U.S. patent application number 14/672759 was filed with the patent office on 2015-10-01 for variable-speed actuator for a power tool.
This patent application is currently assigned to BLACK & DECKER INC.. The applicant listed for this patent is Black & Decker Inc.. Invention is credited to Redeat G. Alemu, Victor A. Dorado Reyes, Erik A. Ekstrom, Michael D. Grove, Alpay Hizal, Alexandros T. Theos, Matthew J. Velderman.
Application Number | 20150282337 14/672759 |
Document ID | / |
Family ID | 53039191 |
Filed Date | 2015-10-01 |
United States Patent
Application |
20150282337 |
Kind Code |
A1 |
Ekstrom; Erik A. ; et
al. |
October 1, 2015 |
VARIABLE-SPEED ACTUATOR FOR A POWER TOOL
Abstract
A power tool is provided including a tool housing, an electric
motor disposed in the housing, and a variable-speed actuator having
a trigger, a sliding member linked to the trigger and moveable in a
longitudinal direction, and a compression spring engaging the
sliding member and a wall arranged at a distance from the sliding
member in the longitudinal direction. A post is disposed on the
wall, where an end of the compression spring engaging the wall is
disposed around the post to limit a lateral movement of the
compression spring.
Inventors: |
Ekstrom; Erik A.;
(Woodstock, MD) ; Velderman; Matthew J.;
(Baltimore, MD) ; Alemu; Redeat G.; (Cockeysville,
MD) ; Grove; Michael D.; (Windsor, PA) ;
Theos; Alexandros T.; (Bel Air, MD) ; Hizal;
Alpay; (Elkridge, MD) ; Dorado Reyes; Victor A.;
(White Marsh, MD) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Black & Decker Inc. |
Newark |
DE |
US |
|
|
Assignee: |
BLACK & DECKER INC.
Newark
DE
|
Family ID: |
53039191 |
Appl. No.: |
14/672759 |
Filed: |
March 30, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61971865 |
Mar 28, 2014 |
|
|
|
Current U.S.
Class: |
173/170 |
Current CPC
Class: |
H01H 21/12 20130101;
H05K 1/021 20130101; B23Q 5/041 20130101; B25F 5/00 20130101; H01H
2235/018 20130101; H05K 7/2039 20130101; H01H 21/24 20130101; H05K
1/181 20130101; H05K 2201/10053 20130101; B23Q 5/10 20130101; H01H
2231/048 20130101; H05K 1/115 20130101; B25F 5/008 20130101; H05K
7/20854 20130101; H02K 7/145 20130101; B25B 21/02 20130101; H01H
9/061 20130101; H02K 11/33 20160101; H05K 5/0026 20130101; H05K
7/20136 20130101; H05K 2201/10151 20130101; H05K 2201/10166
20130101; G05G 5/03 20130101; H01H 15/04 20130101; B25F 5/02
20130101; H02K 9/06 20130101; H01H 2221/044 20130101; H02P 6/14
20130101 |
International
Class: |
H05K 5/00 20060101
H05K005/00; B25F 5/00 20060101 B25F005/00 |
Claims
1. A power tool comprising: a tool housing; an electric motor
disposed in the housing; a variable-speed actuator having a
trigger, a sliding member linked to the trigger and moveable in a
longitudinal direction, and a compression spring engaging the
sliding member and a wall arranged at a distance from the sliding
member in the longitudinal direction; and a post disposed on the
wall, wherein an end of the compression spring engaging the wall is
disposed around the post to limit a lateral movement of the
compression spring.
2. The power tool of claim 1, wherein the post is sized to be
form-fittingly received inside the end of the compression spring
engaging the wall.
3. The power tool of claim 1, wherein the post projects from a
surface of the wall.
4. The power tool of claim 1, further including a pocket recessed
from a surface of the wall, wherein the post projects from inside
the pocket.
5. The power tool of claim 4, wherein the post projects to a
lateral plane along a plane of the wall.
6. The power tool of claim 4, wherein the compression spring is
form-fittingly received within the pocket.
7. The power tool of claim 1, wherein the post includes a lower
surface that projects substantially longitudinally in the direction
of the compression spring, and an upper surface that projects at an
angle to the compression spring.
8. The power tool of claim 1, wherein and end of the sliding member
includes a pocket arranged to receive another end of the
compression spring.
9. The power tool of claim 1, further comprising an electronic
switch and control module including: a module housing including a
bottom surface, side walls, and an open face; a printed circuit
board (PCB) received from the open face of the module housing and
securely disposed within the module housing at a distance from the
bottom surface of the module housing; a plurality of power switches
mounted on a top surface of the PCB, the power switches being
electrically configured to switchably connect a supply of electric
power from a power source to the electric motor; and an
encapsulation member configured to mate with at least one of the
side walls of the module housing around the sliding member and the
spring.
10. The power tool of claim 9, wherein the post is configured to
hold the spring in place prior to mounting the encapsulation
member.
11. The power tool of claim 9, wherein the sliding member houses a
conductive wiper arranged to make sliding contact with a plurality
of conductive tracks on the PCB.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional
Application No. 61/971,865 titled "Electronic Switch Module For A
Power Tool" filed Mar. 28, 2014, content of which is incorporated
herein by reference in its entirety.
BACKGROUND
[0002] Use of cordless power tools has increased dramatically in
recent years. Cordless power tools provide the ease of a power
assisted tool with the convenience of cordless operation.
