WO2018170906A1 - Power tools with integrated circuit boards - Google Patents

Power tools with integrated circuit boards Download PDF

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Publication number
WO2018170906A1
WO2018170906A1 PCT/CN2017/078146 CN2017078146W WO2018170906A1 WO 2018170906 A1 WO2018170906 A1 WO 2018170906A1 CN 2017078146 W CN2017078146 W CN 2017078146W WO 2018170906 A1 WO2018170906 A1 WO 2018170906A1
Authority
WO
WIPO (PCT)
Prior art keywords
circuit board
brushless motor
end cap
motor
rotor
Prior art date
Application number
PCT/CN2017/078146
Other languages
English (en)
French (fr)
Inventor
Hei Man Raymond LEE
Jian Wei He
Li Feng Wang
Original Assignee
Tti (Macao Commercial Offshore) Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Tti (Macao Commercial Offshore) Limited filed Critical Tti (Macao Commercial Offshore) Limited
Priority to AU2017405808A priority Critical patent/AU2017405808A1/en
Priority to CN201790001632.7U priority patent/CN211908570U/zh
Priority to PCT/CN2017/078146 priority patent/WO2018170906A1/en
Priority to EP17902256.1A priority patent/EP3602750A4/de
Publication of WO2018170906A1 publication Critical patent/WO2018170906A1/en

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Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K9/00—Arrangements for cooling or ventilating
    • H02K9/02—Arrangements for cooling or ventilating by ambient air flowing through the machine
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K9/00—Arrangements for cooling or ventilating
    • H02K9/22—Arrangements for cooling or ventilating by solid heat conducting material embedded in, or arranged in contact with, the stator or rotor, e.g. heat bridges
    • H02K9/227—Heat sinks
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K11/00—Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection
    • H02K11/20—Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection for measuring, monitoring, testing, protecting or switching
    • H02K11/21—Devices for sensing speed or position, or actuated thereby
    • H02K11/215—Magnetic effect devices, e.g. Hall-effect or magneto-resistive elements
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K11/00—Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection
    • H02K11/30—Structural association with control circuits or drive circuits
    • H02K11/33—Drive circuits, e.g. power electronics
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K7/00—Arrangements for handling mechanical energy structurally associated with dynamo-electric machines, e.g. structural association with mechanical driving motors or auxiliary dynamo-electric machines
    • H02K7/14—Structural association with mechanical loads, e.g. with hand-held machine tools or fans
    • H02K7/145—Hand-held machine tool
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K2211/00—Specific aspects not provided for in the other groups of this subclass relating to measuring or protective devices or electric components
    • H02K2211/03—Machines characterised by circuit boards, e.g. pcb

