tab) 152 extending up through control PCB 136.Fixture block 152 can directly be welded on control PCB 136, eliminates the needs of extra power line.Whether motor control unit can use communication termination and battery pack communication, pass on can discharge and other information to power tool 100 to allow battery pack.

Power P CB 138 is comprised FET 124, FET 124 and is connected to the motor control unit 130 of control PCB 136 and is controlled by motor control unit 130.As mentioned above, FET 124 is also electrically connected on power source 122 and motor 126.In some embodiments, FET 124 directly connects (namely direct physical ground and/or heating power ground connect) in radiator 154 (such as, by the copper lead-in wire on power P CB 138 directly on a heat sink).In other implementations, FET 124 is directly connected to radiator 154, but has thermally conductive relation with radiator 154.

Forward/backward PCB 140 comprises the forward/backward switch operated by forward/backward selector 110, and forward/backward selector 110 has three positions: advance, retreat and neutral.Described position can by along perpendicular to the plane of the figure of Fig. 1 direction (namely along paper inwards or outwards) mobile forward/backward selector/shuttle (shuttle) and change.When forward/backward selector 110 changes between these three positions, selector 110 switches the forward/backward switch of forward/backward PCB 140, and forward/backward PCB 140 provides signal to motor control unit 130.When pressing trigger squeeze 112, motor control unit 130 causes motor 126 to turn clockwise based on the position of selector 110, is rotated counterclockwise or non rotating (such as, in neutral).

Hall element PCB 142 comprises Hall element 128, its one or more position of rotation for detecting motor 126, speed and acceleration.Hall element PCB 142 is electrically connected on control PCB 136 to provide the output of Hall element 128.As shown in Fig. 3 B and Fig. 5, Hall element PCB 142 comprises through hole 156, and motor shaft 158 is through this through hole 156.When the magnet of rotor rotate stride across Hall element 128 surperficial time, this Hall element 128 exports pulse.Based on the sequential of the pulse from Hall element 128, motor control unit 130 can determine the position of rotor, speed and acceleration.Motor control unit 130 and then utilize motor feedback information control FET 124.

Light-emitting diode (LED) PCB 144 comprises lamp 116, and lamp 116 can be LED.LED PCB 144 is electrically connected on control PCB 136, can operate optionally to activate and forbid lamp 116 to make motor control unit 130.When trigger 112 is pressed and/or when the independently lamp switch on housing 102 is activated optionally to activate/forbid the lamp 116 independent of trigger 112 by user, motor control unit 130 can activate lamp 116.Motor control unit 130 can also comprise delayer, and to make after trigger 112 or lamp switch are pressed or discharge, lamp 116 continues to light a period of time.

Motor control unit 130 is implemented by control PCB 136, and control PCB 136 comprises motor control unit 130, and motor control unit 130 comprises the combination of the hardware and software of the operation controlling power tool 100.Such as, except other aspects, control PCB 136 comprises processing unit (such as, microprocessor, microcontroller or other suitable programmable equipment), memory, input unit and output unit.Except other aspects, processing unit comprises control unit, ALU (ALU) and multiple register, processing unit uses known Computer Systems Organization to implement, Harvard (Harvard) structure such as improved, von Neumann (von Neumann) structure etc.Processing unit, memory, input unit, output unit and be connected to control PCB 136 or connected by one or more control and/or data/address bus as the multiple different module of control PCB 136 part.In some embodiments, control PCB 136 partly or wholly at semiconductor (such as, field programmable gate array [FPGA] semiconductor) chip is implemented, such as, by the chip of register transfer level (RTL) design process exploitation.

The memory of control PCB 136 comprises such as program storage area and data storage areas.It is such as the combination of different kinds of memory of read-only memory (ROM), random access memory (RAM) (such as, dynamic random access memory [DRAM], Synchronous Dynamic Random Access Memory [SDRAM] etc.), Electrically Erasable Read Only Memory (EEPROM), flash memory, hard disk, SD card or other suitable magnetic, optics, physics or electronic storage devices that program storage area and data storage areas can comprise.Processing unit is connected to memory and executive software instruction, this software instruction can be stored in the RAM of memory (such as, in the ROM of in the process of implementation), memory (such as, permanently) or on the computer-readable medium of other non-transitory (such as, other memory or dish).The software being contained in the enforcement of battery pack can be stored in the memory of controller.Software comprises such as firmware, one or more application, routine data, filter, rule, one or more program module and other executable instructions.Processing unit is configured to fetch from memory and perform, except other aspects, and the instruction relevant to the control of battery pack described herein.Processing unit can store different battery parameter and characteristic (comprising the rated voltage of battery pack, chemical characteristic, battery unit characteristic, the maximum discharge current of permission, the maximum temperature etc. of permission).In other structures, control PCB 136 comprises extra, less or different part.

