阅读说明：本技术 电动工具 (Electric tool ) 是由 J·C·巴尔托谢克 S·C·埃利 D·F·莱维特 于 2015-07-01 设计创作，主要内容包括：本申请案涉及电动工具。在至少一个说明性实施例中,一种电动工具可包括电动机,所述电动机包括：转子,其经配置以围绕轴旋转；定子组合件,其包含围绕所述转子布置的至少三个绕组；及至少三个凸耳,其固定到所述定子组合件,其中所述凸耳中的每一者电耦合到所述绕组中的一或多者。所述凸耳可全部布置到穿过所述轴的平面的一侧。所述电动工具可进一步包括：至少三个电线,其中所述电线中的每一者可移除地耦合到所述凸耳中的一者；及控制电路,其经配置以经由所述电线及所述凸耳将电力供应到所述绕组,以驱动所述转子围绕所述轴的旋转。(The present application relates to power tools. In at least one illustrative embodiment, a power tool may include a motor comprising: a rotor configured to rotate about an axis; a stator assembly including at least three windings arranged around the rotor; and at least three lugs secured to the stator assembly, wherein each of the lugs is electrically coupled to one or more of the windings. The lugs may all be arranged to one side of a plane through the shaft. The power tool may further include: at least three wires, wherein each of the wires is removably coupled to one of the lugs; and a control circuit configured to supply power to the windings via the wires and the lugs to drive rotation of the rotor about the shaft.)

1. A power tool, comprising:

a motor comprising a rotor configured to rotate about an axis, a stator assembly arranged around the rotor, and at least one lug secured to the stator assembly, wherein the at least one lug is electrically coupled to a winding on the stator;

at least one wire removably coupled to the at least one lug;

wherein the at least one lug comprises an inner peripheral wall defining an opening extending into the lug; and

at least one ferrule;

wherein the at least one wire extends into the at least one ferrule;

wherein the at least one ferrule removably extends into the opening of the lug and engages the inner peripheral wall of the opening to removably couple the at least one wire to the at least one lug; and is

Configured such that the at least one ferrule is removable from the opening of the lug when the at least one wire remains extended into the at least one ferrule and when the lug remains secured to the stator assembly.

2. The power tool of claim 1, wherein the at least one ferrule is welded to the at least one lug.

3. The power tool of claim 1, wherein the at least one ferrule is removably welded to the at least one lug.

4. The power tool of claim 3, wherein the at least one ferrule is selectively welded, de-welded, and re-welded to the at least one lug.

5. The power tool of claim 1, wherein the at least one lug includes a protrusion extending radially outward from the stator assembly and the opening defines a circular opening.

6. The power tool of claim 5, wherein the at least one wire is surrounded by the protrusion when the at least one wire is received by the circular opening.

7. The power tool of claim 5, wherein the protrusion includes an annular wall defining the circular opening.

8. The power tool of claim 5, wherein an outer perimeter of each protrusion defines a generally rectangular or circular shape.

9. The power tool of claim 1, wherein the at least one lug includes a female socket and the at least one wire includes a male plug configured to be received by the female socket.

10. The power tool of claim 1, wherein the at least one lug is at least two lugs.

11. A power tool, comprising:

a motor comprising a rotor configured to rotate about an axis, a stator assembly arranged around the rotor, and at least two lobes fixed to the stator assembly, wherein the at least two lobes are electrically coupled to windings on the stator;

at least two electrical wires, each removably coupled to one of the at least two lugs;

wherein each of the at least two lugs includes an inner peripheral wall defining an opening extending into each of the at least two lugs; and

at least two ferrules;

wherein each of the at least two wires extends into one of the at least two ferrules, respectively;

wherein each of the at least two ferrules removably extends into the opening of one of the lugs and engages the inner peripheral wall of the opening to removably couple each of the at least two wires to each of the at least two lugs;

is configured such that each of the at least two ferrules is removable from the opening into which the lug extends when each of the at least two wires remains extending into one of the at least two ferrules, respectively, and when each of the at least two lugs remains secured to the stator assembly.

12. The power tool of claim 11, wherein each of the at least two collars is welded to each of the at least two lugs.

13. The power tool of claim 11, wherein each of the at least two collars is removably welded to each of the at least two lugs.

