Black Decker Inc.

Jason Thrush

John Charles Vanko

Jason D McKillican

Michael J Kowalski

Sona R Mathew

Alexander P Davidson

Gregory Besack

Sona R Matthew

Jason D Mckillican

A method of operating a power tool having a motor and a controller is provided. The method includes: receiving a position of a variable-speed input mechanism mounted on the power tool; determining a target speed of the motor corresponding to the position of the variable-speed input mechanism; determining an underspeed threshold corresponding to the target speed; determining a rotational speed of the motor; and interrupting a supply of power to the motor if the rotational speed of the motor is less than the underspeed threshold.

Under-speed and closed-loop speed control in a variable-speed power tool

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 operable to deliver power to the motor. A primary controller is interfaced with the power unit to output drive signals to drive the phases of the motor over a series of sectors of the rotor rotation. The primary controller measures a back-electromotive force voltage of the motor and transitions motor commutation from the present sector to the next sector based in relation to the back-EMF voltage. A second controller is provided to receive at least one of the drive signals, calculate a speed and/or direction of rotation of the motor from the drive signals, and take corrective action to cut off supply of power to the motor if it detects an overspeed condition or incorrect direction of rotation.

Dual-controller system for a sensorless brushless motor control

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Baltimore, MD, United States of America

Jason Thrush