Power tool and control method thereof

Patent metadata

Field	Value
Publication number	US-12525903-B2
Application number	US-202318389441-A
Country	US
Kind code	B2
Filing date	Nov 14, 2023
Priority date	May 14, 2021
Publication date	Jan 13, 2026
Grant date	Jan 13, 2026

Abstract

A power tool includes a brushless motor, including a stator and a rotor; an inverter circuit, including a plurality of switch components, where the plurality of switch components are configured to perform a switch action to control driving of the brushless motor; and a controller, electrically connected to the inverter circuit and the brushless motor, the controller including a load detection module configured to detect a parameter indicating a workload of the brushless motor. In response to the parameter being less than a set threshold, the controller is configured to control the brushless motor to maintain a first target rotational speed; and in response to the parameter being greater than or equal to a set threshold, the controller controls the brushless motor to maintain a second target rotational speed. The first target rotational speed may be greater than the second target rotational speed.

First claim

What is claimed is:

1 . A power tool comprising:
a brushless motor comprising a stator and a rotor; an inverter circuit comprising a plurality of switch components, wherein the plurality of switch components are configured to perform a switch action to control driving of the brushless motor; and a controller electrically connected to the inverter circuit and the brushless motor, the controller comprising a load detection module configured to detect a parameter indicating a workload of the brushless motor, wherein: in response to the parameter being less than a set threshold, the controller is configured to control the brushless motor to maintain a first target rotational speed, in response to the parameter being greater than or equal to the set threshold, the controller is configured to control the brushless motor to maintain a second target rotational speed, the first target rotational speed is greater than the second target rotational speed, and the controller is configured to:
adjust a pulse-width modulation (PWM) duty cycle and/or a conduction angle of a switch component of the plurality of switch components, so that the brushless motor maintains the first target rotational speed or the second target rotational speed, and
increase the PWM duty cycle and/or the conduction angle of the switch component in response to the parameter being less than the set threshold and an actual motor rotational speed being less than the first target rotational speed or in response to the parameter being greater than or equal to the set threshold and the actual motor rotational speed being less than the second target rotational speed, wherein an adjustment priority of the PWM duty cycle is higher than an adjustment priority of the conduction angle, or
decrease the PWM duty cycle and/or the conduction angle of the switch component in response to the parameter being less than the set threshold and an actual motor rotational speed being greater than the first target rotational speed or in response to the parameter being greater than or equal to the set threshold and the actual motor rotational speed being greater than the second target rotational speed, wherein an adjustment priority of the conduction angle is higher than an adjustment priority of the PWM duty cycle.

2 . The power tool according to claim 1 , wherein the controller is further configured to adjust an advance angle of a switch component of the plurality of switch components.

3 . The power tool according to claim 1 , wherein the brushless motor is a three-phase brushless motor, the brushless motor comprises a position sensor, the controller is configured to calculate an actual motor rotational speed based on a signal transmitted by the position sensor, and a conduction angle of each phase in the three-phase brushless motor has a minimum value of 120° and a maximum value of 180°.

4 . The power tool according to claim 1 , wherein the controller is configured to adjust the conduction angle by a fixed increment slope, and a fixed increment associated with the fixed increment slope is a value from 0.1° to 0.5°.

5 . The power tool according to claim 1 , wherein the power tool is an impact fastening tool, wherein the impact fastening tool comprises an impact mechanism, and in response to the parameter being greater than or equal to the set threshold, the impact mechanism is configured to perform an impact action.

6 . The power tool according to claim 1 , wherein:
the power tool is an impact fastening tool, and the impact fastening tool further comprises an impact mechanism; the set threshold is corresponding to whether the impact mechanism performs an impact fastening action; and in a situation that the parameter being less than a set threshold, the impact mechanism does not perform an impact fastening action, and in a situation that the parameter being greater than or equal to the set threshold, the impact mechanism performs an impact fastening action.

7 . The power tool according to claim 1 , wherein in response to the parameter being less than a set threshold, the controller is configured to control the brushless motor to maintain the first target rotational speed in a closed-loop mode.

8 . A method for controlling a power tool, comprising:
detecting, by a controller, a parameter indicating a workload of a brushless motor, and determining an operational status of the power tool based on the parameter; and controlling, by the controller, in response to determining that the parameter is less than a set threshold, the brushless motor to maintain a first target rotational speed; or controlling, by the controller, in response to determining that the parameter is greater than or equal to the set threshold, the brushless motor to maintain a second target rotational speed, wherein: the first target rotational speed is greater than the second target rotational speed; and the controlling, by the controller, the brushless motor to maintain the first target rotational speed, or the controlling, by the controller, the brushless motor to maintain the second target rotational speed comprises:
calculating, by the controller, an actual motor rotational speed of the brushless motor, and
increasing, by the controller, in response to determining that the actual motor rotational speed is less than the first target rotational speed or the actual motor rotational speed is less than the second target rotational speed, a pulse-width modulation (PWM) duty cycle and/or a conduction angle for driving the brushless motor, wherein an adjustment priority of the PWM duty cycle is higher than an adjustment priority of the conduction angle; or
the controlling, by the controller, the brushless motor to maintain the first target rotational speed, or the controlling, by the controller, the brushless motor to maintain the second target rotational speed comprises:
calculating, by the controller, an actual motor rotational speed of the brushless motor, and
increasing, by the controller, in response to determining that the actual motor rotational speed is less than the first target rotational speed or the actual motor rotational speed is less than the second target rotational speed, a pulse-width modulation (PWM) duty cycle and/or a conduction angle for driving the brushless motor, wherein an adjustment priority of the PWM duty cycle is higher than an adjustment priority of the conduction angle.

9 . The method according to claim 8 , further comprising adjusting, by the controller, an advance angle for driving the brushless motor.

10 . The method according to claim 8 , wherein:
the power tool is an impact fastening tool, and the impact fastening tool further comprises an impact mechanism; wherein the set threshold is corresponding to whether the impact mechanism performs an impact fastening action; and in a situation that the parameter being less than a set threshold, the impact mechanism does not perform an impact fastening action, and in a situation that the parameter being greater than or equal to the set threshold, the impact mechanism performs an impact fastening action.

11 . The method according to claim 8 , wherein in response to the parameter being less than a set threshold, the controller is configured to control the brushless motor to maintain the first target rotational speed in a closed-loop mode.

12 . A power tool comprising:
a brushless motor comprising a stator and a rotor; an inverter circuit comprising a plurality of switch components, wherein the plurality of switch components are configured to perform a switch action to control driving of the brushless motor; and a controller electrically connected to

Assignees

• Positec Power Tools Suzhou Co Ltd

Inventors

• Zhan Kang
• Chen Naifu
• Wei Guangdong
• Lu Jun
• Zhu Hang

Classifications

• B25B21/02

  with means for imparting impact to screwdriver blade or nut socket · CPC title

• H02P6/17

  and for generating speed information · CPC title

• H02P27/085

  wherein the PWM mode is adapted on the running conditions of the motor, e.g. the switching frequency · CPC title

• H02P2205/07

  Speed loop, i.e. comparison of the motor speed with a speed reference · CPC title

• H02P6/08

  Arrangements for controlling the speed or torque of a single motor (H02P6/10, H02P6/28 take precedence) · CPC title