Patent Description:
Under a heavy load, since the power supply capability of a grid is sufficiently great, an alternating current power tool, especially for a high-voltage brushless tool, is prone to an overcurrent, which not only easily damages electronic components, but also significantly affects the feeling of using the power tool to a relatively large extent.

<CIT> discloses an electrical device including a device housing, a load supported by the device housing, the load being operable to output at least about <NUM> watts, and a device terminal electrically connected to the load; a battery pack including a pack housing, battery cells supported by the pack housing, the battery cells being electrically connected and having a nominal voltage of up to about <NUM> volts, and a pack terminal electrically connectable to the device terminal to transfer current between the battery pack and the electrical device; and a controller operable to control the transfer of current.

<CIT> discloses a power tool including a brushless motor, a rectifier circuit configured to rectify an AC voltage supplied from an AC power supply and output a rectified voltage, an inverter circuit configured to perform switching actions with respect to the rectified voltage to be supplied to the brushless motor, a controller configured to control the switching actions of the inverter circuit, a trigger having an operating part being operable by a user, a switch rendered ON and OFF in accordance with an operation performed in the operating part, wherein when the switch is ON, the inverter circuit is electrically connected to the AC power supply whereas when the switch is OFF, and the inverter circuit is electrically disconnected from the AC power supply, and a power supply circuit connected between the switch and the AC power supply and configured to supply a voltage to the controller.

To solve the deficiencies of the related art, the present application provides a current limiting control method applicable to an alternating current power tool, which can effectively suppress a large current under a heavy load without affecting the feeling of using the power tool.

To achieve the preceding object, the present application adopts the technical solutions described in the independent claim <NUM>.

In some examples, the random variation of the period of the drive signal within the second preset period range follows the law of a normal distribution.

In some examples, a period of the preset waveform is the same as the period of the drive signal or the duration of each time interval among the periodic time intervals.

In some examples, the preset waveform is set as a triangular waveform or a waveform including a curve.

In some examples, a preset current threshold corresponding to the end of the present time interval is less than a preset current threshold corresponding to the beginning of the present time interval.

In some examples, the power tool further includes a power supply input device and a rectifier module, where the power supply input device is configured to access a power supply required by the power tool when working, and the rectifier module is configured to be electrically connected to the power supply input device and convert electrical energy of the power supply input device into a direct current for the power tool to use.

In some examples, the power tool further includes a power supply circuit and a capacitor circuit, where the power supply circuit is electrically connected to the rectifier module to supply power to at least the control module, and the capacitor circuit is electrically connected between the rectifier module and the driver circuit.

In some examples, the capacitor circuit includes at least one electrolytic capacitor.

In some examples, the ratio of the capacitance value of the electrolytic capacitor to the rated power of the electric motor is higher than <NUM>µF/kW and lower than <NUM>µF/kW.

In some examples, the rectifier module includes a rectifier bridge constituted by four diodes D1, D2, D3, and D4.

In some examples, the current detection module is electrically connected between the control module and the electric motor and includes multiple current detection resistors.

In some examples, the electric motor is configured to be a brushless direct current motor.

In some examples, the brushless direct current motor is controlled by the drive signal.

In some examples, the power tool further includes a rotational speed detection module configured to acquire a rotational speed of the electric motor and a position of a rotor of the electric motor. A large current occurring during the work of the electric motor is simply and effectively suppressed and the feeling of using the power tool is not affected. Thus, the feeling of using the power tool is optimized to a relatively large extent, and the reliability and life of the power tool are improved.

The present application is described below in detail in conjunction with drawings and examples.

A power tool in the present application may be a handheld power tool, a garden tool, or a garden vehicle such as a vehicle-type mower, which is not limited here. The power tool in the present application includes, but is not limited to, alternating current power tools such as a sander, a drill bit, an impact driver, a tapper, and a fastener driver. As long as these power tools can adopt the essence of the technical solutions disclosed below, these power tools may fall within the scope of the present application. Additionally, it is to be noted that for ease of description, only part, not all, of structures related to the present application are illustrated in the drawings.

Referring to <FIG>, a power tool <NUM> is shown exemplarily. The power tool is an angle grinder. The power tool <NUM> mainly includes a housing <NUM>, an electric motor <NUM>, a functional member <NUM>, an alternating current power supply input device <NUM>, and circuitry <NUM> disposed in the housing <NUM>.

