Blower

Abstract

The present invention provides a blower that reduces manufacturing costs by having a structure that allows the motor and power supply to be connected regardless of the type of motor being implemented. [Solution] Electronic components related to constant airflow control are integrated into the motor control board 18, which is the motor-side circuit board. The target airflow acquisition unit 27 belonging to the motor unit 6 and the target airflow switching unit 17 belonging to the power supply unit 8 are connected via a connector 32 to enable communication. Information regarding the target airflow Qs set by the target airflow switching unit 17 of the power supply unit 8 is transmitted to the target airflow acquisition unit 27 of the motor unit 6 via the connector 32, thereby providing a blower that enables constant airflow control via the motor control board 18.

Description

Technical Field

[0001] The present invention relates to a blower device.

Background Art

[0002] In a ventilation device that can be used as a conventional blower device, a configuration for controlling the air volume to be constant so as to match the target air volume is known (for example, see Patent Document 1).

[0003] Hereinafter, the configuration will be described with reference to FIG. 11. FIG. 11(a) is a side view showing a state where a conventional ventilation device 101 is attached to a ceiling, and FIG. 11(b) is a block diagram showing the configuration of a sensorless brushless DC motor 106 and a control circuit 108 in the conventional ventilation device.

[0004] As shown in FIG. 11(a), the conventional ventilation device 101 is installed in the ceiling space of a room and has a suction port 102a below the main body 102. An adapter 103 is provided on the side surface of the main body 102 and is connected to an exhaust port provided on an outer wall or the like through an exhaust duct 104. Inside the main body 102, there are provided blades 105 and a sensorless brushless DC motor 106 for rotating the blades 105, and the suction port 102a is provided with a louver 107 covering the suction port 102a. Further, a control circuit 108 for driving the sensorless brushless DC motor 106 is arranged inside the main body 102. And a remote control device 109 (a switch formed by integrating a power on / off switch 109a and a fan notch setting switch 109b) is arranged on the wall of the room and is connected to the control circuit 108.

[0005] In Figure 11(b), the AC voltage supplied from the commercial power supply 110 is converted to DC by the AC / DC conversion circuit 111, smoothed by the smoothing capacitor 112, and then applied to the inverter circuit 113. The inverter circuit 113 sequentially activates six switching elements to drive the sensorless brushless DC motor 106. The sensorless brushless DC motor 106 consists of a stator 114 with windings and a rotor 115 equipped with magnets. The current detection unit 116 detects the current of each phase flowing through the sensorless brushless DC motor 106, and the rotation detection unit 117 calculates the rotation speed and position of the sensorless brushless DC motor 106. The target airflow calculation unit 118 calculates the target airflow corresponding to the setting of the fan notch setting switch 109b and instructs the airflow calculation unit 119 to use this target airflow. The airflow calculation unit 119 compares the output airflow calculated based on the current detected by the current detection unit 116 and the rotation speed detected by the rotation detection unit 117 with the target airflow. If the output airflow is less than the target airflow, the airflow calculation unit 119 instructs the inverter circuit 113 via the speed control unit 120 to output a larger duty cycle. If the output airflow is greater than the target airflow, the airflow calculation unit 119 instructs the inverter circuit 113 via the speed control unit 120 to output a smaller duty cycle. This configuration allows the rotation speed of the sensorless brushless DC motor 106 to be varied to output the required airflow. [Prior art documents] [Patent Documents]

[0006] [Patent Document 1] Japanese Patent Publication No. 2015-10530 [Overview of the project] [Problems that the invention aims to solve]

[0007] In the ventilation device described in Patent Document 1, electronic components such as an airflow calculation unit are mounted on a control circuit that is provided independently of the sensorless brushless DC motor. By connecting the motor and the control circuit, power is supplied from the power source to achieve constant airflow control. Patent Document 1 discloses, as an example, a configuration in which an inverter circuit having six switching elements is connected to a three-phase sensorless brushless DC motor. In this case, three arms, each consisting of two switching elements connected in series to a DC voltage, are connected in a three-phase bridge configuration, and a three-phase PWM voltage is applied to the motor. In other words, by connecting the control circuit and the sensorless brushless DC motor with three wires, the power source and the sensorless brushless DC motor are connected, and the power necessary for constant airflow control is supplied.

[0008] Let's consider the case where the motor type is changed from three-phase to single-phase. In a single-phase system, for example, the number of switching elements in the inverter circuit becomes four, and the motor and control circuit are connected by two wires. In other words, in order to reflect constant airflow control in the motor when the motor type is changed, it was necessary to change the number of switching elements in the control circuit and also change the method of connecting the motor and the control circuit. To put it another way, because the process of connecting the motor and the power supply differs depending on the type of motor implemented, manufacturing costs tended to increase as the product variations increased.

[0009] The present invention aims to provide a blower that reduces manufacturing costs by having a structure that allows the motor and power supply to be connected regardless of the type of motor being implemented. [Means for solving the problem]

[0010] To achieve the above objective, the blower according to the present invention is a blower having a power supply unit and a motor unit, wherein the power supply unit includes a power supply board that converts the supplied power supply voltage to a predetermined converted voltage and a target airflow switching unit that switches the setting of the target airflow, the motor unit is provided independently of the power supply unit and includes a motor drive circuit unit that outputs supplied power, a motor drive unit that rotates upon receiving supplied power and a motor control board that controls the motor drive unit, the motor control board includes a target airflow acquisition unit that acquires the target airflow, a rotation speed detection unit that detects the rotation speed of the motor drive unit and a predetermined variable corresponding to the converted voltage The motor drive circuit unit comprises a first post-conversion current detection unit that detects the magnitude of the post-conversion current, and a constant airflow calculation unit that calculates the power supply for constant airflow control at a target airflow rate based on the rotational speed detected by the rotational speed detection unit and the magnitude of the post-conversion current detected by the first post-conversion current detection unit. The rotational speed detection unit comprises a rotor position calculation unit that calculates the magnetic pole position of the rotor based on the post-conversion current detected by the first post-conversion current detection unit, and a rotational speed calculation unit that calculates the rotational speed of the motor drive unit based on the change in the magnetic pole position of the rotor calculated by the rotor position calculation unit. The motor drive circuit unit outputs the power supply obtained by the calculation to the motor drive unit. The target airflow acquisition unit is equipped with a connector that electrically connects the target airflow acquisition unit, which belongs to the motor unit, and the target airflow switching unit, which belongs to the power supply unit. The target airflow setting of the target airflow switching unit, which belongs to the power supply unit, is acquired via the connector, thereby achieving the intended purpose. [Effects of the Invention]

