WO1997015111B1 - A brushless dc motor assembly - Google Patents
A brushless dc motor assemblyInfo
- Publication number
- WO1997015111B1 WO1997015111B1 PCT/US1996/016728 US9616728W WO9715111B1 WO 1997015111 B1 WO1997015111 B1 WO 1997015111B1 US 9616728 W US9616728 W US 9616728W WO 9715111 B1 WO9715111 B1 WO 9715111B1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- brushless
- motor assembly
- assembly according
- control board
- motor
- Prior art date
Links
- 238000004804 winding Methods 0.000 claims abstract 16
- 239000007787 solid Substances 0.000 claims 22
- 230000005355 Hall effect Effects 0.000 claims 17
- 239000003990 capacitor Substances 0.000 claims 10
- 238000003475 lamination Methods 0.000 claims 6
- 230000013011 mating Effects 0.000 claims 2
Abstract
A brushless dc motor assembly including a brushless dc motor, and a control board having at least one output connected to a stator winding of said brushless dc motor for providing current flow to said stator winding. Control electronics on the control board control current flow to said stator winding using a microprocessor and based on desired motor operating characteristics. The control electronics include a housekeeping power supply for providing a stable 5v DC signal from a rectified AC line voltage. The control electronics also include a MOSFET output amplifier having a power zener diode connected to the drain thereof, said power zener dissipating temporary back emf resulting from switching of said MOSFET from an on to an off state. A hall device mounted to a stator of said brushless dc motor is also provided. The hall device provides a signal representative of the rotational speed of a rotor of said motor to the control board. The control electronics on said control board control said current flow to said stator winding responsive to said signal from the hall device. The control board is preferably attached to a heatsink whereby the heatsink is attached to MOSFETS on said control board for dissipating heat generated by said MOSFETS.
Claims
1. A brushless dc motor assembly comprising: a brushless dc motor having a rotor and a stator with first and second stator windings; a control board having an input adapted to be connected to an electric power source, phase A and phase B outputs connected to said first and second stator windings, and electronics thereon for establishing a first feedback signal representative of current output to said stator windings; a sensor for sensing the rotational position of said rotor and providing a second feedback signal to said control board representative of said rotational position; and control electronics connected to said control board, said control electronics including a programmable microprocessor for generating phase A and phase B output signals for driving said phase A and B outputs based on programed instructions in said microprocessor and said first and second feedback signals.
2. A brushless dc motor assembly according to claim 1, wherein said phase A and B output signals are provided directly to first and second driving elements, respectively, said driving elements driving said phase A and B output signals as said phase A and B outputs.
3. A brushless dc motor assembly according to claim 1 wherein said control board is disposed within a conduit box secured to said brushless dc motor.
4. A brushless dc motor assembly according to claim l, wherein said programed instructions include soft start instructions for causing said phase A and B output signals to be pulse width modulated signals which cause the speed of said rotor to slowly ramp up based on said first and second feedback signals. 58
5. A brushless dc motor assembly according to claim 4, wherein said pulse width modulated signals are of constant duty cycle, and wherein said soft start instructions cause the speed of said rotor to slowly ramp up by increasing the number of pulses provided at said A and B outputs.
6. A brushless dc motor assembly according to claim 1, wherein said programmed instructions include instructions for causing said phase A and B outputs to establish a user-defined rotor speed.
7. A brushless dc motor assembly according to claim 1, wherein said programmed instructions include instructions for causing said phase A and B outputs to establish a user-defined rotor torque.
8. A brushless dc motor assembly according to claim 1, wherein said programmed instructions include instructions for causing said phase A and B outputs to establish user-defined output currents to said stator windings.
9. A brushless dc motor assembly according to claim 1, wherein said programmed instructions include a lookup table of stored data for controlling said phase A and B output signals, and wherein said instructions include instructions for causing said phase A and B output signals to establish an output current based on said stored data.
10. A brushless dc motor assembly according to claim 1, wherein said programmed instructions include a lookup table of stored data for controlling said phase A and B output signals, and wherein said instructions include instructions for causing said phase A and B outputs signals to establish a rotor speed based on said stored data.