The electric motor <NUM> includes stator windings and a rotor. In some examples, the electric motor <NUM> is a three-phase brushless motor including the rotor with a permanent magnet and three-phase stator windings U, V, and W electronically commutated. In some examples, the three-phase stator windings U, V, and W adopt a star connection. In other examples, the three-phase stator windings U, V, and W adopt a delta connection. However, it must be understood that other types of brushless motors are also within the scope of the present disclosure. The brushless motor may include less or more than three phases.

The functional member <NUM> is used for implementing the function of the power tool <NUM>. The functional member <NUM> is driven by the electric motor <NUM> to operate. For different power tools, functional elements are different. For the angle grinder, the functional member <NUM> is a grinding disc used for implementing a grinding or cutting function.

The alternating current power supply input device <NUM> is configured to access a power supply required by the power tool <NUM> to work. As an example, a power supply in this example is optionally configured to be an alternating current power supply. Specifically, the alternating current power supply input device <NUM> includes an alternating current plug to access alternating current mains of <NUM> V or <NUM> V.

Referring to <FIG>, the circuitry <NUM> of the power tool <NUM> as an example mainly includes a rectifier module <NUM>, a capacitor circuit <NUM>, a power supply circuit <NUM>, a driver circuit <NUM>, a control module <NUM>, a rotational speed detection module <NUM>, and a current detection module <NUM>.

The rectifier module <NUM> constitutes a direct current unit of the power tool <NUM>. The rectifier module <NUM> is configured to receive an alternating current from the alternating current power supply input device <NUM> and output a direct current bus voltage. That is, the rectifier module <NUM> is configured to convert the alternating current inputted by the alternating current power supply input device <NUM> into pulsating direct current output. The rectifier module <NUM> is electrically connected to the alternating current power supply input device <NUM>. As an example, referring to <FIG>, the rectifier module <NUM> includes a rectifier bridge constituted by four diodes D1, D2, D3, and D4, which converts the alternating current into the pulsating direct current output in the same direction with the unilateral conductivity and voltage drop of the diodes.

The capacitor circuit <NUM> is connected in parallel to a direct current bus of the power tool <NUM>. That is, the capacitor circuit <NUM> is connected in parallel between the positive and negative electrodes of the direct current unit in the circuitry <NUM>. As an example, the capacitor circuit <NUM> is optionally connected in parallel between the rectifier module <NUM> and the driver circuit <NUM>. Specifically, the capacitor circuit <NUM> includes an electrolytic capacitor C. The capacitor circuit <NUM> is electrically connected to the rectifier module <NUM>, and a pulsating direct current outputted by the rectifier module <NUM> is filtered and converted into smooth direct current output by the electrolytic capacitor C so that harmonic interference in the pulsating direct current is reduced. Optionally, the ratio of the capacitance value of the electrolytic capacitor C to the rated power of the electric motor <NUM> is higher than <NUM>µF/kW and lower than <NUM>µF/kW. In this manner, a space can be saved, and it is ensured that there is no physically large capacitive element in the hardware circuit.

The power supply circuit <NUM> is configured to supply power to at least the control module <NUM>. As an example, the power supply circuit <NUM> is electrically connected to the rectifier module <NUM> and converts the electrical energy rectified by the rectifier module <NUM> into power supply voltage output adaptable to the control module <NUM>. For example, to supply the power to the control module <NUM>, the power supply circuit <NUM> reduces a voltage which is from the alternating current power supply input device <NUM> and is rectified by the rectifier module <NUM> to <NUM> V, so as to supply the power to the control module <NUM>.

The driver circuit <NUM> is electrically connected to the rectifier module <NUM> and is configured to drive the electric motor <NUM>. An input terminal of the driver circuit <NUM> receives the voltage from the rectifier module <NUM>. Under the drive of the drive signal outputted by the control module <NUM>, the voltage is distributed to each phase winding on the stator of the electric motor <NUM> in a certain logical relationship so that the electric motor <NUM> is started and generates continuous torque. Specifically, the driver circuit <NUM> includes multiple electronic switches. In some examples, an electronic switch includes a field-effect transistor (FET). In other examples, an electronic switch includes an insulated-gate bipolar transistor (IGBT) or the like. In some examples, the driver circuit <NUM> is a three-phase bridge circuit. The driver circuit <NUM> includes three electronic switches Q1, Q3, and Q5 configured as high-side switches and three electronic switches Q2, Q4, and Q6 configured as low-side switches.

