CN201248022Y - Electric tool with motor control module - Google Patents
Electric tool with motor control module Download PDFInfo
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- CN201248022Y CN201248022Y CNU2006900000617U CN200690000061U CN201248022Y CN 201248022 Y CN201248022 Y CN 201248022Y CN U2006900000617 U CNU2006900000617 U CN U2006900000617U CN 200690000061 U CN200690000061 U CN 200690000061U CN 201248022 Y CN201248022 Y CN 201248022Y
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Abstract
The utility model discloses an electric tool which comprises a tool motor and a control module integrated with a switch, wherein the control module is collocated with a programmable tool motor convenient for controlling more than one different electric tool. The control module comprises an electronic clutch used for detecting the error condition showing overload events in the tool, and a microcontroller used for controlling the electronic clutch and starting the protecting action based on the detected error condition so as to remove or reduce the electric energy of the tool motor. The control module is suitable for completing the method that hearing and/or feeling is provided for a tool user to be used as the impendent or current error condition alarm. The control module can prevent a power supply from being carelessly turned on after the overload events are removed, the tool is connected with the power supply, and a power supply switch is switched on or the tool is connected with the power supply and the power supply switch is switched on. The control module is suitable for providing the moment control for the electric tool so as to estimate the temperature of the tool motor and inform that when the tool user needs the maintenance demands.
Description
Prioity claim
The application requires the name of the people such as Samuel G.WOODS that submit on October 12nd, 2005 under the 35U.S.C 119 (e) to be called " UNIVERSAL CONTROL MODULE " U.S. Provisional Patent Application No.60/726,011, and the people's such as Samuel G.WOODS that submit on June 29th, 2006 name is called the U.S. Provisional Application No.60/817 of " CONTROL AND PROTECTION METHODOLOGIES FOR AMOTOR CONTROL MODULE ", 085 rights and interests.At this, the full content of every provisional application is cited as a reference.
Technical field
The utility model relates generally to a kind of electric tool with control module, and this control module is in order to the operation of control motor and realize as switch sections, so that protection motor and related electric device are for example by the electric tool of driven by motor.
Background technology
Typically, for given application, motor is by the special analog or digital circuit control of control motor.For example, the given motor that application examples that can need a kind of special circuit to control to be used for electric device such as power saws are used is used for the different motors that another power tool application is for example bored application and can need another special circuit to control.Special analog or digital control circuit typically is made of different parts.These parts have different values, tolerance and/or Control Software usually and think given motor and/or the unique operating characteristic section of given motor application creation.
The utility model content
The purpose of this utility model just provides a kind of motor control module, and this module controls motor is the operation of the instrument motor of cable electric tool for example, wherein the functional switch sections that is embodied as of control module, for example switch of electric tool.In an example, control module comprises the electric clutch of resisting overload event in order to the protection instrument.Electric clutch in the module can the mechanical clutch in instrument uses with the protection instrument resists overload event.Another guard method in the module comprises provides the sense of hearing and/or tactile feedback to the method for tool user as the warning of erroneous condition imminent or current in the instrument.This can finish by the voltage (motor is turned back) that pulsation instrument motor or turn back (foldingback) are applied to the instrument motor.Microprocessor but pulsation and motor are turned back in the Be Controlled module calls with the TRIAC in the control module and changes or change the voltage that is applied to the instrument motor.
Another guard method of control module prevent overload event removed and instrument insert power supply and its mains switch open after or instrument insert power supply and mains switch open after because of the energising due to neglecting.Guard method again in the module provides Torque Control to electric tool, reaches given set point if measure moment, and it uses motor to turn back.
In another example, the control method in the control module can be estimated the temperature of instrument motor, and when the instrument motor temperature when comprising instrument start-up perhaps can need repairing by communication means subscriber cable electric tool.In an example again, control module is configurable to control the multiple different motors in the multiple different instrument.Control module comprises the microprocessor of the controlled function that is configured to carry out multiple different protection or control tool motor; and comprise at least one memory that is used to store a plurality of soft code coefficients, its can be provided with to enable selected those of difference protection in (enable) or forbidding (disable) module or controlled function.Soft code coefficient comprises a plurality of different selectable inputs, and it can be set to the given input of choosing function, and comprises a plurality of different selectable outputs, and it can be set to the output of choosing function from given.
This module comprises that controller and TRIAC are to control to the electric current of given instrument motor.This module can be carried out the various control algorithm, comprises about synchronization module and AC input signal, average current, the method for compensated amplifier biasing to improve the current measurement precision in the module and the tachometric survey and the control of instrument motor are provided by the hysteresis principle in the comparator that uses controller of the TRIAC of estimating to flow through.In addition, there, controller configuration to proofread and correct the vibration correcting register.
Advantage of the present utility model is, can realize the function of the different instruments of control with a kind of module, and has more function and more reliable than traditional special module.Thereby reduce production costs, improve the quality of products.
Description of drawings
Exemplary embodiment of the present utility model will become from following the detailed description and the accompanying drawings given herein and obtain more all sidedly understanding, wherein identical parts are represented with identical label, at this, its only be by example provide itself and non-limiting exemplary embodiment like this.
Figure 1A is the partial plan view that illustrates according to the electric tool of the control module in the tool housing of exemplary embodiment.
Figure 1B is the view that illustrates according to the switch of the control module that is integrated with switch of exemplary embodiment.
Fig. 1 C is the view that illustrates according to the switch of the control module that is integrated with switch of exemplary embodiment.
Fig. 2 is the isometric projection view of choosing parts according to the instrument motor in the electric tool of the relation that control module, pickup coil assembly, accessory plate and speed disc are shown of exemplary embodiment.
Fig. 3 is the isometric projection view according to the control module of exemplary embodiment.
Fig. 4 is the calcspar that is provided with according to the electronic unit in the control module of exemplary embodiment.
Fig. 5 is the functional flow chart that illustrates according to the absolute clutch mode of exemplary embodiment.
Fig. 6 is the functional flow chart that illustrates according to the DI/DT clutch mode of exemplary embodiment.
Fig. 7 is the flow chart that illustrates according to the no-voltage operation program of exemplary embodiment.
Fig. 8 illustrates to electric tool user tactile feedback as the chart of the alarm mechanism of imminent or current erroneous condition there.
Fig. 9 is the chart of turning back that the electric moter voltage in the electric tool is shown.
Figure 10 A is the flow chart that illustrates according to the motor temperature algorithm for estimating of exemplary embodiment.
Figure 10 B is illustrated in after the power down or how initial tool estimates the flow chart of temperature register value B when powering on.
Figure 11 is according to the estimation motor temperature of the algorithm computation of Figure 10 A and the chart of actual measurement motor stator temperature for the 120V low-angle grinding machine comparison of disposing exemplary control module 100.
Figure 12 is the skeleton diagram according to relation between coefficient input, protection/control method and the device of exemplary embodiment and the coefficient output.
Figure 13 A is the front view of the gear box part 16 among Figure 1A.
Figure 13 B is the viewgraph of cross-section that Figure 13 A A-A along the line in order to the details that mechanical clutch is shown cuts open.
Figure 14 is the calcspar that is provided with according to the electronic unit in the control module of exemplary embodiment.
Figure 15 detects the flow chart whether TRIAC 1420 need trigger from given control method once more in order to illustrate in control module 100 after the initial trigger of TRIAC 120.
Figure 16 A is the zero cross detection circuit calcspar partly that illustrates in order to the control circuit 1400 of finishing zero passage detection.
Figure 16 B illustrates detection AC and supplies with the flow chart of the zero passage of signal with the method for synchronization control module 100 and instrument motor.
Figure 17 illustrates and is used for motor control module 100 in order to determine the exemplary circuit of motor speed.
Figure 18 illustrates the exemplary positive half period and the corresponding sampling current of electric data point of AC voltage waveform.
Figure 19 illustrates for positive AC voltage half cycle and relevant current half in the pure inductive load AC waveform.
Figure 20 illustrate according to exemplary embodiment for the voltage in the slight positive AC of the inductive load half period and sample rate current waveform to describe the method for estimating average current.
Figure 21 illustrate according to another exemplary embodiment for the positive AC of pure inductive load in the half period voltage and sample rate current waveform absolute value describe to estimate the method for average current.
Figure 22 A is in order to the flow chart in order to the method for the average current of estimating the TRIAC by motor control module according to exemplary embodiment to be shown.
Figure 22 B is in order to the flow chart in order to the method for the average current of estimating the TRIAC by motor control module according to another exemplary embodiment to be shown.
Figure 22 C is the flow chart in order to the method for the average current of estimating the TRIAC by motor control module that illustrates according to another exemplary embodiment.
Embodiment
U.S. Patent No. 7,102,303 and the U.S. apply for that openly No.2005/0237011 is referred to herein as a reference.
In an exemplary embodiment, control module is configurable thinks that multiple different platform provides control.For example, the configurable multiple different motors that are used for different application with operation of controller module.Control module can be omnipotent so that the control module of same structure can be programmable to operate multiple different motor.Control module can be programmed to control motor according to different qualities.For example, a kind of control module can be programmed with control mitre saw motor, and another control module can be programmed with control sand mill motor.But it is the same that control module keeps.The control module of describing more all sidedly or the functional switch that is integrated with of control module below at least.
For what describe in detail in this and back, exemplary embodiment is at control of being finished by the electronic circuit in the motor control module of electronic installation and/or guard method.In an example, electronic installation can be to have by AC source voltage to give the instrument motor of electricity with the cutter head of driving electric tool or the cable electric tool of annex.This and after exemplary embodiment control or guard method are shown, its about and include but not limited to: electric tool starts; The one or more overloads or the error event that exceed voltage, speed, electric current, moment and/or temperature threshold; And the alarm mechanism that can warn imminent mistake of tool user and/or overload condition.In order to be provided at the content of this and the described illustrative methods in back, utility model designer at first provides the exemplary block diagram of the electronic devices and components of the skeleton diagram of the exemplary electronic device with control module and control module.
Figure 1A is the partial plan view that illustrates according to the electric tool of the control module in the housing of the instrument of exemplary embodiment.With reference to Fig. 1, electric tool 10 is illustrated and is embodied as rotary cable electric tool 10, will be understood that, exemplary embodiment may be used on the electric tool except the rotary cable electric tool.In the example of Figure 1A, electric tool 10 is depicted as the angle grinding machine of being given electricity by electric power cable 21 by AC line power supply.Angle grinding machine 10 comprises in order to receive by the clamp nut that chimb is arranged 12 in the annex fender 14 of the tool insert of instrument driven by motor or annex.In this example, annex can be for example rotary attachment of mill (not shown).Mill can be attached to gear box 16 by axle, and it is fixed to tool housing 18.
Figure 13 A is the front view of gear box part 16, and Figure 13 B is that the line A-A along Figure 13 A cuts the viewgraph of cross-section with the details that mechanical clutch is shown open.In Figure 13 A, the front view of gear box 16 is shown as and has removed gear box casing so that gear 1304 is shown.In addition, axle lock button 1302 is arranged on the side of gear box 16.Axle lock button 1302 engages the axle lock of the axle that is used for locking electric tool 10 and is changed thereon or remove to allow annex.
With reference to Figure 13 B, it is the viewgraph of cross-section that Figure 13 A A-A along the line cuts open, and axle 1308 is illustrated passes gear box 16 by outer spindle bearing 1320 and inner axis of heart bearing 1322 and terminate in nut 1318.Spindle bearing 1320,1322 feasible energy axles 1308 energy radial motions, as known in the art.Mechanical clutch 1310 can comprise cone clutch 1312, a pair of Belleville spring 1314, packing ring 1316 and nut 1318.Mechanical clutch 1310 for example moves under the anxious situation of stopping of instrument in the mistake that is attributable to overload condition, annex spring etc.Like this, mechanical clutch 1310 is protected the user by unloading lower gear 1304 to remove or to discharge from the inertia of system.Shown in Figure 13 B be axle lock 1306 equally, it can pass through pin 1305 joints by the action that axle is locked button 1302.In Figure 13 B, axle 1308 is depicted as non-locked position.
Cone clutch 1312 is that two D cooperate side surface (lock just) and that have band slight inclination angle.Although do not have in Figure 13 B to show that gear 1304 is slidingly matched with axle 1308 so that the parts of mechanical clutch 1310 to be shown.When load is applied to axle 1308 (for example, under the situation of for example anxious mistake of stopping that causes owing to overload condition, annex spring etc.), cone clutch 1312 becomes to Belleville spring 1314 bias voltages, thereby is supporting packing ring 1316 and nut 1318 bias voltage Belleville springs 1314.This provide carry gear 1304 power to unload lower gear 1306 so that discharge or remove inertia from system.Owing to being operating as of the mechanical clutch that is used for electric tool is known in the art, further go through so that succinct so omit.
With reference to Figure 1A, tool housing 18 is depicted as has removed the part shell body, so that with the magnet ring 22 and the commutator ring 24 immediate relations of armature 20 omnipotent control module 100 (" control module ") is shown.Control module 100 design is with the operation of controlling multiple motor and/or be multiple different motor application (for example, different electric tool) configuration.
In addition, in Figure 1A, the accessory plate 200 that supports pickup coil assembly 250 and speed change dial 270 is shown.As the components that is connected to the control module 100 in the electric tool 10, accessory plate 200 can be included in the tool housing 18.A function of accessory plate 200 is to allow according to electric tool design requirement indicated customization pickup coil and speed change dish.Pickup coil assembly 250 can be attached to accessory plate 200 and configuration to detect motor speed.Speed change dial 270 can be by user's operation so that set and/or change the motor speed of expectation.
With reference to Figure 1B and 1C, the functional switch 193 (Figure 1B) or 195 (Fig. 1 C) that is integrated with of control module 100 and/or control module.A benefit is single electric component, the wiring that it will need less space and simplify power tool application significantly.Another benefit will be that all features of control module will be available to allow the functional in the instrument of (just, control module is separated with switch) of the space that is not used in independent control module of integrated control module.
In an exemplary embodiment, switch can comprise finger operation switch, and it can be trigger, but is not limited to only be trigger, and it is a user input apparatus, but also can be the device that the user who feeds back to electric tool is provided.
Finger operation switch (FOS) can be and have physical motion the switch or the non-moving switch of (translation or rotation or the combination of the two, in a plane or in the three-dimensional).If it is the switch with physical motion, the Optical devices of the resistance variations that its motion can be by resistive element and moving slider (vice versa), linear variable-differential transformer, variable capacitor, detection position then, perhaps any other detect that peace device moving or rotational motion in position detects in one dimension, two dimension or three-dimensional.
FOS can be have pressure sensor, the non-motion switch of straingauge or other power transducer.It can be molded in the soft or pliable and tough plastics, and perhaps it can be " colloid " switch that inside has colloid substance.It can be for example by using two kinds of dissimilar opaque and transparent plastics molded by double injection technology.
FOS can comprise the user that feeds back to following form: luminous (LED, lamp, laser diode, infrared diode, thermoluminescence, electroluminescence, or any other produces the device of various light and diversified color), heat heating (for example, stratie, in order to show that the user should reduce the pressure on the switch), vibration (tactile feedback is given the user to characterize certain situation) or voice signal (for example, as the sound of reporting to the police), perhaps any other type feeds back to the user.The instrument feedback also can include, but not limited to motor temperature, current of electric, instrument moment or device malfunction.