[0011] According to the present invention, a blower device with reduced manufacturing costs can be provided by a structure that allows the motor and power supply to be connected regardless of the type of motor being implemented. [Brief explanation of the drawing]

[0012] [Figure 1] Side view showing the configuration of a blower according to an embodiment of the present invention. [Figure 2] Block diagram showing the configuration of the power supply unit and motor unit according to an embodiment of the present invention. [Figure 3]Block diagram showing the configuration of the power supply unit and motor unit according to Modification 1 of the present invention. [Figure 4] Block diagram showing the configuration of the power supply unit and motor unit according to Modification 2 of the present invention. [Figure 5] Block diagram showing the configuration of the power supply unit and motor unit according to Modification 3 of the present invention. [Figure 6] Block diagram showing the configuration of the power supply unit and motor unit according to Modification 4 of the present invention. [Figure 7] Block diagram showing the configuration of the power supply unit and motor unit according to Modification 5 of the present invention. [Figure 8] Block diagram showing the configuration of the power supply unit and motor unit according to Modification 6 of the present invention. [Figure 9] Block diagram showing the configuration of the power supply unit and motor unit according to Modification 7 of the present invention. [Figure 10] Block diagram of the motor section according to an embodiment of the present invention when it is single-phase. [Figure 11] Diagram showing the configuration of a conventional ventilation system. [Modes for carrying out the invention]

[0013] Embodiments of the present invention will be described below with reference to the drawings. Note that the following embodiments are merely examples of the present invention and do not limit the technical scope of the present invention. Furthermore, throughout all drawings, the same parts are denoted by the same reference numerals, and subsequent descriptions are omitted. In addition, details of parts not directly related to the present invention are omitted in each drawing. (Embodiment) An embodiment of the present invention will be described with reference to Figure 1. Figure 1 is a side view showing the configuration of the blower 1. In this embodiment, a blower that can also be used as a ventilation fan installed on the ceiling of a living room will be described as an example, but the blower can have any configuration as long as it is capable of blowing air.

[0014] The air blower 1 blows out the air sucked in from the outside through, for example, the duct 4 into the living room. The air blower 1 includes a main body case 2, an adapter 3, a louver 7, a power supply unit 8, a motor unit 6, blades 5, a remote control device 9, and a connector 32.

[0015] The main body case 2 is formed in a hollow box shape and forms the outer shell of the air blower 1. The main body case 2 is fixed to an opening provided, for example, on the ceiling of the living room. The main body case 2 sucks air from a suction port 2a provided on one side surface of the box shape and blows out the air from a blowout port 2b provided on the bottom surface of the box shape.

[0016] The adapter 3 is provided on one side surface of the main body case 2 and connects the main body case 2 and the duct 4 in a ventilable manner. In other words, the adapter 3 connects the suction port 2a and the duct 4.

[0017] The louver 7 has a ventilation port for allowing the air in the living room to pass through the inside of the main body case 2. The louver 7 is arranged so as to cover the blowout port 2b vertically below the main body case.

[0018] The motor unit 6 rotates when power is supplied to the air blower 1. The motor unit 6 is provided on the top surface of the box shape of the main body case 2. Details of the motor unit 6 will be described later.

[0019] The power supply unit 8 is provided on the top surface of the box shape of the main body case 2, converts the voltage supplied from the power source into a predetermined voltage, and supplies it to the motor unit 6. Incidentally, if the power supply unit 8 can supply a predetermined voltage to the motor unit 6, it may be provided anywhere on the main body case 2. Details of the power supply unit will be described later.

[0020] The blades 5 are provided inside the main body case 2 and blow out air into the living room by rotating together with the motor unit 6.

[0021] The remote control device 9 is installed on the wall of the living room and receives instructions regarding the control of the blower 1. The remote control device 9 is equipped with, for example, a power switch 9a to switch the blower 1 on and off, and a fan notch switch 9b to set the amount of air blown by the blower 1. The remote control device 9 can be installed in any way, whether wired or wireless, as long as it is connected to the blower 1 in a way that allows it to communicate with it.

[0022] Connector 32 connects the power supply unit 8 and the motor unit 6 in a way that enables communication. Connector 32 is, for example For example, one end is electrically connected to the power supply unit 8 and the other end is electrically connected to the motor unit 6. With this configuration, the motor unit 6 can obtain the airflow setting for the fan notch switch 9b from the power supply unit 8.

[0023] Note that the configuration of the blower 1 in this embodiment is just one example. For example, it may be used as a ventilation fan that draws air from the living room through the outlet 2b and blows it out through the intake 2a by rotating the blades 5 in the opposite direction.

[0024] Next, the configurations of the power supply unit 8 and the motor unit 6 will be explained in detail with reference to Figure 2. Figure 2 is a block diagram showing the configurations of the power supply unit 8 and the motor unit 6. In Figure 2, the power supply unit 8 is supplied with power voltage from the commercial power supply 10. In the following explanation, the AC voltage supplied from the commercial power supply 10 will be referred to as the power supply voltage, and the AC current corresponding to the power supply voltage will be referred to as the power supply current. Furthermore, the DC voltage before it is rectified from AC to DC by the converter 12 (described later) and its magnitude is converted by the voltage conversion unit 14 (described later) will be referred to as the pre-conversion voltage, and the DC current corresponding to the pre-conversion voltage will be referred to as the pre-conversion current. Furthermore, the DC voltage after its magnitude has been converted by the voltage conversion unit 14 will be referred to as the post-conversion voltage, and the DC current corresponding to the post-conversion voltage will be referred to as the post-conversion current.

[0025] The power supply unit 8 comprises a power supply board 11 and a target airflow switching unit 17.