14. The power tool of claim 13, wherein each of the at least two collars is selectively welded, de-welded, and re-welded to each of the at least two lugs.

15. The power tool of claim 11, wherein each of the at least two lugs includes a protrusion extending radially outward from the stator assembly and each of the openings defines a circular opening.

16. The power tool of claim 15, wherein each of the at least two wires is surrounded by the protrusion when each of the at least two wires is received by one of the circular openings.

17. A power tool, comprising:

a motor comprising a rotor configured to rotate about an axis, a stator assembly arranged around the rotor, and at least one lug secured to the stator assembly, wherein the at least one lug is electrically coupled to a winding on the stator; and

at least one wire removably coupled to the at least one lug;

wherein the at least one lug comprises an inner peripheral wall defining an opening extending into the lug;

wherein the at least one electrical wire removably extends into the opening of the lug and conductively engages the inner peripheral wall of the opening to removably couple the at least one electrical wire to the at least one lug; and is

Configured such that the at least one ferrule is removable from the opening of the lug when the at least one wire remains extended into the at least one ferrule and when the lug remains secured to the stator assembly.

18. The power tool of claim 17, wherein the at least one lug includes a protrusion extending radially outward from the stator assembly and the opening defines a circular opening.

19. The power tool of claim 18, wherein the at least one wire is surrounded by the protrusion when the at least one wire is received by the circular opening.

20. The power tool of claim 17, wherein the at least one wire is soldered to the at least one lug.

Technical Field

The present invention relates generally to power tools, and more particularly to motor connections for power tools.

Background

Motors used in power tools (by way of example, brushless direct current ("DC") motors) typically require connections to three large format "phase" wires that supply the high current that drives the motor. In many existing power tools, this connection is typically accomplished by soldering the phase wires to a printed circuit board ("PCB") inside the motor. Traces on the PCB, to which the stator windings of the motor are coupled, then conduct the high current from the phase lines to the soldered termination points. Serving the electric motor with such designs can be difficult, as desoldering the phase line from the PCB can be time consuming and risk damaging the PCB.

Other power tool designs have provided connections between the phase wires and the stator windings of the motor by solder "lugs" mounted to one end of the motor. While such designs may improve serviceability, they have also increased the footprint of the motor (and thus the size of the power tool). First, the solder lugs in such designs add length to the motor assembly. Second, because the solder lugs in such designs have typically been evenly spaced around the circumference of the motor, one or more of the phase lines typically must be wound around the motor for connection to the corresponding solder lug.

Disclosure of Invention

According to one aspect, a power tool may include a motor including (i) a rotor configured to rotate about an axis, (ii) a stator assembly including at least three windings arranged about the rotor, and (iii) at least three lugs secured to the stator assembly, wherein each of the lugs is electrically coupled to one or more of the windings. The lugs may all be arranged to one side of a plane through the shaft. The power tool may further include: at least three wires, wherein each of the wires is removably coupled to one of the lugs; and a control circuit configured to supply power to the windings via the wires and the lugs to drive rotation of the rotor about the shaft.

In some embodiments, each of the wires may be welded to one of the lugs. Each of the lugs may define a circular opening, and each of the wires may be received by one of the circular openings to removably couple each of the wires to one of the lugs. Each of the lugs may include a protrusion extending radially outward from the stator assembly and defining the circular opening. Each of the wires may be surrounded by one of the protrusions when each of the wires is received by one of the circular openings. Each protrusion may include an annular wall defining the circular opening. The outer perimeter of each protrusion may define a generally rectangular or circular shape.

In other embodiments, each of the lugs may include a fastener, and each of the wires may be coupled to one of the lugs by the corresponding fastener. In still other embodiments, each of the lugs may comprise a female receptacle and each of the wires may comprise a male plug configured to be received in one of the female receptacles. The stator assembly may further include a lamination stack supporting the windings. Each of the lugs may be secured to an exterior surface of the lamination stack.

According to another aspect, a power tool may include a motor including (i) a rotor configured to rotate about an axis, (ii) a stator assembly including at least three windings arranged about the rotor, and (iii) at least three lugs secured to the stator assembly, wherein each of the at least three lugs is electrically coupled to one or more of the windings. The at least three lugs may all be arranged to one side of a plane through the shaft. The power tool may further include at least three wires, wherein each of the wires is surrounded by one of the at least three lugs to removably couple each of the wires to one of the at least three lugs.