Fig. 2 is the isometric projection view according to the selected parts of the instrument motor in the electric tool of the relation that control module, pickup coil assembly, accessory plate and speed disc are shown of exemplary embodiment.Fig. 2 illustrates the relation between accessory plate 200 and parts (pickup coil assembly 250 and speed disc 270), control module 100 and the instrument motor 15, and it can be included in the instrument armature 20 that rotates in the instrument motor stator 30.In an example, accessory plate 200, pickup coil assembly 250 and dial 270 can be called " auxiliary circuit board component " altogether.For example, the auxiliary circuit board component is attached to the control module 100 of Figure 1A, and control module 100 is suitable for the operation of control tool motor.
Accessory plate 200 also can comprise speed change dial 270, and it is used as potentiometer as known in the art.In an example, speed change dial 270 parts can comprise a plurality of rigidity ratchets that are positioned on the leaf spring, so that provide audio feedback to the user.In an example, ratchet contact leaf spring is to provide tactile feedback to the user.This is also in order to prevent that speed change dial 270 from moving in any instrument vibration processes.In addition, the use of ratchet can prevent that the user from changing speed inadvertently, thereby provides the tactile feedback that is easy to distinguish to the user.
Fig. 3 is the isometric projection view according to the control module 100 of exemplary embodiment.With reference to Fig. 3, control module 100 comprises upper shell 110, lower house 120, spacer 130 and printed circuit board (PCB) 140 (not shown among Fig. 3).In an example, for example, upper shell 110 can be by making for the active electric component in the control module 100 provides the material of heat radiation, and can cast to have described function.Lower house 120 configurable with support and control module 100 internal part and allow to water jar to produce sealing shroud.In addition, lower house 120 provides the electric insulation zone for the active electric device in the control module 100.
As mentioned above, spacer 130 is held in place the through hole electronic unit in the assembling process of control module 100.In manufacturing process, there are a plurality of electronic units to be attached to PCB140.An effect of spacer 130 is parts to be kept in placely to be maintained fixed jig with elimination in the wave soldering process.Correspondingly, spacer 130 can be placed in assembling process on the power supply lug 150 so that surplus capacity to be provided, and also can provide electric insulation to keep these surplus capacities simultaneously between these parts.
Can provide supplementary insulation by in spacer 130, watering jar.Except the active parts in the control module 100 is held in place, waters tank material and can have the V0 flammability rating.The suitable tank material that waters includes but not limited to one or more of the sealant based on epoxy, single or multicomponent polyurethane or polyurethane gel sealant, single or multicomponent silicon or silica gel sealing agent etc.
Correspondingly, have and water jar thing for example distinguishes the insulant with simple layer as insulant control module 100 and nonisulated control module.In addition, thermal grease conduction can be applied to the active electronic component for example FET in the control module 100 or the upper surface of TRIAC; This is standard in industry.Perhaps, the heat-conducting plate (not shown) can be set, rather than thermal grease conduction.Thermal grease conduction or heat-conducting plate can be used for preventing to water jar thing and ooze out between given active electronic component and upper shell 110, and can be for example adjust size according to the effect of the height of active parts.
Fig. 4 is the calcspar that the electronic unit in the control module 100 is provided with.One or more parts among Fig. 4 can be integrated with switch.Can be arranged on the PCB140 in the control module 100 at this and the described electronic unit in back.Control module 100 comprises the memory 434,436 in order to the function coefficient of one or more soft codings used in the implementation that is stored in each function or algorithm.Because it is specific that given soft encoding function coefficient can be applied as for particular tool, control module 100 can be suitable for controlling the operation of multiple motor and/or multiple different motor application (for example different electric tools).Soft code coefficient can be regarded as and is included in the given function carried out by control module 100 or the coefficient input of algorithm, and comprises the function coefficient that can change or change according to given instrument or tool applications.Soft code coefficient also comprises and the relevant coefficient output of being undertaken by control module 100 of protection action as the result who finishes given function that control module 100 carried out or algorithm.For given application, export and to change as required or to connect to the coefficient input of given function or from the coefficient of given function.This illustrates in Figure 12 in further detail.
Control circuit 400 comprises power supply 405, its provide electric energy to programming to control some operation and/or to instruct some function in the control module 100 or the microcontroller 430 of protectiveness action.Power supply 405 can provide for example VCC of 5V.Service voltage monitor 415 monitors VCC and the detected microcontroller 430 that inputs to is provided.
Microcontroller 430 can provide control signal to control electronic valve 420 to TRIAC 420 by control incoming line 418.In an example, it can be a TRIAC, although electronic valve may be embodied as the arbitrary of field-effect transistor (FET), igbt (IGBT), thyristor (SCR), voltage-operated device etc.Usually, control module 100 is passed through to open and close current of electric, the operation of control tool motor 15 with the periodic intervals relevant with the zero passage of AC curtage waveform via the control signal of microcontroller 430 and the control incoming line 418 that is applied to TRIAC 420.These periodic intervals are caught to take place with AC synchronous waveform ground and measure as number of degrees value ground with the angle of flow.
The angle of flow is determined the point that electronic valve 420 triggers in the AC waveform, gives motor 15 thereby transmit electric energy.For example, the corresponding situation of conducting fully of 180 ° the angle of flow of per half period, wherein electronic valve 420 is triggered so that whole interference-free alternating current is applied to motor 15, just, electronic valve 420 electronic valve 420 so that electric current is flowed through that is triggered continues whole half period of AC input signal.Similarly, the corresponding service voltage that passes through motor 15 that forms the centre that starts from the given half period of 90 ° the angle of flow, like this electronic valve 420 be triggered so that the pact of utilisable energy half pass to motor.Less than the triggering of angle of flow correspondence electronic valves 420 after the given half period of 90 ° so that even the energy delivery of smaller amounts give motor 15.
This and after, unless below particularly point out, electronic valve 420 refers to TRIACs 420.In an example, TRIAC 420 can be single insulation TRIAC, and insulant is the inside in described part there.More specifically, constituting the armature 20 of motor 15 and the operation of motor stator 30 is by 400 controls of the control circuit in the control module 100.In order to control the operation of armature 20 and motor stator 30, microcontroller 430 control flows are through the electric current of armature 20 and motor stator 30 or be applied to armature 20 and the voltage of motor stator 30, perhaps the two, it is the electron period by TRIAC 420.Control circuit 400 can determine when to be opened or closed TRIAC 420, its based on can be stored in the question blank soft code coefficient or from based on measurement factor or the parameter governing equation of voltage, speed, electric current, moment, other outside input (456,458 etc.) or above-mentioned any combination for example.When motor control switch 402 places closure (just " connection ") position, the operation of control module 100 control motors 15, thus allow electric current to flow through.The function of control circuit 400 is positions of monitoring motor control switch 402 and prevents that motor control switch 402 is to start in closed (just " connection ") position motors 15 if electric energy is applied to motor 15.
For example, microcontroller 430 can comprise for example RAM434 or SRAM and programming ROM 436 (variable ROM) for example microprocessor 432, plate upper periphery equipment of flash memory, CPU core for example of the structural nonvolatile memory of one chip.Nonvolatile memory is suitable for keeping canned data, even do not have electric the time.The example of nonvolatile memory comprises RAM (DRAM, SRAM, SDRAM, VRAM etc.), based on the memory of magnetic and light.The type of variable solid-state ROM can comprise Erasable Programmable Read Only Memory EPROM (EPROM) and Electrically Erasable Read Only Memory (EEPROM).EPROM can wipe then by EPROM programmer and rewrites by being exposed to ultraviolet ray, and can discern by the circle at the top " window " that allows UV light to enter.EEPROM for example flash memory allows whole ROM (perhaps ROM storehouse) to be wiped (swash flash back zero) by electricity to write then, do not need it is taken out calculation element.
In an example, microcontroller 430 can be ATMEL AVR
8 digit RISC micro controllers a kind of, the ATmega8 that programmable memory (EEPROM) is dodged in the programming certainly that for example has a 8K byte dodges microcontroller.But the Based Intelligent Control of module 100 is not limited to exemplary microcontroller 430.For example, intelligence controlling device can be embodied as for example application-specific IC (ASIC) of another microcontroller, analog circuit, digital signal processor or one or more digital IC aspect hardware and/or the software.
Control circuit 400 with instrument motor 15 (armature 20 and motor stator 30) and motor control switch 402, TRIAC 420 and connect at the live wire of power supply and the shunt resistance 440 between the neutral line (public) side.In Fig. 4, a side of instrument motor 15 is connected to power supply, for example is connected to the hot side of AC power supplies 407 by motor control switch 402 via electric power cable 21 (Figure 1A).The opposite side of instrument motor 15 is connected to the neutral line side 408 of AC power supplies 407 by TRIAC 420, shunt resistance 440 and electric power cable 21.
Shunt resistance 440 can be embodied as the analog current transducer, and it detects electric current and signal is provided, and this signal amplifies at amplifier 445.Amplifier 445 has first input of a side that is connected to shunt resistance 440 and is connected to second input of the opposite side of shunt resistance 440.The output of amplifier 445 is connected to the given port of microcontroller 430.Shunt resistance 440 only is an example of current sensor, and other current sensor comprises for example current transformer, digital sensor, Hall effect transducer etc.
Microcontroller 430 is included in the analog to digital converter (ADC) there, and its analog-signal transitions that will receive from each transducer is that digital signal is so that microprocessor 432 processing.ADC will be understood that any analog input data that analog input and other control input/output line 456,458 from amplifier 445, monitor 415,425,427, power supply 405, temperature sensor 410 receive are changed into numeral so that microprocessor 432 is handled in ADC in microprocessor 430 and not shown so that clear.
Control circuit 400 also comprises bleeder circuit 450 with resistance 451,452,454 and is used to detect the clamping diode 455 and 457 of one or more zero passages of AC voltage by microcontroller 430.Voltage zero-cross may be defined as AC voltage and passes zero axle and be pressed onto negative voltage or that point when negative electricity is pressed onto positive voltage variation from positive electricity.This point is used for the timing purpose of microcontroller 430 inside.Bleeder circuit 450 is connected to microcontroller 430 by circuitry lines 460 at given port (not shown so that clear).Resistance 451,452 and 454 is the voltage levvl that microcontroller 430 can be used with AC source voltage dividing potential drop.If clamping diode 455 and 457 protection microcontrollers 430 exempt from damage when in the voltage of AC source due to voltage spikes taking place.In an example, the bleeder circuit 450 of all or part can be included in the control circuit 400 or in microcontroller 430.In an example, microcontroller 430 can comprise inner clamping diode 455 and 457.
Control circuit 400 can comprise that design imports the one or more temperature sensors 410 of detected signal to microcontroller 430 in order to detected temperatures with by port.Temperature sensor 410 can be embodied as for example NTC or PTC thermistor, temperature sense IC or thermocouple.But the temperature of temperature sensor 410 communication control modules 100 or specific features be the temperature of TRIAC 420 or microcontroller 430 for example, and it can be used for determining some overload event/erroneous condition.Because the function of this temperature sensor 410 is known, so omit the detailed explanation of its feature operation so that succinct.Can place a plurality of temperature sensors 410 as required in module 100.
In addition, control circuit 400 comprises that two voltage monitors are to monitor the voltage of TRIAC 420, one is gate voltage monitor 425, it is used for determining in whether conducting of negative voltage half-cycle TRIAC 420, one is positive half period voltage monitor 427, and it is in order to determine in positive voltage whether conducting of TRIAC 420 in the half period.Two monitors 425,427 all are essential, because controller 430 only can detect positive voltage.At the negative half-wave in AC cycle, monitor 427 will detect less than voltage.
Control circuit 400 can comprise that one or more I/O (I/O) line 456,458 is so that and telex network.These I/O lines 456 and 458 can be numeral or analog input or numeral output, and can be connected to for example device of the user interface of potentiometer, switch, LED or other form (for example speed disc, tool trigger, on-off switch etc.), to increase the changeability of some systems.
Usually, control circuit 400 as shown in Figure 4 is in order to the instrument Electric Machine Control to be provided and/or to start, exceed the one or more overload of voltage, speed, electric current and moment and/or temperature threshold or the one or more relevant protection of error event with electric tool.Control circuit 400 is methods of controlling or alarm mechanism is provided in order to carrying out, this alarm mechanism warning imminent mistake of tool user and/or overload condition.Correspondingly, since described the general structure and the electronic circuit of control module 100, the illustrative methods of being finished by control circuit 400 is discussed in further detail below.
Overload control
In an example, the control circuit 400 of control module 100 can be used the clutch (EOC) based on the only electronics of software under the control of the microprocessor in the microcontroller 430 432, combine so that motor overload control to be provided independently and/or with mechanical clutch in the instrument.Mechanical clutch can be embodied as for example mechanical clutch shown in Figure 13 B 1310.This and after, mechanical clutch is called " MC ".
In an example, the enforcement of the EOC function that combines with microcontroller 430 or turn off instrument motor 15, or reduce electric moter voltage to than low velocity and moment values.Moreover, by with gear box 16 in MC application controls module in combination 100 in EOC, can use more cheap MC, and still have the relatively long life-span.For example, use operation cycle of the combination of EOC/MC can increase cycle lie from 200 cycles to surpassing for 2000 cycles.This only is exemplary, and EOC/MC is used in combination the cycle lie at least 25% that has improved MC.The functional detection overload/error event of EOC, it is with more detailed discussion below, by it, microcontroller 430 makes instrument 10 dead electricity by disable triac element 420 fully, perhaps to reduce the method control TRIAC 420 of the electric energy of giving instrument 10.
Although there has not been electricity under the situation that instrument is turned off, inertia still remains in the system.Inertia can cause armature 20 and any annex that adheres to continue rotation.This can cause damaging annex (for example mill) and gear and other internal part.Cut off the electricity supply fully at microcontroller 430, after the triggering of disable triac element 420, the MC that use combines with EOC removes the residue inertia in the system (for example instrument 10).This EOC closes and removes combining of residue inertia in the system to the electric current of motor and MC and make and increase the cycle lie of clutch and/or annex.
EOC can be in the inside of control module 100, and can be software program or the step that is stored among for example variable ROM436 of memory as mentioned above.For example, based on half line (half-line) cycle or all fronts (full-line) cycle, but the given parameter of the algorithm continuous monitoring instrument that microcontroller 430 is carried out, for example electric current, motor speed, power supply, motor temperature etc.In an example, the parameter that is monitored is an electric current; Along with load increases, electric current increases like this.Like this, the half period position of microprocessor 432 sampling AC current waveforms and this sampling of digitlization be so that calculate given current value, for example transient current, average current and/or root mean square (RMS) electric current.In another example, the algorithm carried out of microcontroller 430 motor speed of adviser tool motor serially.
In an example, EOC can be embodied as absolute clutch mode, wherein for example average current, RMS electric current or maximum instantaneous current value (if perhaps monitoring motor speed, then be the motor speed threshold value) of setting threshold.If the current value that calculates or measure (for example, transient current, average current or RMS electric current) reaches this threshold value, then functional mistake or the overload condition of detecting of EOC.In another example, threshold value can be set by microprocessor 432 and surpass during preset time for example X cycle, so that avoid instantaneous or pseudo-protection action.
Detect by this, microcontroller 430 starts the protection action based on the output factor in the nonvolatile memory that is stored in the EEPROM that can be embodied as among Fig. 4 or flash memory (as the example of ROM436) in an example.For example, be the output of a disable motor 15 if in absolute clutch mode, be used for the specific soft code coefficient that is stored in ROM436 of EOC function, offend threshold value so and will cause microcontroller 430 disable motors 15.Like this, instrument 10 can place shutdown mode, and microcontroller 430 no longer allows TRIAC 420 conductings there.This is by means of opening TRIAC 420 to the control signal electricity of TRIAC 420 and finish by sending from microcontroller 430 through control incoming line 418.This closes TRIAC 420; Do not allow electric current electric up to applying once more to system by armature 20.
