Dual Controller Architecture for Power Tool Motor Commutation
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Solution Overview
Problem
Conventional power tools have complex program codes in their controllers, making them difficult to write and maintain due to the integration of commutation and user operation control processes within a single controller.
Innovation Solution
The power tool design incorporates two circuit boards: a first circuit board with commutating switches and a controller to regulate motor commutation, and a second circuit board that transmits driving signals to the first board, separating the commutation and user operation processes and simplifying the code.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single controller integrates both commutation control and user operation control, then the control function is complete, but the program code becomes complex and difficult to maintain
Solution Approach 1:
The patent divides the single controller into two separate controllers: a first controller dedicated to motor commutation control and a second controller dedicated to user operation control. This segmentation allows each controller to have specialized, simplified program code while collectively providing complete control functionality. The first controller handles Hall effect sensor signals and commutating switch control, while the second controller handles operator interface signals and generates driving signals for the first controller.
2Device complexity
If a single controller handles all control functions, then the device structure is compact, but troubleshooting and maintenance become difficult
Solution Approach 1:
By separating the controller into two independent modules (first controller for commutation, second controller for operation control), the patent enables isolated troubleshooting. When a malfunction occurs, technicians can independently test each controller without affecting the other, significantly improving diagnostic efficiency and maintenance capability while maintaining relatively compact device structure through coordinated operation of the two controllers.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design reduces the complexity of the program code, facilitates maintenance by identifying which circuit board is malfunctioning, and reduces signal wires, making code maintenance and troubleshooting more efficient.
Implementation Method 1
The Hall effect sensor 14 is used for detecting a position of a rotor of the motor 12 and generating a feedback signal
Data Source
AI summary
A power tool includes a case, a motor, a plurality of Hall effect sensors, a first circuit board, and a second circuit board. The Hall effect sensors detect a position of a rotor of the motor and correspondingly generate position signals. A plurality of commutating switches and a first controller are disposed on the first circuit board. A second controller is disposed on the second circuit board, and could transmit a driving signal to the first controller according to the operating signal of an operator interface. The first controller regulates the commutating switches to commutate according to the driving signal and the position signals, thereby to activate the rotor to rotate. With such design, a commutation process and a user operating process are regulated by the two different controllers, which could efficiently simplify the program code installed in each of the controllers and facilitate the maintenance of the controllers.