Definitions

  • This invention relates to electric power tools, and in particular battery-powered power tools with brushless motor and their internal structures.
  • Electric power tools are widely used in various applications such as building, construction and interior decoration. These power tools provide necessary tool functions to the user using the driving power generated by the on-board drive motor. At the same time, the power tools are usually manufactured to be compact and light-weight, so that the user has no difficulty in carrying and manipulating them.
  • a brushless motor which includes a casing which at least partially accommodates a stator and a rotor, an end cap located adjacent to an end of the brushless motor; and a circuit board which contains a controller for the brushless motor.
  • the circuit board is located outside of a region defined by the end cap and the casing.
  • the circuit board is located further away from the stator or rotor than the end cap along a longitudinal direction defined by a motor shaft.
  • the circuit board is located at an outermost position at the end of the brushless motor with respect to the rotor or stator.
  • the circuit board has a contour substantially the same as that of the end cap.
  • the circuit board further contains a plurality of vias which are adapted to receive struts on the end cap, such that the circuit board is securely mounted on the end cap.
  • the circuit board further contains a plurality of surface-mount elements configured on a surface of the circuit board.
  • a Hall sensor, a power control device, and a logic controller are configured on the circuit board.
  • the end cap is manufactured using die casting.
  • a power tool which contains a tool housing, and a brushless motor as described above.
  • the brushless motor is fixedly mounted to the tool housing and adapted to drive one or more movable part in the power tool.
  • the brushless motor according to the present invention provides improved heat dissipation for both the circuit board, and the interior parts of the motor such as the stator and the rotor.
  • the circuit board is placed outside of the motor casing and the end cap, there is no need to configure a separate heatsink for the circuit board, but the end cap to which the circuit board is mounted becomes a large heatsink for the circuit board.
  • the end cap is preferably made by die casting to increase heat dissipation efficiency.
  • the circuit board as it is exposed to the outside of the motor structure is also benefited to have a better heat dissipation to surrounding environment itself.
  • Fig. 1 is a perspective view of a handheld power tool according to a first embodiment of the present invention.
  • Fig. 2a shows the perspective view of the structure of the drive motor in the power tool in Fig. 1.
  • Fig. 2b shows the perspective view of the structure in Fig. 2a from another viewing angle.
  • Fig. 2c shows the perspective view of the structure in Fig. 2a from a further viewing angle.
  • Fig. 3 is a side view of the structure in Fig. 2a.
  • Fig. 4 is a cross-sectional view of the structure in Fig. 2a along a plane in which the axis of rotation of the motor shaft is located.
  • Fig. 5a is a front view of the circuit board in the structure in Fig. 2a.
  • Fig. 5b is a rear view of the circuit board in Fig. 5a.
  • Fig. 6 shows a side view of the internal structure of an electric tool according to another embodiment of the present invention.
  • Couple or “connect” refers to electrical coupling or connection either directly or indirectly via one or more electrical means unless otherwise stated.
  • the first embodiment of the present invention is an electric power tool which is designed to be handheld.
  • the power tool has a casing which contains a main portion 20 and a handle portion 28.
  • the main portion 20 extends substantially along an axial direction defined by the motor shaft (not shown) of the drive motor 22.
  • the handle portion 28 is connected to and extends from the main portion along a substantially downward direction, but which is inclined from the vertical direction perpendicular to the axial direction.
  • a trigger 26 is configured on the handle portion 28 where the trigger 26 is exposed to the outside for the user’s manipulation to turn on/off the power tool.
  • a battery pack 30 which is detachably connected to the power tool to supply power to the electrical circuit inside the power tool.
  • the drive motor is a brushless DC motor, which contains two end caps 38, 40 located approximately at two end of the motor.
  • the drive motor further contains a casing 34 which is configured to accommodate at least partially the essential parts of the motor such as the rotor and the stator (both not shown) .
  • the casing 34 is located between the two end caps 38, 40.
  • end cap 38 and end cap 40 are therefore firmly connected together by the screws 44.
  • a fan 42 which is covered by the end cap 38.
  • the end caps 38, 40 and the casing 34 are aligned along the axis of rotation defined by the motor shaft 52.
  • a circuit board 32 of the motor is configured at another end of the motor adjacent to the end cap 40.
  • the circuit board 32 is exposed outside of the casing 34 and the end cap 40, and is in fact located at an outermost position on the respective end of the motor.
  • the circuit board 32 is located further away from the stator or rotor than the end cap 40 along a longitudinal direction defined by the motor shaft 52.
  • the size of the circuit board 32 is slightly larger than that of the casing 34 or the end caps 38, 40.
  • the contour of the upper part 41 of the circuit board 32 follows closely with that of the end cap 40, so that they have an identical shape.
  • the lower part 43 of the circuit board 32 extends beyond the end cap 40.
  • the circuit board 32 is mounted to the motor by having one or more struts 36 extending from the end cap 40 into corresponding vias (not shown) on the circuit board 32, thereby holding the circuit board 32 to the end cap 40 firmly.
  • On the circuit board 32 there is a plurality of surface-mount (SMT) elements 50 such as resistors, ICs and capacitors which are electrically connected.
  • SMT surface-mount
  • a connecting wire 47 extends from the circuit board 32 and has a connector 46 on the free end of it. The connecting wire 47 allows the circuit board 32 to connect electrically to other components in the electric tool such as the battery pack or the trigger described in Fig. 1.
  • Fig. 4 in the cross-sectional view one can see that the shaft 52 is rotatably supported by bearings 54 on the end caps 38, 40 respectively.
  • a rotor 58 is mounted on the motor shaft 52 which contains magnets 64. Outside of the rotor 58 there is a stator 62 which contains windings 60 that cooperate with the magnets 64 in the rotor 58.
  • the structure and working principle of the stator and rotor structure in brushless motors are well-known to skilled persons, and thus no further descriptions will be provided here. However, one should note that the motor structure shown in Fig. 4 effectively provides an air path indicated by the arrow 66.
  • the air from external environment may enter into the interior of the motor from one end of the motor and exits another end, at locations between the end caps 38, 40 and the rotor /stator.
  • Such an air path can be formed since there is no circuit board placed within the motor which would otherwise obscure the air flow. Without the circuit board, there is allowed sufficient gap between each one of the end caps 38, 40 and the rotor /stator, so that air could flow through such gap.
  • Figs. 5a and 5b show the circuit board 32 independently.
  • the circuit board 32 has a substantially oval shape, and there are both SMT elements 50 as well as non-SMT elements on the circuit board 32.
  • the SMT elements 50 include a microcontroller 53, and the non-SMT elements include a capacitor 55.
  • the SMT elements 50 and non-SMT elements there are a Hall sensor, a power control device, and a logic controller configured on the circuit board.
  • the circuit board 32 is placed outside of the motor casing and the end caps, so there is no need to configure a separate heatsink for the circuit board 32.
  • the end cap 40 becomes the heatsink for the circuit board 32.
  • the end cap 40 becomes a much larger heatsink than separate heatsinks used in traditional brushless motors.
  • Such a configuration not only simplifies the structure of the motor, but also greatly enhances the heat dissipation efficiency of the motor. The heat dissipation is further improved by the air path created between the end caps 38, 40 and the rotor /stator as mentioned above.
  • the drive motor 122 and the main portion 120 are both arranged along the axial direction of the motor shaft (not shown) .
  • the drive motor 122 is a brushless DC motor, which is located at the rear end of the main portion 120 and covered by an end cap 140 of the main portion 120.
  • the drive motor 122 contains a casing 134 which is made by die casting.
  • the casing 134 supports other components of the motor 122 on the main portion 120.
  • a circuit board 132 of the motor 122 is configured at an end of the motor 122 adjacent to the end cap 140.
  • the circuit board 132 is mounted to the casing 134 by having one or more struts 136 extending from the casing 134 into corresponding vias (not shown) on the circuit board 132, thereby holding the circuit board 132 firmly. As a result, the circuit board 132 is mechanically connected to the drive motor 122. On the circuit board 132, there is a plurality of surface-mount (SMT) elements (not shown) such as resistors, ICs and capacitors which are electrically connected.
  • SMT surface-mount