Perhaps; if different soft code coefficients is stored among the ROM436; it changes the protection action of carrying out in the absolute clutch mode; the offence threshold value can cause microcontroller 430 control TRIACs 420 with pulsation instrument motor 15; it will warn the user error situation, perhaps can be by the output voltage that reduction is issued to instrument motor 15 turn back (folded back) to the electricity of instrument 10.
In another is carried out, defencive function, for example shutting down, pulse or turn back can be based on the detected electric current of EOC over time, just, DI/DT clutch (Δ i/ Δ t).In this example, the variation of current value (for example average current, peak current or RMS electric current) is along with the time is measured, and if the variation of electric current (Δ i) exceed prescribed limit or threshold value, one of top action (shut down, pulse, turn back) can be activated.Like this, the EOC that uses in the DI/DT pattern, it is the algorithm by microprocessor 432 iteration, can investigate N cycle, N=1 wherein, 2,3 etc.In another example, X cycle for example during threshold value can be set at preset time by microprocessor 432 is so that avoid transient state or pseudo-protection action.
Correspondingly, the use of EOC can provide overload protection based on exceeding given threshold value in absolute threshold pattern or DI/DT threshold value pattern, one of several protection actions of there can be at EOC functional or algorithm take place when detecting erroneous condition.Microprocessor 432 is retrieved certain soft code coefficient and is carried out specific protection action based on the soft code coefficient that is retrieved from memory (for example ROM436).The soft code coefficient that points to pending protection action can be described as coefficient output.
The coefficient output of choosing shows pending protection action.For example, ROM436 can comprise the coefficient output that shows the following action of microcontroller 430 startups: (i) tactile feedback, and wherein motor 15 is pulsed power supply so that the warning of the erroneous condition in user's electric tool 10 to be provided by 430 cycles of microcontroller triggering TRIAC 420; Perhaps (ii) turn back, wherein microcontroller 430 angle of flow that reduces TRIAC 420 is to reduce to supply with motor 15; Perhaps (iii) motor shutdown, wherein along with microcontroller 430 is established road TRIAC 420 by cable, TRIAC 420 is forbidden fully; Perhaps (iv) actuate electronic brake, the there electronic brake is algorithm or the software program of being carried out by microcontroller 430; And/or one of (i)-(iv) with (combining v), (the warning LED that v) turns on the tool housing outside is with the imminent or current erroneous condition of caution user.These are exemplary protection actions, and it for example can be carried out when EOC detects overload event.
Because EOC is based on software,, thereby reduces cost and eliminate component wear so it does not have mechanical part.EOC has been described as using with mechanical clutch; But it can be with using with the similar electronic brake of mechanical clutch effect.EOC can react to the abswolute level that speed or electric current reach along with the variation of time or speed or electric current.For example, (2 line cycles 60Hz) can cause the EOC action to increase 8A in 32 milliseconds.Perhaps, (1 line cycle 60Hz) can cause the electric clutch action in 16 milliseconds motor speed to be reduced to 6k rpm from 8k rpm.(4,000rpm) (speed is not 10 when having load, and the situation of abswolute level 000rpm) can cause the electric clutch action for electric current (35A) or speed.
Similar than low velocity and moment values behavior and mechanical clutch.EOC can be used in combination with mechanical clutch or electronic brake.
Fig. 5 is the functional flow chart that illustrates according to the absolute clutch mode of exemplary embodiment.Fig. 5 illustrates EOC functional at absolute clutch mode, and it can or can not use with mechanical clutch (MC) or electronic brake in control module 100.
With reference to Fig. 5, in absolute clutch mode (500), microprocessor 432 receives from current sensor 440 via amplifier 445 detected parameters (being detected current sample in this example).Correspondingly, in absolute clutch mode the functional description of EOC for being configured to sample rate current; This is because the software that is arranged among the ROM436 (just EEPROM, flash memory) is pressed code coefficient (coefficient input) for the input of electric current as the EOC function in absolute clutch mode.Certainly, the function of EOC is configurable with the different parameter of sampling in absolute clutch mode, and it will be with different threshold value rather than based on the threshold value (just voltage, motor speed, motor temperature etc.) of electric current relatively.Like this, the coefficient input that is stored among the ROM436 (EEPROM/ flash memory just) can be pointed to input rather than the electric current of other parameter as the EOC function, for example speed, temperature, voltage or other sensor parameters.
In these examples, these current samples can be the half period position or all fronts period positions (just based on the line cycle) of AC voltage waveform, it is digitized so that calculate given current value, for example instantaneous peak current, average current and/or root mean square (RMS) electric current.Current value that is calculated and threshold ratio be (520), and it can be based on the threshold value of average current, RMS electric current or maximum current as mentioned above.If the current value that is calculated (for example, transient current, average current or RMS electric current) surpasses this threshold value, (520 output is " YES "), algorithm increases progressively timer counter (530); Otherwise the timer counter is eliminated (540).The timer counter-increments provides delay to avoid the puppet protection action of microcontroller 430 for instantaneous situation.
The timer counter then with timer coefficient ratio (550).If the timer counting equals or exceeds timer coefficient (550 are output as " YES "); This shows that EOC detects erroneous condition in absolute clutch mode.
As shown in Figure 5, when detecting error condition (is YES in this overload event based on 550 output), control module 100 starts the protection action.In this example, microcontroller 430 is by sending control signal via control incoming line 418 (Fig. 4) triggering of disable triac element 420 to establish road TRIAC 420 by cable, thereby turns off instrument motor 15.
But; for the different coefficient of EOC function output can be arranged among the ROM436 in case microprocessor 432 retrievals so that microcontroller 430 is taked different protection actions; just; for example; the phase control system of use control circuit 400 calls tactile feedback or motor is turned back; the LED that perhaps just lights on the tool housing carries a state to go on a punitive expedition to subscriber's meter, rather than open circuit TRIAC 420 comes from instrument motor 15 voltage take-offs (and electric current).For illustrative purposes, coefficient output is set to motor by disable triac element 420 and turns off for EOC function (definitely clutch mode) in Fig. 5.
At absolute clutch mode, algorithm is determined no-voltage motion characteristic whether be enabled (570).As following detailed, the no-voltage motion characteristic can be set to functional part of control module 100 so that the electric device that prevents from as possible to adhere to (for example electric tool) situation is below opened: otherwise (a) cable of electric tool inserts, and mains switch is in " ON " position and cable is extracted from AC output; (b) mains switch is in " ON ", and instrument is inserted into and gives electricity, and instrument has reached and caused shutting down (although still inserting) overload event, and overload event removes, and mains switch still is in " ON " position.
The execution of no-voltage action protection feature guarantee in the control module 100 electronic valve for example TRIAC 420 can not trigger with superincumbent situation (a) or (b).Like this, along with enabling the no-voltage feature, microprocessor 432 will start no-voltage operation program 700, and it is with more detailed description below.Otherwise along with no-voltage action forbidding (560 output is " NO "), algorithm is in 580 disable interrupts and enter Infinite Cyclic.This prevents that TRIAC 420 from triggering, and for example algorithm constantly moves identical instruction.
Have only soft coefficient output to be set under the situation of absolute clutch mode mistake, stop instrument motor 15, the action that operation no-voltage operation program 700 just will take place or enter Infinite Cyclic (580).As described in not long ago, soft code coefficient comprises the relevant coefficient output of being taked as the result's who carries out given function that control module 100 carried out and algorithm control module 100 of protection action.Can change for given application as required or be connected with exporting to the coefficient input of given function from the coefficient of given function.Like this, if some other coefficients output is set up, it does not need motor to shut down, and just, turns back, tactile feedback, LED etc., then independent action will take place.
If less than timer coefficient (550 are output as " NO "), carry out the normal iteration of absolute clutch mode from 530 timers counting, monitor next line cycle or the half line current sample (590) in the cycle, and algorithm turn back to 510.
Fig. 6 is the functional flow chart that illustrates according to the DI/DT clutch mode of exemplary embodiment.The EOC that Fig. 6 is illustrated in the DI/DT clutch mode is functional, and it can or can not use with mechanical clutch in control module 100 (MC) or electronic brake.With reference to Fig. 6, in the DI/DT clutch mode (600), microprocessor 432 receives detected parameter.In this specific examples, parameter is from the current sample (610) of current sensor 440 via amplifier 445, and it can be regarded as the parameter of being sampled and can be motor speed at the instrument motor at the motor place of two separate clockings.For example, these can be the half period position of AC voltage waveform or the sampling (just, based on the line cycle) of period position completely, and it is digitized so that calculate given current value, for example, and instantaneous peak current, average current and/or root mean square (RMS) electric current.
Algorithm is carried out and is asked poor function (620) with calculated difference.In this example, from deduct electric current (electric current (X-1)) when the current value (electric current (X)) of front computation of Period from last line computation of Period.Relatively this difference and setting threshold (625), its threshold value that can be based on average current, RMS electric current or maximum current as discussed above.If this difference surpasses this threshold value (just, 625 are output as " YES "), algorithm is determined to enable or is forbidden no-voltage feature (630).Function 635,640 and 700 can be carried out as illustrated in fig. 5, omits like this and explains in detail so that succinct.
Although what use is electric current, obviously can use another parameter, for example motor speed and based on the threshold value of motor speed, so that determine whether to detect erroneous condition to start the protection action in the example of Fig. 6.Correspondingly, in another example, difference can be determined two different opportunitys for motor speed.
If difference is less than or equal to threshold value (just 625 being output as " NO "), algorithm is difference and divided by the threshold value (650) of a coefficient relatively, and it is threshold value/2 in the example of Fig. 6.If difference surpasses threshold value (just 625 being output as " YES "), cycle rate counter is increased progressively by microprocessor 432; Otherwise cycle rate counter is eliminated (660).In an example, if surpassing threshold value/2, difference continues N continuous lines cycle at least, wherein N 〉=2 then detect for example overload event of erroneous condition.
The cycle rate counter increment provides delay to avoid the puppet protection action of microcontroller 430 for instantaneous situation.From function 655; algorithm shown in the example of Fig. 6 determines whether cycle count equals or exceeds 3 (665); thereby show that the difference from 650 has surpassed lasting 4 continuous lines cycles of threshold value; it can be regarded as this only is an example, this counting can send as required be 2,3,4, N thinks the action of motor overload trigger protection.In other words, three continuous differences that surpass threshold value/2 will be crossed over 4 line cycles.In this case, in function 630,635,645 and 700, assess the no-voltage action as described above.Function 660 and 665 output are returned microcontroller 430 to normal running 670, and the DI/DT clutch mode is carried out in the there, monitor next line cycle or half line current sample in the cycle.
Is to help to predict its generation before overload event takes place at a plurality of line period ratios than difference with by the purpose divided by the threshold value of a coefficient.For example, if difference threshold is set to two continuous lines between the cycle average 30 amperes, then measured average current also will compare with 15 amperes (30/2) between consecutive periods.If this recurs repeatedly, although electric current does not surpass 30 amperes, this will be considered to overload event.
Being used in combination of EOC/MC can have some benefit.For example, in cutting is used, if cave at the last branch of cutting wheel, EOC will turn off motor 15 (just, armature 20 and motor stator 30) immediately so.After this soon, mechanical clutch will slide behind the EOC powered-down, thereby dump any residue inertia.This can for example prevent that instrument 10 from damaging or prevent that gear from destroying or division.
The no-voltage action
Fig. 7 is the flow chart that illustrates according to the no-voltage operation program of exemplary embodiment.As mentioned above, the no-voltage operation program can be set to functional part of control module 100, so that prevent accompanying electric device for example electric tool open in following state: the electric power cable 21 that (a) inserts electric tool 10, mains switch is in " ON " position, and cable is extracted from the AC outlet; Perhaps (b) mains switch is at " ON ", and electric tool 10 inserts and give electricity, and electric tool 10 reaches the overload event that causes shutting down (although still inserting), and overload event is clear, and mains switch is in " ON " position.No-voltage action protection program can prevent the electronic valve TRIAC 420 superincumbent situations (a) or one of (b) trigger down for example in the control module 100.
In an example, can a series of voltage inspections be set at 90 ° of phase positions of the AC in each line cycle waveform, so that the voltage of TRIAC 420 has just been passed through in inquiry after control module 100 receives electric energy.If motor control switch 402 closures when applying electric energy, microcontroller 430 will detect the appearance by the voltage of TRIAC 420 so.If motor control switch 402 disconnects when applying electric energy, microcontroller 430 will can not detect any voltage by TRIAC 420 so.If in these are checked, show that AC voltage is arranged, TRIAC 420 can not trigger up to showing that the line given does not have voltage in the cycle so, just, the user forwarded the mains switch wheel to " OFF " before restarting electric tool 10.Need a plurality of continuous inspections with in the elimination system because any random noise due to can causing that short time voltage passes through that the electric spark of TRIAC 420, surge, electricity suppress etc.
In the example of superincumbent Fig. 5, the microprocessor 432 of microcontroller 430 compares current feedback and threshold value (520) for EOC.If EOC disposes absolute threshold and the feedback current value surpasses threshold value, two actions can take place so.No-voltage protection in system is not actuated and (forbid/is not actuated; 560 are output as " NO ") situation under; interruption (580) in algorithm (under the control of microprocessor 432) the forbidding Infinite Cyclic triggers to prevent TRIAC 420, and stays in this ring to turn off electric tool 10 effectively.Like this, all power supplys to instrument motor 15 all stop.
If the no-voltage operation program is enabled in control module 100 (570 are output as " YES "), microprocessor 432, in the iteration of the function of no-voltage operation program 700, inquiry motor control switch 402 is that disconnect or closed.In this example, the no-voltage method of operating is disable interrupts not, but the triggering of TRIAC 420 is based on the no-voltage method forbidding (560) of Fig. 7.
In the example of Fig. 6, microprocessor 432 measure along with the electric current of time and in the past and current cycle store electricity flow valuve in RAM434.In an example, by the algorithm computation DI/DT value of microprocessor 432 iteration as variation (DI/DT=I divided by the transient current of cycle time
2-I
1/ Δ T).This DI/DT value or difference, it can be described as variable Y, can with threshold ratio.If Y surpasses threshold value (625 are output as " YES "), so identical protection sequence of movement (630,635,640/700) can be started by microprocessor 432, as the absolute threshold situation of Fig. 5; Otherwise, Y can with the coefficient of threshold value for example threshold value compare (650) divided by 2.
If divided by 2, counter rises to 3 or 4 times (655,665) to confirm not having pseudo-incident to take place to Y so greater than threshold value.On the other hand, if Y less than threshold value divided by 2, counter is eliminated (660) so.If counter reaches 3 or 4, counter is set and identical protection (630,635,640/700) is performed so, as top absolute threshold situation.For example, if counter equals 3, these data that show 4 continuous lines cycles have surpassed the threshold value of threshold value divided by 2 reduction.
Referring now to Fig. 7, situation recited above (a) or one of (b) trigger and start (705), wherein whether algorithm detects (710) AC voltage waveform negative zero passage (just voltage half cycle passes through zero and arrives negative half-cycle).This is the synchronizing step of algorithm when it waits for zero passage, and will circulate and be detected up to negative zero passage.In case detect positive zero passage, the microprocessor 432 of microcontroller 430 can begin to check the position (715) of switch 402.Should only when specific half-wave shape can only be detected voltage, be only necessary with the synchronous of positive half period at microcontroller 430.But by using other voltage monitoring circuit 425, sampling is possible during negative half-cycle.