11. A brushless dc motor assembly according to claim 1, wherein said programmed instructions include a lookup table of 59 stored data for controlling said phase A and B output signals, and wherein said instructions include instructions for causing said phase A and B outputs signals to establish a rotor torque based on said stored data.
12. A brushless dc motor assetnbly comprising according to claim 1, said assembly further comprising: a dc bus on said control board; electronics connected to said control board for establishing a bus voltage on said dc bus from said electric power source; and a housekeeping power supply connected to said control board, said housekeeping power supply including a solid state device having conducting and non-conducting states, wherein said solid state device is in said conducting state when said bus voltage is present on said dc bus for establishing a stable dc output from said bus voltage for operation of said control electronics.
13. A brushless dc motor assembly according to claim 12, wherein said solid state device has first and second terminals for conducting current when said device is in said conducting state and a third terminal for controlling the conductive state of said solid state device, and wherein said third terminal is connected to a zener diode which is connected in series with a resistor across said dc bus, and wherein said first and second terminals are connected in series with a capacitor across said dc bus, and wherein said solid state device conducts to charge said capacitor responsive to said bus voltage, and wherein said dc output is a capacitor voltage at said second terminal.
14. A brushless dc motor according to claim 13, wherein said second terminal is connected to said dc bus through a diode, said diode preventing discharge of said capacitor in the event that said bus voltage is lost. 60
15. A brushless dc motor according to claim 13, wherein said solid state device is a MOSFET.
16. A brushless dc motor according to claim 15, wherein said third terminal is a gate of said MOSFET, said second terminal is a source of said MOSFET, and said first terminal is a drain of said MOSFET.
17. A brushless dc motor according to claim 16, wherein said drain of said MOSFET is connected to said bus voltage through a diode, said diode preventing discharge of said capacitor when said bus voltage is lost.
18. A brushless dc motor according to claim 12, wherein said input is an ac input, and wherein an ac-dc converter is connected in series with said ac input, said bus voltage being derived from an output of said ac-dc converter.
19. A brushless dc motor according to claim 18, wherein said output of said ac-dc converter is filtered by a filter network for establishing said bus voltage.
20. A brushless dc motor assembly according to claim 12 wherein said control board is disposed within a conduit box secured to said brushless dc motor.
21. A brushless dc motor assembly according to claim 12 wherein said control electronics include a microprocessor, and wherein said dc output is provided as a reference input to said microprocessor.
22. A brushless dc motor assembly according to claim 1, said assembly further comprising: first and second driving elements connected to said phase A and B output signals for driving said phase A and B output signals as said phase A and B outputs of said control board; and 6 1 a power zener diode connected to said phase A and B outputs, said power zener diode dissipating temporary back emf resulting from switching of said first and second driving elements from an on to an off state.
23. A brushless dc motor assembly according to claim 22, wherein said control board has a dc bus thereon and electronics connected thereto for establishing a bus voltage from said electric power source on said dc bus, and wherein said power zener diode comprises: a solid state device having conducting and non¬ conducting states, said solid state device having first and second terminals for conducting current when said device is in said conducting state and a third terminal for controlling the conductive state of said solid state device, and wherein said first terminal is connected to said phase A and B outputs and said second terminal is connected to said bus voltage, and wherein a zener diode is connected between said first terminal and said third terminal, and wherein said solid state device conducts to re-circulate increased voltage at said phase A and B outputs as said driving elements switch from on to off states.
24. A brushless dc motor assembly according to claim 23, wherein a resistor is connected between said second terminal and said third terminal.
25. A brushless dc motor according to claim 23, wherein said solid state device is a MOSFET, and wherein said third terminal is a gate of said MOSFET, said second terminal is a source of said MOSFET, and said first terminal is a drain of said MOSFET.
26. A brushless dc motor assembly according to claim 25, wherein a resistor is connected between said gate and said source of said MOSFET.
AMENDED SHEET(ARπCLE19)
27. A brushless dc motor according to claim 23, wherein said input is an ac input, and wherein an ac-dc converter is connected in series with said ac input, said bus voltage being derived from an output of said ac-dc converter.
28. A brushless dc motor assembly according to claim 22, wherein said control board is disposed within a conduit box secured to said brushless dc motor.