[0026] The power supply board 11 converts the power supply voltage supplied from the commercial power supply 10 into a converted voltage usable by the motor section using mounted electronic components. The power supply board 11 comprises a converter 12, a smoothing capacitor 13, a voltage conversion unit 14, an isolated voltage detection unit 15, and a power supply control unit 16.

[0027] The converter 12 rectifies the AC voltage supplied from the commercial power supply 10 into DC. The converter 12 is provided by connecting four diodes in a diamond shape, for example, as shown in Figure 2.

[0028] The smoothing capacitor 13 smooths out the pulsations contained in the voltage rectified by the converter 12. In this way, the power supply voltage supplied from the commercial power supply 10 is rectified and smoothed by the converter 12 and the smoothing capacitor 13 to the pre-conversion voltage, which is a DC voltage.

[0029] The voltage conversion unit 14 consists of a primary coil to which the pre-conversion voltage is applied and a secondary coil to which the post-conversion voltage is generated. The magnitude of the voltage is converted by the difference in the number of turns between the primary and secondary coils. In the voltage conversion unit 14, a magnetic flux is generated when the pre-conversion voltage is applied to the primary coil, and the generated magnetic flux intersects the secondary coil, converting the pre-conversion voltage into a post-conversion voltage of a predetermined magnitude. Here, the predetermined magnitude of the voltage is the voltage required for the motor unit 6, and in this embodiment, it is converted to 29V as an example.

[0030] In the voltage conversion unit 14, it is preferable that the secondary coil is insulated from the primary coil. In other words, the power supply board 11 is electrically insulated before and after the conversion to the converted voltage. By insulating the primary coil from the secondary coil, it is possible to prevent the converted current from entering areas other than the target airflow switching unit 17 and the motor drive circuit unit 21 described later.

[0031] The isolated voltage detection unit 15 detects the magnitude of the converted voltage converted by the voltage conversion unit 14. The isolated voltage detection unit 15 is electrically isolated from the primary coil, similar to the secondary coil in the voltage conversion unit 14.

[0032] The power control unit 16 adjusts the magnitude of the voltage applied to the primary coil by controlling the ON / OFF ratio of the switching elements that perform opposing ON / OFF operations. For example, if the magnitude of the converted voltage detected by the isolated voltage detection unit 15 is greater than 29V, the power control unit 16 will adjust the voltage applied to the primary coil. The ON ratio of the switching element is reduced, and when it is less than 29V, the ON ratio of the switching element is increased to control the magnitude of the converted voltage to a predetermined value.

[0033] The target airflow switching unit 17 switches the setting of the target airflow Qs in accordance with the airflow indicated by the fan notch switch 9b in Figure 1. The target airflow switching unit 17 is, for example, a variable resistor connected to the secondary coil of the voltage conversion unit 14, and may be configured to increase the resistance value as the target airflow Qs increases, thereby dividing the converted voltage.

[0034] The motor unit 6 is a three-phase motor and is provided independently of the power supply unit 8. The motor unit 6 comprises a motor drive unit 19, a motor control board 18, and a housing 20.

[0035] The motor drive unit 19 consists of a rotor with magnets and a stator around which windings are wound. Here, the windings are star-connected coils consisting of three windings, one for each of the three phases: U-phase, V-phase, and W-phase, i.e., three-phase windings. The motor drive unit 19 is driven by power supplied from the power supply unit 8, which rotates the blades 5 mounted on the motor drive unit 19.

[0036] The motor control board 18 controls the motor drive unit 19 using mounted electronic components. The motor control board 18 includes a motor drive circuit unit 21, a first post-conversion current sensor 22, a first post-conversion current detection unit 23, a rotation speed detection unit 24, a rotor position calculation unit 25, a rotation speed calculation unit 26, a motor drive logic generation unit 30, a target airflow acquisition unit 27, a constant airflow data storage unit 28, a constant airflow calculation unit 29, a modulation unit 31, and an advance angle adjustment unit 38.

[0037] The motor drive circuit 21 is an inverter circuit equipped with six switching elements that perform opposing ON / OFF operations. The motor drive circuit 21 consists of an upper stage and a lower stage, and by connecting three arms, each consisting of two switching elements connected in series, in a three-phase bridge configuration, it converts the DC voltage to a three-phase PWM AC voltage and applies it to the motor drive unit 19. In other words, the motor drive circuit 21 outputs the power supply, which is the power required to drive the motor drive unit 19, to the motor drive unit 19.

[0038] The first post-conversion current sensor 22 is, for example, a shunt resistor, and the voltage generated by the current flowing through this shunt resistor is amplified and output to the first post-conversion current detection unit 23.

[0039] The first post-conversion current detection unit 23 detects the post-conversion current corresponding to the post-conversion voltage based on the magnitude of the voltage amplified by the first post-conversion current sensor 22.

[0040] The rotation speed detection unit 24 detects the rotation speed of the motor drive unit 19. The rotation speed detection unit 24 is, for example, a Hall element and detects the change in the magnetic field caused by the rotation of the rotor in the motor drive unit 19. One or more rotation speed detection units 24 may be provided.

[0041] The rotor position calculation unit 25 calculates the rotational position of the motor drive unit 19 based on the changes in the magnetic field of each phase of the motor drive unit 19 detected by the rotational speed detection unit 24.

[0042] The rotation speed calculation unit 26 calculates the rotation speed of the motor drive unit 19 based on the changes in the magnetic field of each phase of the motor drive unit 19 detected by the rotation speed detection unit 24.

[0043] The motor drive logic generation unit 30 determines how to energize the six switching elements based on the rotational position of the motor drive unit 19 calculated by the rotor position calculation unit 25. In other words, the motor drive logic generation unit 30 determines what kind of rotating magnetic field to generate in the stator of the motor drive unit 19.