Motor control unit 130 also with one or more sensor communication to monitor the temperature, voltage, electric current etc. of power tool 100 and connected battery pack.The protective capability that motor control unit 130 also can comprise, it is based on multiple default or calculated fault condition value, and fault condition value is relevant with the temperature, electric current, voltage etc. of the operation of hand-held power tool.

Multiple connections of the power tool 100 between control PCB 136, power P CB 138, forward/backward PCB 140, Hall element PCB 142 and light-emitting component LED PCB 144 can cause complexity in housing 102 and the line arrangement taken up room.

Fig. 6-Fig. 7 shows brushless power instrument 200, and it has and power tool 100 similarity, but has different electronics layouts.Power tool 200 has the circuit and assembly complexity that reduce compared to power tool 100.In addition, power tool 200 compacter and more effective layout makes more have flexibility ratio in design, such as, by allowing to use different handles and size of main body and shape.Power tool 200 element similar to power tool 100 is similarly indicated with simplified illustration.

Power tool 200 comprises surfboard shape (surfboard) PCB 202 of the combination of the function of each combining control PCB 136, power P CB 138, forward/backward PCB 140 and LED PCB 144, instead of uses independent control PCB 136, power P CB 138, forward/backward PCB 140 and LED PCB 144.In conjunction with surfboard shape PCB 202 comprise the forward/backward switch 203 (see Fig. 8 C) of the FET 124 of power P CB 138, the lamp 116 of LED PCB 144, the motor control unit 130 of control PCB 136 and forward/backward PCB 140.Correspondingly, being connected by the conductor on the surfboard shape PCB 202 of combination, substituting in housing 102 for connecting the circuit of different PCB.

As shown in the figure, in conjunction with surfboard shape PCB 202 there is elongated shape, its length is greater than the twice of its width.In conjunction with surfboard shape PCB 202 there is the rear portion of contiguous motor 126 and the front portion of contiguous trigger 112.On the surfboard shape PCB 202 that Hall element PCB 142 is positioned at combination and less perpendicular (that is, within vertical 15 degree) in the surfboard shape PCB 202 combined.

In addition, in conjunction with surfboard shape PCB 202 be positioned near fan 149, therefore cooling blast 204 is through the FET 124 of surfboard shape PCB 202 that combines and other parts.Fan 149 grasps that cooling blast 204 is drawn onto fan 149 from the surfboard shape PCB 202 combined, or as shown in the figure, cooling blast 204 is pushed to the surfboard shape PCB 202 of combination from fan 149.In addition, air inlet and outlet are formed and think that cooling blast 204 provides import and outlet pathway on housing 102.

In conjunction with the part of surfboard shape PCB 202 be expose.In other words, in conjunction with surfboard shape PCB 202 be not encapsulation or be sealed in housing 102, and not protected to avoid liquid in housing 102 to arrive FET 124 or motor control unit 130.The surfboard shape PCB 202 exposing combination improves the thermal management of wherein part.Such as, cooling blast 204 can operate to arrive and cool FET 124, such that FET 124 can motor 126 can operate at higher power level in the operation of higher levels of current, and at the higher moment of torsion of generation of longer time.

As shown in Fig. 8 A-Fig. 8 C, FET 124 is arranged on the surfboard shape PCB 202 of combination along the direction of general planar.On the contrary, the FET 124 of power tool 100 is vertically arranged on power P CB 138.In conjunction with surfboard shape PCB 202 also have mounted thereto with radiator 206 that the is relative side at FET 124 to provide the cooling of FET 124.Radiator 206 is thermally connected to FET 124 and comprises radiating fin 208 with the heat dispersion of heat radiation device 206.In some cases, one or more radiators is positioned at the same side of FET 124, to make the surfboard shape PCB 202 of FET 124 and combination between radiator 206 and one or more extra radiator.This one or more extra radiator heat is connected to FET 124 to provide extra thermal management.In conjunction with the front portion 209 of bottom surface of surfboard shape PCB 202 comprise lamp 116 and be arranged on the forward/backward switch 203 above on 209.FET 124 is arranged on the rear portion 210 of the bottom surface of the surfboard shape PCB 202 of combination.Radiator 206 is arranged on the rear portion 210 of the upper surface of the surfboard shape PCB 202 of combination.Hall element PCB 142 on surfboard shape PCB 202, and is roughly formed inverted "T"-shaped jointly.