Conventionally, cordless tools have been driven by Permanent Magnet
(PM) brushed motors that receive DC power from a battery assembly
or converted AC power. In a PM brushed motor, commutation is
achieved mechanically via a commutator and a brush system. By
contrast, in a brushless DC motor, commutation is achieved
electronically by controlling the flow of current to the stator
windings. A brushless DC motor includes a rotor for providing
rotational energy and a stator for supplying a magnetic field that
drives the rotor. Comprising the rotor is a shaft supported by a
bearing set on each end and encircled by a permanent magnet (PM)
that generates a magnetic field. The stator core mounts around the
rotor maintaining an air-gap at all points except for the bearing
set interface. Included in the air-gap are sets of stator windings
that are typically connected in either a three-phase wye or Delta
configuration. Each of the windings is oriented such that it lies
parallel to the rotor shaft. Power devices such as MOSFETs are
connected in series with each winding to enable power to be
selectively applied. When power is applied to a winding, the
resulting current in the winding generates a magnetic field that
couples to the rotor. The magnetic field associated with the PM in
the rotor assembly attempts to align itself with the stator
generated magnetic field resulting in rotational movement of the
rotor. A control circuit sequentially activates the individual
stator coils so that the PM attached to the rotor continuously
chases the advancing magnetic field generated by the stator
windings. A set of sense magnets coupled to the PMs in the rotor
assembly are sensed by a sensor, such as a Hall Effect sensor, to
identify the current position of the rotor assembly. Proper timing
of the commutation sequence is maintained by monitoring sensors
mounted on the rotor shaft or detecting magnetic field peaks or
nulls associated with the PM.
[0003] Conventionally, power switches are provided within the power
tool in close proximity to the motor or within the handle.
Electronics including a controller for controlling the power
devices are also provided within the handle or in the vicinity of
the motor. A trigger switch assembly is also provided, preferable
on the handle where it is easy for the user to engage. A
forward/reverse bar is also provided in the vicinity of the trigger
assembly. The controller is coupled to the trigger assembly, the
forward/reverse bar, and the power devices, and regulates the flow
of power through the power devices based on the inputs from the
trigger assembly and the forward/reverse bar. All the connectivity
between these modules requires substantial wiring. Also, since the
power devices generate a considerable amount of heat, they should
be arranged within the power tool to transfer heat away from the
power devices effectively. It would be desirable to provide a
modular design for packaging these components. However, assembly of
the module to include all these components, particularly the
trigger switch assembly and the forward/reverse bar, presents many
challenges.
SUMMARY
[0004] According to an aspect of the invention, a directional input
unit is provided for a power tool having an electric motor, where
the input unit is configured to output a signal indicative of a
rotational direction of the electric motor. In an embodiment, the
input unit comprises: a forward/reverse actuator having a lever
extending from an engagement member and pivotable around a pivot
member, the lever having a contact tip; and a biasing member
including a lever engaging member engaging the contact tip and
having an upper portion and a lower portion with a groove formed at
an end common point of the upper and lower portions, the biasing
member further including a first leg extending downwardly from the
upper portion and arranged to be securely received inside an
opening of a holder, and a second leg extending upwardly from the
lower portion outside the opening between the lever engaging member
and the first leg.
[0005] In another aspect of the invention, a power tool is provided
including a tool housing, an electric motor disposed in the
housing; a forward/reverse button disposed on the housing; and a
directional input unit engageable by the forward/reverse button and
configured to output a signal indicative of a rotational direction
of the electric motor. In an embodiment, the input unit comprises:
a forward/reverse actuator having a lever extending from an
engagement member and pivotable around a pivot member, the lever
having a contact tip, wherein the engagement member is moveable via
the forward/reverse button; and a biasing member including a lever
engaging member engaging the contact tip and having an upper
portion and a lower portion with a groove formed at an end common
point of the upper and lower portions, the biasing member further
including a first leg extending downwardly from the upper portion
and arranged to be securely received inside an opening of a holder,
and a second leg extending upwardly from the lower portion between
the lever engaging member and the first leg.
[0006] In an embodiment, the biasing member further includes an
extension portion extending substantially longitudinally between
the end of the upper portion and the first leg.
[0007] In an embodiment, the first leg includes at least one of a
humped surface or an angular rib arranged to hold securely hold the
biasing member inside the opening of the holder.
[0008] In an embodiment, the holder includes a post configured to
hold the biasing member in an upright position with respect to the
forward/reverse actuator, the post having two walls with the
opening formed between the two walls, where the second leg is
disposed outside the two walls and is resiliently engageable with
an outer surface of one of the walls.
[0009] In an embodiment, the biasing member applies a biasing force
against the lever to bias the forward/reverse actuator in one of a
forward, locked, or reverse positions.
[0010] In an embodiment, the lever holds an electrical connector
having a curved profile arranged to make contact with a pair of
conductive pads to generate a signal indicative of at least one of
a forward or a reverse position.
[0011] In an embodiment, a top portion of the first leg is
resiliently moveable inside the opening to apply a biasing force
against the lever when the lever tip engages the upper portion of
the lever engaging member.
[0012] In an embodiment, the second leg engages a wall of the
holder to apply a biasing force against the lever when the lever
tip engages the lower portion of the lever engaging member.
[0013] In an embodiment, the biasing member further includes an
extension portion extending substantially longitudinally between
the end of the upper portion and the first leg.
