Control device, in particular steering control device

Abstract

The invention relates to a control device (10a-e), in particular a steering control device, having an electronics unit (12a-e) for operating at least one electric motor (14a-e) and / or for detecting at least one operating variable of the electric motor (14a-e) and having at least one circuit board (16a-e), on which the electronics unit (12a-e) is arranged at least partially. It is proposed here that the circuit board (16a-e) is produced by means of a 3D printing method.

Description

TECHNICAL FIELD

[0001] The invention relates to a control device. Furthermore, the invention relates to an actuator assembly having such a control device, to a steering system having such an actuator assembly and to a method for producing such a control device. BACKGROUND

[0002] Steering systems are known from the prior art which comprise a steering actuator having an electric motor and having a control device for controlling the operation of the electric motor. Here, the control device is usually arranged in an electronics housing which adjoins the electric motor and comprises an electronics unit which is arranged on at least one circuit board.

[0003] It is difficult to arrange the entire electronics in the electronics housing, wherein at the same time a good heat dissipation of the electronics unit must be ensured. In order to increase the area of the circuit board, it is proposed in the later publication DE 10 2020 202 364 A1 to have a circuit board having a base plate and two side plates which are bendable relative to the base plate. Thereby, the existing installation space in the electronics housing can be better utilized. However, in this case, due to the partially rigid shape (Teilstarren-Form), there are still options for improvement, in particular with regard to handling, heat dissipation and installation space utilization.

[0004] Furthermore, there are different 3D printing methods by means of which circuit boards can now also be produced in a very cost-effective manner and in almost any shape. In this regard, reference is made by way of example to US 2019 / 0098771 A1.

[0005] Against this background, it is the task of the invention to provide a control device which has improved properties with regard to construction. This task is solved by the features according to the invention, while advantageous constructional embodiments and modifications of the invention can be gathered from the following. SUMMARY

[0006] The invention relates to a control device, in particular a steering control device, having an electronics unit for operating at least one electric motor and / or for detecting at least one operating variable of the electric motor and having at least one circuit board, the electronics unit being arranged at least partially, preferably at least mostly and particularly preferably completely on the circuit board.

[0007] It is proposed that the circuit board is produced by means of a 3D printing method. By means of this constructional solution, it is possible, inter alia, to provide a control device having an advantageous structure. In particular, an advantageous flexibility can be achieved, by means of which the circuit board can be advantageously matched to a predefined installation volume. Furthermore, an advantageous efficiency, in particular a manufacturing efficiency, an assembly efficiency, a structural space efficiency and / or a cost efficiency, can be improved. In particular, a predefined installation volume can be used particularly effectively in this respect. Furthermore, in particular, the heat dissipation of the control device can be improved.

[0008] A "control device" is understood in this respect, inter alia, as at least one component, in particular a subassembly, of an actuator assembly, which is in particular in at least one operating state provided for controlling the operation of at least one electric motor of the actuator assembly. The electric motor is in particular configured as a brushless motor and is advantageously configured as an asynchronous motor or a permanently excited synchronous motor and preferably comprises at least one motor shaft, which in particular defines an axis of rotation of the electric motor. Furthermore, the electric motor can advantageously comprise a motor housing, which is in particular configured as a receiving housing, and / or at least one bearing end cap. Furthermore, the control device preferably comprises an electronics housing, which is in particular adjoined to the electric motor, advantageously to the bearing end cap, and is preferably directly coupled to the electric motor, in which at least the electronics unit and the circuit board are arranged. Furthermore, the electronics unit comprises in particular control electronics, in particular in the form of a control logic and / or power electronics, for operating the electric motor and / or detection electronics for detecting at least one operating variable, such as a rotor position and / or a temperature, of the electric motor. The electronics unit thus comprises a plurality of electronic components, wherein in particular at least one of the electronic components can be configured as a power electronic component and can be part of a power electronics.