In addition, in conjunction with surfboard shape PCB 202 be centrally located in power tool 200, and to be positioned on trigger 112, and under motor 126 and driving mechanism 148.Fig. 7 shows and is positioned on the trigger 112 and region 211 considered be positioned under motor 126." under motor " does not require that the surfboard shape PCB 202 combined is just in time under motor 126, but is being parallel under the line of bottom surface extension of motor 126.Correspondingly, the surfboard shape PCB 202 of combination shortened does not extend back the surfboard shape PCB 202 that makes to combine partly just in time under motor 126 (as shown in Figure 7) in power tool 200, and it still can be considered to " under motor ".Similarly, " on trigger " does not require that the surfboard shape PCB 202 combined is just in time on trigger, but in region 211.

Medially location allows line relatively short between several parts of power tool 200 to connect.In addition, in conjunction with surfboard shape PCB 202 exposure, the characteristic that do not encapsulate also makes the connection of the part arrived on it have greater flexibility.Namely, line substantially directly can arrive the part of the surfboard shape PCB 202 of combination, instead of the inbound port/outbound port of restriction by encapsulating housing, connects to allow shorter more direct line.More specifically, in conjunction with surfboard shape PCB 202 near the terminal of Hall element PCB 142, lamp 116, trigger 112, forward/backward switch 203 and motor 126).Such as, Fig. 8 A shows the short-term 212 of the surfboard shape PCB 202 for connecting Hall element PCB 142 and combination.Line 212 can be pliable and tough or rigidity, and it is connected to the middle part of the surfboard shape PCB 202 of combination substantially.In addition, as shown in the figure, the length of line 212 be less than motor 126 diameter, be less than the surfboard shape PCB 202 of combination length 1/4th and be less than the diameter of Hall element PCB 142.Although in conjunction with the upper surface of surfboard shape PCB 202 be basically parallel to the longitudinal axis of motor shaft 128, in conjunction with surfboard shape PCB 202 relative to motor shaft 158 from motor side to the outlet side of power tool 200 angulation slightly.As Figure 6-Figure 7, in conjunction with surfboard shape PCB 202 relative to motor shaft 158, there is the angle being less than 5 degree downward slightly.

In some embodiments, forward/backward selector 110 comprises the magnet that is installed on wherein and the surfboard shape PCB 202 combined has the forward/backward Hall element (not shown) of alternative forward/backward switch 203.When forward/backward selector 110 is moved, described forward/backward Hall element detects the motion of the magnet of inserting, and indicates the forward/backward position of selector 110 or the signal of motion to be provided to motor control unit 130.

In conjunction with surfboard shape PCB 202 comprise typical arrangement of parts.In some embodiments, different parts (such as one or more FET 124) is arranged on the different piece (such as, upper surface substitutes bottom surface, anterior alternative rear portion) of the surfboard shape PCB 202 of combination.

In some embodiments, power tool 200 is that (non-hammer) bores/drive power tool, and it comprises similar electronics layout, housing, motor etc., but comprises the different driving mechanism 148 without hammer mechanism.

Fig. 9-Figure 11 shows the brushless impact wrench power tool 250 comprising and impact output unit 252.Impact wrench is the another kind of type for generation of rotating the hand-held power tool exported, but it comprises the beater mechanism 254 different from the hammer driving mechanism 148 of power tool 100 and power tool 200.

Power tool 250 comprises the layout similar to power tool 200.More specifically, power tool 250 comprises the housing 256 with handle portion 258 and motor casing body 260.Motor casing body 260 holds motor 126 and is positioned on handle portion 258.Handle portion 258 comprises the battery interface 114 for connecting battery pack.In addition, power tool 250 comprises surfboard shape PCB 202 and the Hall element PCB 142 of combination.The layout of power tool 250 has wiring and the assembly complexity of minimizing relative to power tool 100.In addition, the compacter and efficient layout of power tool 250 makes to have greater flexibility at design aspect, such as, by allowing the size and dimension of different handles and main body.Power tool 250 element similar with 200 to power tool 100 is similarly indicated with simplified illustration.