Landscapes

  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Microelectronics & Electronic Packaging (AREA)
PCT/CN2017/078146 2017-03-24 2017-03-24 Power tools with integrated circuit boards WO2018170906A1 (en)

Priority Applications (4)

Application Number Priority Date Filing Date Title
AU2017405808A AU2017405808A1 (en) 2017-03-24 2017-03-24 Power tools with integrated circuit boards
CN201790001632.7U CN211908570U (zh) 2017-03-24 2017-03-24 无刷电动机和包含其的电动工具
PCT/CN2017/078146 WO2018170906A1 (en) 2017-03-24 2017-03-24 Power tools with integrated circuit boards
EP17902256.1A EP3602750A4 (de) 2017-03-24 2017-03-24 Elektrowerkzeuge mit leiterplatten

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/CN2017/078146 WO2018170906A1 (en) 2017-03-24 2017-03-24 Power tools with integrated circuit boards

Publications (1)

Publication Number Publication Date
WO2018170906A1 true WO2018170906A1 (en) 2018-09-27

Family

ID=63584976

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/CN2017/078146 WO2018170906A1 (en) 2017-03-24 2017-03-24 Power tools with integrated circuit boards

Country Status (4)

Country Link
EP (1) EP3602750A4 (de)
CN (1) CN211908570U (de)
AU (1) AU2017405808A1 (de)
WO (1) WO2018170906A1 (de)

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN213661375U (zh) * 2020-11-17 2021-07-09 东莞市力宸机电科技有限公司 一种电机模组及应用该电机模组的电动工具

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102158034A (zh) * 2010-02-11 2011-08-17 浙江三花股份有限公司 直流无刷电机泵的电机及其制作方法、直流无刷电机泵
KR101245176B1 (ko) * 2012-10-19 2013-03-25 송병로 에칭 박막 코일 권선을 이용한 전동기
US20130313925A1 (en) 2012-05-24 2013-11-28 Milwaukee Electric Tool Corporation Brushless dc motor power tool with combined pcb design
CN104967253A (zh) * 2015-07-16 2015-10-07 莱克电气股份有限公司 高速无霍尔三相吸尘器电机
US20160037659A1 (en) 2014-07-31 2016-02-04 Denso Corporation Electronic device

Family Cites Families (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP5522504B2 (ja) * 2008-09-29 2014-06-18 日立工機株式会社 電動工具

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102158034A (zh) * 2010-02-11 2011-08-17 浙江三花股份有限公司 直流无刷电机泵的电机及其制作方法、直流无刷电机泵
US20130313925A1 (en) 2012-05-24 2013-11-28 Milwaukee Electric Tool Corporation Brushless dc motor power tool with combined pcb design
KR101245176B1 (ko) * 2012-10-19 2013-03-25 송병로 에칭 박막 코일 권선을 이용한 전동기
US20160037659A1 (en) 2014-07-31 2016-02-04 Denso Corporation Electronic device
CN104967253A (zh) * 2015-07-16 2015-10-07 莱克电气股份有限公司 高速无霍尔三相吸尘器电机

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
See also references of EP3602750A4

Also Published As

Publication number Publication date
CN211908570U (zh) 2020-11-10
AU2017405808A2 (en) 2020-11-19
AU2017405808A1 (en) 2019-10-10
EP3602750A4 (de) 2020-11-11
EP3602750A1 (de) 2020-02-05

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