29. A brushless dc motor assembly according to claim 1, wherein said sensor is a hall effect sensor, and wherein said hall effect sensor is mounted within a hall effect sensor assembly, said assembly comprising a body portion with at least one leg extending therefrom, and wherein said hall effect sensor assembly is removably secured to said stator by mating engagement of said at least one leg with a corresponding opening in said stator.
30. A brushless dc motor assembly according to claim 29, wherein said at least one opening is a stator ground hole in said stator.
31. A brushless dc motor assembly according to claim 29, wherein said at least one opening is a space between pole laminations of said stator.
32. A brushless dc motor assembly according to claim 29, wherein said hall effect sensor is disposed within said body portion.
33. A brushless dc motor assembly according to claim 32, wherein said hall effect sensor is disposed within said body portion to be off-center with respect to successive stator poles.
34. A brushless dc motor assembly according to claim 32, wherein said hall effect sensor is disposed within said body
AMENDED SHEET(ARTICLE19* 63 portion at lead angle of approximately 15 degrees relative to said stator windings.
35. A brushless dc motor assembly according to claim 29, wherein said assembly comprises first and second legs, and wherein said first leg matingly engages a stator ground hole and said second leg matingly engages a space between pole laminations of said stator.
36. A brushless dc motor assembly according to claim 35, wherein said second leg is a T-shaped leg, and wherein base portion of said T-shaped leg matingly engages said space between pole laminations of said stator.
37. A brushless dc motor assembly comprising according to claim 1, wherein said control board is disposed within a conduit box, and wherein said control board is mounted to a heat sink, said heat sink being secured to said conduit box with a first portion of said heat sink closing an open portion of said conduit box.
38. A brushless dc motor assembly according to claim 37, wherein said control board is disposed within a slot formed in said heat sink
39. A brushless dc motor assembly according to claim 37, wherein said first portion of said heat sink has fins thereon which extend outward from said conduit box for dissipating heat generated by heat generating elements connected to said control board.
40. A brushless dc motor assembly according to claim 37, wherein said control board is secured to said heat sink in parallel with said first portion of said heat sink, and wherein heat generating elements connected to said control board are secured below said control board to a second portion of said heat sink. 64
41. A brushless dc motor assembly according to claim 40, wherein said heat generating elements are secured to said second portion by a removable retainer bar.
42. A brushless dc motor assembly according to claim 37, wherein said heat sink is generally L-shaped, and wherein a second portion of said heat sink closes a second open portion of said conduit box adjacent to said open portion.
43. A brushless dc motor assembly according to claim 42, wherein said open portion is a top of said conduit box, and said second open portion is a side of said conduit box.
44. A brushless dc motor assembly according to claim 42, wherein said control board is secured to said heat sink in parallel with said first portion of said heat sink, and wherein heat generating elements connected to said control board are secured below said control board to said second portion of said heat sink.
45. A brushless dc motor assembly according to claim 44, wherein said heat generating elements are secured to said second portion by a removable retainer bar.
46. A brushless dc motor assembly comprising: a brushless dc motor; a control board having an input adapted to be connected to a electric power source, at least one output connected to a stator winding of said motor, a dc bus, and electronics connected thereto for establishing a bus voltage from said electric power source on said dc bus; control electronics connected to said control board for generating an output signal on said at least one output based on desired motor operating characteristics; and a housekeeping power supply connected to said control board, said housekeeping power supply including a solid state device having conducting and non-conducting states, wherein 65 said solid state device is in said conducting state when said bus voltage is present on said dc bus for establishing a stable dc output from said bus voltage for operation of said control electronics.
47. A brushless dc motor assembly according to claim 46, wherein said solid state device has first and second terminals for conducting current when said device is in said conducting state and a third terminal for controlling the conductive state of said solid state device, and wherein said third terminal is connected to a zener diode which is connected in series with a resistor across said dc bus, and wherein said first and second terminals are connected in series with a capacitor across said dc bus, and wherein said solid state device conducts to charge said capacitor responsive to said bus voltage, and wherein said dc output is a capacitor voltage at said second terminal .