In case two zero passages all detect (715 are output as " YES "), the value of checkpoint is set to phase point 1 (720).Phase point 1 can be 130 ° of angle of flow places at TRIAC 420, perhaps based on preset time (100 milliseconds).Function 725 is that a cyclic program reaches up to definite checkpoint, detects the voltage (730) by TRIAC 420 at that time.In this example, use sampled voltage, will be understood that by motor control switch 402, this only be one can be detected exemplary parameter; Electric current by motor control switch 402 can be sampling parameter rather than voltage.If detect some positive voltages, suppose that so switch 402 is closed 730.Program turns back to 710 and repeat then, thereby does not allow TRIAC 420 conductings, otherwise does not have voltage to be detected by TRIAC 420.
Under this situation (730 are output as " NO "), algorithm judges whether the voltage waveform in N the continuous lines cycle (N 〉=2) of given quantity after testing.In the specific examples of Fig. 7, algorithm judges whether the AC voltage waveform (735) in three continuous lines cycles after testing.If YES determines whether the voltage by TRIAC is high (740), and in that event, algorithm inserts 745 and postpones to wait for switch 402 (it also can be called trigger or ON/OFF switch) closure.If the voltage by TRIAC 420 still is high (750 are output as " YES ") after the stand-by period, switch 402 closures and no-voltage operation program 700 terminate in 780 so; Electric tool 10 can open so that normal running.Like this, function 740,745 and 750 distinguishes that electric tool 10 is turned off owing to some overload condition but switch 402 remains the situation of ON.
On the other hand, if do not detect three continuous lines cycles of AC voltage waveform, algorithm judges that whether all (755) detection electricity all after testing.This program can have every a plurality of checkpoints of line cycle.The checkpoint of test is many more, and the random noise in the system suppresses manyly more.For example, if three independent checkpoints are arranged at the angles of flow of 130,70 and 30 degree, and these three points to have continued three continuous lines cycles detected, program guarantees that effectively switch 402 differentiates point along the AC sine wave continuously at 9 and open really so.Differentiate point if only detect one, noise can influence system unfriendly.
Like this, if 755 be output as YES, the algorithm echo check is in the 710 negative zero passages of checking the next line cycles so.Tested if not all checkpoints, determine checkpoint 2 whether after testing (760) so, and or stowage survey point 2 (770), or stowage survey point 3 (765), it is based in 760 judgement.This and after, 755, AC cycle rate counter (temp2) increases progressively, and process turns back to 725 checkpoint.This AC cycle rate counter (temp2) is how microcontroller 430 knows three all consecutive periods after tested.If voltage occurs in any checkpoint by TRIAC 420, microcontroller 430 supposition switches are closed and restart whole procedure 705 so.
Above example to have described the parameter that is detected be that the voltage by TRIAC 420 is to disconnect or closed situation so that determine switch 402.But, can not check voltage in the whole AC cycle, and detect electric current (just, on average, RMS, peak current etc.).The TRIAC 420 if definite electric current is flowed through can suppose that then switch 402 is closed.Otherwise, not detecting electric current, switch 402 disconnects.Moreover, in aforesaid testing process, can carry out repeated detection by a plurality of AC cycle to increase noise suppressed.
The algorithm that needs repairing
In another example, but the algorithm that microprocessor 432 iteration need repairing whether need repairing so that show electric tool 10.The example that needs repairing can be the brush in the replacing instrument motor 15, perhaps applies the gear of grease in the gear box 16 again.Electric tool can use the general-purpose machine with commutator brush.For example, the commutator ring 24 of Figure 1A can have commutator brush thereon.These brushes typically need be changed before the end-of-life of instrument.Determine when that the replacing brush can be based on the threshold value coefficient, its some combinations of measuring, apply electric moter voltage, speed, switch circulation or these parameters by Time Calculation, current of electric are set.Give the user the sign that needs repairing can by the optical indicator on the tool housing 18 for example LED carry out.Perhaps, for example, can need repairing by the tactile feedback warning user with some specific vibration modes, perhaps instrument can be set to shut down and finish up to maintenance.
In an example, during the startup of microprocessor 432, how long microprocessor 432 computational tools 10 have moved and with itself and threshold value coefficient ratio.In this example, the threshold value coefficient can for example be set based on the time in 100 hours.If instrument running time surpasses 100 hours, so the optical indicator on the tool housing 18 for example the LED (not shown) can light with the warning user and need repairing.For example, LED can remain on " ON " up to resetting in the maintenance center or by the user.
In this example, the maintenance that needs is a brush changing.After brush changing carries out, can use a kind of of method that several indicating devices reset.For example, for the reset threshold coefficient, maintenance center representative or user can physically remove brush and the instrument of giving 10 is given.Owing to do not have brush in the instrument, so detect less than electric current, microprocessor 432 detects the reading of low current (low current of comparing with threshold value just) and supposition " not having electric current " like this.Do not have electric current to be detected if continue at least one second, then microprocessor 432 can be carried out replacement process.In an example, replacement process can comprise threshold value coefficient (100 hours) be multiply by some coefficients (for example 2) and/or prolong that one is fixed or variable replacement during.Owing to be set the new running time that needs repairing, so LED is gone electricity and brush to be replaced back in the instrument motor 15.
In another example, can use outside the replacement.Brush is replaced the outside replacement module that instrument then is inserted into energising.Then, applying electric energy is actuated to instrument and tool switch.Replacement limit module current of electric hangs down and can not rotate to being enough to motor to low-down value.This needs reset indication and reset indicator for maintenance microcontroller 430 identifications.Outside replacement module can be used in the maintenance center or be bought by tool user.
In another example, code can be imported by tool user.Behind brush changing, instrument is given.The combination of this switch periods that code input can be the speed disc setting, varying speed switch is set, a period of time is interior etc.In other words, this code can be the operation of user's input of instrument control or the order or the opportunity of action.For example, bore to reset and to actuate the mains switch ON/OFF 5 times in needing among the user 10 seconds, wait for 10 seconds, actuate mains switch ON/OFF 5 times in then in 10 seconds once more to finish replacement.
Tactile feedback
Fig. 8 and Fig. 9 illustrate to AC cable electric tool user tactile feedback as the chart of the alarm mechanism of imminent or current erroneous condition there.Before turning off electric tool 10 owing to some erroneous condition, when perhaps relative with shutdown, expectation can provide the operator of the warning of some types to electric tool 10.Be similar to the situation when in possessory automobile, making a mistake situation or in generating process, can damage (just spark plug is owing to oil starvation damages) and on panel board, give the warning light that the owner continues a preset time before owing to erroneous condition at engine.
In a single day in an example, detected under-voltage or overheated situation can be used as the mechanism of cut-out, just reaches threshold value, control module 100 stops output current.But, before for example under-voltage or overheated threshold value of erroneous condition triggering reaches, but its close imminent operating limit that can turn off electric tool 10 automatically of the alarm mechanism alert operator in the electric tool 10.Alarm mechanism can be (the having loudspeaker or buzzer) that for example can hear or use expectation illumination scheme LED and be visible for example.
The common U.S. Patent No. 6,479,958 that transfers people such as Thompson is described the method for the breakthrough Torque Control that is used for electric tool.In the example in the patent of ' 958, electric tool control can show that the given parameter of electric machine of the beginning of for example stall situation of some erroneous condition is provided with by detection.In the response to imminent stall situation, when the mains switch of instrument kept connecting, motor was with the number of times of the frequency pulsation some relevant harmoniously with the natural reonant frequency of motor.Finish this so that transmit a series of moment pulse that has greater than the peak torque of the average moment of being transmitted in the series.This is known as " breakthrough moment ", and allows the user of electric tool to finish given work so that motor does not burn out or stall fully.
But in another configuration that here will describe, motor 15 can be broken through moment and be pulsed and do not finish the work by using, but user instrument 10 that can be by warning instrument 10 just near or in imminent mistake (just, shutdown or stall situation).In an example, pulsation can be given electric tool and customizes.Pulsation is as the touch feeling or the aposematic mechanism of the physics of giving the user.
Like this, when control module 100 was the time-based system of phase control, any logic can trigger the output pulse as alarm mechanism.For example, for example given speed, moment, temperature, electric current or electric current along with the parameter of the variation of time be can by microprocessor 432 measure and with some threshold ratios so that start the parameter of tactile feedback, instrument motor 15 is pulsed when meeting or exceeding given threshold value thus.
Fig. 8 illustrates the result of tactile feedback, and wherein, it is complete " OFF " that TRIAC 420 falls from complete " ON ".With reference to Fig. 8, regional A illustrates TRIAC 420 and triggers down in conducting fully (just, microprocessor keeps the angle of flow to spend so that conducting fully 180).Impulse duration B comprises that a series of TRIAC 420 " ON/OFF " triggers.TRIAC 420 is " ON " a period of time C, at " OFF " a period of time D.B during time C+D represents one.B repeats one group number of times E then during this time.Correspondingly, provide Fig. 8 to have the tactile feedback of " ON/OFF " pulse fully to illustrate.
In another example, tactile feedback can be finished by the angle of flow that changes.With reference to Fig. 9, pulse diagram illustrates the result of tactile feedback, and wherein TRIAC 420 can drop to the lower angle of flow from the higher angle of flow or rise to the higher angle of flow from the low angle of flow, rather than complete " ON/OFF ".In case the microprocessor 432 of microcontroller 430 detects that, then control module 100 should be exported in pulse modulation, microprocessor 432 can or reduce the angle of flow, the less angle of flow of ordering at B point or C from being conducting to fully of ordering at A, perhaps can increase the angle of flow, from low spot for example C increase the angle of flow to an A (opening fully).This execution can utilize coefficient same as shown in Figure 8 in " ON/OFF " haptic feedback process fully.Correspondingly, for example the parameter of duty cycle (the parameter D among Fig. 8 with C ratio), burst length (the parameter E among Fig. 8), non-pulse time (parameter A of Fig. 8) etc. can be as required according to given electric tool or application change.
In an example, the phase control attribute that imminent erroneous condition can be utilized control module 100 in the warning user control module 100 is being that tactile feedback (A of Fig. 8, B, C, D, E) is provided with soft coding parameter to produce " trembling " effect in motor 20 speed in ROM.The little circulation change of this motor speed can be selected so that can influence tool performance but provide the user for be about to taking place or the sense of hearing and the tactile feedback of current erroneous condition sharply.
Turn back
Usually, the control circuit 400 in the control module 100 can dispose with the maximum power fan-out capability of minimizing instrument 10 so that produce " turning back " situation.The operator both can recognize and can feel also that this situation was " dying down " of the performance of electric tool 10.The operator can be prompted to retreat and avoid imminent erroneous condition (just, under-voltage, overheated, overcurrent, etc.).
For example, turn back and to surpass given set point or threshold value and carry out based on motor temperature.When reaching erroneous condition (temperature upper limit, set point or threshold value), microcontroller 430 sends control signal via controlling incoming line 418 to reduce the angle of flow that TRIAC 420 triggers pro rata with the temperature increase.When temperature raise above threshold value or set point, this less angle of flow was held the electric moter voltage that is applied to instrument motor 15 with reduction.
In this specific examples, turning back is intended to protect motor 15 and notifies the user when instrument 10 is too warm.If temperature continue to increase, electric moter voltage continue to reduce up to otherwise electric moter voltage becomes 0 or reach minimum voltage and voltage and no longer raise along with temperature and reduce.By the electric moter voltage of turning back, temperature is lower than threshold value or set point with beginning to be reduced to, and electric moter voltage can increase once more under threshold value or set point.The function of turning back can be kept being reduced under the set point up to temperature, and perhaps temperature no longer reduces, and has perhaps reached low instrument speed setting.
Turn back and to use as protection action by microcontroller 430 for the input of offence except that temperature.Can use and turn back to reduce moment or assisted user (for example, instrument rotates about cutter or annex) out of control.
Fig. 9 is the chart that the example of turning back of the electric moter voltage in the cable AC electric tool is shown.At first, when being lower than some coefficient threshold value, TRIAC 420 complete conductings trigger (A point) when the given measurement parameter (voltage, electric current, temperature, moment etc.) of system.Along with parameter is increased on this threshold value, the angle of flow begin to descend (from the A point to the B point).If the parameter of measuring continues further to be increased on the threshold value, the angle of flow will continue reduction (from the B point to the C point) so.This process will continue up to reaching arbitrary (for example being 30 degree) that some set the minimum angle of flow.This minimum angle of flow remains unchanged and reduces up to measured parameter.Perhaps, module 100 is configurable with closing tool 10 after reaching this to set the minimum angle of flow.If TRIAC 420 begins to reduce in triggering of C point and measurement parameter, the angle of flow will be got back to the B point from the increase of C point so.Along with measurement parameter continues to be reduced under the threshold value, the angle of flow will continue to turn back to the complete conducting that A is ordered from the increase of B point.
Torque Control
Motor temperature is estimated
Figure 10 A is the skeleton diagram of motor temperature algorithm for estimating.This example uses average current as input, but other for example measures the temperature of RMS electric current, peak current, transistor or thermocouple or the input that speed can be used as the motor temperature assessment function.
Algorithm is to multiply by the principle that resistance is directly proportional with the RMS current squaring based on the temperature of motor.Suppose that resistance is constant in the instrument motor 15, estimate that temperature can be by accurate measurement along with the electric current of time is finished.At first, n current sample carries out a period of time determining average current by microprocessor 432 with specific interval or incremental time M (n and M can change according to each instrument 10), this electric current 1002 by square.The square value of this electric current can be represented by numeric parameter A.Squared current term A be illustrated in preset time section P to finish to following motor temperature will be which type of estimates (P is more much bigger than increment M in the there), suppose that electric current keeps constant.
Term A will compare with temperature register value B (input being shown 1004).B is illustrated in the undulating value of motor temperature in the real-time estimation of current point, and it upgrades with each increment M ground.For example, temperature register value B=0 shows that motor temperature is in ambient temperature (room temperature just), and temperature register value B=1300 can represent the motor temperature C of 130 degree.Each parameter A and B are integer values.
1006, the difference between A and the B is illustrated in current time and estimates to have much difference between the estimated value of over and done with rear motor 15 temperature of temperature and time period P.1008, this difference C (integer value, it can be called pre-ratio and regulate C) is divided by scalar E (also being integer value).Scalar E can be regarded as and changes the variable scalar adjusting of temperature register to the response speed of electric current variation, and can think the time constant of motor 15.Because each motor has different time constant E, this value can change along with instrument.The result of C/E represents the adjustment value F of motor 15.This adjustment value F represents the degree that temperature increases or reduces in incremental time M.
1010, F (signed values) joins temperature register value B or then from wherein deducting to produce new temperature register value H to use next iteration 1012.If electric current remains unchanged, along with the time advances P, the value of H is corresponding or equal the value of A so that new estimation motor temperature near or equal in fact what estimation motor temperature will be when time durations P finishes.
Like this, by the current measurement of A reflection (just, based on the constant of the average current in that time increment square, what estimation motor temperature will be when time durations P finishes) and temperature register value B between difference big more, the increase of temperature register value B or reduce must be big more after calculating.If integer value A and B equate that this expression motor temperature does not change so.Like this, temperature register value B always expects to equal electric current square (A just) in time, and will be as required along with time increase/minimizing to keep this relation.Any point in the time checks that it is at that given time that temperature register value B will provide motor temperature for what ratio estimate.
As an example, if average current is along with interval M is increased to 20 amperes (they increase parameter A, because it is the function of current squaring) from 5 amperes, temperature register value B will increase very soon, and the expression motor temperature sharply increases, because electric current significantly increases.If average current drops to 10 amperes (A declines) from 20 amperes then, B will reduce along with the time-temperature register value, mean the reduction of motor temperature.