[0014] According to another aspect of the invention, a power tool
is provided comprising: a tool housing; an electric motor disposed
in the housing; and a variable-speed actuator having a trigger, a
sliding member linked to the trigger and moveable in a longitudinal
direction, and a compression spring engaging the sliding member and
a wall arranged at a distance from the sliding member in the
longitudinal direction. The power tool further includes a post
disposed on the wall, wherein an end of the compression spring
engaging the wall is disposed around the post to limit a lateral
movement of the compression spring.
[0015] In an embodiment, the post is sized to be form-fittingly
received inside the end of the compression spring engaging the
wall. In an embodiment, the post projects from a surface of the
wall.
[0016] In an embodiment, the power tool further includes a pocket
recessed from a surface of the wall, where the post projects from
inside the pocket. In an embodiment, the post projects to lateral
plane along a plane of the wall. In an embodiment, the compression
spring is form-fittingly received within the pocket.
[0017] In an embodiment, the post includes a lower surface that
projects substantially longitudinally in the direction of the
compression spring, and an upper surface that projects at an angle
to the compression spring.
[0018] In an embodiment, and end of the sliding member includes a
pocket arranged to receive another end of the compression
spring.
[0019] In an embodiment, the power tool includes an electronic
switch and control module having: a module housing including a
bottom surface, side walls, and an open face; a printed circuit
board (PCB) received from the open face of the module housing and
securely disposed within the module housing at a distance from the
bottom surface of the module housing; a plurality of power switches
mounted on a top surface of the PCB, the power switches being
electrically configured to switchably connect a supply of electric
power from a power source to the electric motor; and an
encapsulation member configured to mate with at least one of the
side walls of the module housing around at least the sliding member
and the spring. In an embodiment, the post is configured to hold
the spring in place prior to mounting the encapsulation member. In
an embodiment, the sliding member houses a conductive wiper
arranged to make sliding contact with a plurality of conductive
tracks on the PCB.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] Example embodiments of the present invention will become
more fully understood from the detailed description given herein
below and the accompanying drawings, wherein like elements are
represented by like reference numerals, which are given by way of
illustration only and thus are not limitative of the example
embodiments of the present invention.
[0021] FIG. 1 depicts a longitudinal cross-sectional view of a
power tool with a housing half removed, according to an
embodiment;
[0022] FIGS. 2A and 2B depict perspective views of an electronic
control module from two different angles, according to an
embodiment;
[0023] FIGS. 3A and 3B respectively depict expanded front and back
perspective views of the electronic control module, according to an
embodiment;
[0024] FIGS. 4A and 4B respectively depict a zoomed-in perspective
view and a cross-sectional view of a the electronic control module
showing the arrangement of a power switch and a heat sink on a
printed circuit board (PCB), according to an embodiment;
[0025] FIG. 5 depicts a top view of the PCB alone without any
mounted components, according to an embodiment;
[0026] FIG. 6 depicts a partial perspective view of the electronic
control module showing an encapsulation member sealed over the PCB,
according to an embodiment;
[0027] FIG. 7 depicts a partial perspective view of the electronic
control module showing mating features for mounting the
encapsulation member to the control module housing, according to an
embodiment;
[0028] FIGS. 8A and 8B depict side and perspective views of a
biasing member (forward/reverse spring), according to an
embodiment;
[0029] FIGS. 9A-9C depict cross-sectional views of a
forward/reverse actuator relative to the biasing member in forward,
locked, and reverse positions, respectively, according to an
embodiment;
[0030] FIG. 10 depicts a partial perspective view of the electronic
control module without the encapsulation member, according to an
embodiment;
[0031] FIG. 11 depicts a cross-sectional view of the variable-speed
actuator within the enclosed compartment, according to an
embodiment; and
[0032] FIG. 12 depicts a zoomed-in view of a post for the
variable-speed compression spring, according to an embodiment.
DESCRIPTION
[0033] With reference to the FIG. 1, a power tool 100 constructed
in accordance with the teachings of the present disclosure is
illustrated in a longitudinal cross-section view. Power tool 100 in
the particular example provided may be a hand held impact driver,
but it will be appreciated that the teachings of this disclosure is
merely exemplary and the power tool of this invention could be any
power tool. The power tool shown in FIG. 1 may include a housing
102, an electric motor 104, a battery pack 108, a transmission
assembly (gear case) 114, and an output spindle 116. The gear case
114 may be removably coupled to the housing 102. The housing 102
can define a motor housing 111 and a handle 112.
[0034] According to an embodiment, motor 104 is received in motor
housing 111. Motor 104 may be any type of motor and may be powered
by an appropriate power source (electricity, pneumatic power,
hydraulic power). In an embodiment, the motor is a brushless DC
electric motor and is powered by a battery pack 108.