[0009] Furthermore, the circuit board comprises, inter alia, a carrier substrate, in particular in the form of a matrix, which is printed by means of a 3D printing method, and preferably comprises at least one conductor track which is printed by means of a 3D printing method and is arranged on the carrier substrate. The circuit board can also comprise, inter alia, a plurality of conductor tracks which are printed by means of a 3D printing method and are arranged on the carrier substrate. Furthermore, the circuit board can also comprise, in principle, at least a part of an electronics unit, in particular at least one active or passive and printed by means of a 3D printing method, electronic component, for example a resistor, a capacitor, an inductor and / or a sensor element. The 3D printing method can be, for example, a stereolithography method, a laser sintering method, a laser beam melting method, an electron beam melting method, a fused deposition modeling method or a fused filament fabrication method and / or an aerosol jet 3D printing method. However, the 3D printing method is preferably an inkjet printing method and / or a material jetting method, for example in the form of a multi-material jetting method and / or a polymer jetting method. Furthermore, the circuit board can be designed, inter alia, as a flexible circuit board. However, it is advantageous if the circuit board is at least partially, preferably at least largely and particularly preferably completely rigid and / or shape-stable. Furthermore, the circuit board is preferably designed monolithically. "Monolithically" is to be understood, inter alia, as being at least materially bonded and / or mutually formed. Material bonding can be established, for example, by means of a gluing process, an injection-molding process, a melting process, a soldering process and / or other processes. However, it is advantageous if "monolithically" is to be understood as one piece and is formed, inter alia, from one body and / or in one body. Furthermore, the expression "at least largely" is to be understood, inter alia, as at least 55%, advantageously at least 75% and particularly advantageously at least 90%. "Is provided" is to be understood, inter alia, as being specially programmed, designed and / or equipped. "The object is provided for a certain function" is to be understood, inter alia, as the object fulfilling and / or performing this certain function in at least one application state and / or operating state.

[0010] It is further proposed that the circuit board has at least one first circuit board section and at least one second circuit board section which is connected to the first circuit board section, in particular integrally, wherein the first circuit board section is arranged perpendicular to a motor shaft of the electric motor, in particular perpendicular to the motor shaft already mentioned above, and the second circuit board section is arranged at an angle to the first circuit board section and in particular, viewed in the direction perpendicular to the motor shaft of the electric motor, at an angle of at least 80°, advantageously at least 90° and / or at most 170°, advantageously at most 150°, to the first circuit board section. Here, the in particular equipable surface and / or main extension plane of the first circuit board section and the in particular equipable surface and / or main extension plane of the second circuit board section in particular enclose an angle of at least 80°, advantageously at least 90° and / or at most 170°, advantageously at most 150°. Furthermore, the first and second circuit board sections can in particular be connected to one another such that the connection region of the first and second circuit board sections has sharp edges or curved sections with a defined radius and / or rounded sections. The first circuit board section is in particular rigidly and / or shape-stably configured and is in particular provided for receiving at least one electronic component of an electronics unit. The second circuit board section is in particular rigidly and / or shape-stably configured and is in particular provided for receiving at least one further electronic component of the electronics unit. The arrangement of the first circuit board section perpendicular to the motor shaft of the electric motor is in particular to be understood as meaning that the in particular equipable surface and / or main extension plane of the first circuit board section is arranged perpendicular to the rotational axis and / or longitudinal extension direction of the motor shaft. The "main extension plane" of an object is in particular to be understood as meaning the plane which is parallel to the largest side of a smallest, in particular imaginary, hexahedron which completely encloses the object. Thereby, in particular an advantageous utilization of a given installation volume and a particularly large area expansion of the circuit board can be achieved.

[0011] The first and second circuit board sections can in particular be arranged relative to one another such that the first and second circuit board sections at least partially overlap when viewed in the direction of the motor shaft. It is however advantageously proposed that the first and second circuit board sections are arranged relative to one another such that the first and second circuit board sections are free of overlap when viewed in the direction of the motor shaft. Here, the first and second circuit board sections are in particular arranged relative to one another such that the first and second circuit board sections are free of intersection and / or overlapping regions when viewed in the direction of the motor shaft. Thereby, in particular an advantageously simple assembly of the circuit board can be achieved. Furthermore, in particular thermal properties can be improved.