The three electronic switches Q1, Q3, and Q5 as the high-side switches are disposed between a power supply line of the rectifier module <NUM> and phase coils of the electric motor <NUM> separately. The three electronic switches Q2, Q4, and Q6 as the low-side switches are disposed between the phase coils of the electric motor <NUM> and a ground line separately.

Gate terminals UH, UL, VH, VL, WH, and WL of the six electronic switches Q1 to Q6 are electrically connected to the control module <NUM>, and each drain or source of each of the electronic switches is connected to the stator winding of the electric motor <NUM>. The electronic switches Q1 to Q6 are turned on or off at a certain frequency according to drive signals outputted by the control module <NUM> to change the power state loaded by the rectifier module <NUM> on the winding of the electric motor <NUM>.

The driver circuit <NUM> is a circuit for driving, by switching the power-on state of each phase winding of the electric motor <NUM> and controlling the power-on current of each phase winding, the electric motor <NUM> to rotate. The sequence in which phase windings are on and the time when each phase winding is on depend on the position of the rotor. To make the electric motor <NUM> rotate, the driver circuit <NUM> has multiple drive states. In a drive state, the stator winding of the electric motor <NUM> may generate a magnetic field, and the control module <NUM> outputs a control signal based on a different position of the rotor to control the driver circuit <NUM> to switch a drive state. In this manner, the magnetic field generated by the stator winding is rotated so that the rotor is driven to rotate, thereby driving the electric motor <NUM>.

The rotational speed detection module <NUM> is configured to acquire at least one of a measured rotational speed of the electric motor <NUM> and the position of the rotor. In some examples, the rotational speed detection module <NUM> includes a sensor which can directly detect the speed and position of the electric motor <NUM>, such as a Hall sensor. In other examples, the rotational speed detection module <NUM> is configured to estimate the position of the rotor of the electric motor <NUM> according to at least phase voltages of the electric motor <NUM> and current values of the stator windings.

The current detection module <NUM> is configured to collect a current of the electric motor <NUM>, where the current may be a bus current of the electric motor <NUM> or a phase current of each phase winding of the electric motor <NUM>. As an example, the current detection module <NUM> detects the phase current of each phase winding of the electric motor <NUM>, and the bus current of the electric motor <NUM> may be calculated from the detected three-phase current values. In some examples, the current detection module <NUM> includes a Hall current sensor for directly detecting the phase current of each phase winding of the electric motor <NUM>. As another example, referring to <FIG>, current detection resistors R1, R2, and R3 are separately connected in series between the driver circuit <NUM> and the phase windings of the electric motor <NUM>, and the current detection module <NUM> may calculate the phase current of each phase winding or the bus current by detecting voltages across the detection resistors. Specifically, the current detection module <NUM> may calculate phase currents of the three-phase stator windings U, V, and W by detecting the voltages across the current detection resistors R1, R2, and R3 separately. As another example, referring to <FIG>, the current detection module <NUM> is configured to detect the internal resistance of an electronic switch in the on state in the driver circuit <NUM> and calculate, based on the internal resistance of the electronic switch in the on state and a voltage value across the electronic switch, the current flowing through the electronic switch, where the current of the electronic switch is a phase current of the corresponding winding of the electric motor <NUM>. Specifically, the current detection module <NUM> separately detects a voltage across each of the three drive switches Q1, Q3, and Q5 as the high-side switches and calculates the phase currents of the corresponding three-phase stator windings U, V, and W. In this manner, the power tool can detect the phase currents of the corresponding windings of the electric motor <NUM> without additional hardware, thereby saving a cost.

The control module <NUM> is electrically connected to at least the power supply circuit <NUM>, the driver circuit <NUM>, and the current detection module <NUM> and is configured to control the driver circuit <NUM> to work. In some examples, the control module <NUM> may be a dedicated control chip (such as a microcontroller unit (MCU)).

A first example of the present application will be described next.

Referring to <FIG>, the control module <NUM> outputs the drive signals, and the drive signals are separately applied to the gate terminals UH, UL, VH, VL, WH, and WL of the six electronic switches Q1 to Q6 and are used for controlling the conduction states of the multiple electronic switches Q1 to Q6 so that the electric motor <NUM> is driven. The electric motor <NUM> is configured to be a three-phase brushless direct current motor, and a drive signal is configured to be a PWM signal. A period of the PWM signal is denoted by T<NUM>, and the control module <NUM> limits the current of the electric motor within periodic time intervals T<NUM>. A periodic time interval here may be understood as a current limiting period of the electric motor, and T<NUM> is defined as the current limiting period of the electric motor below.