[0044] The target airflow acquisition unit 27 acquires the target airflow Qs set in the target airflow switching unit 17. Here, the target airflow acquisition unit 27 belongs to the motor unit 6, and the target airflow switching unit 17 belongs to the power supply unit 8, which is independent of the motor unit 6. The target airflow acquisition unit 27, which belongs to the motor unit 6, is connected to the target airflow switching unit 17, which belongs to the power supply unit 8, via a connector 32 so as to be able to communicate. In other words, the target airflow acquisition unit 27 and the target airflow switching unit 17 are electrically connected via the connector 32. The target airflow acquisition unit 27 can acquire the target airflow Qs set in the target airflow switching unit 17 via the connector 32. In other words, the target airflow acquisition unit 27 can acquire the airflow setting of the fan notch switch 9b via the connector 32. The target airflow acquisition unit 27 determines the magnitude of the target airflow Qs based on, for example, the magnitude of the divided voltage obtained by dividing the converted voltage in the target airflow switching unit 17.

[0045] Furthermore, the connection via connector 32 may be detachable. In other words, the motor unit 6 is detachably attached to the power supply unit 8 via connector 32.

[0046] The constant airflow data storage unit 28 stores the relationship between the converted current, the rotational speed of the motor drive unit 19, and the output airflow Qn of the blower 1. The constant airflow data storage unit 28 has multiple storage units corresponding to the fan notch switch 9b, and can select which storage unit's data to use from among the multiple storage units based on the target airflow Qs acquired by the target airflow acquisition unit 27.

[0047] The constant airflow calculation unit 29 increases or decreases the duty cycle instruction value so that the relationship between the converted current and the rotational speed of the motor drive unit 19 becomes a predetermined relationship. Here, the predetermined relationship is the relationship stored in the constant airflow data storage unit 28. The constant airflow calculation unit 29 compares whether the output airflow Qn, calculated based on the converted current detected by the first converted current detection unit 23 and the rotational speed of the motor drive unit 19 calculated by the rotational speed calculation unit 26, is higher or lower than the target airflow Qs acquired by the target airflow acquisition unit 27. If the output airflow Qn is smaller than the target airflow Qs, the constant airflow calculation unit 29 instructs the motor drive logic generation unit 30 to output a larger duty cycle. If the output airflow Qn is larger than the target airflow Qs, the constant airflow calculation unit 29 instructs the motor drive logic generation unit 30 to output a smaller duty cycle. In other words, the constant airflow calculation unit 29 calculates the power supply required to perform constant airflow control at the target airflow Qs. In this way, the constant airflow calculation unit 29 performs calculations to control the airflow by reducing the deviation between the output airflow Qn and the target airflow Qs.

[0048] The advance angle adjustment unit 38 adjusts the advance angle of the motor drive unit by correcting the phase of the rotating magnetic field determined by the motor drive logic generation unit 30 based on the calculations of the constant airflow calculation unit 29.

[0049] The modulation unit 31 outputs pulses to the motor drive circuit unit 21 based on the duty cycle instruction value of the constant airflow calculation unit 29. The modulation unit 31 varies the rotation speed of the motor drive unit 19 by sequentially conducting six switching elements at a predetermined duty cycle ON / OFF ratio to output the required airflow.

[0050] The housing 20 is the outer casing of the motor unit 6 and is formed, for example, in a hollow cylindrical shape. The motor control board 18 and the motor drive unit 19 are arranged inside the housing 20, preventing foreign matter such as water and dust from adhering to the motor control board 18 and the motor drive unit 19.

[0051] Now, referring to Figure 10, we will explain the case where the motor is single-phase. Figure 10 is a block diagram when the motor section 6 in Figure 2 is replaced with a single-phase motor, which is motor section 6a. Since it is a single-phase motor, the winding arranged in the motor drive section 19a is a single winding, i.e., a single-phase winding.

[0052] The motor drive circuit section 21a is equipped with four switching elements, and the motor drive section 19a is equipped with four switching elements. Connect the two arms and apply voltage.

[0053] The target airflow acquisition unit 27 acquires the target airflow Qs set by the target airflow switching unit 17 via the connector 32.

[0054] The constant airflow calculation unit 29 outputs a duty cycle instruction value to the modulation unit 31 so as to reduce the deviation between the target airflow Qs acquired by the target airflow acquisition unit 27 and the output airflow Qn of the blower 1.

[0055] The modulation unit 31 outputs pulses to the motor drive circuit unit 21a based on the duty cycle instruction value of the constant airflow calculation unit 29. The modulation unit 31 varies the rotation speed of the motor drive unit 19a by sequentially conducting four switching elements at a predetermined duty cycle ON / OFF ratio to output the required airflow.

[0056] This configuration makes it possible to achieve constant airflow control even with the single-phase motor unit 6a.

[0057] By the way, in Patent Document 1, as shown in Figure 11(a), constant airflow control is performed by a control circuit 108 that is independent of the sensorless brushless DC motor 106. In other words, the electronic components related to constant airflow control were concentrated on the control circuit 108 side, which obtains the airflow setting from the fan notch switch 9b. In this structure, if the type of motor was changed, in order to reflect the constant airflow control to the motor, it was necessary to change the number of switching elements in the control circuit and also change the method of connecting the motor and the control circuit. In other words, because the process of connecting the motor and the power supply differed depending on the type of motor being implemented, manufacturing costs tended to increase as the product variations increased.

[0058] In this invention, as shown in Figure 2, electronic components related to constant airflow control are integrated into the motor control board 18 belonging to the motor unit 6, and the target airflow acquisition unit 27 belonging to the motor unit 6 and the target airflow switching unit 17 belonging to the power supply unit 8 are connected via a connector 32 to enable communication. By transmitting information regarding the target airflow Qs set in the target airflow switching unit 17 of the power supply unit 8 to the target airflow acquisition unit 27 of the motor unit 6 via the connector 32, constant airflow control becomes possible on the motor control board 18. With this structure, even if the motor is single-phase as shown in Figure 10, constant airflow control can be achieved by connecting the target airflow switching unit 17 and the target airflow acquisition unit 27 with the connector 32, just as in the case of a three-phase motor in Figure 2. In other words, a blower capable of constant airflow control can be realized with a common process of connecting the motor and power supply with a single connector, regardless of the type of motor implemented.

[0059] As described above, a blower capable of constant airflow control can be realized using a common process regardless of the type of motor implemented. Therefore, even when increasing the product variations, manufacturing costs can be reduced and blowers can be provided.