[0012] Furthermore, the second circuit board section can extend, at least when viewed perpendicular to the motor axis, from the first circuit board section in a direction facing the electric motor. In this case, the circuit board and in particular the first circuit board section can advantageously be arranged, in particular fixed, on a housing cover of the electronics housing, whereby the circuit board can advantageously be assembled together with the housing cover and in particular in one work step.

[0013] However, as an alternative, the second circuit board section can also extend, at least when viewed perpendicular to the motor axis, from the first circuit board section in a direction opposite the electric motor. In this case, the circuit board and in particular the first circuit board section can advantageously be arranged, in particular fixed, at a bearing end cover of the electric motor. Thereby, in particular, a modification of the existing structure can be minimized and the structure of the control device known from the prior art can advantageously be largely retained.

[0014] Furthermore, it is proposed that the electronics unit and in particular the control electronics comprise at least one power electronics component, preferably configured as a switching element, and advantageously comprise a plurality of power electronics components, in particular configured as switching elements. The power electronics components can in particular be arranged on the first circuit board section and preferably on a side of the first circuit board section facing the electric motor. However, it is preferably proposed that at least one power electronics component is arranged on the second circuit board section. Here, the power electronics components are preferably arranged on a side of the second circuit board section facing the electric motor. Thereby, in particular, the heat distribution of the control device can be further improved.

[0015] Furthermore, it is proposed that the control device comprises at least one motor contact, for example in the form of a solder joint and / or a fusion joint, and advantageously comprises a plurality of motor contacts, preferably configured in the same way, for electrically connecting the electric motor. Here, the electronics unit and advantageously the control electronics are electrically connected to the electric motor in particular via the motor contacts. The motor contacts can in particular be arranged on the first circuit board section, whereby in particular an advantageously compact connection of the electric motor can be achieved. However, it is preferably proposed that at least one motor contact is arranged on the second circuit board section, whereby in particular a particularly advantageous heat distribution can be achieved.

[0016] According to another constructive concept, it is proposed that the circuit board comprises a carrier substrate printed by means of a 3D printing method and at least one conductor track printed by means of a 3D printing method, wherein the conductor track extends at least partially over the first circuit board section and the second circuit board section. Thus, the conductor track is arranged, in particular, on the first circuit board section and the second circuit board section. The circuit board can comprise, in particular, also a plurality of conductor tracks printed by means of a 3D printing method, which extend at least partially over the first circuit board section and the second circuit board section. Thereby, an advantageously flexible contacting can be realized, in particular.

[0017] If the circuit board has an at least substantially U-shaped, at least substantially C-shaped or rectangular cross section, viewed in a direction perpendicular to a motor axis of the electric motor, in particular perpendicular to the motor axis already mentioned above, and the electronics unit is distributed over at least three sides of the circuit board, a particularly efficient utilization of a given installation volume and an advantageous heat distribution can be realized, in particular. In this case, the circuit board comprises, in particular, at least three advantageously mutually angularly arranged sides and / or at least three, in particular equipable, surfaces, wherein at least one electronic component of the electronics unit is arranged on each side and / or surface. An "at least substantially U-shaped" object is to be understood in this respect, in particular, as an object which deviates from a reference object of U-shape by at most 30%, preferably at most 20% and particularly preferably at most 10% of the area share. This is to apply, in particular, accordingly also to the expression "at least substantially C-shaped". In this case, the circuit board can be configured, for example, as a hexahedron, a hollow hexahedron, a cylinder or a hollow cylinder. Here, a "cylinder" is to be understood, in particular, as a general or mathematical cylinder, such that the cylinder can in principle have an arbitrarily shaped base and / or top surface, for example a circular, elliptical or arbitrary polygonal shape.

