Control unit of modular construction and method for its assembly

Abstract

The invention relates to a modularly constructed control unit (100) and a method for assembling the same, which can be adapted, in particular in terms of interface functions, to electric motors selected from a predetermined number i of electric motors, in particular of the same power class, wherein the control unit (100) has at least two circuit boards (L1, L2) selected from a group of N different circuit boards (L1, L2,..., LN) on which interface functions, electrical elements, electronic components or control units for operating the electric motors are present.

Description

Technical Field

[0001] The present invention relates to an interface scheme for a modular construction of an electric drive, particularly an electric motor. Background Technology

[0002] Today, electric drive technology is present in various fields, such as homes, businesses, and especially many areas of industrial production. Its importance increases particularly in these contexts as production automation levels rise. At the heart of electric industrial drives are, on the one hand, the electric motor as an energy converter between the power grid and the working machines requiring mechanical energy, and on the other hand, the motor controller. Power electronics are one of the three central components of every electric drive. Their tasks are to control the motor, communicate with the controller, and diagnose the drive.

[0003] The term "power electronics" refers to everything related to controlling, converting, or switching electrical energy using electronic components. This has started from a few 100 mA and a few volts, but extends to a few 100 kV and a few 1000 A. At lower voltages and currents, the challenge lies not in the absolute values ​​themselves, but in conversion with exceptionally high efficiency and the lowest possible EMV radiation.

[0004] Power electronic devices or power electronic systems always consist of at least control or regulation components, power components themselves, and interfaces for connection and communication with other electronic components, where necessary. These power components, often simply referred to as "power electronic devices," are themselves composed of multiple parts that must always be coordinated with each other and with the application.

[0005] Due to the diversity of applications and their specific requirements, the interfaces needed for a particular motor or electric drive are implemented on a single power electronic device. This means that power electronics integrate all the necessary interfaces for known applications. In this respect, even within the same power level, there is high variance in power electronics.

[0006] However, in addition to reducing the number of variations, it is also desirable to obtain full functionality for applications, and in particular, to achieve flexibility in the design of power electronics for multiple motors and power levels. Summary of the Invention

[0007] Therefore, the objective of this invention is to overcome the aforementioned disadvantages of the prior art and to provide an improved, cost-effective solution for motor controllers and their power electronics.

[0008] This task is accomplished by combining features as described below.

[0009] According to the present invention, a control unit with a modular construction is provided, which is specifically adapted in terms of interface functions, more precisely for motors selected from a predetermined number i of motors, especially motors of the same power class (especially in terms of structural size and power span), wherein the control unit has at least two circuit boards selected from a group consisting of N different circuit boards (L1, L2, ..., LN), on which interface functions, electrical components, electronic components or control units for operating the motors are provided, wherein the circuit board serving as the base circuit board is equipped with power electronics for the motors and is housed in a first housing of the control unit, and wherein on another circuit board, in particular additional interface functions of the power electronics are provided separately from the power electronics, and the second circuit board is housed in a second housing separate from the first housing, and wherein the first housing has a housing wall surrounding the first circuit board, on which the second housing is mounted outside the first housing.

[0010] A further advantage is that the second housing is a junction box, and the second circuit board is surrounded by its circumferentially enclosed walls. Therefore, the supplementary circuit board can be installed separately in the junction box.

[0011] Another advantageous design is one in which the second housing is supported or mounted on an external, stepped opening of the first housing in a housing section, thereby complementing the shape of the first housing. In particular, the two housings are each formed as segments of a substantially cylindrical body and, when assembled together, substantially complement each other to form a common cylindrical body or jointly define a corresponding cylindrical envelope curve.

[0012] In another preferred embodiment of the invention, the second housing integrally has a cable inlet with a cable threaded sleeve connector for connecting an electrical connection connector thereon.

[0013] Modular separation of complementary housings is also advantageous, as the two housings then each have their own sealing plane or sealing function, separate from each other.

[0014] As previously explained, controllers can be modularly assembled from a set of circuit boards for specific motors, while simultaneously combining sealing, assembly, and electrical functions in a simple and cost-effective manner. For this purpose, a set of circuit boards is provided, on which the aforementioned interface functions, electrical components, electronic parts, or control units for operating the motor are located. In particular, at least one of the circuit boards is equipped with power electronics for the motor, and wherein some or more of the interface functions, especially the original interface functions of the power electronics, are separately located from the power electronics or on one or more additional circuit boards.