48. A brushless dc motor according to claim 47, wherein said second terminal is connected to said dc bus through a diode, said diode preventing discharge of said capacitor in the event that said bus voltage is lost.
49. A brushless dc motor according to claim 47, wherein said solid state device is a MOSFET.
50. A brushless dc motor according to claim 49, wherein said third terminal is a gate of said MOSFET, said second terminal is a source of said MOSFET, and said first terminal is a drain of said MOSFET.
51. A brushless dc motor according to claim 50, wherein said drain of said MOSFET is connected to said bus voltage through a diode, said diode preventing discharge of said capacitor when said bus voltage is lost. 66
52. A brushless dc motor according to claim 46, wherein said input is an ac input, and wherein an ac-dc converter is connected in series with said ac input, said bus voltage being derived from an output of said ac-dc converter.
53. A brushless dc motor according to claim 52, wherein said output of said ac-dc converter is filtered by a filter network for establishing said bus voltage.
54. A brushless dc motor assembly according to claim 46 wherein said control board is disposed within a conduit box secured to said brushless dc motor.
55. A brushless dc motor assembly according to claim 46 wherein said control electronics include a microprocessor, and wherein said dc output is provided as a reference input to said microprocessor.
56. A brushless dc motor assembly comprising: a brushless dc motor,- a control board having an input adapted to be connected to a electric power source, phase A and phase B outputs connected to phase A and phase B stator windings of said motor; control electronics connected to said control board for generating phase A and phase B output signals based on desired motor operating characteristics; first and second driving elements connected to said phase A and B output signals for driving said phase A and B output signals as said phase A and B outputs of said control board; and a power zener diode connected to said phase A and B outputs, said power zener diode dissipating temporary back emf resulting from switching of said first and second driving elements from an on to an off state. 67
57. A brushless dc motor assembly according to claim 56, wherein said control board has a dc bus thereon and electronics connected thereto for establishing a bus voltage from said electric power source on said dc bus, and wherein said power zener diode comprises: a solid state device having conducting and non¬ conducting states, said solid state device having first and second terminals for conducting current when said device is in said conducting state and a third terminal for controlling the conductive state of said solid state device, and wherein said first terminal is connected to said phase A and B outputs and said second terminal is connected to said bus voltage, and wherein a zener diode is connected between said first terminal and said third terminal, and wherein said solid state device conducts to re-circulate increased voltage at said phase A and B outputs as said driving elements switch from on to off states.
58. A brushless dc motor assembly according to claim 57, wherein a resistor is connected between said second terminal and said third terminal.
59. A brushless dc motor according to claim 57, wherein said solid state device is a MOSFET, and wherein said third terminal is a gate of said MOSFET, said second terminal is a source of said MOSFET, and said first terminal is a drain of said MOSFET.
60. A brushless dc motor assembly according to claim 59, wherein a resistor is connected between said gate and said source of said MOSFET.
61. A brushless dc motor according to claim 56, wherein said input is an ac input, and wherein an ac-dc converter is connected in series with said ac input, said bus voltage being derived from an output of said ac-dc converter. 68
62. A brushless dc motor assembly according to claim 56 wherein said control board is disposed within a conduit box secured to said brushless dc motor.
63. A brushless dc motor assembly comprising: a brushless dc motor having a rotor and a stator with at least one stator winding,- a control board having an input adapted to be connected to an electric power source, and at least one output connected to said at least one stator winding,- a hall effect sensor mounted to said stator for sensing the rotational position of said rotor and providing a hall effect feedback signal representative of said rotational position; and control electronics connected to said control board for generating at least one output signal for driving said at least one output based on said hall effect feedback signal; wherein said hall effect sensor is mounted within a hall effect sensor assembly, said assembly comprising a body portion with at least one leg extending therefrom, and wherein said hall effect sensor assembly is removably secured to said stator by mating engagement of said at least one leg with a corresponding opening in said stator.
64. A brushless dc motor assembly according to claim 63, wherein said at least one opening is a stator ground hole in said stator.
65. A brushless dc motor assembly according to claim 63, wherein said at least one opening is a space between pole laminations of said stator.