[0060] The structure described in the embodiment is merely one example of the present invention and does not limit the technical scope of the present invention. Functions may be added or removed as needed. The goal is to provide a blower 1 with reduced manufacturing costs by connecting the target airflow acquisition unit 27 belonging to the motor unit 6 and the target airflow switching unit 17 belonging to the power supply unit 8 via a connector 32 in a way that enables communication. Several modified examples described below will explain structures with functions different from the embodiment. (Variation 1) A modified example of the embodiment will be described with reference to Figure 3. In Figure 3, the power supply board 11 includes a pre-conversion current sensor 33 and a pre-conversion current detection unit 34.

[0061] The pre-conversion current sensor 33 is, for example, a shunt resistor connected to the primary coil of the voltage conversion unit 14. The voltage generated by the current flowing through this shunt resistor is amplified and output to the pre-conversion current detection unit 34.

[0062] The pre-conversion current detection unit 34 detects the pre-conversion current corresponding to the pre-conversion voltage based on the magnitude of the voltage amplified by the pre-conversion current sensor 33.

[0063] The power control unit 16 controls the ON / OFF ratio of the switching elements based on the magnitude of the pre-conversion current detected by the pre-conversion current detection unit 34. For example, if the magnitude of the detected pre-conversion current is greater than the current threshold, which is the overcurrent threshold, the switching elements are turned OFF or the ON ratio of the switching elements is reduced. In other words, if the magnitude of the pre-conversion current is greater than or equal to a predetermined current threshold, the supply of the converted voltage to the motor unit 6 is stopped or limited.

[0064] This configuration limits the pre-conversion current flowing through the primary coil of the voltage conversion unit 14 to prevent it from becoming an overcurrent, thus limiting the post-conversion current output from the secondary coil to a size that does not become an overcurrent. (Modification 2) Next, a modified example of the embodiment 2 will be described with reference to Figure 4. In Figure 4, the power supply board 11 includes a second post-conversion current sensor 35 and a second post-conversion current detection unit 36.

[0065] The second post-conversion current sensor 35 is, for example, a shunt resistor connected to the secondary coil of the voltage conversion unit 14. The voltage generated by the current flowing through this shunt resistor is amplified and output to the second post-conversion current detection unit 36.

[0066] The second post-conversion current detection unit 36 ​​detects the post-conversion current corresponding to the post-conversion voltage based on the magnitude of the voltage amplified by the second post-conversion current sensor 35.

[0067] The power control unit 16 controls the ON / OFF ratio of the switching element based on the magnitude of the converted current detected by the second converted current sensor 35. For example, if the magnitude of the detected converted current is also large enough to exceed the current threshold (overcurrent threshold), the switching element is turned OFF, or the ON ratio of the switching element is reduced. In other words, if the magnitude of the converted current is greater than or equal to a predetermined current threshold, the supply of the converted voltage to the motor unit 6 is stopped or limited.

[0068] By detecting the magnitude of the converted current flowing to the motor section 6 and controlling the magnitude of the pre-conversion current flowing to the primary coil, the converted current can be limited to a size that does not cause overcurrent with greater precision than in Modification 1. (Variation 3) Next, a modified example 3 of the embodiment will be described with reference to Figure 5. In Figure 5, the motor control board 18 includes a converted voltage detection unit 37.

[0069] The converted voltage detection unit 37 detects the magnitude of the converted voltage on the motor control board 18 and outputs it to the constant airflow calculation unit 29. In other words, the converted voltage detection unit 37 detects the magnitude of the converted voltage applied to the motor drive circuit unit 21.

[0070] The constant airflow calculation unit 29 compares the voltage required for the power supplied by the motor drive circuit unit 21 to the motor drive unit 19 with the magnitude of the converted voltage detected by the converted voltage detection unit 37, and corrects the constant airflow control calculation based on the difference. For example, if the converted voltage is smaller, the duty cycle instruction value is increased, and if the converted voltage is larger, the duty cycle instruction value is decreased.

[0071] With this configuration, even if the conversion accuracy of the voltage conversion unit 14 is low, power can be stably supplied to the motor drive unit 19, thus enabling precise constant airflow control. (Modification 4) Next, a modified example 4 of the embodiment will be described with reference to Figure 6. In Figure 6, the motor control board 18 includes a modulation reflection unit 39.

[0072] The modulation reflection unit 39 feeds back the pulses output from the modulation unit 31 to the motor drive circuit unit 21 to the constant airflow calculation unit 29. In other words, the modulation reflection unit 39 outputs information to the constant airflow calculation unit 29 about the duty cycle at which the pulses were output to the motor drive circuit unit 21.

[0073] The constant airflow calculation unit 29 compares the duty cycle instruction value specified by the constant airflow calculation unit 29 with the duty cycle of the pulse output by the modulation unit 31 and corrects the constant airflow control calculation based on the difference. With this configuration, constant airflow control can be achieved with high accuracy, similar to the modified example 3. (Variation 5) Next, a modified example 5 of the embodiment will be described with reference to Figure 7. In Figure 7, the power supply unit 8 includes a humidity sensor 40, a human detection sensor 41, and a delay switching timer 42.

[0074] The humidity sensor 40 is located in the power supply unit 8 and acquires the humidity of the space to which the blower 1 is blowing air and outputs it to the target airflow switching unit 17. Here, the space to which air is blown air can be, for example, a living room in which the blower 1 is installed. If the humidity acquired by the humidity sensor 40 is above a predetermined humidity threshold, the target airflow switching unit 17 switches the target airflow Qs to a setting greater than the target airflow Qs, thereby eliminating user discomfort in high humidity conditions.

[0075] The human detection sensor 41 is located in the power supply unit 8 and acquires the presence or absence of people in the space to be air-blown by the blower 1, and outputs this information to the target airflow switching unit 17. The human detection sensor 41 detects the presence or absence of people in the room where the blower 1 is installed, for example, by using infrared light. If the human detection sensor 41 detects that no people are present, the target airflow Qs is switched to a setting smaller than the target airflow Qs, allowing the blower 1 to be operated in an energy-saving manner.