Referring to <FIG>, the current limiting period T<NUM> is set to be the same as the period T<NUM> of the PWM signal. The control module <NUM> is configured to acquire a phase current value Iphase of the electric motor <NUM> in real time through the current detection module <NUM> within a present period among the current limiting periods T<NUM> and compare the phase current value Iphase with a preset current threshold Iref. If the phase current value Iphase exceeds the preset current threshold Iref, an electronic switch is turned off within remaining time of the present period among the current limiting periods T<NUM> so that the current flowing towards the electric motor <NUM> is off, and an electronic switch is turned on when a present period T<NUM> of the PWM signal ends so that the current flowing towards the electric motor <NUM> is restored. In this example, the preset current threshold Iref may be set otherwise according to the type of the electric motor in an actual application and an actual application scenario. It is to be further noted here that the electronic switch turned off in this example is specifically the electronic switch which is in the on state at present and the electronic switch turned on in this example is the electronic switch which is controlled by the drive signal at present to be turned on.

Under a heavy load, since the power supply capability of a grid voltage is sufficiently great, an overcurrent may occur in the electric motor. As a result, components in the power tool are damaged, and the service life of the power tool is reduced. Referring to <FIG>, the overcurrent occurs in the electric motor under the heavy load, which is indicated by point b in <FIG>. With the preceding technical solution for limiting the current, when the phase current value Iphase exceeds the preset current threshold Iref, the control module <NUM> turns off the electronic switch immediately so that the current flowing through the electric motor <NUM> will not increase, which is indicated by point a in the figure. When the present period of the PWM signal ends, the control module <NUM> turns on the electronic switch again so that the current flowing towards the electric motor <NUM> is restored, which is indicated by point c in the figure. In this example, the current detection module detects the phase current of the electric motor <NUM> so that the current of the electric motor is limited period by period. Of course, a bus current value of the electric motor may be detected so that the current of the electric motor is limited period by period.

A control method of the electric motor in the power tool <NUM> within one current limiting period will be described below in detail in conjunction with <FIG>. The method includes the steps described below.

In S101, the phase current value of the electric motor is acquired.

In S102, it is determined whether the phase current value of the electric motor exceeds the preset current threshold. If yes, S103 is performed. If no, S104 is performed.

In S103, the electronic switch which is on at present is turned off.

In S104, it is determined whether the present current limiting period ends. If yes, S105 is performed. If no, S101 is performed.

In S105, the electronic switch which is controlled by the drive signal at present to be turned on is turned on. The flow returns to S101.

When the load of a grid increases or decreases significantly, the grid voltage may fluctuate, thereby affecting a user's feel.

As shown in <FIG>, in this example, the control module <NUM> controls the period T<NUM> of the PWM signal for driving the electric motor <NUM> to vary continuously within a first preset period range, and the current limiting period T<NUM> of the electric motor <NUM> is set to be the same as the period T<NUM> of the PWM signal. The first preset period range is optionally set to [<NUM>. 5T<NUM>, 2T<NUM>], where T<NUM> denotes an initial period of the PWM signal. When the grid voltage is lower than or equal to a present counter-electromotive force of the electric motor <NUM>, the period T1 of the PWM signal keeps constant. On the contrary, when the grid voltage is higher than the present counter-electromotive force of the electric motor <NUM>, the period T1 of the PWM signal varies continuously within the first preset range. In conjunction with <FIG> and <FIG>, the continuous variation which the period T<NUM> of the drive signal is set to perform within the first preset period range may be obtained through the following formula: <MAT> where f<NUM> denotes an initial frequency corresponding to the initial period T<NUM> of the PWM signal, f<NUM> denotes a frequency corresponding to the period T<NUM> of the PWM signal, and θ denotes a phase of a present grid voltage.

A control method for limiting the current of the electric motor <NUM> in the power tool <NUM> period by period will be described below in detail in conjunction with <FIG>. The method includes the steps described below.

In S201, the phase current value of the electric motor is acquired.

In S202, it is determined whether the phase current value of the electric motor exceeds the preset current threshold. If yes, S203 is performed. If no, S204 is performed.

In S203, the electronic switch which is on at present is turned off.