Following equation illustrates the calculating of parameter A, B, C, D, E and the H of Figure 10 A.In perfection or ideal system, current squaring multiply by resistance and provides temperature.But in real system, other factors for example fan speed, motor speed and electric current is the output of how to measure the system that will influence.In the equation below, parameter A term FinalAverage
nExpression; And the expression motor estimation temperature that will arrive along with the time (just, in this example at section P preset time).Register value B is by term TempReg
[n-1]Expression, and along with refreshing of determining of a large amount of current measurements of time interval M or new temperature register value is expressed as TempReg
n
In order to regulate these system parameterss, estimate that the equation of motor temperature can be revised a little.For example, in calculating parameter A (average current square function), voltage compensation item or the multiplier that is called Vfactor are added into to be fit to 230V instrument and 120V instrument.Because the average current that the 230V instrument stands is the 120V instrument stand roughly half, so system needs the multiplier factor with proper operation.Multiplier Vfactor can be set to " 1 " for the 120V instrument, be set to " 2 " for the 230V instrument.
There is a levels of current threshold value relevant (being referred to herein as " intermediate point threshold value ") with fan speed.In certain current level, the heat of removing by the fan in the electric tool 10 from system reduces along with fan speed reduces.Add a factor to compensate this because the loss that the heat due to the fan speed that reduces is removed.Calculated value (the FinalAverage of A
n) depend on average current be on the intermediate point threshold value or under and different.The factor (the Iavg below if average current on the intermediate point threshold value, adds
n-Midpt)
2, its only be calculate average current square deduct threshold current value Midpt.This factor will cause at the electric current of the current ratio on the intermediate point under intermediate point and cause higher estimation temperature.The amount that temperature increases is directly proportional with the amount that the electric current on intermediate point increases.
Moreover, can add a variable with the compensate for slower low motor speeds.This can be reflected by expression formula (MaxDial-DialSetpoint) * SpdFactor.Parameter MaxDial is the A/D reading that is read by microprocessor 432, and its correspondence is set in the maximum on the speed change dial 270, and parameter DialSetpont is the A/D reading that correspondence is set in the actual speed on the speed change dial 270.If these equate that then this velocity compensation variable is 0.Parameter S pdFactor is the constant coefficient that changes along with instrument, and affords redress when the dial plate setting is speed of being set in rather than maximum the setting.
When taking average current to measure, top motor speed compensation is essential, because the angle of flow of TRIAC 420 influences the precision that average current is measured.In lower conducting (than low velocity), average current is measured not as accurate at the full angle of flow (at full speed), must be compensated so measure.This flow process depends on any measurement scheme of use and changes.When using average current, all compensating factors all are used.If use the RMS electric current, then do not need so much compensating factor.If use transistor or thermocouple, then without any need for compensating factor.
Correspondingly, the value of A-FinalAverage, it carries out n primary current with specific interval at time period M by microcontroller 430 measures and to calculate to obtain final average current, can be calculated by one of two following mathematical equation, depend on average current be on the intermediate point threshold value or under.Equation (1) is the situation of average current under threshold level, and equation (2) is that average current is equal to or higher than the fan necessary quilt compensation of loss (Iavgn-Midpt)
2The situation of levels of current.
Correspondingly, the calculating of the H among Figure 10 A is reflected in following equation (3) and (4).The value of H is a temperature register value new or that rewrite, and the renewal of reflection motor temperature is estimated.In fact B parameter, C, E and F shown in equation (3) and (4) reflection Figure 10 A illustrate H=B+F, wherein F=C/E and C=A-B.Like this, the term in equation (3) and (4) is as follows.H＝B+(A-B)/E。Equation (3) merges the FinalAverage as a result from equation (1)
n, wherein average current is under the intermediate point threshold value, and equation (4) merges equation (2) to calculate FinalAverage (wherein average current is equal to or higher than the intermediate point threshold value):
Molecule in the second portion of each equation (3) and (4) is the parameters C of Figure 10 A, its expression (A-B) or the difference degree between our estimation temperature of current time and motor will reach after the time P temperature.Scalar E, it is a denominator term in each second portion of equation (3) and (4), it is the constant coefficient that is called Divisor in equation (3), its with equation (4) in to compare be different, equation (4) has in order to the denominator term of calculating the measurement average current that surpasses the intermediate point threshold value (in order to the loss of compensation fan), and divided by the scalar factor that is called HighCurDivisor.These scalars Divisor and HighCurDivisor are penalty coefficients, its be provided with change for the used time of the new estimation of temperature H to be determined so that it reaches A.Two different divisors are used, because at higher electric current, the heat/cool rates of motor 15 is owing to the loss of fan speed changes.Like this, at reduced-current, the Divisor scalar is used to equation (3), and for high current, the HighCurDivisor scalar is used to equation (4).
Like this, scalar E is that variable scalar is regulated, and it changes temperature and deposits the speed that response current changes.This can change along with instrument.In this example, the shape of cooling curve will surpass intermediate point and change along with electric current.The adjustment value F of the result of C/E (second of equation (3) and (4) whole merchant's part just) expression motor 15.In other words, the result of C/E represents the degree that temperature increases or reduces in incremental time M.
Figure 10 B illustrates how to determine the estimation temperature of motor when the starting flow chart of the initial value B in temperature register just.In case the memory of before having learnt is just lost in instrument 10 power down, microcontroller 430, unless information is based on regular preservation.Therefore, what method definite motor 15 should be arranged is in the temperature when instrument 10 powers on for the first time.Should not determine that the motor 15 that has moved some times under heavy load can be closed and open fast once more, and microcontroller 430 gets back to zero with the replacement temperature register, show room temperature instrument 10.If this generation, instrument 10 will may burn very much.
Potential possibility in order to prevent that instrument from burning provides the programs in 1014 beginnings.When the electro-hot regulator (just, transducer 410) that each microcontroller 430 upgrades temperature register value B or microcontroller 430 temperature was measured, these values were stored in the nonvolatile memory (RAM434).During startup, transducer 410 values of the nearest temperature register value of storage and microcontroller 430 temperature (1014) situation that is retrieved before just in the end instrument is turned off with the state of the motor 15 before that obtains just in the end cutting off the power supply.Time delay is added into (1016) to obtain to estimate the measurement of motor temperature and controller temperature when instrument powers on.When predefined delay back starts (1016), temperature sensor on the plate of microcontroller 430 (410) is read to estimate the controller temperature relevant with motor temperature, just, if microcontroller 430 temperature are high in fact, can suppose that so motor 15 temperature also are high, as long as the temperature-time constant of microcontroller 430 is high a lot of unlike the thermal constant of motor 15.
After this postponed, microprocessor 432 was measured this controller temperature, without transducer 410, and determine a kind of of 4 kinds of states: (1) microcontroller 430 is in room temperature, (2) microcontroller 430 does not change temperature, and (3) microcontroller 430 is warm and (4) microcontroller 430 is hot.These states are by relatively Current Temperatures data and last data of preserving are determined.
If (1018 output is NO in not change to determine to power on temperature since the last time, module 100 is not that first is given), and transducer 410 values are greater than room temperature (1022 are output as NO), but formerly in the qualification edge of temperature, just near start-up temperature (less than the difference 12%, 1026 are output as YES), (TempReg in equation (3) or (4) just of the old value B in the temperature register
[n-1]) be resumed (1024) to show not change (1024,1026) of motor temperature.If determine that from transducer 410 microcontroller 430 temperature are less than room temperature when module 100 is given electricity for the first time, the value of the B in the temperature register is reset and is got back to zero (1022) so, shows room temperature or ambient temperature (1020), just cold electronic electric tool 10.
If (1030 outputs are hot) of microcontroller 430 is defined as warm (1030 outputs are NO) or heat, the new value of temperature register value B in step 1028 or 1032 from nonvolatile memory preloaded the EEPROM (ROM436) for example.In an example, warm microcontroller 430 can be 80 ℃, and the microcontroller 430 of heat (the therefore instrument 10 of heat) can be 150 ℃.The B value that has identical B value or rewrite in temperature register, the motor temperature assessment function is finished about Figure 10 A as described above.
Perhaps, determine when powering on instrument be cold, warm or heat be the TRIAC 420 in measurement module 100 or the instrument 10 or the gate voltage of other electric device so that determine the other method of initial temperature register value B.The temperature of active device can be determined by its junction voltage.These devices can comprise that TRIAC, transistor, diode or other comprise the silicon device of the PN or the NP utmost point.Therefore, electronic module 100 or microcontroller 430 temperature can be estimated, and do not used for example thermocouple of extra transducer 410.The knot of the door driving transistors of TRIAC 420 can be used for determining temperature rather than uses electro-hot regulator 410.This can be by following explained.
The temperature and the voltage relationship of knot can be limited by equation as follows (5)
V
r(T
1)-V
r(T
0)=k
T(T
1-T
0) equation (5)
Wherein:
T
0＝25℃
T
1=junction temperature (℃)
V
r(T
0)=at 25 ℃ of junction voltages
V
r(T
1)=at T
1Junction voltage
k
TThe temperature coefficient of=knot
For top example values be:
T
0＝25℃
T
1＝？(℃)
V
r(T
0)＝0.7V
V
r(T
1)＝0.65V
k
T＝-2.0mV/℃
Conversion equation (5) is to find the solution T
1Unit temp obtains:
Actual value can be depending on the circuit 400 interior used devices of module 100 and changes.Correspondingly, determine that in power up instrument as the input of temperature algorithm for estimating is that potential benefit cold, warm or heat is to detect the parts that existed for example at the transistorized voltage of door driving place of TRIAC 420, so that estimate or determine module 100 temperature/controller 430 temperature when starting.Correspondingly, module 100 or microcontroller 430 temperature can be estimated, and be need not to use for example electro-hot regulator of extra transducer 410.
Compare on motor 15 with direct placement electro-hot regulator or thermocouple, the motor temperature estimation routine in the employing module 100 can reduce cost and provide the easiness of use.Described method does not need extra transducer or cable and finishes, because all signal and peripheral equipments of needing are directly to be structured in the module 100.Place thermocouple, electro-hot regulator or on motor 15 or the task of cable on every side and be not easy to finish, and have cable fusing or short circuit risk together.Top algorithm provides cheap, effective and easy method to estimate motor temperature, and does not need physically near motor 15.
In addition,, for example turn back etc. so that trigger the protection mechanism of type of alarm by the input that can be used as microcontroller 430 as the determined estimation motor temperature of the described motor temperature algorithm for estimating of Figure 10 A by tactile feedback, motor.When motor temperature begins tightly near the motor overload situation, for example during the high-temperature set point, the user can avoid reaching overload (owing to reaching overheating limit), because the control of microcontroller 430 by TRIAC 420 angles of flow starts tactile feedback or turns back, perhaps start and turn back with (just as warning, the instrument motor is just near overheating limit) the combination illuminated of LED, or start tactile feedback and combining of illuminating as the LED on the tool housing 18 of warning.Therefore, the motor temperature algorithm can be used to estimate in real time that at difference motor temperature is to avoid or to detect imminent motor overload situation as possible.
Figure 11 is the algorithm computation of Figure 10 A of the estimation motor temperature obtained by to(for) the grinding machine comparison of the small-sized angle of the 120V that disposes exemplary control module 100 and the chart of actual measurement motor stator temperature.The data assessment motor temperature algorithm of describing is estimated and the real electrical machinery temperature.As can be seen from Figure 11, produce the increase or the minimizing of the experimental test motor load of rendering results, and opening/closing instrument motor is to experience all aspects of motor temperature algorithm as possible.Algorithm causes simulating the actual measurement motor temperature in fact, and the worst situation is that the difference in any data point is about 13 degree.
Figure 12 is in the control module 100 between coefficient input, control and the guard method and/or concentrate user's input of the function in the middle column be expressed as Figure 12 and from the skeleton diagram of the relation of the coefficient output of the row on the right of these functions.In the row, output factor ALC refers to that above-mentioned breakthrough moment is finished given work with the user who allows electric tool so that motor is not burnt or complete stall on the right.
Figure 12 be in order to demonstrate single overall control module 100 can be how for example EEPROM or flash memory are programmed to meet the demand of multiple different instruments again by nonvolatile memory.
Protection or the controlled function discussed at present, for example motor temperature algorithm for estimating, overload control (absolute and Di/Dt clutch mode), tactile feedback etc. can enable or forbid by this permanent mnemonic.In addition, the coefficient input and output can enable control or guard method for each and whether be stored in nonvolatile memory for example in EEPROM or the flash memory and change based on specific soft programming coefficient.
Figure 12 on the left side illustrates exemplary coefficient input, and it can be input to some function.As shown, these functions can comprise EOC function, aforesaid torque limit function, motor overload function (it can comprise the motor temperature algorithm for estimating among Figure 10 A-B).Function also can comprise can with change that firmware relatively all is configured to simulate by changing these soft code coefficients in the nonvolatile memory, digital, active height or active low input.
For different functions different input and output can be set, and different functions can be enabled in control module 100 or forbid.For example, can in given cable electric tool absolute clutch mode be set for EOC, it uses electric current as input, if threshold value is exceeded, turns off instrument with the output of function.Different instruments can have the Di/Dt clutch mode, if by operating speed as the input of function and exceed threshold value and open LED and be provided with as the output of function.Like this, two independent instruments that have same general control module 100 in inside can be configured to has different functions, and its sampling different parameters is also exported Different Results (just, moving based on the difference protection of different output factors).
Soft code coefficient in the nonvolatile memory (be configured to EEPROM then be EEPROM if it can be RAM434, flash memory or variable ROM436) provides and changes module 100 and how interact with instrument 10 and need not to change the firmware of microcontroller 430 inside or the ability of basic code.By only changing the nonvolatile memory of microcontroller 430, tool performance can be changed, and this is impossible before this.
Figure 14 is the calcspar that the electronic unit in control module 100 is provided with.One or more switches that are integrated with of the parts of Figure 14.Can be arranged as on the PCB140 of control circuit 1400 parts in control module at this and the described electronic unit in back.The control circuit 1400 of control module 100 comprises the memory 1434,1436 in order to the one or more soft encoding function coefficient that uses in the implementation that is stored in each controlled function or algorithm.Because it is specific that given soft encoding function coefficient can be used according to particular tool, so control module 100 can be suitable for controlling the operation of multiple motor and/or multiple different motor application (for example different electric tool).
Soft code coefficient can be understood as the coefficient input that is included in given function or algorithm being carried out by control module 100, and can comprise the function coefficient that can change or change for particular tool or tool applications.Soft code coefficient comprises that also the coefficient relevant with control of being adopted by control module 100 as the result who carries out given function in the control module 100 or algorithm and/or protection action export.Export and to change according to given application as required or to connect to the coefficient input of given function or from the coefficient of given function.
Control circuit 1400 comprises provides electric energy to programming to control some operation and/or to point to some function in the module 100 or protect the microcontroller 1430 that moves.Power supply 1405 can be supplied with for example VCC of 5V.Service voltage monitor 1415 monitors VCC and provides to detect and is input to microcontroller 1430.
The angle of flow is determined the point that TRIAC 1420 triggers in the AC waveform, both has been that positive half period also is negative half-cycle, thereby has transmitted electric energy to motor 15.For example, the corresponding situation of conducting fully of 180 ° the angle of flow of per half period, wherein TRIAC 1420 is triggered so that be applied to motor 15 from the whole interference-free alternating current of AC power supplies 1407, just, TRIAC 1420 is triggered so that for each positive and negative half period electric current of AC input signal TRIAC 1420 of flowing through.Similarly, the corresponding AC service voltages that pass through motor 15 that form the centres that start from the given half period of 90 ° of angles of flow, like this TRIAC 1420 be triggered so that the pact of utilisable energy half be delivered to motor.Angle of flow correspondence under 90 ° given later half cycle trigger TRIAC 1420 so that even the energy of smaller amounts be passed to motor 15.