66. A brushless dc motor assembly according to claim 63, wherein said hall effect sensor is disposed within said body portion. 69
67. A brushless dc motor assembly according to claim 66, wherein said hall effect sensor is disposed within said body portion to be off-center with respect to successive stator poles.
68. A brushless dc motor assembly according to claim 66, wherein said hall effect sensor is disposed within said body portion at lead angle of approximately 15 degrees relative to said at least one stator winding.
69. A brushless dc motor assembly according to claim 63, wherein said assembly comprises first and second legs, and wherein said first leg matingly engages a stator ground hole and said second leg matingly engages a space between pole laminations of said stator.
70. A brushless dc motor assembly according to claim 69, wherein said second leg is a T-shaped leg, and wherein base portion of said T-shaped leg matingly engages said space between pole laminations of said stator.
71. A brushless dc motor assembly comprising: a brushless dc motor having a rotor and a stator with at least one stator winding; a control board disposed within a conduit box, said control board having an input adapted to be connected to an electric power source, and at least one output connected to said at least one stator winding,- control electronics connected to said control board for generating at least one output signal for driving said at least one output based on said hall effect feedback signal,- wherein said control board is mounted to a heat sink, said heat sink being secured to said conduit box with a first portion of said heat sink closing an open portion of said conduit box. 70
72. A brushless dc motor assembly according to claim 71, wherein said control board is disposed within a slot formed in said heat sink
73. A brushless dc motor assembly according to claim 71, wherein said first portion of said heat sink has fins thereon which extend outward from said conduit box for dissipating heat generated by heat generating elements connected to said control board.
74. A brushless dc motor assembly according to claim 71, wherein said control board is secured to said heat sink in parallel with said first portion of said heat sink, and wherein heat generating elements connected to said control board are secured below said control board to a second portion of said heat sink.
75. A brushless dc motor assembly according to claim 74, wherein said heat generating elements are secured to said second portion by a removable retainer bar.
76. A brushless dc motor assembly according to claim 71, wherein said heat sink is generally L-shaped, and wherein a second portion of said heat sink closes a second open portion of said conduit box adjacent to said open portion.
77. A brushless dc motor assembly according to claim 76, wherein said open portion is a top of said conduit box, and said second open portion is a side of said conduit box.
78. A brushless dc motor assembly according to claim 76, wherein said control board is secured to said heat sink in parallel with said first portion of said heat sink, and wherein heat generating elements connected to said control board are secured below said control board to said second portion of said heat sink. 71
79. A brushless dc motor assembly according to claim 78, wherein said heat generating elements are secured to said second portion by a removable retainer bar.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| AU74551/96A AU7455196A (en) | 1995-10-17 | 1996-10-17 | A brushless dc motor assembly |
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US567795P | 1995-10-17 | 1995-10-17 | |
| US60/005,677 | 1995-10-17 |
Publications (4)
| Publication Number | Publication Date |
|---|---|
| WO1997015111A2 WO1997015111A2 (en) | 1997-04-24 |
| WO1997015111A3 WO1997015111A3 (en) | 1997-06-05 |
| WO1997015111A9 WO1997015111A9 (en) | 1997-07-24 |
| WO1997015111B1 true WO1997015111B1 (en) | 1997-08-21 |
Family
ID=21717138
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/US1996/016728 WO1997015111A2 (en) | 1995-10-17 | 1996-10-17 | A brushless dc motor assembly |
Country Status (2)
| Country | Link |
|---|---|
| AU (1) | AU7455196A (en) |
| WO (1) | WO1997015111A2 (en) |
Families Citing this family (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE19826458A1 (en) | 1998-06-13 | 1999-12-16 | Papst Motoren Gmbh & Co Kg | Arrangement with an electric motor |