In S204, it is determined whether the present current limiting period ends. If yes, S205 is performed. If no, S206 is performed.

In S205, the electronic switch which is controlled by the drive signal at present to be turned on is turned on.

In S206, the grid voltage and the counter-electromotive force of the electric motor are acquired.

In S207, it is determined whether the present counter-electromotive force of the electric motor exceeds the grid voltage. If yes, S208 is performed. If no, S201 is performed.

In S208, the period T<NUM> of the drive signal is reset.

In S209, the current limiting period T<NUM> is reset. The flow returns to S201.

In the first example described above, the control method for limiting the current of the power tool period by period is disclosed, where the current limiting period is the same as the period of the PWM signal all the time, the electronic switch is turned off when the detected phase current of the electric motor is greater than the preset current threshold, and the electronic switch is turned on again and the phase current of the electric motor continues to be detected in real time when the present period of the PWM signal ends. In another aspect, the period of the PWM signal is set to vary continuously with the fluctuation of the grid voltage within the first preset period range, which can make effective compensations in accordance with the fluctuation of the grid voltage to improve the user's feel and the service life of the power tool.

A second example of the present application will be described next.

The second example differs from the first example described above in that the control module <NUM> controls the period T<NUM> of the PWM signal for driving the electric motor <NUM> to vary randomly within a second preset period range, and the current limiting period T<NUM> of the electric motor <NUM> is set to be the same as the period T<NUM> of the PWM signal all the time. Referring to <FIG>, the period T<NUM> of the PWM signal varies randomly within the second preset period range. Specifically, it may be set that the initial period T<NUM> of the PWM period superimposed with a white noise varies according to the law of a normal distribution. In this example, the initial period T<NUM> of the PWM signal for driving the electric motor <NUM> is set to <NUM>, and the period T<NUM> of the PWM signal superimposed with the white noise varies randomly within the second preset period range [<NUM>, <NUM>], and the variation satisfies the law of the normal distribution.

The overcurrent occurs in the electric motor under the heavy load, which is indicated by point b in <FIG>. With the preceding technical solution for limiting the current, when the phase current value Iphase exceeds the preset current threshold Iref, the control module <NUM> turns off the electronic switch immediately so that the current flowing through the electric motor <NUM> will not increase, which is indicated by point a in the figure. When the present period of the PWM signal ends, the control module <NUM> turns on the electronic switch again so that the current flowing towards the electric motor <NUM> is restored, which is indicated by point c in the figure. In this example, the current detection module detects the phase current of the electric motor <NUM> so that the current of the electric motor is limited period by period. Of course, the bus current value of the electric motor may be detected so that the current of the electric motor is limited period by period.

It is to be noted that the second preset range set in this example should be set autonomously according to the actual application scenario of the power tool.

In S301, the phase current value of the electric motor is acquired.

In S302, it is determined whether the phase current value of the electric motor exceeds the preset current threshold. If yes, S303 is performed. If no, S304 is performed.

In S303, the electronic switch which is on at present is turned off.

In S304, it is determined whether the present current limiting period ends. If yes, S305 is performed. If no, S301 is performed.

In S305, the period T<NUM> of the drive signal is reset.

In S305, the current limiting period T<NUM> is set according to the reset period T<NUM> of the drive signal.

In S305, the electronic switch which is controlled by the drive signal at present to be turned on is turned on. The flow returns to S301.

In the second example described above, the control method for limiting the current of the power tool period by period is disclosed, where the current limiting period is the same as the period of the PWM signal all the time, the electronic switch is turned off when the detected phase current of the electric motor is greater than the preset current threshold, and the electronic switch is turned on again and the phase current of the electric motor continues to be detected in real time when the present period of the PWM signal ends. In another aspect, the period of the PWM signal is set to vary randomly within the second preset period range. The preceding random variation satisfies the law of the normal distribution. In this example, the period of the PWM signal is set to vary randomly according to the law of the normal distribution within the preset range, and the EMI of the driver circuit is reduced through frequency jitter. Thus, the reliability of the power tool is improved.

A third example of the present application will be described next.