In some embodiments, each of the wires may be welded to one of the at least three lugs. In other embodiments, each of the at least three lugs may include a fastener, and each of the wires may be coupled to one of the at least three lugs by the corresponding fastener. In still other embodiments, each of the at least three lugs may comprise a female receptacle and each of the wires may comprise a male plug configured to be received in one of the female receptacles.

According to another aspect, an electric motor may include: a rotor configured to rotate about an axis; a stator assembly including at least three windings arranged around the rotor; and at least three lugs secured to the stator assembly, each of the at least three lugs being electrically coupled to one or more of the windings. Each of the at least three lugs may include a protrusion extending radially outward from the stator assembly. The protrusion may define a circular opening configured to receive an electrical wire. The projections of the at least three lugs may all be arranged to one side of a plane through the shaft.

In some embodiments, each protrusion may include an annular wall defining the circular aperture. Each projection may further include a pair of planar faces arranged opposite each other and interconnected by the annular wall. An outer perimeter of each of the pair of planar faces may define a generally rectangular shape. In other embodiments, the outer perimeter of each of the pair of planar faces may define a generally circular shape. The stator assembly may further include a lamination stack supporting the windings. Each of the at least three lugs may be secured to an exterior surface of the lamination stack.

Drawings

The concepts described in this disclosure are illustrated by way of example and not by way of limitation in the figures of the accompanying drawings. For simplicity and clarity of illustration, elements illustrated in the figures are not necessarily drawn to scale. For example, the dimensions of some of the elements may be exaggerated relative to other elements for clarity.

FIG. 1 is a side elevational view of an illustrative power tool;

FIG. 2 is an end elevational view of the power tool of FIG. 1;

FIG. 3 is an enlarged cross-sectional view of a motor included in the power tool (taken about line 3-3 of FIG. 1) with the remainder of the power tool omitted for clarity;

FIG. 4 is a partial perspective view of various components associated with the motor of the power tool of FIG. 1 with the remainder of the power tool omitted for clarity; and is

Fig. 5 is an enlarged partial perspective view of various components associated with the motor of the power tool of fig. 1 with the remainder of the power tool omitted for clarity.

Detailed Description

While the concepts of the present disclosure are susceptible to various modifications and alternative forms, specific exemplary embodiments thereof have been shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that there is no intention to limit the inventive concepts to the specific forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention.

Referring now to fig. 1, an illustrative power tool 10 is shown. The power tool 10 is illustratively embodied as a cordless power tool (in particular, a pistol-like impact tool). In various embodiments, the power tool 10 may embody a pistol-grip impact tool, a coaxial impact tool, or an angle impact tool, such as a right angle impact tool. However, it should be appreciated that in other embodiments, the power tool may be embodied as a cordless power tool that does not include an impact mechanism (e.g., a drill, a ratchet, a saw blade, or the like).

The illustrative power tool 10 includes a tool housing 12 as shown in fig. 1. The tool housing 12 includes a main body 14 and a rear cover 16. The body 14 defines an interior space 18 in which a motor 20 of the power tool 10 is positioned. The rear cover 16 is coupled to the body 14 when the power tool 10 is assembled to enclose the interior space 18 and define a rear end 22 positioned opposite an output end 24 of the power tool 10. The rear cover 16 is coupled to the body 14 using fasteners 26 (best seen in fig. 2) that extend through the rear cover 16 and into the interior space 18.

The body 14 of the tool housing 12 defines a handle 28 on which a trigger 30 is provided, as shown in fig. 1. The trigger 30 is used to turn the motor 20 on/off and control the speed of the motor 20 during use of the power tool 10. A user interface 32 spaced from the trigger 30 is also provided on the tool housing 12, particularly the rear cover 16, as best seen in fig. 2. In the illustrative embodiment, the user interface 32 is used to select one of a plurality of operating modes of the power tool 10. For example, in some embodiments, user interface 32 may be used to select a particular operating mode from among those described in U.S. provisional patent application No. 62/171,504 filed on 5.6.2015. In other embodiments, the user interface 32 may simply adjust the maximum power supplied to the motor 20 when the trigger 30 is fully depressed.