Figure 12-Figure 14 shows the brushless impact driver power tool 270 comprising and impact output unit 272.Impact driver power tool 270 is another kind of types for generation of rotating the hand-held power tool exported, and it has the beater mechanism 274 similar to beater mechanism 254.In addition, power tool 270 comprises the clip 276 for power tool 270 being hung over different objects (such as hook or tool belt).

Power tool 270 comprises the layout similar with power tool 250 to power tool 200.More specifically, power tool 270 comprises the housing 278 with handle portion 280 and motor casing body 282.Motor section 282 is held motor 126 and is positioned on handle portion 280.Handle portion 280 comprises the battery interface 114 for connecting battery pack.In addition, power tool 270 comprises surfboard shape PCB 202 and the Hall element PCB 142 of combination.The layout of power tool 270 has wiring and the assembly complexity of minimizing relative to power tool 100.In addition, the compacter and efficient layout of power tool 270 makes to have greater flexibility at design aspect, such as, by allowing the size and dimension of different handles and main body.Power tool 270 element similar with 200 to power tool 100 is similarly indicated with simplified illustration.

Although in conjunction with the physical layout of surfboard shape PCB 202 can be substantially similar with each of power tool 270 to power tool 200, power tool 250, the grade of the specific software and hardware of motor control unit 130 and electronic component and FET 124 can be different and can be optimized each instrument.

Figure 15 shows the brushless impact wrench power tool 300 of another kind comprising and impact output unit 252 and beater mechanism 254, and is connected to the battery pack 301 of battery interface 114.Power tool 300 element similar to above-described power tool by similar sign with simplified illustration.

To power tool 200,250 similar with 270, the layout of power tool 300 has the wiring complexity of minimizing and the cost of minimizing compared to power tool 100.But power tool 300 has different PCB and arranges, does not wherein comprise the surfboard shape PCB 202 of combination.Alternatively, in conjunction with the part of surfboard shape PCB 202 be positioned at roughly on the PCB of the annular near described motor.The independently PCB similar with forward/backward PCB 140 to LED PCB 144 can be arranged in power tool 300, to be respectively used to comprise and to support the switch 203 of lamp 116.

More specifically, as shown in figures 16 a-16b, power tool 300 comprises and is stacked on Hall on motor 126 and FET PCB 302 and control PCB 304, and has the hole for allowing motor shaft 158 to pass through.Hall and FET PCB 302 keep interval by pad 305 (being also referred to as Self-Clinching Standoffs) and control PCB 304.Hall and FET PCB 302 comprise Hall element 128 and FET 124, and control PCB 304 comprises motor control unit 130.In addition, the radiator 306 with substantially annular or cast is fixed between Hall and FET PCB 302 and motor 126.Radiator 306 is substantially for passing heat from FET 124.

Figure 17 A-Figure 17 B show in greater detail Hall and FET PCB 302.Hall and FET PCB 302 have the shape that center is provided with the substantial circular of through hole 308.Motor shaft 158 and motor brush 309 (see such as Figure 21) are by this through hole 308.Hall and FET PCB 302 have the smooth mounting surface of two cardinal principles: first surface 310 (see Figure 17 A) and second surface 312 (see Figure 17 B).FET 124 is arranged on Hall and FET PCB 302 along smooth direction.Similarly, control PCB 304 has through hole 314 and the smooth mounting surface of two cardinal principles: first surface 316 (see Figure 18 A) and second surface 318 (see Figure 18 B).FET 124 is shown as and is arranged on first surface 310, Hall element 128 can be arranged on second surface 318, and FET 124 and Hall element 128 stagger with similar to PCB 142 close to rotor magnet (see such as Fig. 5) with about 120 degree.Control PCB 304 also comprises control PCB installing hole 319.Control PCB 304 and Hall and FET PCB 302 are relative to motor shaft 158 coaxial positioning and surface 310,312,316 and 318 is substantially parallel to each other.PCB 302 and 304 is fixed on the end of motor 126.By FET 124 and Hall element 128 being positioned independent Hall and the FET PCB 302 of the end being fixed on motor 126, Hall and FET PCB 302 can receive a large amount of air stream 204 and realize extra cooling for except the internal wiring except reducing power tool 300.