The third example differs from the preceding example in that the control module <NUM> outputs the PWM signal having the initial period T<NUM> to control the driver circuit <NUM> to drive the electric motor <NUM> to operate, as shown in <FIG>. The control module <NUM> acquires the phase current value of the electric motor <NUM> in real time through the current detection module <NUM> and compares the acquired phase current value with a preset current range. In this example, preset current thresholds include a first preset current threshold Iref1 and a second preset current threshold Iref2. The first preset current threshold Iref1 is set as an upper limit, and the second preset current threshold Iref2 is set as a lower limit. When the phase current value Iphase of the electric motor <NUM> acquired by the control module <NUM> is greater than the first preset current threshold Iref1, the control module <NUM> immediately turns off the electronic switch which is in the on state at present. When the phase current value Iphase of the electric motor <NUM> acquired by the control module <NUM> is less than the second preset current threshold Iref2, the control module <NUM> controls the electronic switch which is controlled by the drive signal at present to be turned on to be turned on. In a specific setting process, the difference between the first preset current threshold Iref1 and the second preset current threshold Iref2 is inversely proportional to an inductance value of the electric motor and is proportional to the counter-electromotive force of the electric motor in a normal working process. Those skilled in the art may rationally design the preset current range according to the type of the electric motor and the actual application scenario.

In S401, the phase current value of the electric motor is acquired.

In S402, it is determined whether the phase current value of the electric motor is greater than the first preset current threshold. If yes, S403 is performed. If no, S404 is performed.

In S403, the electronic switch which is on at present is turned off.

In S404, it is determined whether the phase current value of the electric motor is less than the second preset current threshold. If yes, S405 is performed. If no, S401 is performed.

In S405, the electronic switch which is controlled by the drive signal at present to be turned on is turned on. The flow returns to S401.

In the third example described above, the control method for limiting the current of the power tool period by period is disclosed, where the phase current of the electric motor is acquired through the current detection module, the electronic switch is turned off once it is detected that the phase current exceeds the first preset current threshold, and the electronic switch is turned on and the current flowing towards the electric motor is restored once the phase current value of the electric motor is less than the second preset current threshold. A large current occurring during the work of the electric motor may be simply and effectively suppressed through the technical solution in the preceding example, and the feeling of using the power tool is not affected.

It is to be understood that in the first example and the second example described above, the preset current threshold is set so that no large current occurs in the electric motor, thereby protecting electronic components. However, due to the existence of the current limiting period in the first example and the second example described above, the current flowing through the electric motor may generate a second harmonic when the preset current threshold is a fixed value.

A fourth example of the present application will be described next.

Referring to <FIG>, the preset current threshold Iref is optionally set as the fixed value, and the phase current acquired in real time is compared with the preset current threshold Iref, where phase current <NUM> is the waveform of the phase current value Iphase of the electric motor in a normal working state, and phase current <NUM> is the waveform of the phase current value Iphase of the electric motor after the current is limited. When the phase current value Iphase exceeds the preset current threshold Iref, the electronic switch which is in the on state at present is turned off within the remaining time of the present period among the current limiting periods T<NUM> so that the current flowing towards the electric motor is off, and the electronic switch is turned on when the present period T<NUM> of the PWM signal ends so that the current flowing towards the electric motor is restored. According to the preceding current limiting method, the second harmonic indicated by point a in <FIG> will appear, which will affect the normal operation of the power tool.

In order that the problem in the first example and the second example described above is solved, the preset current threshold Iref in this example is not fixed and satisfies the variation law of a preset waveform.

Referring to <FIG>, the preset waveform is optionally set as a triangular waveform, and a period T<NUM> of the triangular waveform is the same as the current limiting period T<NUM>. The slope K of the triangular waveform is in the following range:<MAT> where I<NUM> denotes the phase current value at a power-on moment. It is to be understood that those skilled in the art may typically debug a specific circuit to set Iref to a value so that the relatively proper value is acquired. It is to be understood that the manner in which the range of K is calculated is provided in this example, but a value of K needs to be acquired by those skilled in the art by debugging the circuit within the preceding range of K.

Referring to <FIG>, phase current <NUM> is the waveform of the phase current of the electric motor whose current is not limited, phase current <NUM> is the waveform of the phase current of the electric motor when the preset current threshold Iref is the fixed value, and phase current <NUM> is the waveform of the phase current of the electric motor when the preset current threshold Iref has the triangular waveform. It may be clearly seen from <FIG> that no significant second harmonic is generated in the phase current of the electric motor in phase current <NUM>.