Referring now to fig. 3, the body 14 and the rear cover 16 are disassembled to show the components of the motor 20. The motor 20 is illustratively embodied as a brushless DC motor. As such, the motor 20 generally includes a rotor 34 for providing rotational energy (e.g., to a drive train or drive train of the power tool 10) and a stator 36 for supplying a rotating magnetic field that drives rotation of the rotor 34. The motor 20 also includes a rear end cap 38 and a front end cap 40 spaced from the end cap 38 and positioned closer to the output end 24 of the power tool 10 than the end cap 38. The end caps 38, 40 cooperate to align the rotor 34 and the stator 36 such that the rotor 34 and the stator 36 extend parallel to the shaft 42. The rotor 34 includes a shaft 44 supported on at least one end by a bearing 46 such that the rotor 34 is configured to rotate about the shaft 42. In addition, the rotor 34 includes one or more permanent magnets 48 that generate a magnetic field.

Referring now to fig. 4, the power tool 10 illustratively includes a control circuit 50 (shown diagrammatically) and a number of "phase" lines 52 electrically coupling the control circuit 50 to the motor 20. In the illustrative embodiment, the control circuit 50 is located in the handle 28 of the power tool 10. It will be appreciated that the power tool 10 includes one or more additional components (e.g., a transmission or drive train) typically present in power tools, which are not shown in the figures or described herein.

Referring now to fig. 5, motor 20 includes a stator assembly 54 having a number of windings arranged around rotor 34 with air gaps between the windings. In the illustrative embodiment (i.e., a four-pole, six-tooth, three-phase brushless DC motor), the stator assembly 54 includes three windings distributed about the shaft 42 to form an even number of poles. In particular, each stator winding includes a pair of windings arranged on opposite sides of the shaft 42. The stator windings may be electrically connected to each other in various configurations, including but not limited to a series delta configuration, a parallel delta configuration, a series wye (Y-shape) configuration, and a parallel wye configuration.

As shown in fig. 5, the stator assembly 54 further includes a lamination stack 56 that supports (and typically surrounds) the stator windings. The stator assembly 54 also includes a pair of insulators 58 (only one of which is shown in fig. 4) arranged at opposite ends of the stator assembly 54 to isolate the stator windings from other components of the motor 20.

During operation of the motor 20, when power is selectively supplied to one of the stator windings (by the control circuit 50 via one of the wires 52), the resulting current in the stator windings generates a magnetic field that is coupled to the rotor 34. The magnetic field associated with the permanent magnets in the rotor 34 attempts to align itself with the magnetic field generated by the stator 36, resulting in rotational movement of the rotor 34. The control circuit 50 may sequentially activate the stator windings such that the permanent magnets 48 of the rotor 34 continuously chase the progressive magnetic field generated by the stator windings. The illustrative embodiment of the motor 20 also includes a sensor, such as a hall effect sensor, that provides a signal to the control circuit 50 indicative of the current position of the rotor 34 (relative to the stator 36). The control circuit 50 may utilize this signal when sequentially activating the stator windings to maintain proper timing of the commutation sequence.

In the illustrative embodiment of fig. 5, the motor 20 further includes a number of solder lugs 60 or electrical terminals that are secured to the stator assembly 54. Each of the solder lugs 60 extends radially outward from a base block 62 secured to one of the insulators 58 of the stator assembly 54 and an exterior surface 64 of the lamination stack 56 of the stator assembly 54. It is contemplated that other mounting locations for the solder lugs 60 (e.g., the end caps 38) are possible. Each of the solder lugs 60 is electrically coupled to one or more of the stator windings. In the illustrative embodiment of fig. 5 in which stator assembly 54 includes three windings, motor 20 also includes three solder lugs 60, with one solder lug 60 electrically coupled to each stator winding.

The solder lugs 60 may be formed of a metal, metal alloy, or any other material suitable for conducting electrical current between the wires 52 and the stator windings. In some embodiments, the solder lugs 60 may be permanently fixed to the stator assembly 54 (e.g., the exterior surface 64 of the lamination stack 56) and/or permanently electrically coupled to the stator windings.

