There are provided a brushless motor control device and a brushless motor control method that can suppress occurrence of step-out caused by reverse rotation, in low-speed sensorless control of a brushless motor. The brushless motor control device applies, to a brushless motor, a positive pulse generating torque in a rotation direction of the brushless motor and a negative pulse generating torque in a reverse rotation direction, and detects a rotation direction by using a magnetic saturation voltage generated when the positive and negative pulses are applied. The control device sets an upper limit value to a motor application duty represented by a value obtained by subtracting an application duty of the negative pulse from an application duty of the positive pulse.

There are provided a brushless motor control device and a brushless motor control method that can suppress occurrence of step-out caused by reverse rotation, in low-speed sensorless control of a brushless motor. The brushless motor control device applies, to a brushless motor, a positive pulse generating torque in a rotation direction of the brushless motor and a negative pulse generating torque in a reverse rotation direction, and detects a rotation direction by using a magnetic saturation voltage generated when the positive and negative pulses are applied. The control device sets an upper limit value to a motor application duty represented by a value obtained by subtracting an application duty of the negative pulse from an application duty of the positive pulse.

A motor drive system for use with a motor comprising a first high-side switch coupled to a high voltage bus and the motor. A first low-side switch coupled to the motor and a return, a turn ON and turn OFF of the first high-side switch and the first low-side switch provides a phase current for the motor. A system controller configured to receive a phase current sense signal representative of the phase current of the motor and configured to begin an alignment sequence to align the motor to a goal alignment position, wherein during the alignment sequence at least one of the first high-side switch or the first low-side switch is turned ON and OFF having an alignment duty ratio, and the system controller is configured to end the alignment sequence in response to a sensed decrease in the phase current sense signal or a first duration has elapsed.

A control unit for a brushless DC motor of a power tool having a rotor and a stator is provided. The control unit detects an initial position of the rotor, commutates the motor beginning at the initial position of the rotor using a low-speed motor commutation scheme until an output speed of the rotor exceeds a speed threshold, and commutates the motor based on a back-electromotive force (back-EMF) voltage of the motor after the output speed of the rotor exceeds the speed threshold. In the low-speed commutation scheme, the control unit applies a first set of voltage pulses to a present sector and a second set of voltage pulses to a next sector, and detects a transition of the rotor from the present sector to the next sector based on motor current measurements associated with the first set of voltage pulses and the second set of voltage pulses.

A control unit for a brushless DC motor of a power tool having a rotor and a stator is provided. The control unit detects an initial position of the rotor, commutates the motor beginning at the initial position of the rotor using a low-speed motor commutation scheme until an output speed of the rotor exceeds a speed threshold, and commutates the motor based on a back-electromotive force (back-EMF) voltage of the motor after the output speed of the rotor exceeds the speed threshold. In the low-speed commutation scheme, the control unit applies a first set of voltage pulses to a present sector and a second set of voltage pulses to a next sector, and detects a transition of the rotor from the present sector to the next sector based on motor current measurements associated with the first set of voltage pulses and the second set of voltage pulses.

A method of controlling a brushless permanent-magnet motor having a phase winding and a rotor, includes applying voltages of first and second opposing polarities to the phase winding when the rotor is oscillating about a parking position, measuring a plurality of first times, each first time including a time taken for current flowing through the phase winding in response to an applied voltage of the first polarity to exceed a threshold and measuring a plurality of second times, each second time including a time taken for current flowing through the phase winding in response to an applied voltage of the second polarity to exceed the threshold. The method includes determining which of an average magnitude of the plurality of first times and an average magnitude of the plurality of second times has the smaller average magnitude, and determining an amplitude peak of the plurality of times having the smaller average magnitude. The method includes using the amplitude peak to calculate a time window, setting a timer corresponding to the time window at a subsequent determined amplitude peak, and applying a drive voltage to the phase winding during the time window.

A method of controlling a brushless permanent-magnet motor having a phase winding and a rotor, includes applying voltages of first and second opposing polarities to the phase winding when the rotor is oscillating about a parking position, measuring a plurality of first times, each first time including a time taken for current flowing through the phase winding in response to an applied voltage of the first polarity to exceed a threshold and measuring a plurality of second times, each second time including a time taken for current flowing through the phase winding in response to an applied voltage of the second polarity to exceed the threshold. The method includes determining which of an average magnitude of the plurality of first times and an average magnitude of the plurality of second times has the smaller average magnitude, and determining an amplitude peak of the plurality of times having the smaller average magnitude. The method includes using the amplitude peak to calculate a time window, setting a timer corresponding to the time window at a subsequent determined amplitude peak, and applying a drive voltage to the phase winding during the time window.

A control unit for a brushless DC motor of a power tool having a rotor and a stator is provided. The control unit detects an initial position of the rotor, commutates the motor beginning at the initial position of the rotor using a low-speed motor commutation scheme until an output speed of the rotor exceeds a speed threshold, and commutates the motor based on a back-electromotive force (back-EMF) voltage of the motor after the output speed of the rotor exceeds the speed threshold. In the low-speed commutation scheme, the control unit applies a first set of voltage pulses to a present sector and a second set of voltage pulses to a next sector, and detects a transition of the rotor from the present sector to the next sector based on motor current measurements associated with the first set of voltage pulses and the second set of voltage pulses.

A control system for a multiphase electric motor comprises processing means arranged to determine a pattern of PWM voltage waveforms to be applied to respective phases of the motor, the processing means assigning different PWM patterns for use with different motor positions. In use for a given rotational position of the motor the processing means is normally adapted to apply PWM waveforms according to the assigned PWM pattern unless a different PWM pattern is currently in use at that time, except that in the event that the demanded voltage waveforms cannot be achieved with the current PWM pattern the processing means is adapted to force the PWM pattern to change. Upon the rotor moving into a different position associated with a different assigned pattern the processing means forces the PWM pattern to change to the assigned PWM pattern.

A power tool is provided including a brushless motor having a stator defining a plurality of phases and a rotor. A power unit is provided including power switches and a control unit outputs a drive signal to the motor switches to drive the phases of the motor using a trapezoidal control scheme over a series of sectors. The control unit sets a conduction band within which each phase is commutated to a baseline value that is greater than 120 degrees, sets at least one commutation transition point as a function of the set conduction band, and within each sector, monitors an open-phase voltage of the motor to detect a back electromotive force (back-EMF) voltage of the motor and control commutation of at least one phase based on the open-phase voltage of the motor in relation to the at least one commutation transition point.