[0035] According to an embodiment of the invention, power tool 100
further includes an integrated electronic switch and control module
200 (hereinafter referred to as "electronic control module", or
"control module"). Electronic control module 200, in an embodiment,
may include a controller and electronic switching components for
regulating the supply of power from the battery pack 108 to motor
105. In an embodiment, electronic control module 200 is disposed
within the handle 112 below the motor housing 111, though it must
be understood that depend on the power tool shape and
specifications, electronic control module 200 may be disposed at
any location within the power tool. Electronic control module may
also integrally include components to support a user-actuated input
unit 110 (hereinafter referred to as "input unit" 110) for
receiving user functions, such as an on/off signal, variable-speed
signal, and forward-reverse signal. In an embodiment, input unit
100 may include a variable-speed trigger 120, although other input
mechanism such as a touch-sensor, a capacitive-sensor, a speed
dial, etc. may also be utilized. In an embodiment, an on/off signal
is generated upon initial actuation of the variable-speed trigger
120. In an embodiment, a forward/reverse button 122 is additionally
provided on the tool 100. The forward/reverse button 122 may be
pressed on either side of the tool in a forward, locked, or reverse
position. In an embodiment, the associated circuitry and components
of the input unit 110 that support the variable-speed trigger 120
and the forward/reverse button 122 may be fully or at least
partially integrated into the electronic control module 200. Based
on the input signals from the input unit 110 and associated
components, the controller and electronic switching components of
the electronic control module 200 modulate and regulate the supply
of power from the battery pack 108 to motor 105. Details of the
electronic control module 200 are discussed later in detail.
[0036] While in this embodiment, the power source is battery pack
108, it is envisioned that the teachings of this disclosures may be
applied to a power tool with an AC power source. Such a power tool
may include, for example, a rectifier circuit coupled to the AC
power source.
[0037] It must be understood that, while FIG. 1 illustrates a power
tool impact driver having a brushless motor, the teachings of this
disclosure may be used in any power tool, including, but not
limited to, drills, saws, nailers, fasteners, impact wrenches,
grinders, sanders, cutters, etc. Also, teachings of this disclosure
may be used in any other type of tool or product that include a
rotary electric motor, including, but not limited to, mowers,
string trimmers, vacuums, blowers, sweepers, edgers, etc.
[0038] The electronic control module 200 is described herein,
according to an embodiment of the invention. FIGS. 2A and 2B depict
perspective views of electronic control module 200 from two
different angles, according to an embodiment. FIGS. 3A and 3B
depict exploded front and back views of the same module 200,
according to an embodiment. Reference is made to these drawings
herein.
[0039] Electronic control module 200, in an embodiment, includes a
printed circuit board (PCB) 202 arranged and mounted inside a
module housing 204. Module housing 204 includes a bottom surface
227, side walls 228, and an open face. PCB 202 is inserted through
the open face and secured inside the module housing 204. Side walls
228 include retention features 229 for securely holding the PCB 202
at a distance from the bottom surface 227. Control module 200
includes two compartments--an enclosed compartment 210a that houses
and encloses a first part of the PCB 202 and components associated
with the input unit 110, as described below, and an open
compartment 210b, and partially encloses a second part of the PCB
202. Within the open compartment 210b, module housing 204 encloses
the lower surface and the sides of PCB 202, but leaves the upper
surface of the PCB 202 substantially exposed. Mounted on the upper
surface of PCB 202 are a series of power switches 206 and a series
of heat sinks disposed over the power switches 206 and secured to
the PCB 202. As discussed below in detail, this arrangement allows
cooling air to transfer heat away from the heat sinks 208 within
the power tool 100, but protects the input unit 110 components from
any dust and debris from the cooling air.
[0040] According to an embodiment, control module 200 includes a
controller 218. In an embodiment, the controller may be mounted to
a lower surface of the PCB 202 and be in electronic communication
with the rest of the PCB 202 components through vias (not shown).
In an embodiment, controller 218 may be a programmable
micro-controller, micro-processor, or other processing unit capable
of controlling the motor and various aspects of power tool. For
example, controller 218 may be programmed to turn on and off power
switches 206, as discussed below, to control commutation of the
brushless motor. In an embodiment, controller 218 may be coupled to
a series of gate drivers disposed on the PCB 202, which in turn are
connected to the gates of the power switches 206. Alternatively,
controller 218 may be a circuit chip that includes both a
micro-controller and the gate drivers and be coupled directly to
the gates of the power switches 206. Using the gate drivers,
controller 218 turns the power switches 206 on or off selectively
to commutate the motor and control the speed of the motor.
Additionally, the controller may be programmed to various tool and
battery pack operation features, such as tool and/or temperature
control, battery pack voltage control, and tool over-current
detection and control, etc. In an alternative embodiment, the
controller may be an Application Specific Integrated Circuit (ASIC)
configured to control the aforementioned aspects of the motor,
battery, and power tool.
[0041] In an exemplary embodiment, power switches 206 may be Field
Effect Transistors (FETs). In an embodiment, six power switches
206, including three high-side power switches and three low-side
power switches, are arranged and coupled together as a three-phase
bridge rectifier circuit. Using the gate drivers, controller 218
sequentially turns the power switches 206 on and off within each
phase of the brush motor 104 commutation. Further, the controller
218 performs pulse-width modulation (PWM) of the power switches 206
within each phase to regulate the speed of the motor based on speed
signals received from input unit 110, as described below.
Controller 218 further controls the direction of motor commutation
based on a forward/reverse signal received from input unit 110,
also discussed below.
[0042] It is noted that while the power switches 206 discussed
herein are FETs, other types of power switches such as BJTs or
IGBTs may be utilized. Additionally, while power switches 206 are
arranged as a three-phase bridge rectifier for driving a
three-phase brushless motor, other number and arrangement of power
switches may be used to drive other types of motors, including
brushed or brushless motors.
[0043] As described above, module housing 204 leaves the upper
surface of the PCB 202 exposed, thus allowing heat to dissipate
from the heat sinks 208. Electronic control module 200 may be
placed within a path of air flow inside the power tool, e.g.,
inside the power tool handle 112 in fluid communication with motor
fan 106 so that airflow generated by motor fan 106 runs through the
handle 112. The air flow generated within the handle further
improves heat dissipation from the electronic control module
200.