In an example, TRIAC 1420 can be the TRIAC of single isolation, and the there isolation is the inside at parts.More specifically, armature 20 is to be controlled by the control circuit 1400 of control module 100 inside with the operation that comprises the motor stator 30 of motor 15.In order to control the operation of armature 20 and motor stator 30, the electron period control flows of microcontroller 1430 by TRIAC 1420 is through the electric current of armature 20 and motor stator 30 or be applied to armature 20 and the voltage of motor stator 30, perhaps the two.In an example, control circuit 1400 can based on can be stored in the question blank soft code coefficient or from control equation or control method based on measurement factor or parameter for example voltage, speed, electric current, moment, other external electrical input (1456a, 1458a etc.) or above any combination determine when and open and close TRIAC 1420.TRIAC 1420 is control switch devices of one type, and it can not be closed for " disconnection " or by control circuit 1400.But other for example installs that FET, IGBT etc. can close.Closing of TRIAC 1420 by 15 decisions of AC and motor, thus it causes electric current to be reduced to zero to allow TRIAC 1420 to close in each AC half period.This does not reduce and the control ability that is called the relevant TRIAC of method 1420 at this.
When motor control switch 1420 is when placing closure (just " connection ") position, the operation of control module 100 control motors 15, thus allow electric current to flow through.The function of control circuit 1400 be the position of monitoring motor control switch 1402 and when preventing that if power supply is applied to motor 15 motor control switch 1402 is in the position of closure (just " connection ") motor 15 start.
In an example, microcontroller 1430 can be ATMEL AVR
One of 8 digit RISC micro controllers, the ATmega8 sudden strain of a muscle microcontroller of programmable memory (EEPROM) is dodged in the programming certainly that for example has the 8K byte.In this and the described example in back, ROM1436 can be meant for example flash memory EEPROM or only be EEPROM436 of nonvolatile memory.
But the Based Intelligent Control of control module 100 is not limited to exemplary microcontroller 1430.For example, intelligence controlling device can be embodied as another microcontroller, analog circuit, digital signal processor or pass through for example application-specific IC (ASIC) of one or more digital IC in hardware and/or software.
Control circuit 1400 with instrument motor 15 (armature 20 and motor stator 30) is connected with the hot side of motor control switch 1402, TRIAC 1420 and power supply and the shunt resistance 1440 between neutrality (public) side.In Figure 14, a side of instrument motor 15 is connected to power supply, for example is connected to the hot side of AC power supplies 1407 by motor control switch 1402 via electric power cable 21 (Fig. 1).The opposite side of instrument motor 15 is connected to the neutral side 1408 of AC power supplies 1407 by TRIAC 1420, shunt resistance 1440 and electric power cable 21.
Shunt resistance 1440 can be embodied as the analog current transducer, and it detects by the electric current of TRIAC 1420 and motor 15 and the representative low voltage signal is provided, and it amplifies at amplifier 1445.Amplifier 1445 has first input of a side that is connected to shunt resistance 1440 and is connected to second input of the opposite side of shunt resistance 1440.In an example, amplifier 1445 can be biased (just, bias voltage can be applied to input to change amplifier output).The output of amplifier 1445 can be connected to the given port of microcontroller 1430.Shunt resistance 1440 only is an example of current sensor, and for example, the alternating current transducer comprises current transformer, digital sensor, hall effect sensor etc.
Control circuit 1400 also comprises by the voltage trimming circuit 1450 of diode 1455 and 1457 clamps and comprises the RC filter that is made of resistance 1451 and capacitor 1452.Resulting signal input 1460, it is the output of voltage trimming circuit 1450, is utilized with the desirable sinusoidal AC voltage signal on the real-time etection theory (supplying with from the AC of AC power supplies 1407) by microcontroller 1430 and passes zero axle and become negative voltage or become the point of positive voltage from negative voltage from positive voltage.This point is used for the timing and the synchronous purpose of microcontroller 1430 inside of control module 100.
If it is not damaged in clamping diode 1455 and 1457 protection microcontrollers, the 1430 AC source voltages due to voltage spikes to take place.In an example, all or part of voltage trimming circuit 1450 can be included in the control circuit 1400 or in the microcontroller 1430.In an example, clamping diode 1455 and 1457 is the inside at microcontroller 1430.
Control circuit 1400 can comprise one or more temperature sensors 1410, its in order to detected temperatures and import detected signal via port to microcontroller 1430.Only show a transducer 1410 in order to know.Temperature sensor 1410 can be embodied as for example NTC or PTC transistor, temperature detection IC or thermocouple.But the temperature of temperature sensor 1410 communication control modules 100 or specific features be the temperature of TRIAC 1420 or microcontroller 1430 for example.Because the function of this temperature sensor 1410 is known, so omit the detailed explanation of its feature operation so that succinct.A plurality of temperature sensors 1410 can be placed on the assigned address in the module 100 as required.
In addition, control circuit 1400 comprises two voltage monitors that are used to monitor TRIAC 1420, one is the gate voltage that is used to monitor TRIAC 1420 to determine that whether the gate voltage monitoring circuit (monitor 1425) of conducting and one are in order to monitor that TRIAC voltage is to determine the whether positive VAC half period monitoring circuit (monitor 1427) of conducting of during positive AC half period TRIAC 1420 at TRIAC during the negative AC half period of the AC waveform that is applied to TRIAC 1,420 1420.
TRIAC gate voltage monitor 1425 comprises in order to not only monitoring the positive AC half period but also to monitor the circuit of negative AC half period, but the software in the microcontroller 1430 is not because the measurement function of carrying out among the ADC1433 utilizes gate voltage monitor 1425 at positive half period.Correspondingly, two monitors 1425,1427 all are used, because microcontroller 1430 can not use gate voltage monitor 1425 during TRIAC 1420/ current of electric is measured, it is to utilize ADC1433 fully at positive half period.During the negative half-wave in AC cycle, monitor 1427 detects less than voltage, and its supplied with digital signal is to microcontroller 1430.In addition, two monitors 1425,1427 all are used to detect TRIAC 1420 whether conducting after triggering, and it will be discussed in further detail below.
Usually, the control circuit 1400 of Figure 14 is used to make control module 100 to provide control for instrument motor 15.Correspondingly, because the general structure and the electronic circuit of control module 100 are described, exemplary control method is discussed in further detail below.
The TRIAC conduction detection
In traditional simulation TRIAC AC Electric Machine Control, need trigger again TRIAC 1420 to guarantee if during the specific AC half period to the electric current of instrument motor temporarily to zero (because the error event (for example from the voltage disturbance in AC supplys of AC power supplies 1407) in the electric feed system, or owing in short-term engine commutator disturbance current) TRIAC 1420 get back to and open.If motor (for example motor 15) is the general-purpose machine that typically has commutator, the there current of electric can decay to zero rapidly in exchange process, if perhaps brush jumps out of commutator, this situation can frequently take place.
In order to determine traditional simulation AC electric machine control system that whether TRIAC 1420 has closed after triggering only monitor the TRIAC gate voltage with determine TRIAC be " opening " or " pass " (just, when voltage for just and on some threshold values the time " opening ", still for negative and under threshold value).But in traditional digital system, the there power supply is limited (as the situation of control circuit 1400), typically can not the whole AC cycle monitor the TRIAC gate voltage.For example, in positive AC half period process, need to measure TRIAC AC electric current, the result is used for determining that the gate voltage whether TRIAC has triggered again can not be by for example ADC1433 measurement of identical analog to digital converter (ADC).During the negative AC half period, the TRIAC gate voltage can monitor by identical ADC because electric current be bear and do not need measured (just, be assumed to identical) with positive half period.Therefore, may only carry out the TRIAC conduction detection in the half period at negative AC.
Correspondingly, in the exemplary embodiment, TRIAC conduction detection algorithm can be finished by the microprocessor 1432 of microcontroller 1430, and wherein the TRIAC conduction detection can be carried out in two half periods of AC waveform.Usually, method is checked the whether conducting after it triggers according to given control algolithm of each AC half period TRIAC 1420.The actual samples of two voltage monitoring circuits 1425 of algorithm comparison and the 1427 TRIAC voltage/gate voltages that carry out and expectation state are determined TRIAC 1420 ON/OFF with each half period of supplying with signal at AC.
TRIAC gate voltage monitor 1425 monitors negative AC half period and positive VAC1/2 cycle, and voltage monitor 1427 monitors the positive AC half period of TRIAC voltage.Usually, after showing the zero passage that the half period begins, and afterwards in given delay over and done with (delay is provided to wait for that known given control algolithm triggers TRIAC 1420 in the given AC half period), if determine that based on sample voltage value TRIAC 1420 does not have conducting after it triggers, then control module 100 attempts to trigger once more TRIAC 1420.This inspection can repeat for several times up to some minimum firing points with given interval, just, for example the angles of flow up to 30 degree be exceeded-the positive and negative half period of AC waveform the two.This point is represented back 30 degree of 180 degree half-sine waves in the cycle.
If not conducting of TRIAC 1420 when determining to reach minimum firing point, then TRIAC 1420 did not trigger or triggers once more for the remaining half period.Whether trigger up to minimum firing point TRIAC 1420 by checking, if TRIAC 1420 or owing to some erroneous condition lost efficacy or it does not trigger then TRIAC 1420 disconnects.
If observe the AC line cycle of continuous quantity, there TRIAC 1420 has been failed conducting, and switch 1420 is considered to disconnect so.The switch 1420 that this enable detection disconnects and do not need the ability of current measurement circuit.
Figure 15 detects the flow chart whether TRIAC 1420 need be triggered by given control method once more in order to illustrate in control module 100 after TRIAC 1420 initial trigger.The typical control method finished in control module 100 needs the given angle of flow, its for the positive and negative half period of AC waveform all set trigger angle for unanimity or balance.But some method can cause the positive and negative trigger angle to differ from one another and change each other, but its average equating that still provides in two polarity triggers.
With reference to Figure 15, in first half period, it is in the negative-positive zero passage variation of AC waveform and therefore when positive AC detected in the half period (1510) in this example, delay over and done with (1515) triggers TRIAC 1420 with the known given control algolithm in the wait microcontroller 1430 in the half period after, by using positive CAC1/2 periodic voltage monitor 1427, check that the voltage (1520) that passes through TRIAC 1420 is so that trigger.If monitor 1427 detects by the voltage of TRIAC 1420 (1530 are output as " YES "), this produces logic high signal in microcontroller 1430, its expression TRIAC 1420 is OFF, and microcontroller 1430 will attempt to trigger once more TRIAC 1420 to keep conducting (1540) by line 1418 by sending a triggering signal.If 1530 output is " NO ", this shows that TRIAC 1420 is ON and conducting (1545), thereby produces logic low in microcontroller 1430.
After triggering TRIAC 1420 once more, if determine that TRIAC 1420 is ON and conducting, repeat identical inspection 1520, just, if minimum firing point does not also reach (1550 are output as " NO "), 1427 with the interval repeated sampling of the fixing rule voltage by TRIAC 1420.In an example, monitor 1427 can be gone over up to minimum firing point by the voltage of TRIAC by per 9 degree ground repeated samplings after TRIAC 1420 has triggered.
As mentioned above, if minimum firing point reaches (1550 are output as " YES "), the state of TRIAC 1420 is not made variation, TRIAC 1420 remains on its current ON or OFF state (1555) detects next zero passage variation up to microprocessor 1432.Similarly, if TRIAC 1420 after minimum firing point has has met or exceeded still for OFF, then it remains the pass in the remaining half period and crosses null transformation up to next that detects the phase half period.Correspondingly, top execution can provide simple logic to be input to digital system (microcontroller 1430), it can be easily and determines " ON/OFF " state of TRIAC 1420 during the positive AC half period apace, and does not need to can be used for measuring the ADC1433 source of TRIAC 1420 electric currents.
During negative half-cycle, will be if TRIAC 1420 is an ON TRIAC gate voltage for negative, as a result, for ADC133 in the microcontroller 1430, aanalogvoltage is moved by level so that 0V (at Men Chu) becomes about 1.8V.This is that such ADC1433 can measure negative gate voltage.Therefore, TRIAC 1420ON provides the aanalogvoltage lower than threshold value, and the TRIAC OFF correspondence aanalogvoltage higher than threshold value, and it can be about 1.0V in an example.
Correspondingly, in case microcontroller 1430 detected second or next cross null transformation (among Figure 15 1560), its be in this example detect the AC waveform just-when bearing null transformation, and the setting at 1562 places postpones past tense, and TRIAC 1420 conduction detection are assessed in the half period at negative AC.Usually, the TRIAC gate voltage is by gate voltage monitor 1425 sampling (1565), and 1570 with some threshold ratios (for example nominal analog voltage) to determine that TRIAC 1420 is ON or OFF.In an example, if being OFF and measuring voltage, TRIAC 1420 (for example is higher than this threshold value, the nominal analog voltage, 1570 are output as " YES "), it will be triggered (1575) once more by microcontroller 1430, perhaps be defined as ON and conducting (1580), because provide the aanalogvoltage that is lower than threshold value at negative half-cycle TRIAC 1420ON.
As mentioned above, microcontroller 1430 will by check at regular intervals continue to attempt to guarantee TRIAC 1420 from its moment that is triggered up to reaching minimum firing point (1585 are output as " the YES ") state of remaining on out (1585 are output as " NO "), the triggering of TRIAC 1420 is no longer crucial for the remaining half period after this.TRIAC 1420 remains on its current state (1590), and repeats 1510 step during zero cross detection below.
Correspondingly, TRIAC 1420 " ON/OFF " is determined and can be finished by use gate voltage monitor 1425 and/or positive VAC1/2 periodic voltage monitor 1427 in two half periods of TRIAC.In case " ON/OFF " state of TRIAC is determined, logic-based or based on the magnitude of voltage (depending on the half period that is monitored) of TRIAC 1420, TRIAC 1420 or attempt to set up once more the conducting of TRIAC 1420 for the residual A C half period as required and trigger once more, otherwise for during the half period by ensuing inspection maintenance ON.Trigger once more typically to be restricted to the trial of determined number and in a single day to spend and (for example reach minimum firing point in the half period any given 180, very little voltage is applied to motor 15 to cause the point of any visible moment or rotation, for example the 30 degree angles of flow) just stop.
Another function of algorithm be guarantee in case from before the conducting of AC half period stop, TRIAC 1420 just triggers once more.The conduction interval of this extension is typical for the motor load that the there electric current can significantly lag behind voltage, as a result, the electric current from the exemplary negative AC half period will continue before to enter the positive AC half period for " pass " in TRIAC 1420 actual transition.
Therefore, the triggering of TRIAC 1420 will can not begin up to TRIAC 1420 from before the AC half period transfer OFF to.This pass close point can be by monitoring the TRIAC electric current, determining to set up when actual closing of TRIAC 1420 from the TRIAC gate voltage of monitor 1425 and/or from the TRIAC voltage of monitor 1427.