Hall and FET PCB 302 also comprise Hall and FET PCB installing hole 320, motor down-lead pad 322 and copper busbar 324.Copper busbar 324 allows that Hall and FET PCB 302 have additional space for other functions, such as high electric current wiring (high current traces).Correspondingly, copper busbar 324 is skipped on Hall and FET PCB 302, and does not take the space on Hall and FET PCB 302.In alternative embodiments, the wiring on Hall and FET PCB 302 is used to replace copper busbar 324.

Hall and FET PCB installing hole 320 allow the metal Self-Clinching Standoffs 305 (see Figure 16 A-Figure 16 B) of radiator 306 by Hall and FET PCB 302.Metal Self-Clinching Standoffs 305 provides space and allows control PCB 304 to be connected to radiator 306 between PCB 302 and 304.Self-Clinching Standoffs 305 reception is inserted into the control PCB construction bolt of the installing hole 319 of control PCB 304 so that control PCB 304 is fixed on radiator 306.In some embodiments, control PCB 304 and Hall and FET PCB 302 are all fixed on radiator 306 by control PCB construction bolt.

In addition, in some embodiments, Hall and FET PCB installing hole 320 may be used for allowing the metal Self-Clinching Standoffs 305 of radiator 306 by Hall and FET PCB 302 and for Hall and FET PCB 302 are fixed on radiator 306.Tightly Hall and FET PCB 302 being fixed on radiator 326 allows heat be more easily dissipated to radiator 306 from Hall and FET PCB 302 and minimize Hall and the vibration between FET PCB 302 and motor 126.In other execution modes of the present utility model, the quantity of installing hole 319 and 320 and their positions on PCB 302 and 304 are different.In addition, in other embodiments, the general shape of PCB 302 and 304 is different.

Figure 19 A-Figure 19 G shows process motor 126, Hall and FET PCB 302 and radiator 306 linked together.Figure 19 A shows the motor stator 330 of motor 126, and motor 126 has the plastic end cover plate 332 and 334 of each end laying respectively at motor stator 330 and enters into six motor down-leads 336 of plastic end cover plate 334.Line support feature 338 be plastic end cover plate 334 a part and for suitably guiding motor down-lead 336, as mentioned below.Figure 19 B shows the radiator 306 be placed on the plastic end cover plate 334 of motor stator 330.In some embodiments, the metal Self-Clinching Standoffs 305 of radiator 306 may be used for installing control PCB 304 and/or locating Hall and FET PCB 302.

Figure 19 C shows the radiator 306 using radiator construction bolt 340 to be anchored on motor stator 330.The end relative with the end being connected with radiator 306 that clip 342 is connected to motor stator 330 installed by radiator.Radiator construction bolt 340 threadingly engages in the metal Self-Clinching Standoffs of radiator 306 and radiator installs clip 342 so that radiator 306 is fixed on motor stator 330.In some embodiments, the quantity of radiator installation elements and position are different.

As shown in Figure 19 D, after fixed heat sink 306, motor down-lead 336 is bent downwardly to be adapted in line support feature 338 subsequently.Before motor down-lead 336 is welded in Hall and FET PCB 302, be wound around motor down-lead 336 to reduce the stress on motor down-lead 336 around line support feature 338.In some embodiments, glue can be applied to motor down-lead 336 so that motor down-lead 336 is fixed on radiator 306.

Figure 19 E shows the radiator pad 344 being placed on radiator 306 top.Radiator pad 344 is electrical insulator that is thin, that have high thermal conductivity.These features allow radiator pad 306 to allow heat to be dissipated from Hall and FET PCB 302 by radiator 306 metal heat sink 306 electrical isolation Hall and FET PCB 302 simultaneously.

Figure 19 F shows and is placed on Hall on radiator pad 344 and FET PCB 302 and radiator 306.Motor down-lead 336 is aligned in the opening of motor down-lead pad 322, and the metal Self-Clinching Standoffs 305 of radiator 306 is by the installing hole 320 of Hall and FET PCB.In order to keep the contact between Hall and FET PCB 302 and radiator 306, downward power is applied to Hall and FET PCB 302.

As shown in Figure 19 G, motor down-lead 336 is welded in motor down-lead pad 322 to generate pad 345, and motor down-lead 336 is not only electrically connected on Hall and FET PCB 302 by pad 345, and is linked together by these two part machineries.After generation pad 345, motor down-lead 336 cuts off near motor down-lead pad 322.As mentioned above, except pad 345, Hall and FET PCB 302 can use Hall and FET PCB construction bolt to be fixed on radiator 306 (it is fixed on motor 126).