[0076] The delay switching timer 42 is a device for returning the airflow setting, which has been switched based on the humidity sensor 40 or the human detection sensor 41, back to the original target airflow Qs after a predetermined time has elapsed. When the time measured by the delay switching timer 42 exceeds a predetermined time threshold, the target airflow switching unit 17 returns the airflow setting back to the original target airflow Qs. For example, if the setting is switched to a level higher than the target airflow Qs by the humidity sensor 40, the timer starts measuring time when the humidity changes from above a predetermined humidity threshold to below the humidity threshold. Similarly, if the setting is switched to a level lower than the target airflow Qs by the human detection sensor 41, the timer starts measuring time when the presence of a person changes from no person to a person present. By measuring a predetermined time with the delay switching timer 42, it is possible to suppress the airflow setting from switching multiple times in a short period of time less than the time threshold, thereby stabilizing the operation of the blower 1. (Experimental variation 6) Next, a modified example 6 of the embodiment will be described with reference to Figure 8. In Figure 8, the power supply unit 8 is equipped with a thermal fuse 43.

[0077] The thermal fuse 43 is installed between the second coil of the voltage conversion unit 14 and the motor drive circuit unit 21, and disconnects the motor unit 6 and the power supply unit 8 when the temperature of the power supply unit 8 exceeds a predetermined temperature threshold. In other words, the thermal fuse 43 stops supplying voltage to the motor unit 6 and forcibly stops the blower 1 when the temperature of the power supply unit 8 exceeds a predetermined temperature. With this configuration, even if a fire occurs around the blower 1, the temperature of the power supply unit 8 will not exceed a predetermined temperature. If the temperature exceeds a certain level, the blower 1 is forcibly stopped, thus preventing the fire from spreading to the surrounding area due to the blower's airflow. (Example 7) Next, a modified example 7 of the embodiment will be described with reference to Figure 9. Figure 2 shows a motor with a sensor, such as a Hall element, for detecting the magnetic pole position of the rotor, but it may also be a sensorless motor without a sensor. The case of a sensorless motor will be explained using Figure 9.

[0078] Figure 9 is a block diagram showing the configuration of the power supply unit 8 and the motor unit 6 in a sensorless motor. The power supply unit 8 is the same as in Figure 2, so its explanation is omitted.

[0079] The motor unit 6 is a three-phase sensorless motor and is provided independently of the power supply unit 8. The motor unit 6 comprises a motor drive unit 19, a motor control board 18, and a housing 20.

[0080] The motor drive unit 19 consists of a rotor with magnets and a stator around which windings are wound. Here, the windings are star-connected coils consisting of three windings, one for each of the three phases: U-phase, V-phase, and W-phase, i.e., three-phase windings. The motor drive unit 19 is driven by power supplied from the power supply unit 8, which rotates the blades 5 mounted on the motor drive unit 19.

[0081] The motor control board 18 controls the motor drive unit 19 using mounted electronic components. The motor control board 18 includes a motor drive circuit unit 21, a first post-conversion current sensor 22, a first post-conversion current detection unit 23, a rotation speed detection unit 24a, a rotor position calculation unit 25, a rotation speed calculation unit 26, a motor drive logic generation unit 30, a target airflow acquisition unit 27, a constant airflow data storage unit 28, a constant airflow calculation unit 29, and a modulation unit 31.

[0082] The motor drive circuit 21 is an inverter circuit equipped with six switching elements that perform opposing ON / OFF operations. The motor drive circuit 21 consists of an upper stage and a lower stage, and by connecting three arms, each consisting of two switching elements connected in series, in a three-phase bridge configuration, it converts the DC voltage to a three-phase PWM AC voltage and applies it to the motor drive unit 19. In other words, the motor drive circuit 21 outputs the power supply, which is the power required to drive the motor drive unit 19, to the motor drive unit 19.

[0083] The first post-conversion current sensor 22 is, for example, a shunt resistor inserted between the lower stage and the negative potential side of each phase of the inverter circuit, which is the motor drive circuit section 21. The voltage generated by the current flowing through each of these shunt resistors is amplified and output to the first post-conversion current detection section 23.

[0084] The first post-conversion current detection unit 23 detects the post-conversion current for each phase corresponding to the post-conversion voltage based on the magnitude of the voltage for each phase amplified by the first post-conversion current sensor 22.

[0085] The rotation speed detection unit 24a detects the rotation speed of the motor drive unit 19. The rotation speed detection unit 24a includes a rotor position calculation unit 25 and a rotation speed calculation unit 26.

[0086] The rotor position calculation unit 25 calculates the magnetic pole position of the rotor based on the change in current flowing through the motor windings as the rotor rotates in the motor drive unit 19, that is, the converted current detected by the first converted current detection unit 23. In this modified example, the rotor position calculation unit 25 calculates the magnetic pole position of the rotor based on the converted current for each phase detected by the first converted current detection unit 23.

[0087] The rotational speed calculation unit 26 calculates the rotational speed of the motor drive unit 19 based on the change in the magnetic pole position of the rotor calculated by the rotor position calculation unit 25. The rotational speed of the drive unit 19 is the rotational speed detected by the rotational speed detection unit 24.

[0088] The motor drive logic generation unit 30 determines how to energize the six switching elements based on the rotational position of the motor drive unit 19 calculated by the rotor position calculation unit 25. In other words, the motor drive logic generation unit 30 determines what kind of rotating magnetic field to generate in the stator of the motor drive unit 19.

[0089] The target airflow acquisition unit 27 acquires the target airflow Qs set in the target airflow switching unit 17. Here, the target airflow acquisition unit 27 belongs to the motor unit 6, and the target airflow switching unit 17 belongs to the power supply unit 8, which is independent of the motor unit 6. The target airflow acquisition unit 27, which belongs to the motor unit 6, is connected to the target airflow switching unit 17, which belongs to the power supply unit 8, via a connector 32 so as to be able to communicate. In other words, the target airflow acquisition unit 27 and the target airflow switching unit 17 are electrically connected via the connector 32. The target airflow acquisition unit 27 can acquire the target airflow Qs set in the target airflow switching unit 17 via the connector 32. In other words, the target airflow acquisition unit 27 can acquire the airflow setting of the fan notch switch 9b via the connector 32. The target airflow acquisition unit 27 determines the magnitude of the target airflow Qs based on, for example, the magnitude of the divided voltage obtained by dividing the converted voltage in the target airflow switching unit 17.