As best seen in fig. 5, each of the solder lugs 60 includes a tab 66 coupled to the base block 62 and extending radially outward from the base block 62. The divider 68 is coupled to the base block 62 and extends radially outward therefrom between the solder lugs 60. Specifically, one divider 68A extends radially outward from the base block 62 between a pair of solder lugs 60, and another divider 68B extends radially outward from the base block 62 between another pair of solder lugs 60.

The protrusion 66 illustratively has a generally rectangular shape as shown in fig. 5. Specifically, the outer perimeter of each of the tabs 66 defines a generally rectangular shape. However, in other embodiments, the outer perimeter of each of the projections 66 may define another suitable geometric form of shape. For example, the outer perimeter of each of the projections 66 may define a generally circular or trapezoidal shape.

Each projection 66 illustratively includes a planar face 70 and another planar face 72 positioned opposite the planar face 70, as shown in fig. 5. The planar faces 70, 72 are interconnected by an annular wall 74. The annular wall 74 of each projection 66 defines a circular aperture 76 extending through each of the planar faces 70, 72. The circular aperture 76 is sized to receive the wire 52, as described in more detail below.

As best seen in fig. 5, each of the wires 52 is inserted through one of the circular apertures 76 of the tabs 66 such that each of the wires 52 is surrounded by one of the tabs 66. In that manner, the projections 66 are configured to receive and support the electrical cord 52 when the power tool 10 is assembled (or reassembled). While received and supported by the projections 66, each of the wires 52 may be soldered to one of the solder lugs 60 to removably couple the wire 52 to the solder lug 60.

The ferrule 78 may be placed in contact with the wire 52 prior to soldering to the solder lug 60, as shown in fig. 5. Specifically, the ferrule 78 may be crimped onto the wire 52 to provide strain relief to the wire 52 and to prepare the wire 52 for insertion through the circular aperture 76.

In the illustrative embodiment (best seen in fig. 4), each of the solder lugs 60 is arranged below the centerline of the motor 20 (i.e., the shaft 42). In other words, the solder lugs 60 are all disposed to one side of a plane passing through the shaft 42. Using fig. 4 as an example, the solder lugs 60 are all disposed below a plane passing through the shaft 42 and extending generally into and out of the page of fig. 4. Moreover, in the illustrative embodiment, the solder lugs 60 are all arranged within the footprint of the stator assembly 54 when viewed from a perspective orthogonal to the plane. This configuration provides easier winding of the wires 52 to the motor 20, and therefore easier assembly of the power tool 10. This configuration also improves serviceability of the power tool 10 by allowing easier desoldering/re-welding of the wire 52 from/to the motor 20. Further, since the solder lugs 60 do not extend beyond the end of the motor 20, the overall length of the power tool 10 may be reduced.

It is contemplated that in other embodiments of the power tool 10, the solder lugs 60 may be replaced with another type of lug 60 that allows the wire 52 to be removably coupled to the lug 60. For example, in some embodiments, each of the lugs 60 may include a fastener such that each of the wires 52 may be removably coupled to one of the lugs 60 by tightening the corresponding fastener (and decoupled from the lug 60 by loosening the corresponding fastener). In still other embodiments, each of the lugs 60 may include a female receptacle and each of the wires 52 may include a male plug configured to be received in one of the female receptacles to removably couple the wires 52 to the lugs 60. By way of example, the male plug of the cord 52 may be frictionally secured in the female receptacle of the lug 60.

While certain illustrative embodiments have been described in detail in the drawings and foregoing description, such illustration and description are to be considered as exemplary and not restrictive in character, it being understood that only illustrative embodiments have been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected. For example, while the concepts of the present invention have been described primarily with reference to brushless DC motors, it is contemplated that the presently disclosed teachings may also be applicable to other types of motors, such as brushed DC motors and/or alternating current motors.

There are a number of advantages of the present invention that derive from the various features of the apparatus, systems, and methods described herein. It will be noted that alternative embodiments of the apparatus, systems, and methods of the present disclosure may not include all of the features described yet still benefit from at least some of the advantages of such features. Those skilled in the art may readily devise their own implementations of the apparatus, system, and method that incorporate one or more of the features of the present disclosure.