After Hall and FET PCB 302 are fixed on the combination of motor 126 and radiator 306, control PCB 304 is fixed on radiator 306 subsequently, and Hall and FET PCB 302 are between radiator 306 and control PCB 304.Control PCB 304 uses the control PCB construction bolt by metal Self-Clinching Standoffs 305 holds to be fixed on radiator 306.

Figure 20 shows the end relative with the end with Hall and FET PCB 302 of motor stator 330.Motor stator 330 this view showing line cross-over design, it is wound with line after plastic end cover plate 332.The line being wound around motor stator 330 around plastic end cover plate 332 allows line to advance 180 degree from a pole of motor stator 330 to a relative pole in an efficient way.The line 346 be wound is positioned at the top of edge part 348, and line 346 is wound around around motor stator 330 and is radially positioned at the outside of the protuberance 349 upwards extended from edge part 348.As shown in the figure, without any point, there are three lines and be positioned identical circumferential position and along the stacking situation of edge part 348.On the contrary, only have at most two lines stacking, reduce with the entire length of the height and motor stator 330 that allow protuberance 349.

In some embodiments, control PCB 304 is not adjacent to and locates around the Hall of motor shaft 158 and FET PCB 302, and metal Self-Clinching Standoffs 305 is not by Hall and FET PCB 302.On the contrary, the length of metal Self-Clinching Standoffs 305 is reduced to make it end at the surface of Hall and FET PCB 302.The metal Self-Clinching Standoffs 305 that length is reduced does not reoffer interval function, and as shown in figure 21, metal Self-Clinching Standoffs 305 holds Hall and FET PCB construction bolt Hall and FET PCB 302 are fixed on radiator 306 and motor 126 combines.

In the execution mode that the not contiguous Hall of control PCB 304 and FET PCB 302 are located, control PCB 304 can be called as control PCB 304a.Control PCB 304a can be arranged in several positions of power tool 300.Hall and FET PCB 302 are connected to control PCB 304a by cable connector 350 and flat cable (not shown).

Figure 22 A-Figure 22 C shows the exemplary position that control PCB 304a can be arranged in power tool 300.In Figure 22 A, similar to the power P CB 138 of power tool 100, control PCB 304a is arranged in the handle portion 258 of power tool 300.In Figure 22 B, similar to the surfboard shape PCB 202 combined, control PCB 304a to be positioned on trigger 112 and handle portion 258 and to be positioned under motor 126 and beater mechanism 254.In Figure 22 C, similar to the control PCB 136 of power tool 100, control PCB 304a is positioned at handle portion less than 258 and is positioned on battery interface 114.

Although Figure 15-Figure 22 is described relative to impact wrench power tool 300, but described different layout and electric machine assembly can be implemented in the power tool of other types, the power tool of these other types can be such as without hammer drill/driver power tool, hammer drill/driver power tool (see Fig. 1-Fig. 9) and impact driver power tool (Figure 12-Figure 14).

Above power tool (such as, power tool 200, power tool 250, power tool 270 and power tool 300) is described to wireless battery powered instrument.Battery pack such as battery pack 301 for powering for power tool can be such as 18 volt lithium ion battery pack.But the battery pack with other battery chemistries composition, shape, voltage levvls etc. may be used for other execution modes.In some embodiments, these power tools are the instrument of wired Alternating Current Power Supply.Such as, in order to substituting battery interface 114 and battery pack, described power tool comprises the AC power line being connected to transformer block, and this transformer block is the part adaptation of described power tool and changes AC power.The instrument of these Alternating Current Power Supplies also can comprise one of them of above-described layout, the surfboard shape PCB comprising combination arranges and the PCB of annular arranges one of them.

Figure 23 A and Figure 23 B shows the optional brushless motor structure 399 that may be used for the configuration of alternative as shown in Figure 15 and Figure 22 A-Figure 22 C.Brushless motor structure 399 comprises metal end sheet 400 and is positioned at the outstanding end flaps 402 of opposed end of motor 126.Metal end sheet 400 and outstanding end flaps 402 are more clearly shown in Figure 24 C and Figure 24 A respectively.Metal end sheet 400 and outstanding end flaps 402 have the shape of round substantially.In brushless motor structure 399, metal end sheet 400 is for the plastic end cover plate 332 shown in alternate figures 19A.When motor 126 is in mode of operation, the plastic material of plastic end cover plate 332 can be surrendered to be out of shape or to move at elevated temperatures.Described movement can comprise the relative movement between PCB 302 and motor coil, this danger that lead-in wire 336 may be caused to break.