[0044] In an embodiment, the PCB 202 is further potted with a layer
of potting compound (not shown) in the open compartment 210b. The
layer of potting compound, in an embodiment, substantially covers
most of the circuit components on the PCB, but leave a top plate of
heat sinks 206 exposed so the heat sinks 208 can dissipate heat
away from the power switches 206. While the potting compound is not
shown in FIGS. 2A-3B, the control module of FIG. 1 is shows with
the potting compound disposed inside the housing 202.
[0045] FIGS. 4A and 4B depict zoomed-in perspective and
cross-sectional views of PCB 202, showing the arrangement of heat
sink 208 and power switch 206 (in this case a FET) mounted over PCB
202, according to an embodiment. Heat sink 208 includes two legs
mounted on the PCB 202. The main plate of heat sink 208 is located
directly above power switch 206 at close proximity thereto. This
allows heat to be transferred directly from power switch 206 to the
heat sink 208 through a small air gap between the two. In an
embodiment, the main plate of the heat sink 208 has a surface area
of 10 to 40 mm.sup.2, preferably 15-35 mm.sup.2, more preferably
20-30 mm.sup.2, that is exposed after the potting compound is
applied. In addition, one or more of the legs of the heat sink 208
is electrically connected to the drain of power switch 206 on the
PCB 202. This arrangement further improves heat transfer from the
FET 206 to the heat sink 208.
[0046] It is noted that while in this embodiment discrete heat
sinks 208 are mounted on respective power switches 206, a lower
number of heat sinks 208 may be utilized instead. In an alternative
embodiment of the invention, a single heat sink is mounted on the
PCB over the power switches 206 to provide a higher surface area
for heat transfer.
[0047] Referring back to FIGS. 2A through 3B, in an embodiment, a
series of output wires 212 are secured on one end to a surface of
the PCB 202. These wires connect the outputs of the power switches
three-phase bridge rectifier to the power terminals the brushless
motor 104. In an embodiment, a series of control signal wires 214
are also secured to a wire receptacle 215a. In an embodiment, wire
receptacle 215a is mounted on the PCB and is in electrical
communication with the controller 218. The control signal wires 214
allow the controller 218 to communicate with other parts of the
power tool 100, such as the motor 104 and the battery 108. In an
embodiment, hall signals from the brushless motor hall sensors
communicate with the controller 218 through these control signal
wires 214. Control signal wires 214 may additionally be provided
with a control terminal 215b to ease plug-in connectivity of
external wires with the control signal wires 214. In an embodiment,
a pair of power input wires 217 are also secured on the surface of
PCB 202. These wires are coupled to a power source (e.g., battery
108) via a power terminal 216 to supply power from the power source
to the power switches 206.
[0048] In an embodiment, control module 200 includes an
encapsulation member 260 that mates with the module housing 204 to
form the enclosed compartment 210a of control module 200. As
discussed below in detail, encapsulation member 260 protects
components associated with input unit 110 from dust and debris.
Encapsulation member 260 also includes wire retaining features 262
and wire guide features 264 for retaining and positioning signal
wires 214 and/or power output wires 212 away from the housing 204.
Encapsulation member 260 further includes mating features 266 that
mate with corresponding mating features 268 on the module housing
204. In an embodiment, the mating features 268 include lips that
snap fit into slots in mating features 266. In an embodiment,
encapsulation member 260 further includes an opening 269 that
allows control signal wires 214 to connect to PCB-side control
terminal 215a.
[0049] Additionally, in an embodiment, control module 200 includes
an additional cover 270 that covers a lower portion of PCB 202.
Cover 270 also includes wire retaining features 272 for retaining
the power wires 217, as well as wire guide features 274 for guiding
the wires 217 around circuit components (e.g., capacitors 280)
mounted on PCB 202. Cover 270 further includes mating features 276
that mate with corresponding mating features 278 on the module
housing 204. In an embodiment, the mating features 278 include lips
that snap-fit into slots in mating features 276.
[0050] In an embodiment, control module 200 is additionally
provided with an auxiliary control terminal 252 mounted on a top
portion of the PCB 202 that allows the controller 218 with other
motor or tool components. In an embodiment, auxiliary control
terminal 252 allows the controller 218 to communicate with an LED
provided on the tool 100. In an embodiment, auxiliary control
terminal 252 is provided outside and adjacent to the enclosed
compartment 210a.
[0051] The input unit 110 is discussed herein, according to an
embodiment of the invention. According to an embodiment, input unit
110 is at least partially integrated into control module 200. In an
embodiment, input unit 110 incorporates electro-mechanical elements
for variable-speed detection, on/off detection, and forward/reverse
detection inside the enclosed compartment 210a of control module
200, as discussed herein.