[0015] The number of circuit boards N and the number of motors i, as well as other quantities or partial quantities mentioned, are of course understood as integers, and therefore as positive numbers selected from the group of natural numbers.

[0016] The power section has the following key components to distinguish it from other supplementary circuit boards:

[0017] 1. Power semiconductors (e.g., FET, MOSFET overview, IGBT, TRIAC)

[0018] 2. Intermediate circuit capacitors

[0019] 3. Low-inductance structure between intermediate circuit capacitors and power semiconductors

[0020] 4. Control circuit = driver

[0021] 5. Power supply for the driver

[0022] 6. Monitoring and cut-off devices

[0023] These components can also be combined into modules.

[0024] The solution according to the invention is a particularly ingenious separation of the functional units of the motor controller, thereby significantly reducing the variance in the number of motor controllers without lacking basic functionality. On the other hand, by separating the specific interface functions of the power electronics onto one or more other (separate and independent) circuit boards, basic solutions, improved solutions, and advanced solutions can be achieved for the user through ingenious combinations without having to modify the power electronics individually.

[0025] In another preferred embodiment of the invention, two or more circuit boards differ in their topology only through separately implemented functional components and / or additional elements. This particular modular structure can be seen as an implementation of the aforementioned stages, enabling users to always achieve basic solutions and complementary, different improved solutions and advanced solutions using a single power electronics device.

[0026] Furthermore, it is advantageous that multiple interface functions are combined into an interface function group and integrated as such an interface function group on at least two or more of the circuit board.

[0027] It is particularly advantageous that at least one of the circuit boards (the base circuit board) has the basic functional components required to control the selected motor.

[0028] A further advantage is that at least one of the additional circuit boards (the supplementary circuit board) is constructed with additional functional components to supplement the functionality of the circuit board with the basic functional components.

[0029] In another preferred embodiment of the invention, the circuit board having basic functions for operating an electric motor has at least one interface for customer-specific functions.

[0030] Another advantage is that the base circuit board has an interface for connecting to the supplementary circuit board, and in particular, an interface for powering the corresponding supplementary circuit board.

[0031] In addition to this group, another aspect of the invention relates to a method for assembling a motor controller for a motor of a specific power level from a group of circuit boards, wherein, depending on the function to be achieved, at least a circuit board having power electronics and at least one or more additional circuit boards are selected from the group, and these circuit boards are electrically connected to each other through their interfaces, wherein at least one circuit board is selectively selected on which the interface function of the power electronics is arranged separately from the circuit board having the power electronics.

[0032] In addition to the circuit board assembly, another aspect of the invention relates to an electric motor having a motor controller comprising at least one first circuit board and another circuit board respectively selected from the circuit board assembly, the first circuit board having power electronics.

[0033] In principle, all publicly disclosed features can be combined arbitrarily, as long as it is technically possible and meaningful. Attached Figure Description

[0034] Other advantageous improvements of the invention are indicated above or shown in more detail below with reference to the accompanying drawings in conjunction with the description of preferred embodiments of the invention.

[0035] It is shown that:

[0036] Figure 1 Two exemplary diagrams illustrating a modularly constructed control unit;

[0037] Figure 2 A diagram showing the separate control unit in its various components, and

[0038] Figure 3 An exemplary assembly of a base circuit board and a supplementary circuit board is shown. Detailed Implementation

[0039] The following references only to exemplary embodiments Figures 1 to 3 The present invention is described in detail, wherein the same reference numerals in the figures denote structurally and / or functionally identical or similar components.

[0040] exist Figure 1 and Figure 2Two exemplary diagrams of a modularly constructed control unit 100 are shown in the figure.

[0041] The modularly constructed control unit 100 has a first base housing 1 and a housing 2 separate from the first base housing. Power electronics LE are mounted in the first housing 1 of the control unit 100, while a separate circuit board L2 is disposed in the junction box 2, separate from the power electronics LE. The junction box 2 is mounted on the housing wall surrounding the first circuit board 1 and thus fitted onto the housing 1, or more precisely, fitted outside the first housing 1.

[0042] The second circuit board L2 is surrounded by its circumferentially enclosed wall 4 in the junction box, wherein a removable cover 4a forms part of the wall 4. The base housing 1 has a can-shaped cover 7 and a bottom plate. The second housing 2 is placed on a housing section on an external, stepped opening of the first housing 1 and thereby complements the shape of the first housing 1.

