A method of starting a permanent magnet synchronous motor (PMSM) with field oriented control (FOC) includes: opening a first control loop of the PMSM; setting a first direction for a first current component of the PMSM; aligning a rotor of the PMSM to the first direction; after aligning the rotor, setting a second direction for the first current component, where the second direction is rotated from the first direction by 90 degrees; after setting the second direction, starting the rotor while the first control loop of the PMSM remains open; after starting the rotor, increasing a rotation speed of the rotor by operating the first control loop in a first closed-loop mode; and after increasing the rotation speed of the rotor, controlling the rotation speed of the rotor by operating the first control loop in a second closed-loop mode different from the first closed-loop mode.

A method of starting a permanent magnet synchronous motor (PMSM) with field oriented control (FOC) includes: opening a first control loop of the PMSM; setting a first direction for a first current component of the PMSM; aligning a rotor of the PMSM to the first direction; after aligning the rotor, setting a second direction for the first current component, where the second direction is rotated from the first direction by 90 degrees; after setting the second direction, starting the rotor while the first control loop of the PMSM remains open; after starting the rotor, increasing a rotation speed of the rotor by operating the first control loop in a first closed-loop mode; and after increasing the rotation speed of the rotor, controlling the rotation speed of the rotor by operating the first control loop in a second closed-loop mode different from the first closed-loop mode.

A motor control actuator that drives a permanent magnet synchronous motor (PMSM) with sensorless Field Oriented Control includes a sampling circuit that generates a measurement signal by measuring a back electro motive force (BEMF) of the PMSM, while the PMSM rotates; a PLL that receives the measurement signal and extracts an amplitude and an angle of the BEMF from the measurement signal; and a motor controller that generates a first set of two phase alternating current (AC) voltage components based on an estimated rotor angle, generates a second set of two phase AC voltage components based on the amplitude and the angle, and generates control signals for driving the PMSM based on the first set of two phase AC voltage components. The motor controller performs a catch spin sequence for restarting the PMSM while rotating, the catch spin sequence includes a synchronizing period followed by a closed loop control period.

A motor control actuator that drives a permanent magnet synchronous motor (PMSM) with sensorless Field Oriented Control includes a sampling circuit that generates a measurement signal by measuring a back electro motive force (BEMF) of the PMSM, while the PMSM rotates; a PLL that receives the measurement signal and extracts an amplitude and an angle of the BEMF from the measurement signal; and a motor controller that generates a first set of two phase alternating current (AC) voltage components based on an estimated rotor angle, generates a second set of two phase AC voltage components based on the amplitude and the angle, and generates control signals for driving the PMSM based on the first set of two phase AC voltage components. The motor controller performs a catch spin sequence for restarting the PMSM while rotating, the catch spin sequence includes a synchronizing period followed by a closed loop control period.

A power tool is provided including a housing, a brushless motor disposed within the housing, a power switch circuit that supplies power from a power source to the brushless motor, and a controller configured to apply a drive signal to the power switch circuit to control the supply of power to the brushless motor. The controller is configured to receive at least one signal associated with a phase current of the motor, detect an angular position of the rotor based on the phase current of the motor within a variable speed range of zero to at least 15,000 rotations-per-minute (RPM), and control the drive signal based on the detected angular position of the rotor to electronically commutate the motor within a torque range of zero to at least 15 newton-meters (N.m.) and a power output of zero to at least 1500 watts.

A power tool is provided including a housing, a brushless motor disposed within the housing, a power switch circuit that supplies power from a power source to the brushless motor, and a controller configured to apply a drive signal to the power switch circuit to control the supply of power to the brushless motor. The controller is configured to receive at least one signal associated with a phase current of the motor, detect an angular position of the rotor based on the phase current of the motor within a variable speed range of zero to at least 15,000 rotations-per-minute (RPM), and control the drive signal based on the detected angular position of the rotor to electronically commutate the motor within a torque range of zero to at least 15 newton-meters (N.m.) and a power output of zero to at least 1500 watts.

A power tool is provided including a housing, a brushless motor disposed within the housing, a power switch circuit that supplies power from a power source to the brushless motor, and a controller configured to apply a drive signal to the power switch circuit to control the supply of power to the brushless motor. The controller is configured to receive at least one signal associated with a phase current of the motor, detect an angular position of the rotor based on the phase current of the motor within a variable speed range of zero to at least 15,000 rotations-per-minute (RPM), and control the drive signal based on the detected angular position of the rotor to electronically commutate the motor within a power output of zero to at least 1500 watts.

A power tool is provided including a housing, a brushless motor disposed within the housing, a power switch circuit that supplies power from a power source to the brushless motor, and a controller configured to apply a drive signal to the power switch circuit to control the supply of power to the brushless motor. The controller is configured to receive at least one signal associated with a phase current of the motor, detect an angular position of the rotor based on the phase current of the motor within a variable speed range of zero to at least 15,000 rotations-per-minute (RPM), and control the drive signal based on the detected angular position of the rotor to electronically commutate the motor within a power output of zero to at least 1500 watts.

A power tool is provided including a housing, a brushless motor disposed within the housing, a power switch circuit that supplies power from a power source to the brushless motor, and a controller configured to receive at least one signal associated with a phase current of the motor, detect an angular position of the rotor based on the phase current of the motor, and apply a drive signal to the power switch circuit to control a commutation of the motor based on the detected angular position of the rotor. The controller detects an initial sector within which the rotor is located at start-up, apply the drive signal so as to rotate the motor to a parking angle associated with the detected initial sector, and control a commutation sequence to drive the motor beginning at the parking angle.

A power tool is provided including a housing, a brushless motor disposed within the housing, a power switch circuit that supplies power from a power source to the brushless motor, and a controller configured to receive at least one signal associated with a phase current of the motor, detect an angular position of the rotor based on the phase current of the motor, and apply a drive signal to the power switch circuit to control a commutation of the motor based on the detected angular position of the rotor. The controller detects an initial sector within which the rotor is located at start-up, apply the drive signal so as to rotate the motor to a parking angle associated with the detected initial sector, and control a commutation sequence to drive the motor beginning at the parking angle.