Zero passage detection
In an example, what the control circuit 1400 of control module 100 can dispose thinks that to finish the zero passage detection method TRIAC 1420 sets up reliable phase angle control (being also referred to as trigger angle control or angle of flow control).Zero passage detection make AC supply with (its be from AC power supplies 1407 to electric tool 10 and the input AC voltage signal of control module 100) and control module 100 can be synchronous so that supply with the noise suppressed that one or two the situation of supplying with external action in the signal input by AC instrument control self with from AC power supplies 1407 at AC provides aspiration level for normal AC.Like this, accurate zero passage detection makes can more accurately be the more accurately timing of expectation trigger angle control of TRIAC 1420, provide the method for noise suppressed to set up zero crossing simultaneously to supply with on the waveform (for example, independent AC generator) at AC with noise.
Figure 16 A is the calcspar that is depicted as the zero cross detection circuit part of the control circuit 1400 of finishing zero passage detection; Figure 16 B is the flow chart that the method for the zero passage that the AC of testing tool 10 supplies with is shown.Shown in Figure 16 A, low pass filter 1450 (seeing Figure 14) can be selectively with microcontroller 1430 in digital blanking circuit 1620 combine to finish zero passage detection.In an example, digital blanking circuit 1620 can be the algorithm based on software that is stored among the EEPROM1436 and is finished by microprocessor 1432.
But digital blanking circuit 1620 can detect zero passage, and need not supply with the filtering input via the AC of RC filter 1450.In this example, AC supplies with in microcontroller 1430 and is imported the (not shown) digitlization to produce digital signal by normal digital.Because having the numeral input, microcontroller knows, so omit its detailed description.Digital signal then in microcontroller 1430 based on handling in the digital blanking circuit 1620 of software.The functional noise zero passage that is called under the control of microprocessor 1432 and does not expect to eliminate of numeral blanking circuit 1620, it is below with reference to the more detailed description of Figure 16 B.
With reference to Figure 16 A and Figure 16 B, it illustrates the example of using selectable filtering, and the part of supplying with signal from the AC of AC power supplies 1407 illustrates signal by LPF1450 filtering to produce the filtering simulation.Analog output signal in microcontroller 1430 by the digital input digitization of microcontroller 1430 to produce digital signal.This digital signal is input to digital blanking (blanking) circuit 1620 based on software then, the noise zero passage that its function is not expected with elimination by microprocessor 1432 iteration.As previously mentioned, digital blanking circuit 1620 be stored in the memory can be by the algorithm based on software of microprocessor 1432 from EEPROM1436 visit.
Referring now to Figure 16 B, in order to finish zero passage detection, the numeral blanking function, under the control of microprocessor 1432, first zero passage that acceptance is represented by digital signal changes the detected effectively zero cross signal (1650) for given (or current) the AC half period into, ignores then or refuses for specific black-out intervals remaining zero passage (1655) in digital signal.For example, the frequency that can supply with based on AC of this black-out intervals and changing.All zero passages all are rejected up to this black-out intervals over and done with.In black-out intervals past back (just, supply with for 50Hz, after 10 milliseconds black-out intervals is over and done with) occur in zero passage that next relative polarity changes and be accepted (1660) then and be next the effective zero passage in that half period of AC service voltage waveform.
For each given AC half period, this process is repeated (1670) and is used to each AC half period so that only there is first AC to pass through zero point.This black-out intervals (just for 50Hz being 10 millisecond in the previous example) can be reduced allowing control module 100 in AC service voltage frequency range (40Hz-70Hz just) operation, the result, and the half period black-out intervals can reduce to about 6-8 millisecond.For example, the exemplary black-out intervals of supplying with for AC of given half period can be 6.125 milliseconds.
Use digital blanking, by or need not filtering, can make and can in low-cost system, detect zero passage that sane zero cross signal is provided simultaneously, and it supplies with for example portable generator for the very common AC voltage of noise is jamproof.Other purposes of low pass filter can be eliminated and occur in zero passage most of high-frequency noise on every side that AC supplies with signal.Use can be eliminated other " mistake " zero passage based on the digital blanking unit of software, and it can occur in whole AC and supply with the half period, is caused by for example portable generator in unusual source.
The current measurement bias correction
For example in the instrument 10, in control module 100, need accurate current measurement at the AC electric tool for the control purpose.Correspondingly, the voltage bias in the current measurement circuit should be calculated (current measurement just should be corrected) to guarantee the precise current measurement.In Figure 14, current measurement circuit comprises along separate routes 1440 being that the simulation low voltage value of representative electric current is so that measure with the actual measurement current transitions.Along separate routes 1440 can be low-resistance value (for example 5 milliohms), the result, from 1440 representative voltage (just 5 millivolts every ampere) along separate routes can be exaggerated with allow digitial controller for example microcontroller 1430 differentiate and measure electric current.This amplification is to be provided by amplifier 1445.
In instrument 10, big electric current to the peak value of 50A at least is with to be measured; But this provides the little low voltage signal by shunt 1440 only.In an example, the voltage signal that electric current is measured in representative can be about 0.25V.Typical digital system for example microcontroller 1430 has the analog to digital converter (ADC) of 2.5V, ADC1433 for example, and it will be differentiated and about 2.5 millivolts import (10 bit resolutions just) from 1440 voltage signal along separate routes.Therefore, in order to maximize the resolution of ADC1433,10 gain can be introduced by using the amplifier 1445 between shunt 1440 and the ADC1433.
For example, amplifier 1445 can be the full amplitude of oscillation amplifier of for example single power supply of operational amplifier (op-amp).Amplifier 1445, as all amplifiers, can be biased, for example, can have the bias voltage or the bias voltage that apply in its input.In an example, resistance component can be used to be adjusted in the actual shunting voltage of amplifier 1445 inputs, so that output is able to bias voltage.With compare from 1440 0.25V input signal along separate routes, this bias voltage can be significant.
Correspondingly, in order to compensate this bias voltage, no matter amplifier 1445 bias voltage by this way positive still negative, still allows real zero current value to be measured from the output of amplifier 1445 by ADC1433 under all biasing situations of amplifier 1445 so that op-amp biasing.For example, the input of amplifier 1445 by this way bias voltage so that along with the output of zero current input amplifier 1445 is set on the 0V or is " ground connection ", no matter whether amplifier setovers.
As the result of amplifier 1445 bias voltages, when real zero current situation exists, measure ADC value essential so that determine to be applied to the offset that zero current is setovered that is also referred to as that actual current measures.Offset or zero current biasing are the ADC values of measuring in the situation that does not have electric current-TRIAC 1420 not have to trigger.For example, finish in this functional test program in the manufacture process of control module 100.
In this test situation, zero current is that ADC value known existence and ADC133 output can be measured and be recorded among the EEPROM1436 offset as the voltage bias in the expression amplifier 1445.Usually, offset (just " biasing ADC value " or zero current bias voltage) is deducted from actual current ADC value with acquisition in controller and is measured for the real current of particular sample (by amplifier 1445 and 1440 amplifications along separate routes).More specifically, measure in order to determine real current, pass through the average current value of TRIAC 1420 in for example given half period, in case microcontroller 1430 detects by the positive zero passage of the trend of AC waveform,, and in microcontroller 1430, add together in the repeated acquisition the half period of positive voltage really from the ADC of shunt 1440/op-amp 1445 sampling.For each the continuous mutually ADC value from ADC1433 output, microcontroller 1430 deducts offset (zero current biasing) to obtain the real current measurement for that ADC value.Positive AC half period end (just, microcontroller 1430 detects the negative zero passage of trend of AC waveform), the value of summation is by average (divided by hits), and at this point, the result is proportional with the average A C electric current that flows through during the AC half period.By this way, be able to from real current ADC measures, remove from any amplifier biasing of amplifier 1445, and no matter actual amplifier 1445 biasing bias voltages whether.
The potential benefit of amplifier bias voltage is to measure negative current.ADC1433 is integrated in the microcontroller 1430 usually.It uses the Vcc identical with microprocessor 1432 in the microcontroller 1430 (typically ,+5Vdc, still may for+3.0Vdc or any other voltage).Therefore, have only Vss (ground potential or 0.0 volt) but and the voltage ADC1433 between the Vcc measure.
Typically, the voltage by shunt 1440 is exaggerated so that the maximum instantaneous electric current becomes Vcc (and Vcc is the analog references of ADC1433).This is to finish by the amplification coefficient of resonance-amplifier 1445.Typically, the voltage of Vcc is by 1433 digital values that change full scale into.For 10 ADC, full scale is the digital value of 1023 countings, and 0.0 volt of digital value that transformation value is a zero count.
In first example, 64 amperes peak value is represented full scale ADC output, zero ampere representative, zero ADC output, perhaps zero count.Then, keep identical amplification coefficient simultaneously by electrical bias being added to amplifier circuit, the value of magnification of offset null electric current becomes possibility to Vcc/2, causes 511 or 512ADC counting.
Similarly, 32 amperes transient current becomes 1023 countings, and 32 amperes transient current becomes the zero counting.In this second example, 64 amperes value now for surpass range and will be reduced to digital value 1023.The electrical bias that is applied to amplifier does not need and makes zero current equal the same big of Vcc/2.
In the 3rd example, allow electrical bias be applied to amplifier 1445 so that zero ampere causes the 96ADC counting, and the gain of amplifier 1445 remain unchanged.So little negative AC circuit can be measured, just, and little ADC value to 0 counting.In this example, the output of amplifier biasing amplifier 1445 is so that 96 ADC counting equals 0 ampere, suppose 1 ampere of per 16 counting, zero ADC counting will be represented-6 amperes so, and the 16ADC counting will be represented-5 amperes, and the 32ADC counting will be represented-4 amperes, the 48ADC counting will be represented-3 amperes, the 64ADC counting will be represented-2 amperes, and the 80ADC counting will be represented-1 ampere, and the 96ADC counting will be represented 0 ampere.The full scale electric current no longer is 64 amperes but 58 amperes.This provides revises the AC current measurement and makes that be the process useful that allows according to application need for little negative current or big negative electric current.
In module 100,, can measure the positive half period electric current for positive AC voltage half cycle.Because the AC electric current is the little amount of lagging voltage one typically, so some electric currents that flow through during positive AC voltage half cycle are born.Therefore, aforesaid amplifier 1445 bias voltages allow these little negative currents to be able to measure when the positive voltage AC half period begins.If negative current is reversed and thinks positive in microcontroller 1430, in fact the whole AC half period of electric current can be measured so.This will this and after discuss in further detail.
Current correction
Correct current correction is necessary for the accurate trigger angle control of TRIAC 1420 equally.Current correction all is necessary from the position of practice to the shunt that takes into account the operating characteristic with wide region, amplifier, analog references and ADC.The precision of current measurement can be by 1440 precision along separate routes, in the Voltage Reference (not shown) decision of op-amp1445 amplifier gain and amplifier bias voltage or biasing, ADC1433 precision and ADC1433.
Current correction can carry out to be identified for measuring the ADC offset of all current measurements (for example during control module 100 is made) during the test phase.In this case, TRIAC 1420 conduction known and precise current, it is by 1440 detecting along separate routes, amplifies and is input to ADC1433 to determine the ADC offset at op-amp1445.
This ADC offset is used for calculating the current correction factor (CCF) during test phase.For example, CCF equals 128 times of desired values poor divided by measured value and zero current value.Like this, the zero current value for 0,320 desired value, 320 measured value, CCF are 128.
CCF is recorded in the nonvolatile memory of microcontroller 1430 and is used for the real-time calculating of microcontroller 1430 to calculate actual current value from measuring current value.For example, this CCF value is stored among the EEPROM1436 and the microcontroller 1430 of Be Controlled module 100 in function software use to measure all current measurements, so that all inexactnesies of control module 100 are corrected away.
In an example, CCF can calculate by this way so that the value of 1440 resistance, amplifier 1445 gains and ADC reference voltage 1433 provides 128 perfect current correction factor values along separate routes.If 1440 resistance is lower than nominal value along separate routes, CCF will be greater than 128 so.If 1440 resistance is higher than nominal value along separate routes, CCF will be less than 128 so.Similarly, if the amplifier gain of amplifier 145 is lower than nominal value, CCF will be greater than 128 so, and if be higher than nominal value then less than 128.
If the ADC reference voltage is lower than nominal value, the value returned of ADC1433 will be lower than 128 greater than nominal value and CCF so.If the ADC reference voltage is greater than nominal value, the value returned of ADC1433 is lower than nominal value and CCF will be greater than 128 so.Like this, in order to measure the correction of current value, measure that current value is multiplied by CCF and divided by 128.
Correspondingly, to become the factor be 1 product to 128 CCF.If shunt resistance is 1/2nd of nominal value, CCF will be 256 so.Further flow through during the normal running transient current of TRIAC 1420 of supposition is the electric current that provide 128 value just.So, this measurement current value of 64 multiply by 256 and CCF and divided by 128 will recover 64 measure correct value 128.Will be understood that before applying CCF any current offset must be removed from current measurement.
The rotating speed of tachometric survey and control lags behind
In another example, measure and control for motor speed, control module 100 can be utilized hysteresis.In the revolution speed control system on basis, speed is by using magnet and the nigh pickup coil of placement (inductor) on the motor definite.For example, the motor speed with testing tool motor 15 of pickup coil assembly 250 configurations.As shown in Figure 2, in instrument motor 15 (it is included in the instrument armature 20 that rotates in the instrument motor stator 30), along with the rotation of armature 20, picked up to provide the pin-point reading of motor speed by pickup coil assembly 250 from the magnetic field of the magnet on the armature 20.Like this, along with motor 15 rotates, the voltage of the coil by pickup coil assembly 250 increases sinusoidally and reduces.It is fast more that armature 20 rotates, and sinusoidal frequency is high more.
Figure 17 illustrates the exemplary circuit that is used for motor control module 100 to determine motor speed.Figure 17 is provided to illustrate by use and picks up inductor and comparator so that the set of pulses in the output microcontroller 1430 is measured the method for motor speed.The speed of pulse frequency and motor 15 is directly proportional.In case actual speed is measured, microcontroller 430 just can carry out control algolithm and import the desired value of determining with control survey speed to being controlled by each.
The microcontroller for example microcontroller 1430 among Figure 14 can comprise one or more comparators, is higher or lower than reference voltage if comparator illustrates, but its triggered response.As shown in figure 17, circuit 1700 comprises comparator 1710, bleeder circuit 1720, RC filter 1730 and hysteretic, resistive (being depicted as R3).Bleeder circuit 1720 (resistance R 1 and R2) produces fixed voltage reference (Vref) as an input 1715 to comparator 1710.Second input (rotating speed input 1725) is the voltage signal (Vcoil) from pickup coil assembly 250.Rotating speed input 1725 is entered the noisiness of comparator 1710 with reduction by 1730 filtering of RC filter.When Vcoil was increased to above Vref, the microprocessor 1432 in the microcontroller 1430 was seen a low output at comparator 1710.When electric moter voltage (Vcoil) dropped under the Vref, microprocessor 1432 was seen a high output at comparator 1710.
The time durations that microcontroller 1430 is measured between these height-low-Gao conversion, motor speed can be determined.Do not lag behind, reference voltage Vref be fix and will not change.If measurement voltage signal Vcoi1 is around the Vref fluctuation and induce noise in system, microprocessor 1432 will be seen a plurality of high/low conversion that cause the non-precise speed measurement of microcontroller 1430 so.
In order to prevent this generation, microcontroller 430 uses hysteretic, resistive and application comparator lags behind from pickup coil tachometric survey is provided.In Figure 17, circuit 1700 comprises by three hysteretic, resistive (R3) of software by 1740 controls of the port pin on the microcontroller 1430.If port pin 1740 is configured to output and is connected to earth point, resistance R 3 influences the dividing potential drop of R1 and R2 generation by reducing Vref so.