[0043] Junction box 2 has a cable inlet 5 with a cable threaded sleeve connector 6.

[0044] exist Figure 3 The diagram shows only an exemplary first functional embodiment, and more specifically, a group consisting of two circuit boards, namely a first circuit board L1 and a supplementary circuit board L2, each having an interface function SF.

[0045] On circuit board L1, in addition to motor controller 10, there are DC / DC converter 20, power supply 30, PWM module 40, and various other interfaces and interface functions SF not mentioned in detail, as well as interface functions of customer interface.

[0046] The circuit board L2 contains the MOD bus, controller, connector 50 for power supply from the first circuit board L1, and other interface functions SF.

[0047] therefore, Figure 1 The diagram illustrates a portion of a group consisting of at least two circuit boards L1 and L2, on which interface functions, electrical components, electronic parts, or control units for operating electric motors are present. These interface functions, electrical components, or control units are selected from a predetermined number of electric motors, particularly those of the same power rating. This combination of two selected circuit boards here, for example, constitutes a basic controller with different functions for controlling the respective electric motors, wherein, for example, circuit board L2 can be replaced by an extended circuit board to provide additional functions for the same motor or motors of the same power rating. Here, circuit board L1 is provided with power electronics LE for the electric motors on which it can be equipped, wherein, however, some of the interface functions of power electronics LE are mounted separately on the second circuit board L2.

Claims

1. A modularly constructed control unit, the control unit being adaptable in terms of interface functionality for a motor selected from a predetermined set of motors of the same power rating, wherein, The control unit has at least two circuit boards selected from a group of N different circuit boards. These circuit boards contain interface functions, electrical components, electronic parts, or control units for operating the motor. A first circuit board, serving as a base circuit board, is equipped with power electronics for the motor and is housed within a first housing of the control unit. A second circuit board, serving as a supplementary circuit board, has additional interface functions for the power electronics separately from the power electronics. This second circuit board is housed in a second housing separate from the first housing. The first housing has a housing wall surrounding the first circuit board, on which the second circuit board is mounted outside the first housing. The second housing is supported on an external, stepped opening of the first housing in a housing section, thereby completing the shape of the first housing.

2. The modular control unit according to claim 1, characterized in that, The second housing is a junction box, and the second circuit board is surrounded by its circumferentially enclosed walls.

3. The control unit with a modular structure according to claim 1 or 2, characterized in that, The second housing integrally has a cable inlet with a cable threaded sleeve fitting, and / or the second housing integrally has a plug fitting / plug connector.

4. The control unit with a modular structure according to claim 1 or 2, characterized in that, The two shells are constructed as separate, independent shells, each having its own sealing plane.

5. The control unit with a modular structure according to claim 1 or 2, characterized in that, The two shells are each formed as segments of a substantially cylindrical body and, in the assembled state, are combined to form a substantially cylindrical body.

6. The control unit with a modular structure according to claim 1 or 2, characterized in that, Multiple interface functions are combined into an interface function group and integrated as such an interface function group on at least two or more of the N different circuit boards.

7. The control unit with a modular structure according to claim 1 or 2, characterized in that, At least one of the N different circuit boards, excluding the first circuit board, is constructed as the supplementary circuit board with additional functional components to supplement the functionality of the circuit board with the basic functional components.

8. The control unit with a modular construction according to claim 1 or 2, characterized in that, The circuit board having basic functions for operating the electric motor has at least one interface for customer-specific functions.

9. The control unit with a modular structure according to claim 1 or 2, characterized in that, An interface for connecting to the supplementary circuit board is present on the base circuit board.

10. The control unit with a modular construction according to claim 9, wherein, The interface for connecting to the supplementary circuit board includes an interface for supplying power to the supplementary circuit board.

11. A method for assembling a control unit according to any one of claims 1 to 10 for a motor of a specific power rating, wherein, Depending on the function to be achieved, at least a base circuit board with power electronics and at least one or more additional supplementary circuit boards are selected, and the circuit boards are electrically connected to each other through their interfaces, wherein at least one supplementary circuit board is selected on which the interface function of the power electronics is arranged separately from the base circuit board with the power electronics.

12. The assembly method according to claim 11, wherein, The supplementary circuit board is installed in the junction box of the control unit.

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