The preset waveform in this example is the triangular waveform. Of course, the preset waveform may be set as a waveform including a curve. Referring to <FIG>, the preceding waveform including the curve is defined as waveform F here, and a period T<NUM> of waveform F is the same as the current limiting period T<NUM>. It is to be understood that the current value at the beginning of a current limiting period T<NUM> in waveform F is the same as the current value at the beginning of a current limiting period T<NUM> in the triangular waveform. Similarly, the current value at the end of a current limiting period T<NUM> in waveform F is the same as the current value at the end of a current limiting period T<NUM> in the triangular waveform. In other words, point m and point n in <FIG> correspond to point m' and point n' in <FIG>, respectively. Referring to <FIG>, phase current <NUM> is the waveform of the phase current of the electric motor when the preset current threshold Imax is the fixed value, and phase current <NUM> is the waveform of the phase current of the electric motor when the preset current threshold Imax has waveform F. It may be clearly seen from <FIG> that no significant second harmonic is generated in the phase current of the electric motor in phase current <NUM>. Of course, a specific parameter of waveform F needs to be designed according to a specific circuit structure. It is to be further noted here that the preset waveform in the preceding example is not limited to the triangular waveform and the waveform including the curve described above. In the preset waveform, a current threshold corresponding to the end of the present current limiting period T<NUM> is less than a current threshold corresponding to the beginning of the present current limiting period T<NUM>.

In conjunction with <FIG>, a control method for limiting the current period by period will be described next in detail through the example in which the preset waveform is the triangular waveform. The method includes the steps described below.

In S11, the phase current value of the electric motor is acquired.

In S12, it is determined whether the phase current value of the electric motor exceeds a present preset current threshold. If yes, S203 is performed. If no, S204 is performed.

In S13, the electronic switch which is on at present is turned off.

In S14, it is determined whether the present current limiting period ends. If yes, S205 is performed. If no, S206 is performed.

In S15, the electronic switch which is controlled by the PWM signal at present to be turned on is turned on.

In S16, the grid voltage and the counter-electromotive force of the electric motor are acquired.

In S17, it is determined whether the present counter-electromotive force of the electric motor exceeds the grid voltage. If yes, S208 is performed. If no, S201 is performed.

In S18, the period of the PWM signal is reset.

In S19, the current limiting period T and the period of the triangular waveform are set to be equal to the present period of the PWM signal. The flow returns to S201.

In S21, the phase current value of the electric motor is acquired.

In S22, it is determined whether the phase current value of the electric motor exceeds a present current threshold. If yes, S23 is performed. If no, S24 is performed.

In S23, the electronic switch which is on at present is turned off.

In S24, it is determined whether the present current limiting period ends. If yes, S25 is performed. If no, S21 is performed.

In S25, the period of the PWM signal is reset.

In S26, the current limiting period and the period of the triangular waveform are set to be equal to the present period of the PWM signal.

Claim 1:
A power tool (<NUM>), comprising:
a housing (<NUM>);
an electric motor (<NUM>) disposed in the housing (<NUM>);
a driver circuit (<NUM>) comprising a plurality of electronic switches (Q1, Q2, Q3, Q4, Q5, Q6);
a control module (<NUM>) electrically connected to the driver circuit (<NUM>) and outputting a drive signal to control the driver circuit (<NUM>) to cause the electric motor (<NUM>) to operate; and
a current detection module (<NUM>) configured to acquire a current value of the electric motor (<NUM>);
wherein the control module (<NUM>) is further configured to:
acquire a bus current value of the electric motor (<NUM>) or a phase current value of the electric motor (<NUM>) in real time through the current detection module (<NUM>) within periodic time intervals; and
turn off an on-state electronic switch among the plurality of electronic switches (Q1, Q2, Q3, Q4, Q5, Q6) within remaining time of a present time interval when the acquired bus current value of the electric motor (<NUM>) or the phase current value exceeds a preset current threshold, wherein the current flowing through the electric motor (<NUM>) will not increase when turning off the electronic switch;
and
turn on an electronic switch among the plurality of electronic switches (Q1, Q2, Q3, Q4, Q5, Q6) which is controlled by the control module (<NUM>) at present to be on when a present period of the drive signal ends, wherein the current flowing towards the electric motor (<NUM>) is restored when turning on the electronic switch;
wherein a duration of each time interval among the periodic time intervals is the same as a period corresponding to the drive signal at present; and a period of the drive signal varies randomly within a preset period range;
characterized in that
the preset current threshold is not fixed and satisfies a variation law of a preset waveform.