[0052] In an embodiment, input unit 110 includes a forward/reverse
actuator 220 supported by the enclosed compartment 210a portion of
the module housing 204. In an embodiment, forward/reverse actuator
220 includes a contact member 220a, which holds an electrical
connector 222 and is disposed inside the enclosed compartment 210a
of the module housing 204, and an engagement member 220b, which is
located outside the module housing 204. In an embodiment,
engagement member 220b is in moving contact with forward/reverse
button 122 on the power tool 100. A pivot member 220c located
between the contact member 220a and engagement member 220b is
supported by the module housing 204 and provides a pivot point for
the forward/reverse actuator. A biasing member 224 is secured to
the module housing 204 to engage and bias the contact member 220a
in a forward, neutral (e.g., locked), or reverse direction. In an
embodiment, biasing member 224 is secured in an opening of a
holder, i.e. a post 226 that projects from the bottom surface 227
of the module housing 204 within the enclosed compartment 210a. In
an embodiment, PCB 202 is provided with a through-hole 254 that
receives the post 226. When the user presses the forward/reverse
button 122 from either side of the tool to a forward, locked, or
reverse position, the forward/reverse button 122 moves the
engagement member 220 around the pivot portion 220c. Pivoting
movement of the engagement member 220b around the pivot portion
220c causes the electrical connector 222 of contact member 220a to
make or break contact with a contact-sensing member against the
biasing force of the biasing member 224. In an embodiment, contact
sense member includes a pair of conductive tracks 250 arranged on
PCB 202.
[0053] In an embodiment, one of the conductive tracks 250 is
electrically connected to power source 108 and the other is
connected to and sensed by controller 218. Voltage is present and
sensed by the controller 218 when electrical connector 222 makes
contact with the pair of conductive tracks 250, thus electrically
connecting the two conductive tracks 250. Presence or lack of
sensed voltage is indicative of whether the motor should rotate in
the forward or reverse direction. Functional details of use and
electrical connectivity of conductive tracks 250 for
forward/reserve detection are discuss in co-pending Patent
Publication no. 2012/0292063 filed May 21, 2012, which is
incorporated herein by reference in its entirety.
[0054] According to an embodiment, input unit 110 further includes
a variable-speed actuator 230. Variable-speed actuator includes a
link member 232 that extends out of the module housing 204 from a
sliding member 234 that is arranged inside the module housing 204
and supports a conductive wiper 236. Link member 232 is coupled to
trigger 120 that is engageable by the user. The sliding member 234
supports and engages a compression spring 238 its longitudinal end
opposite link member 232. Compression spring 238 is located between
an inner wall of the module housing 204 and the sliding member 234.
When the user presses the trigger 120, the sliding member 234 moves
against a biasing force of the spring 238.
[0055] Conductive wiper 236 contacts a speed-sensing member located
on the surface of the PCB 202. In an embodiment, the speed-sensing
member is a series of variable-speed conductive tracks 240 arranged
on the PCB 202. Actuation of the trigger 120 moves the conductive
wiper 236 over the conductive tracks 240. Initial movement of the
conductive wiper 236 over the conductive tracks 240 generates a
signal that turns controller 218 ON. Additionally, an analog
variable-voltage signal is generated based on the movement of the
conductive wiper 128 over the conductive tracks and that signal is
sent to the micro-controller. This signal is indicative of the
desired motor speed. Functional details of ON/OFF and
variable-speed detection using conductive tracks 240 are discuss in
co-pending Patent Publication no. 2012/0292063 filed May 21, 2012,
which is incorporated herein by reference in its entirety. It must
be understood, however, that any known variable-voltage
speed-sensing mechanism, such as a resistive tape, may be a
utilized within the scope of the invention.
[0056] It is noted that the moving mechanical parts of the
forward/reverse actuator 220 and variable-speed actuator 230
(including the electrical connector 222 and conductive wiper 236),
alone or in combination with conductive tracks 240 and 250, are
referred to in this disclosure as "electro-mechanical"
elements.
[0057] FIG. 5 depicts a top view of PCB 202 alone without any
components mounted. As shown herein, PCB 202 is provided with metal
traces 282 for mounting the power switches 206, as well as
variable-speed conductive tracks 240 and forward/reverse conductive
250. Through-hole 254 and auxiliary terminal 252 is also shown in
this figure.
[0058] In an embodiment, a layer of silicon conformal coating is
applied to the PCB 202 to protect it from dust, debris, moisture,
and extreme temperature changes. However, since the conductive
tracks 250 and 240 need to remain exposed to make electrical
contact with the forward/reverse electrical connector 222 and
variable-speed conductive wiper 236, a high temperature resistant
tape 284 is applied to the PCB 202 over the conductive tracks 240
and 250 before the silicon conformal coating is applied. The high
temperature resistant tape 284 ensures that the silicon conformal
coating does not cover the conductive tracks 240 and 250.
[0059] In an embodiment, since no conformal coating is provided to
protect the conductive tracks 250 and 240, conductive tracks 250
and 240 are prone to damage from debris, contamination, and
moisture. In addition, electro-mechanical components of the input
unit (i.e., forward/reverse actuator 220 and variable-speed
actuator 230, particularly forward/reverse electrical connector 222
and variable-speed conductive wiper 236) are also similarly prone
to damage or faulty contact with the conductive tracks 200 and 250.
For this reason, the conductive tracks 250 and 240 and the
electro-mechanical elements of the input unit 110 are arranged
inside the enclosed compartment 210a of the control module 200,
where the encapsulation member 260 mates with the module housing
204 to seal and protect these components from dust, contamination,
and/or moisture. In an embodiment, encapsulation member 260
substantially encloses the area 284 around the conductive tracks
250 and 240. In an embodiment, encapsulation member also encloses
the space around the electro-mechanical components including
contact member 220a of the forward/reverse actuator 220, sliding
member 234 of the variable-speed actuator 230, spring 238, etc.