But in case low-Gao conversion takes place, port pin 1740 is configured to output once more and is connected to Vcc.This changes bleeder circuit 1720 so that it comprises the parallel connection of R1 and R3, increases the value (because the value of Vref is to be determined by the value of R1, R2 and R3) of Vref like this.Vcoil is increased to higher value before comparator 1710 will change output gain now.
Correspondingly, microcontroller 1430 provides the tachometric survey by using hysteretic, resistive R3 application comparator to lag behind near the pickup coil the rotary magnet that nestles up motor 15.Use change/conversion of the horizontal Vref of Voltage Reference that lags behind to make second rotating speed of comparator 1710 import more impossible comparator 1710 outgoing events that change reference levels (because the transformation of port pin 1740 is moved with reference to the transition point away from comparator 1710) and minimise false that surpass of any noise on 1725.This combination can provide the software level control of comparator 1710 outputs, and reliable velocity measurement more is provided potentially, because the noise in the rotating speed input (second input 1725) is compensated to regulate Vref by using hysteretic, resistive R3.
Average current is estimated
Just also can calculate average current for negative amplitude in the negative AC half period, must be identical but should be worth with the average current during the positive amplitude in the fundamental frequency time period.Correspondingly, the low current that flows during positive half period in an example will be used to estimate average current.
Typically, when average current calculating was not under an embargo, the RMS electric current calculates to be forbidden in microcontroller.Correspondingly, the example of verifying below calculate to be described about average current, and it is understood to for accurate control flows and can obtains by using RMS to calculate through the accurate estimation of the electric current of TRIAC 1420.
Figure 18 illustrates the exemplary positive half period of AC voltage waveform.With reference to Figure 18, the time durations that tends between the negative zero passage (1820) of positive zero passage (1810) and trend is defined as positive half period.During positive half period, by 1440 the measured and accumulation of electric current along separate routes; These are depicted as sampling 1830.Typically in the end of positive half period, this is accumulated divided by hits, thereby the average current of the TRIAC 1420 of flowing through during the positive half period of AC voltage waveform is provided.
As previously mentioned, bias voltage op-amp1445 allows negative current to be able to be measured by ADC1433 with mobile ADC counting, the low limit to bias voltage.But apply bias voltage and move the scope of measured currents value effectively to amplifier 1445 so that the minority of negative current magnitude can the positive AC half period bear-just changing near measurement.
Because motor 15 bears the part inductive load, so the AC electric current can not be fully and AC voltage homophase, but will be a little homophase not.Phase angle between the voltage and current will be neither 0 degree (pure resistance), neither 90 degree (pure induction), but betwixt somewhere.Like this, electric current will have about the in-phase component of voltage and in-phase component not.
Have some inductions, when voltage waveform when either direction passes through zero electric current with non-vanishing.Like this, just in time after the positive voltage zero-cross of trend, perhaps just in time before the negative voltage zero-cross of trend, it is negative or positive that any current measurement can be respectively.
Figure 19 illustrates the AC voltage and current waveform for pure inductive load.The average algorithm for estimating of traditional electric current is all each current measurement summations, then divided by the end of positive half period (when voltage waveform when the negative direction of trend passes through zero) measurement number (hits).If some is measured indivedual current samples and bears, value actual deducting from the electric current sum of positive voltage half period that these are negative; This calculating that will estimate average current is from its actual value biased downward, because only for the positive AC half period assumed average current value of electric current.
For example, with reference to Figure 19, if load (instrument motor 15) is pure induction, then the average current of positive voltage half period will be zero just.In Figure 19, the negative region below current curve, from 0 to 90 degree equals the positive region below the current curve just, from 90 to 180 degree.Like this, during this period, average current accurately is zero.But real current obviously is not zero, but some nonzero values.
Figure 20 illustrate according to exemplary embodiment for the voltage and current waveform of the positive AC of slight inductive load in the half period describe to estimate the method for average current.As shown in figure 20, can ignore indivedual negative currents in order to the improvement algorithm of estimating true average current (for positive half period) measures; These samplings can not be added into or be accumulated to current measurement in the positive half period and in.Like this, the summation of current measurement will equal that two non-negative currents of crossing between the null transformation are measured and.As shown in figure 20, two measurements at 2010 marks will be left in the basket.
Correspondingly, will be accumulated, then divided by the sum of all measurements in the half period between two zero passage change points, so that determine the estimation average current by the ADC value that ADC1433 determines from 1440 non-negative samplings of measuring along separate routes.Resulting estimation average current value will be more near true average.Another estimation of average current will be accumulated the ADC value of being determined from 1440 non-negative samplings of measuring along separate routes by ADC1433, then divided by the sum of the non-negative measurement in the half period between two zero passage change points.Correspondingly, in the example of Figure 20, ignore the estimation that negative current is measured the average current that can improve the TRIAC 1420 of flowing through.
Figure 21 illustrate according to another exemplary embodiment for pure inductive load at the waveform of the positive voltage and current of AC in the half period to describe the method for estimating average current.Do not ignore negative current and measure, if indivedual negative current measure in fact from current measurement and deduct, rather than be coupled with, then current measurement and will produce more sane average current estimation.This is to be equivalent to before summation all current measurements be taken absolute value because deduct negative measurement.
Correspondingly, as shown in figure 21, the average current of positive voltage half period equals the average current of positive current half period.If current waveform is about 90 degree phase point symmetries, as shown in figure 21, the estimation of the average current of the TRIAC 1420 of flowing through can in addition more sane.Moreover so that zero current (reading the ADC value by microcontroller 1430 determines) is the intermediate point of measuring range, accurately current measurement can be carried out in the whole 360 degree AC cycles by measuring bias voltage op-amp1445 for shunt 1440.
For example, op-amp1445 can be at its input bias voltage so that its output to ADC1433 allows the positive and negative current measurement of full scope to be able to be measured in output place of ADC1433 by microcontroller 1430.This can be measured the intermediate point of bias voltage zero current shunting sign to exemplary measuring range so that comprise a large amount of negative scopes with positive current measurement.Exemplary range can be between+/-32 Ampere currents.This allows electric current to be calculated in the whole AC cycle.
Figure 22 A is used to illustrate according to the estimation of the exemplary embodiment flow chart by the method for the average current of the TRIAC of motor control module.Figure 22 C is used to illustrate according to the estimation of another exemplary embodiment flow chart by the method for the average current of TRIAC 1420.The chart of the corresponding Figure 20 of Figure 22 A and 22B, the chart of the corresponding Figure 21 of Figure 22 C.
With reference to Figure 22 A, microcontroller 1430 detects the positive zero passage (2210) of trend of AC voltage waveform, and it is that microcontroller 1430 beginnings are by a shunt 1440/op-amp1445 triggering (2220) of sample rate current at regular intervals.For each ADC voltage, the given current sample that its representative receives from ADC1433, microcontroller 1430 will be determined adjusted value (2230).This finishes to obtain adjusted current sampling data by deduct the zero current biasing from the ADC value.This zero offset is also referred to as top offset, and previous definite in test/correction in the manufacture process of control module 100.Zero current biasing is stored in nonvolatile memory for example among ROM or the EEPROM1436.
As shown in figure 20, microcontroller 1430 then only with those adjusted be positive value addition (2240) with determine with.The negative current sampling is left in the basket.In case microcontroller detects the negative zero passage (2250) of trend of AC voltage waveform, just with summation divided by hits to determine the estimation average current.Figure 22 B is identical with Figure 22 A, except estimating that average current is by summation divided by non-negative hits rather than all hits and definite (2260a).
Figure 22 C comprises that step identical with Figure 22 A except step 2240b is to estimate average current.This is illustrated in the alternative method of using the absolute value of all current samples in the sum operation.Like this, microcontroller 1430 is being determined and middle absolute value addition (2240) with the current sample of positive AC in the half period.Therefore, the negative current sampling of positive AC in the half period is included in during average current calculates, but by use absolute value to join and in.
Oscillator in the microcontroller is proofreaied and correct
The reference clock that a lot of microprocessors and microcontroller use internal oscillator to carry out as program command.Typically, these internal oscillators and inaccuracy, and can adjust by the oscillator correcting register in the microcontroller.
The microprocessor producer adjusts these oscillator correcting registers to be given in certain frequency of oscillation under nominal operation voltage and the nominal room temperature in its factory.In other operating voltage and other temperature, the vibration fundamental frequency can depart from nominal value.
In some applications, for example measure AC line frequency, the precise frequency of keeping operation becomes important.The precise frequency that this need vibrate.This can realize by the correction of carrying out functional test and oscillator correcting register subsequently in the motor control module that comprises microprocessor or microcontroller.
Oscillator in the microcontroller 1430 of control module 100 should be adjusted, because need to measure AC line frequency to determine that it is the 50Hz or the 60Hz of typical frequency of operation, still AC line frequency is another value, is used for communicating by letter with control module 100 so that the different frequency that loads and read coefficient is essential for the proper operation of electric tool.Correspondingly, the exemplary execution of the vibration fundamental frequency in the correction microcontroller 1430 is to calculate the vibration number that control module 100 is given between the electric continuous AC line zero passage.But sample rate current or voltage.
Correspondingly, in general example, the oscillator correcting register in the microcontroller 1430 can be corrected so that the fundamental frequency that vibrates enables the accurate measurement of AC line frequency.For example, the initial oscillator correcting register is set, counts with definite by the number of the hunting of frequency between the continuous zero passage of the counting of the software in the microcontroller 1430 AC waveform.This counting can compare with the nominal count value (some threshold values just) that is stored in the microcontroller 1430.If counting is less than the nominal count value, the oscillator correcting register is proofreaied and correct by the vibration fundamental frequency that microcontroller 1430 increases in the vibration register so.If counting is more than or equal to the nominal count value, microcontroller 1430 reduces the vibration fundamental frequency in the vibration register.
Exemplary embodiment so is described, obviously, its much mode change.These variations should not be considered as breaking away from exemplary embodiment, and all these will be that conspicuous modification is intended to be included in the scope of this appended claim for those skilled in the art.
Claims (2)
1. an electric tool is characterized in that, comprising:
The instrument motor,
Be integrated with the control module of switch, wherein said control module disposes and is arranged as programmable so that a kind of excessively described instrument motor of different electric tools more than the control.
2. electric tool as claimed in claim 1; it is characterized in that; described control module comprises the electric clutch in order to the erroneous condition of the expression overload event in the testing tool, and comprises in order to control described electric clutch and in order to start the microcontroller of protection action with the electric energy of removing or be reduced to described instrument motor based on described detected erroneous condition.
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US72601105P | 2005-10-12 | 2005-10-12 | |
| US60/726,011 | 2005-10-12 | ||
| US60/817,085 | 2006-06-29 |
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| CN201248022Y true CN201248022Y (en) | 2009-05-27 |
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| Application Number | Title | Priority Date | Filing Date |
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| CNU2006900000617U Expired - Lifetime CN201248022Y (en) | 2005-10-12 | 2006-10-12 | Electric tool with motor control module |
| CNU2006201478219U Expired - Lifetime CN201275751Y (en) | 2005-10-12 | 2006-10-12 | Universal control module |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CNU2006201478219U Expired - Lifetime CN201275751Y (en) | 2005-10-12 | 2006-10-12 | Universal control module |
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| Country | Link |
|---|---|
| CN (2) | CN201248022Y (en) |
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| CN102656657A (en) * | 2009-12-16 | 2012-09-05 | 胡斯华纳有限公司 | Electric hand tool with activation indication device |
| CN103036454A (en) * | 2011-10-08 | 2013-04-10 | 通嘉科技股份有限公司 | Power supply, power management device and low-voltage and excess-temperature protective method |
| CN103068529A (en) * | 2010-09-30 | 2013-04-24 | 日立工机株式会社 | Power tool |
| CN103796802A (en) * | 2011-08-30 | 2014-05-14 | 喜利得股份公司 | Method and device for monitoring the current of a hand-power tool driven by a battery |
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| CN108098531A (en) * | 2016-11-25 | 2018-06-01 | 南京德朔实业有限公司 | Angle grinder, electric tool and braking method thereof |
| CN109586536A (en) * | 2018-12-29 | 2019-04-05 | 陕西特恩电子科技有限公司 | A kind of AC servo motor and operation method having positive and negative rotating function |
| CN110535401A (en) * | 2018-05-25 | 2019-12-03 | 茂达电子股份有限公司 | Motor drive circuit |
| CN110875706A (en) * | 2018-08-29 | 2020-03-10 | 南京德朔实业有限公司 | Electric tool |
| WO2021083379A1 (en) * | 2019-10-31 | 2021-05-06 | 苏州宝时得电动工具有限公司 | Control apparatus, electric tool main body and tool system |
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2006
- 2006-10-12 CN CNU2006900000617U patent/CN201248022Y/en not_active Expired - Lifetime
- 2006-10-12 CN CNU2006201478219U patent/CN201275751Y/en not_active Expired - Lifetime
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| US9460869B2 (en) | 2009-12-16 | 2016-10-04 | Husqvarna Ab | Electric hand tool with activation indication device |
| CN102656657B (en) * | 2009-12-16 | 2015-04-15 | 胡斯华纳有限公司 | Electric hand tool with activation indication device |
| CN102656657A (en) * | 2009-12-16 | 2012-09-05 | 胡斯华纳有限公司 | Electric hand tool with activation indication device |
| CN103068529A (en) * | 2010-09-30 | 2013-04-24 | 日立工机株式会社 | Power tool |
| CN103796802B (en) * | 2011-08-30 | 2016-06-15 | 喜利得股份公司 | For to the method and the device that carry out current monitoring by battery-driven Hand-held machine tool |
| CN103796802A (en) * | 2011-08-30 | 2014-05-14 | 喜利得股份公司 | Method and device for monitoring the current of a hand-power tool driven by a battery |
| CN103036454A (en) * | 2011-10-08 | 2013-04-10 | 通嘉科技股份有限公司 | Power supply, power management device and low-voltage and excess-temperature protective method |
| CN103326644B (en) * | 2013-07-04 | 2015-11-25 | 丽水学院 | A kind of control method of series-wound motor speed-adjusting driving system |
| CN104518483A (en) * | 2013-09-26 | 2015-04-15 | 鸿富锦精密工业（深圳）有限公司 | Overload protection system |
| CN108098531A (en) * | 2016-11-25 | 2018-06-01 | 南京德朔实业有限公司 | Angle grinder, electric tool and braking method thereof |
| CN108098531B (en) * | 2016-11-25 | 2021-08-27 | 南京德朔实业有限公司 | Angle grinder, electric tool and braking method thereof |
| CN110535401A (en) * | 2018-05-25 | 2019-12-03 | 茂达电子股份有限公司 | Motor drive circuit |
| CN110535401B (en) * | 2018-05-25 | 2021-06-01 | 茂达电子股份有限公司 | Motor driving circuit |
| CN110875706B (en) * | 2018-08-29 | 2021-08-27 | 南京德朔实业有限公司 | Electric tool |
| CN110875706A (en) * | 2018-08-29 | 2020-03-10 | 南京德朔实业有限公司 | Electric tool |
| CN109586536A (en) * | 2018-12-29 | 2019-04-05 | 陕西特恩电子科技有限公司 | A kind of AC servo motor and operation method having positive and negative rotating function |
| WO2021083379A1 (en) * | 2019-10-31 | 2021-05-06 | 苏州宝时得电动工具有限公司 | Control apparatus, electric tool main body and tool system |
| CN114193402A (en) * | 2021-12-30 | 2022-03-18 | 无锡知荣电子有限公司 | Control method of electric impact tool |
| CN114193402B (en) * | 2021-12-30 | 2024-04-16 | 无锡知荣电子有限公司 | Control method of electric impact tool |
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