[0090] Furthermore, the connection via connector 32 may be detachable. In other words, the motor unit 6 is detachably attached to the power supply unit 8 via connector 32.

[0091] The constant airflow data storage unit 28 stores the relationship between the converted current, the rotational speed of the motor drive unit 19, and the output airflow Qn of the blower 1. The constant airflow data storage unit 28 has multiple storage units corresponding to the fan notch switch 9b, and can select which storage unit's data to use from among the multiple storage units based on the target airflow Qs acquired by the target airflow acquisition unit 27.

[0092] The constant airflow calculation unit 29 increases or decreases the duty cycle instruction value so that the relationship between the converted current and the rotational speed of the motor drive unit 19 becomes a predetermined relationship. Here, the predetermined relationship is the relationship stored in the constant airflow data storage unit 28. The converted current used by the constant airflow calculation unit 29 may be the converted current of all phases or the converted current of one phase. The constant airflow data storage unit 28 also stores the relationship between the converted current corresponding to the converted current used by the constant airflow calculation unit 29, the rotational speed of the motor drive unit 19, and the output airflow Qn of the blower 1.

[0093] The constant airflow calculation unit 29 compares whether the output airflow Qn, calculated based on the converted current detected by the first converted current detection unit 23 and the rotational speed of the motor drive unit 19 calculated by the rotational speed calculation unit 26 (detected by the rotational speed detection unit 24), is higher or lower than the target airflow Qs acquired by the target airflow acquisition unit 27. If the output airflow Qn is smaller than the target airflow Qs, the constant airflow calculation unit 29 instructs the motor drive logic generation unit 30 to output a larger duty cycle. If the output airflow Qn is larger than the target airflow Qs, the constant airflow calculation unit 29 instructs the motor drive logic generation unit 30 to output a smaller duty cycle. In other words, the constant airflow calculation unit 29 calculates the power supply required to perform constant airflow control at the target airflow Qs. In this way, the constant airflow calculation unit 29 performs calculations to reduce the deviation between the output airflow Qn and the target airflow Qs and perform constant airflow control.

[0094] The modulation unit 31 outputs pulses to the motor drive circuit unit 21 based on the duty cycle instruction value of the constant airflow calculation unit 29. The modulation unit 31 varies the rotation speed of the motor drive unit 19 by sequentially conducting six switching elements at a predetermined duty cycle ON / OFF ratio to output the required airflow.

[0095] The housing 20 is the outer casing of the motor unit 6 and is formed, for example, in a hollow cylindrical shape. The motor control board 18 and the motor drive unit 19 are arranged inside the housing 20, preventing foreign matter such as water and dust from adhering to the motor control board 18 and the motor drive unit 19.

[0096] This configuration makes it possible to achieve constant airflow control even with the sensorless motor unit 6.

[0097] As mentioned earlier, in a structure like that described in Patent Document 1, if the type of motor was changed, it was necessary to change the number of switching elements in the control circuit and also change the method of connecting the motor and the control circuit in order to reflect constant airflow control in the motor. In other words, because the process of connecting the motor and the power supply differed depending on the type of motor implemented, manufacturing costs tended to increase as the variety of products increased.

[0098] In this invention, as shown in Figure 9, electronic components related to constant airflow control are integrated into the motor control board 18 belonging to the motor unit 6, and the target airflow acquisition unit 27 belonging to the motor unit 6 and the target airflow switching unit 17 belonging to the power supply unit 8 are connected via a connector 32 to enable communication. By transmitting information regarding the target airflow Qs set in the target airflow switching unit 17 of the power supply unit 8 to the target airflow acquisition unit 27 of the motor unit 6 via the connector 32, constant airflow control becomes possible on the motor control board 18. With this structure, even if the motor is single-phase, constant airflow control can be achieved by connecting the target airflow switching unit 17 and the target airflow acquisition unit 27 with the connector 32, just as in the case of the three-phase motor in Figure 9. In other words, a blower capable of constant airflow control can be realized with a common process of connecting the motor and power supply with a single connector, regardless of the type of motor implemented.

[0099] As described above, a blower capable of constant airflow control can be realized using a common process regardless of the type of motor implemented. Therefore, even when increasing the product variations, manufacturing costs can be reduced and blowers can be provided.

[0100] The structure described in Modification 7 is merely one example of the present invention and does not limit the technical scope of the present invention. Functions may be added or removed as needed. The goal is to provide a blower 1 with reduced manufacturing costs by a structure that connects the target airflow acquisition unit 27 belonging to the motor unit 6 and the target airflow switching unit 17 belonging to the power supply unit 8 in a communicative manner via a connector 32. Furthermore, Modification 7 may be a configuration that combines at least one variation of Modifications 1 to 6. [Industrial applicability]

[0101] The blower device according to the present invention can be applied, for example, as a ventilation fan installed on the ceiling. [Explanation of Symbols]

[0102] 1. Blower 2. Main unit case 2a Inlet 2b Air outlet 3 adapters 4 ducts 5 feathers 6, 6a Motor section 7 Louvers 8 Power supply section 9 Remote control device 9a Power switch 9b Fan Notch Switch 10 Commercial power supply 11 Power supply board 12 Converters 13. Smoothing Capacitor 14 Voltage conversion section 15. Isolated voltage detection unit 16 Power supply control unit 17 Target airflow switching section 18 Motor control board 19, 19a Motor drive unit 20 Housing 21, 21a Motor drive circuit section 22 First converted current sensor 23 First post-conversion current detection unit 24, 24a Rotation speed detection unit 25 Rotor position calculation unit 26. Rotation speed calculation unit 27 Target air volume acquisition section 28 Constant airflow data storage unit 29 Air volume constant calculation section 30 Motor drive logic generation unit 31 Modulation section 32 connectors 33 Pre-conversion current sensor 34 Pre-conversion current detection unit 35 Second converted current sensor 36 Second post-conversion current detection unit 37. Voltage detection unit after conversion 38. Timing adjustment section 39 Modulation Reflection Section 40 Humidity Sensor 41 people detection sensors 42 Delayed switching timer 43 Thermal fuse 101 Ventilation system 102 Main Unit 102a Inlet 103 Adapter 104 Exhaust duct 105 feathers 106 Sensorless Brushless DC Motor 107 Louvers 108 Control circuits 109 Remote control device 109a Power On / Off Switch 109b Fan notch setting switch 110 Commercial power supply 111 AC / DC Converter 112 Smoothing Capacitor 113 Inverter Circuit 114 Stator 115 Rotor 116 Current detection unit 117 Rotation detection unit 118 Target air volume calculation section 119 Air volume calculation section 120 Speed ​​control unit