Use metal end sheet 400 that PCB 302 can be allowed to be rigidly connected between motor 126.Metal end sheet 400 and radiator 306 comprise through hole 404 and 405 respectively, and to hold threaded fastener 406, threaded fastener 406 can stator between fixing metal end flaps 400 and radiator 306 330 and outstanding end flaps 402.Threaded fastener 406 can be the bolt forming screw thread.Radiator 306 is connected to metal end sheet 400 to clamp the brshless DC motor between radiator 306 and metal end sheet 400 by threaded fastener 406, thus radiator 306 is rigidly connected to motor 126.PCB 302 is rigidly connected to radiator 306 by bolt 408; Therefore, radiator 306 is rigidly connected to brshless DC motor 126 and rigidly PCB 302 is connected to motor 126.

In some embodiments, threaded fastener 406 is fixed on metal end sheet 400 by nut or analog.Motor configuration 399 comprises four through holes 404 and securing member 406 that the circumference along motor 126 distributes with about 90 degree compartment of terrains.PCB 302 is by being connected to radiator 306 with 6 bolts 408 of about 60 degree of compartment of terrains distribution.As Figure 24 D shows in greater detail, radiator 306 is annular and six through holes 410 comprised for holding bolt 408.Motor 126 has axial length 409, and threaded fastener 406 is along the excircle extension axial length 409 of motor 126.

Brushless motor structure 399 also comprises line cross-over design described in reference diagram 20.Such as, brushless motor structure 399 comprises the closing panel 407 of line 346 having edge part 348, protuberance 349 and be wound around.Stacking more than two lines without any point at identical circumferential position along edge part 348.Closing panel 407 more clearly shows in Figure 24 B and Figure 25 A-Figure 25 B.Closing panel 407 comprises two location projecting plates 450 in depressed part 452 corresponding to two of being contained in metal end sheet 400.Then each location projecting plate 450 axial direction also comprised along motor 126 extends radially-inwardly the clamp 454 that (that is, towards motor shaft) extend on the excircle of metal end sheet 400.The radially inner part of clamp 454 is arranged in the passage 456 (see Figure 23 A-Figure 23 B) on the excircle of motor 126.Clamp 454 is radially outward bending to allow metal end sheet 400 to be axially inserted in the depressed part 458 of the annular of closing panel 407.Once metal end sheet 400 is axially inserted into, clamp 454 turn back to radially-inwardly position firmly closing panel 407 is connected to metal end sheet 400 (see Figure 25 A).

As shown in fig. 24 a, outstanding end flaps 402 (being also referred to as the second end cover plate) comprises line supporting bracket 412.Line supporting bracket 412 provides strain to alleviate to reduce the stress on lead-in wire 336, thus minimizing lead-in wire 336 damages or the risk of breakage.Lead-in wire 336 was wound around around line supporting bracket 412 before arriving the welding contact point (pad 345) on PCB 302.Line supporting bracket 412 axially extends towards PCB 302 from the excircle point of outstanding end flaps 402.Line supporting bracket 412 comprises the passage 414 for holding lead-in wire 336.By passage 414 one of them after, lead-in wire 336 bends about 90 degree (see Figure 23 A) towards the welding contact point on PCB 302.Electric machine structure 399 comprises three cover line supporting brackets, 412, the plate 412 distributed around outstanding end flaps 402 and corresponds to a lead-in wire 336.Line supporting bracket 412 along the circumference of outstanding end flaps 402 with about 120 degree of intervals.

Therefore, except other aspects, the utility model provides layout design and the assembly of brushless power instrument.Different feature and advantage of the present utility model are stated in following claims.

Claims

1. a power tool, is characterized in that, this power tool comprises:

Housing;

Brshless DC motor, this brshless DC motor is in described housing, and wherein said brshless DC motor comprises rotor and stator, and wherein said rotor is connected to motor shaft and exports to produce to rotate;

Endless metal end flaps, this endless metal end flaps is positioned at the first end of described brshless DC motor;

Radiator, this radiator at second end relative with described first end of described brshless DC motor to make described brshless DC motor between described radiator and described endless metal end flaps, wherein said radiator and described endless metal end flaps are fixed together to clamp described brshless DC motor, thus described radiator is rigidly connected to described brshless DC motor; And

Printing board PCB, this printing board PCB is positioned at the second end of described brshless DC motor and is fixed on described radiator.