[0060] Referring back to FIGS. 3A and 3C, in an embodiment, mating
surfaces of encapsulation member 260 and module housing 204
includes support features 286a, 286b that receive and support link
member 232 of variable-speed actuator 230, forming an aperture for
the link member 232 to slidably extend out of the module housing
204. In an embodiment, the link member 232 is laterally secured in
the aperture via one or more rings 233. Similarly, mating surfaces
of encapsulation member 260 and module housing 204 includes pivot
support features 288a, 288b that receive and support pivot member
220c of forward/reverse actuator 220, forming an aperture for the
engagement member 220b of the forward/reverse actuator 220 to
extend out of the module housing 204.
[0061] In an embodiment, encapsulation member 260 not only protects
the input unit 110 from dust and contamination, it also acts as a
mechanical constrain for its mechanical components. In an
embodiment, encapsulation member 260 includes a first chamber 290
that houses the sliding member 234 and compression spring 238 of
the variable-speed actuator 230, and a second chamber 292 that
houses the contact member 220a of the forward/reverse actuator 220.
The first chamber 290 forms an axial channel for the back and forth
movement of the sliding member 234 and mechanically restrains its
lateral movement. In an embodiment, this arrangement ensures that
there is always contact between the wiper 236 and the conductive
tracks 240. Similarly, the second chamber 290 facilitates the
pivoting movement of the forward/reverse actuator 220.
[0062] Referring now to FIGS. 6 and 7, additional features for
sealing the enclosed compartment 210a from outside contamination
are discussed herein, according to an embodiment.
[0063] As shown in FIG. 6, according to an embodiment,
encapsulation member 260 includes a wall 294 arranged to rest on
the PCB 202 when the encapsulation member 260 is mounted in order
to fully enclose the enclosed compartment 210a, in an embodiment.
In an embodiment, an adhesive may be applied to block any gaps
between the wall 294 and the PCB 202. Alternatively, in an
embodiment, during the assembly process, encapsulation member 260
is mounted on the module housing 204 immediately or shortly after
conformal coating 295 is applied to PCB 202, preferably prior to
conformal coating 295 cooing down. In this manner, once conformal
coating 295 is cooled and hardened, it acts as a seal between the
wall 294 of the encapsulation member 260 and the PCB 202.
[0064] As shown in FIG. 7, and as discussed above, encapsulation
member 260 further includes mating features 266 that mate with
corresponding mating features 268 on the module housing 204. In an
embodiment, mating surfaces of encapsulation member 260 and module
housing 204 are additionally respectively provided with tongue 296
and groove 298 features to seal the mating surfaces of
encapsulation member 260 and the housing 204 and block or reduce
entry of dust or contamination into the enclosed compartment
210a.
[0065] While exemplary embodiments of the invention are discussed
with reference to a module housing 204, it must be understood that
the compartmental concepts of the invention for sealing the
electro-mechanical components associated with the input unit 101
components while leaving the power switches 206 exposed may be
applied to alternative embodiments. For example, it is envisioned
that a PCB 202 is disposed within a tool housing 102 without a
separate module housing 204. In that case, an encapsulation member
may be provided to around the enclosed compartment 210a of the PCB
202, with walls mounted and sealed to both surfaces of the PCB 202.
Alternatively, encapsulation member may be mounted directly on the
PCB 202 without a need for a separate module housing 204. It is
also envisioned that in some alternative embodiments, the enclosed
compartment 210a is formed by an integral part of the tool housing
204 rather than a separate piece.
[0066] Another aspect of the invention is described herein with
reference to FIGS. 8 and 9A-9C.
[0067] As described above, most power tools used for drilling and
cutting operations need to be operated in both forward and reverse
directions. The forward/reverse actuator 220 described above is
provided for that purpose. Moreover, in an embodiment, the
forward/reverse actuator 220 may be provided with a third
setting--a locked position--to secure lock the power tool system
from running inadvertently. Effective, repeatable and reliable
positional control of the contact member 220a (hereinafter also
referred to as "lever" 220a) is needed to provide all three
functions (i.e., forward run, reverse run, and lock). In an
embodiment, this position control is provided by biasing member 224
(herein also referred to as forward/reverse spring 224), described
herein.
[0068] In an embodiment, forward/reverse spring 224 includes a
lever engaging member 302 that includes upper and lower portions
302a and 302b with a groove formed 302c therebetween. In an
embodiment, the upper and lower portions 302a, 302b are arranged at
an obtuse angle 8 of approximately 120 to 150 degrees with respect
to one another. The groove 302c is formed at the end common point
(vertex) of the angle between the upper and lower portions 302a,
302b, towards the interior of the angle. The lever engaging member
302 engages a contact tip 300 of lever 220a of the forward/reverse
actuator 220 to bias the forward/reverse actuator 220 in a forward
(FIG. 9A), locked (FIG. 9B), or reverse (FIG. 9C) positions.
Extending longitudinally from an end of upper portion 302a is an
extension portion 304 that is substantially horizontal with respect
to a plane of the PCB 202. A first leg 306 extends downwardly from
an end of the extension portion 304 at close to a right angle.