| DE19836882A1 (en) * | 1998-08-14 | 2000-02-17 | Papst Motoren Gmbh & Co Kg | Electric motor has characteristic field stored as digital values for associating parameter and motor speed values, and microcontroller or microprocessor |
| JP2001128432A (en) * | 1999-09-10 | 2001-05-11 | Jianzhun Electric Mach Ind Co Ltd | Ac power supply drive type dc brushless electric motor |
| JP3658310B2 (en) * | 2000-11-16 | 2005-06-08 | 東芝テック株式会社 | PWM control circuit, electric blower and vacuum cleaner |
| DE112013004738A5 (en) * | 2012-09-26 | 2015-07-23 | Schaeffler Technologies AG & Co. KG | An electronic module comprising an electric motor, preferably an electrically commutated motor |
| US11139722B2 (en) | 2018-03-02 | 2021-10-05 | Black & Decker Inc. | Motor having an external heat sink for a power tool |
Family Cites Families (11)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4528486A (en) * | 1983-12-29 | 1985-07-09 | The Boeing Company | Controller for a brushless DC motor |
| US4636936A (en) * | 1984-04-19 | 1987-01-13 | General Electric Company | Control system for an electronically commutated motor |
| US4626750A (en) * | 1985-09-10 | 1986-12-02 | Curtis Instruments, Inc. | Solid state d.c. motor control |
| US4893067A (en) * | 1987-05-06 | 1990-01-09 | Black & Decker Inc. | Direct current motor speed control |
| US4959797A (en) * | 1987-12-11 | 1990-09-25 | Tensor Development, Inc. | System for tightening threaded fastener assemblies |
| US4958269A (en) * | 1988-07-27 | 1990-09-18 | Eaton Corporation | Current control for microprocessor motor drive |
| US5331258A (en) * | 1992-03-30 | 1994-07-19 | Solaria Research Enterprises, Ltd. | Synchronous-rectification type control for direct current motors and method of making |
| US5410229A (en) * | 1992-07-31 | 1995-04-25 | Black & Decker Inc. | Motor speed control circuit with electronic clutch |
| US5317245A (en) * | 1992-10-29 | 1994-05-31 | Mfm Technology, Inc. | Brushless DC motor control network |
| US5486747A (en) * | 1993-07-29 | 1996-01-23 | United Technologies Motor Systems | General purpose motor controller |
| EP0643473B1 (en) * | 1993-09-15 | 1998-04-29 | PAPST-MOTOREN GmbH & Co. KG | Device for a collectorless dc motor commutated with a semiconductor device |
-
1996
- 1996-10-17 WO PCT/US1996/016728 patent/WO1997015111A2/en active Application Filing
- 1996-10-17 AU AU74551/96A patent/AU7455196A/en not_active Abandoned
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| CA2597773C (en) | Method for operation of a two-phase electronically-commuted motor and motor for carrying out said method | |
| US7688011B2 (en) | Control circuit for an electronically commutated motor | |
| US8446120B2 (en) | Electronic switching module for a power tool | |
| EP0240172B1 (en) | Pwm motor operating circuit with rfi suppression | |
| KR100911070B1 (en) | Blower and electric device with such blower mounted thereon | |
| CN102165680B (en) | Synchronous Rectifier Triggering | |
| US6664750B2 (en) | D.C. motor bridge coil driver | |
| US20080315807A1 (en) | Method for Operating an Electronically Commutated Motor, and Motor for Carrying Out a Method Such as This | |
| CN110445427A (en) | Electric tool | |
| WO2007004429A1 (en) | Brushless dc motor and electric device using the same | |
| US8054020B2 (en) | Electric motor | |
| WO1997015111B1 (en) | A brushless dc motor assembly | |
| JP3889445B2 (en) | Electronic commutation type high-efficiency electric motor | |
| EP4311101B1 (en) | Power tool | |
| US20220149760A1 (en) | Alternating current power tool and startup method thereof | |
| EP0930697A1 (en) | A system for controlling a brushless electric motor | |
| US6548983B2 (en) | PWM-pulse control system | |
| US12145235B2 (en) | Alternating current power tool | |
| WO1997015111A3 (en) | A brushless dc motor assembly | |
| WO2005036297A1 (en) | Bi-directional dc-dc converter for voltage level adjustment in a hybrid propulsion system | |
| CN113632380A (en) | Power electronic device and method for supplying voltage to a driver circuit of a power semiconductor switch | |
| EP0964507B1 (en) | A control circuit for an electric motor without commutator | |
| US20230402952A1 (en) | Motor control controller system and methods | |
| RU2155436C1 (en) | Field current regulating device for series-wound motor | |
| JP2684221B2 (en) | Chopper power supply |