2. power tool according to claim 1, is characterized in that, described printing board PCB comprises the through hole that Hall element, power switch component and described motor shaft extend through.

3. power tool according to claim 2, it is characterized in that, this power tool comprises the control PCB with motor control unit further, and this motor control unit can be connected to described Hall element communicatedly to receive the motor position information from described Hall element, and

Described power switch component is to be sent to described power switch component to drive described brshless DC motor by control signal.

4. power tool according to claim 1, is characterized in that, described radiator is annular.

5. power tool according to claim 1, it is characterized in that, this power tool comprises securing member further, described radiator is fixed on described endless metal end flaps by this securing member, wherein said brshless DC motor has axial length, and described securing member extends the axial length of described brshless DC motor.

6. power tool according to claim 1, it is characterized in that, this power tool comprises securing member further, and described radiator is fixed on described endless metal end flaps by this securing member, and wherein said securing member is held by the through hole of the through hole of described radiator and described endless metal end flaps.

7. power tool according to claim 1, is characterized in that, this power tool comprises closing panel further, and this closing panel is positioned on the described endless metal end flaps on the first end of described brshless DC motor.

8. power tool according to claim 7, it is characterized in that, described metal end sheet comprises depressed part and described closing panel comprises location projecting plate, and this location projecting plate adapts in described depressed part and also therefore makes described closing panel and the alignment of described metal end sheet.

9. power tool according to claim 8, it is characterized in that, described location projecting plate comprises clamp further so that described closing panel is fixed on described metal end sheet, and described clamp axially extends and extends radially inwardly subsequently on described metal end sheet.

10. power tool according to claim 1, is characterized in that, this power tool comprises the annular recess had towards described brshless DC motor further, and described endless metal end flaps is contained in described annular recess.

11. power tools according to claim 1, is characterized in that, this power tool comprises the second end cover plate further, and this second end cover plate is between described radiator and described second end of described brshless DC motor.

12. power tools according to claim 11, is characterized in that, described the second end cover plate comprises line supporting bracket, and each line supporting bracket has the passage guiding a part for motor down-lead to extend to described printing board PCB.

13. power tools according to claim 11, is characterized in that, motor down-lead

Be contained in the passage of the line supporting bracket of described the second end cover plate,

Extend along described passage at first direction, and

At the exit bend of described passage to extend towards described printing board PCB in second direction.

14. 1 kinds of power tools, is characterized in that, this power tool comprises:

Housing;

Radiator, this radiator is positioned at second end relative with described first end of described brshless DC motor, and wherein said brshless DC motor is between described radiator and described endless metal end flaps;

Threaded fastener, described radiator is fixed on described endless metal end flaps by this threaded fastener, and wherein said brshless DC motor has axial length, and described threaded fastener extends the axial length of described brshless DC motor; And

Printing board PCB, this printing board PCB is positioned at the second end of described brshless DC motor and is fixed on described radiator, and wherein said printing board PCB comprises the through hole that Hall element, power switch component and described motor shaft extend through.

15. power tools according to claim 14, is characterized in that, this power tool comprises the second end cover plate further, and this second end cover plate is between described radiator and described second end of described brshless DC motor.

16. power tools according to claim 15, is characterized in that, described the second end cover plate comprises line supporting bracket, and each line supporting bracket has the passage guiding a part for motor down-lead to extend to described printing board PCB.

17. power tools according to claim 15, is characterized in that, described radiator comprises the shaft through-hole that described motor shaft extends through.

18. 1 kinds of power tools, is characterized in that, this power tool comprises:

Housing;

Closing panel, the described endless metal end flaps that this closing panel is positioned at the first end of described brshless DC motor is fixed on described endless metal end flaps;

Radiator, this radiator at second end relative with described first end of described brshless DC motor to make described brshless DC motor between described radiator and described endless metal end flaps, wherein said radiator and described endless metal end flaps are fixed together to clamp described brshless DC motor, thus described radiator is rigidly connected to described brshless DC motor;

19. power tools according to claim 18, is characterized in that, this power tool comprises the second end cover plate further, and this second end cover plate is between described radiator and described second end of described brshless DC motor.

20. power tools according to claim 19, is characterized in that, described the second end cover plate comprises line supporting bracket, and each line supporting bracket has the passage guiding a part for motor down-lead to extend to described printing board PCB.