First leg 306 is securely places in an opening between first and
second walls 320, 322 of post 226 projecting from a bottom surface
227 of the module housing 204. In an embodiment, first leg 306
includes an angular rib 308 that engages first wall 320 to secure
the first leg 306 within the opening. In an embodiment, first leg
306 also includes a humped surface 310 that is pressed against the
first wall 320 to provide further stability. In an embodiment,
extending from an end of the lower portion 302b is a second leg 312
folding inwardly and positioned between the lever engaging member
302 and the first leg 306. In an embodiment, the second leg 312
extends upwardly along an axis that is less than parallel to an
axis of the first leg 306 (e.g., where the two axes for an angle of
less than 20 degrees, preferably less than 10 degrees). When
assembled, second leg 312 engages an outer face of second wall 322
of the post 226. Second leg 312 includes a contact portion 314 that
makes contact with the outer face of second wall 322, in an
embodiment.
[0069] As shown in FIG. 9A, in a forward direction, contact tip 300
engages the upper portion 302a of the lever engaging member 302 and
is biased away from the PCB 202. In this position, the biasing
force is applied by the upper portion 302a and a top of the first
leg 306 of the forward/reverse spring 224, which is resiliently
forced towards the first wall 320. The second leg 312 in this
position has minimal or no contact with the second wall 322 and
thus applies less biasing force on the contact tip 300.
[0070] As shown in FIG. 9B, as the forward/reverse actuator 220 is
pivoted to the locked position, contact tip 300 slides down the
upper portion 302a until it reaches the groove 302c of the lever
engaging member 302. As the contact tip 300 slides down, the
biasing force on the contact tip 300 is applied by both the first
and second legs 306 and 312 against the first and second walls 320
and 322, respectively. When in the locked position, in an
embodiment, only one leg of the electrical connector 222 is in
contact with the PCB 202.
[0071] As shown in FIG. 9C, as the forward/reverse actuator 220 is
pivoted to the reverse position, contact tip 300 slides down from
the groove 302c over the lower portion 302b of the lever engaging
member 302. As the contact tip 300 slides down, the biasing force
on the contact tip 300 is applied mostly by the second legs 312,
which comes into substantial contact with the second wall 322. When
in the reverse position, in an embodiment, both legs of the
electrical connector 222 are in contact with the conductive tracks
250 on the PCB 202, which send a voltage signal to the controller
218 indicative of the reverse position.
[0072] It is noted that forward/reverse spring 224 is very easy to
assemble into the housing 204. Whereas conventional designs
required complicated retention features and precision assembly,
assembling the forward/reverse spring 224 simply involves insertion
of the first leg 306 into the post 226 opening.
[0073] In an embodiment, each leg of the electrical connector 222
includes a curved profile, as shown in FIGS. 9A-9C. This profile
allows the electrical connector 222 to have a smoother transition
as it makes contact and slides over the conductive tracks 250 of
the PCB 202.
[0074] FIG. 10 provides a zoomed-in view depicting the arrangement
of the forward/reverse actuator 220 and forward/reverse spring 224
within the housing 204, according to an embodiment.
[0075] Another aspect of the invention is described herein with
reference to FIGS. 10-12. As discussed above, compression spring
238, sliding member 234, and link member 232 of the variable-speed
actuator 230 are enclosed by encapsulation member 260. During the
assembly process, the spring 238 is at least partially compressed
to allow its first end to engage the sliding member 234 and its
second end to engage another restraining member, such as an inner
wall of the housing 204. Since the spring 238 has to be left in its
partially-compressed state, it is difficult to hold spring 238 down
in place while the encapsulation cover 240 is mounted on the module
housing 204 as the spring 238 tends to spring out of place.
[0076] To solve this problem, according to an embodiment of the
invention, a spring post 244 is provided on the inner wall of the
housing 204 where an end of the compression spring 238 makes
contact. In an embodiment, a pocket 245 is additionally provided as
a recess within the inner wall of the module housing 204 and the
post 244 projects from a center of the pocket 245. In other words,
the pocket 245 forms as a halo around the post 244. FIG. 11
provides a cross-sectional view of the spring 234 engaging the post
244 and pocket 245. FIG. 12 provides a zoomed-in view of the post
244 and pocket 245. An end of the compression spring 238 is places
around the spring post 244 within the pocket 245 during the
assembly process. Post 244 and pocket 245 prevent the end of the
spring 238 from moving around and springing out of position. In
particular, in an embodiment, post 244 fits form-fittingly inside
the inner diameter of the compression spring 238, while the
compression spring fits form-fittingly inside the pocket 245.
[0077] In an embodiment, post 244 includes a lower surface 248 that
projects substantially longitudinally and an upper surface 249 that
is slanted away from the inner wall of the housing 204. The lower
surface 248 of the post helps retain the spring 238 in place along
its longitudinal axis and blocks the spring 238 from springing
upward, while the upper surface 249 provides for easier assembly of
the spring 238 over the post 244, i.e., by sliding the spring 238
over the post 244.
[0078] In addition, in an embodiment, sliding member 234 is also
provided with a pocket 246. The other end of the spring 238 is
received inside the pocket 246 of the sliding member 234. The
pocket 246 also prevents the spring 238 from moving around and
springing out of position.
[0079] The combination of the sliding member pocket 246, post 244,
and post pocket 245 decrease the degree of freedom of compression
spring 238 during the assembly process. Constraining the motion of
compression spring 238 during the assembly process makes the
control module 200 assembly easy and decreases the time required
for the assembly.
[0080] The example embodiments of the present invention being thus
described, it will be obvious that the same may be varied in many
ways. Such variations are not to be regarded as departure from the
spirit and scope of the example embodiments of the present
invention, and all such modifications as would be obvious to one
skilled in the art are intended to be included within the scope of
the following claims.
* * * * *