Claims

1. A blower having a power supply unit and a motor unit, The aforementioned power supply unit is A power supply board that converts the supplied power supply voltage to a predetermined converted voltage, It includes a target airflow switching unit for switching the target airflow setting, The motor section is It is provided independently of the aforementioned power supply unit, A motor drive circuit section that outputs supplied power, A motor drive unit that rotates upon receiving the aforementioned power supply, The motor includes a motor control board for controlling the motor drive unit, The motor control board is A target airflow acquisition unit that acquires the aforementioned target airflow, A rotation speed detection unit for detecting the rotation speed of the motor drive unit, A first post-conversion current detection unit detects the magnitude of a predetermined post-conversion current corresponding to the aforementioned post-conversion voltage, The system includes an airflow constant calculation unit that calculates the power supply for constant airflow control at the target airflow rate based on the rotation speed detected by the rotation speed detection unit and the magnitude of the converted current detected by the first converted current detection unit, The rotation speed detection unit is A rotor position calculation unit calculates the magnetic pole position of the rotor based on the converted current detected by the first converted current detection unit, The motor drive unit comprises a rotational speed calculation unit that calculates the rotational speed of the motor drive unit based on the change in the magnetic pole position of the rotor calculated by the rotor position calculation unit, The motor drive circuit section is, The power supply obtained by the calculation of the constant airflow calculation unit is output to the motor drive unit. The aforementioned target airflow acquisition unit is: The motor unit is equipped with a connector that electrically connects the target airflow acquisition unit and the power supply unit, A blower that acquires the setting of the target airflow of the target airflow switching unit belonging to the power supply unit via the connector.

2. The blower according to claim 1, wherein the motor unit is detachably provided with respect to the power supply unit.

3. The aforementioned target airflow switching unit is The power supply board is electrically connected and divides the converted voltage based on the setting of the target airflow. The aforementioned target airflow acquisition unit is The blower according to claim 1, wherein the target airflow volume is obtained by the target airflow volume switching unit based on the magnitude of the divided voltage.

4. The motor control board is The power supply board includes a converted voltage detection unit that detects the converted voltage, The constant airflow calculation unit is, The blower according to claim 1, which calculates the difference between the voltage required for outputting the supplied power and the converted voltage detected by the converted voltage detection unit, and corrects the calculation of constant airflow control based on that difference.

5. The motor control board is The system includes a modulation unit that modulates the supplied power based on a predetermined duty cycle, The constant airflow calculation unit is, The blower according to claim 1, wherein the calculation of constant airflow control is corrected based on the duty cycle.

6. The aforementioned power supply unit is Equipped with a humidity sensor that acquires the humidity of the space to which air is blown, The aforementioned target airflow switching unit is The air blower according to claim 1, wherein if the humidity acquired by the humidity sensor is above a predetermined humidity threshold, the target airflow is switched to a setting greater than the target airflow.

7. The aforementioned power supply unit is The humidity sensor is equipped with a delay switching timer that measures the time elapsed since the humidity acquired by the humidity sensor changed from above a predetermined humidity threshold to below a predetermined humidity threshold. The aforementioned target airflow switching unit is The blower according to claim 6, wherein if the time measured by the delay switching timer is greater than or equal to a predetermined time threshold, the setting is returned from a setting greater than the target airflow to the target airflow.

8. The aforementioned power supply unit is It is equipped with a human detection sensor that detects the presence or absence of people in the space to which air is being blown. The aforementioned target airflow switching unit is The blower according to claim 1, wherein when the person detection sensor detects the absence of a person, the target airflow is switched to a setting smaller than the target airflow.

9. The aforementioned power supply unit is The system includes a delay switching timer that measures the time elapsed since the detection of a person by the person detection sensor changed from the presence of a person to the absence of a person. The aforementioned target airflow switching unit is The blower according to claim 8, wherein if the time measured by the delay switching timer is greater than or equal to a predetermined time threshold, the setting is returned from a setting smaller than the target airflow to the target airflow.

10. The aforementioned power supply unit is A second post-conversion current detection unit for detecting the magnitude of the post-conversion current, The blower according to claim 1, further comprising a power control unit that stops or limits the supply of the converted voltage to the motor unit when the magnitude of the converted current detected by the second converted current detection unit in the power supply unit is greater than or equal to a predetermined current threshold.

11. The aforementioned power supply board is A converter that converts alternating current to direct current, The system includes a voltage conversion unit that converts the pre-conversion voltage, which has been converted to DC by the converter, into a predetermined post-conversion voltage. The aforementioned power supply unit is A pre-conversion current detection unit detects the magnitude of a predetermined pre-conversion current corresponding to the pre-conversion voltage, The blower according to claim 1, further comprising a power control unit that stops or limits the supply of the converted voltage to the motor unit when the magnitude of the pre-conversion current detected by the pre-conversion current detection unit is greater than or equal to a predetermined current threshold.

12. The aforementioned power supply board is The blower according to claim 1, wherein the voltage before and after conversion to the converted voltage is electrically isolated.

13. The motor section is The blower device according to claim 1, further comprising a housing for housing the motor drive unit and the motor circuit board.

14. The aforementioned power supply unit is The blower according to claim 1, further comprising a thermal fuse that stops supplying the converted voltage from the power supply board to the motor unit when the temperature of the power supply unit exceeds a predetermined temperature threshold.

Images