Brushless dc motor control unit

Abstract

An electrical switch unit for use with a variable speed electrical device includes a housing for a pair of electrical switching contacts, and an actuator operably connected with one of those contacts. A signaling module is associated with the electrical switch unit, and has signaling circuitry for sensing the movement of the actuator and outputting a signaling module signal indicative of the sensed movement or position of the actuator. A power module with a power switching device controllably supplies power from the DC power source to the DC motor at a speed corresponding to the sensed movement or position of the actuator. A control module receives the signaling module signal, and outputs a control module signal to control the power module.

What is claimed is: 
     
         1 . An electrical switch unit for use with a variable speed electrical device to control operation of a DC motor of the electrical device, the electrical switch unit comprising:
 a housing which houses a pair of electrical switching contacts, and, an actuator operably connected with at least one of the pair of electrical switching contacts, the actuator being configured for movement relative to the pair of electrical switching contacts in response to operation of a finger-operable trigger so as to arrange the pair of electrical switching contacts into at least one of a closed configuration wherein power is able to be supplied from the DC power source to the DC motor via the pair of electrical switching contacts, and, an opened configuration wherein power is not able to be supplied from the DC power source to the DC motor via the pair of electrical switching contacts;   a signaling module associated with the electrical switch unit comprising signaling circuitry for sensing the movement of the actuator and outputting a signaling module signal indicative of the sensed movement or position of the actuator;   a power module comprising at least one power switching device for controllably supplying power from the DC power source to the DC motor;   a control module comprising control circuitry for receiving the signaling module signal, and responsive to the received signaling module signal, outputting a control module signal to control the at least one power switching device of the power module wherein the at least one power switching device controllably supplies power from the DC power source to the DC motor to allow operation of the DC motor at a speed corresponding to the sensed movement or position of the actuator; and   wherein, the electrical switch unit is characterized in that the at least one of the pair of electrical switching contacts, the signaling module, and the control module are integrally formed together in a first PCB, the first PCB including a first end located within the housing and extending outwardly of the housing so as to terminate at a second end, said first PCB further including at least one of electrical conductive pins, conductive pathways, and conductive buses integrally formed in the first PCB via which the at least one of the pair of electrical switching contacts, the signaling module, and the control module are in electrical communication; and   wherein the power module is formed in a second PCB that is separate from the first PCB.   
     
     
         2 . The electrical switch unit of  claim 1 , wherein the DC motor includes a brushless DC motor. 
     
     
         3 . The electrical switch unit of  claim 1 , wherein the at least one power switching device includes a MOSFET device. 
     
     
         4 . The electrical switch unit of  claim 1 , further including a protective resin coating for protecting components of at least one of the signaling module, the control module and the power module. 
     
     
         5 . The electrical switch unit of  claim 1 , wherein the first PCB and the second PCB are arranged substantially perpendicularly to each other. 
     
     
         6 . The electrical switch unit of  claim 1 , wherein the first PCB and the second PCB are arranged substantially spaced apart and parallel to each other. 
     
     
         7 . The electrical switch unit of  claim 1 , further including a heat dissipation and/or heat dispersion element arranged in thermal communication with a bottom region of the power module to allow heat dissipation from the power module. 
     
     
         8 . The electrical switch unit of  claim 1 , further including a first and second heat dissipation and/or heat dispersion element arranged in thermal communication with a bottom region and a top region of the power module respectively to allow heat transfer from the power module. 
     
     
         9 . The electrical switch unit of  claim 1 , further including at least one of an electrical power tool and an electrical gardening tool. 
     
     
         10 . A customizable electrical switch unit for use with an electrical device to control operation of a DC motor of the electrical device, the electrical switch unit comprising:
 a housing which houses a pair of electrical switching contacts, and, an actuator operably connected with at least one of the pair of electrical switching contacts, the actuator being configured for movement relative to the pair of electrical switching contacts so as to arrange the pair of electrical switching contacts into at least one of a closed configuration wherein power is able to be supplied from the DC power source to the DC motor via the pair of electrical switching contacts, and, an opened configuration wherein power is not able to be supplied from the DC power source to the DC motor via the pair of electrical switching contacts;   a signaling module associated with the electrical switch unit comprising signaling circuitry for sensing the movement of the actuator and outputting a signaling module signal indicative of the sensed movement or position of the actuator;   and an electrical connection interface via which at least one of a control module and a power module are able to be selectably connected to the electrical switch unit for customised operation of the electrical switch unit, wherein said power module comprises at least one power switching device for controllably supplying power from the DC power source to the DC motor; and the control module comprises control circuitry for receiving the signaling module signal, and responsive to the received signaling module signal, outputting a control module signal to control the at least one power switching device of the power module wherein the at least one power switching device controllably supplies power from the DC power source to the DC motor to allow operation of the DC motor at a speed corresponding to the sensed movement or position of the actuator, and whereby the at least one of the control module and the power module are able to be integrally formed together with the pair of electrical switching contacts and/or together with the signaling module associated with the electrical switch unit for relatively direct electrical communication therebetween.