[0018] Furthermore, it is proposed, preferably, that the circuit board comprises a carrier substrate printed by means of a 3D printing method, which is made of at least two different materials. In this case, the first circuit board section and the second circuit board section can be made of different materials, for example. Furthermore, the circuit board section of the circuit board, on which the power electronics are arranged, and another circuit board section of the circuit board, on which the control logic and / or detection electronics are arranged, can be made of different materials. In this respect, for example, an especially expensive heat-resistant material can be used for the circuit board section, and an especially inexpensive less heat-resistant material can be used for the other circuit board section. Furthermore, as an alternative or in addition, an inner circuit board section of the circuit board can have a different material than an outer circuit board section of the circuit board, whereby, for example, the heat conduction capability, the electrical conductivity and / or the robustness of the circuit board can be improved. Furthermore, costs can be advantageously reduced.

[0019] As an alternative or supplementary solution, the circuit board includes at least two conductor lines printed using 3D printing methods, the conductor lines being made of different materials. In this case, for example, the conductor line for electrically connecting power electronic devices and another conductor line for electrically connecting control logic devices and / or detection electronic devices can be made of different materials. In this regard, for example, a first material with high conductivity can be used for the conductor line and a second material with lower conductivity can be used for the other conductor line. Furthermore, as an alternative or supplementary solution, the inner conductor line, especially the conductor line integrated and / or embedded in the carrier substrate, can have a different material than the outer conductor line, especially the conductor line disposed on the outer surface of the carrier substrate. Thus, the conductor line can be particularly flexible in matching different requirements. In addition, it is advantageous to reduce costs.

[0020] As an alternative or supplementary solution, the circuit board includes at least one conductor line printed by a 3D printing method, the conductor line having at least two conductor line segments made of different materials. For example, the conductor line extending at least partially on a first circuit board segment and a second circuit board segment can be made of at least two different materials. In this case, the first conductor line segment arranged on the first circuit board segment and the second conductor line segment arranged on the second circuit board segment can be made of different materials. In this case, as an alternative, other materials for the conductor line can be used in the connection area of ​​the first and second circuit board segments. Furthermore, the conductor lines in the areas of power electronics and in the areas of control logic devices and / or detection electronics can be made of different materials. In addition, in this case, it is particularly possible to directly integrate different components into the conductor line, such as resistors advantageously printed by a 3D printing method, sensor elements advantageously printed by a 3D printing method, and / or circuit board fuses advantageously printed by a 3D printing method. Thus, it is particularly possible to make the individual conductor lines particularly flexible in matching different requirements. In addition, it is advantageous to reduce costs.

[0021] In another configuration it is proposed that the electronic unit comprises at least one electronic component which is integrated and / or embedded in the circuit board. Here, the electronic component is preferably at least mostly or completely surrounded by the carrier substrate of the circuit board and is advantageously integrated and / or embedded in the circuit board in a 3D printing method. The electronic component can be, for example, a resistor, a capacitor, an inductor and / or a sensor element, for example a sensor element of a detection electronics, and can also be printed, in particular by means of a 3D printing method. Thereby, in particular a particularly flexible and / or compact circuit board can be provided.

[0022] Furthermore, it is proposed that the control device comprises at least one cooling element, for example in the form of a cooling block, which is integrated and / or embedded in the circuit board. Here, the cooling element is preferably at least mostly or completely surrounded by the carrier substrate of the circuit board and is advantageously integrated and / or embedded in the circuit board in a 3D printing method. The cooling element can also be printed, in particular by means of a 3D printing method. The cooling element is made, in particular, of a thermally conductive material having a thermal conductivity of at least 15 W / mK, preferably at least 100 W / mK and particularly preferably at least 200 W / mK and is, in particular, provided for cooling the electronic unit and, in particular, the power electronics. Furthermore, the cooling element is particularly preferably configured in one piece and is advantageously connected in one piece with the circuit board. By means of the cooling element, in particular, the heat dissipation of the electronic unit and, in particular, of the power electronics can be further improved.

[0023] If the cooling element comprises a base body which is located inside with respect to the circuit board and which is, in particular, assigned to the electronic unit, advantageously to the power electronics, and a plurality of dissipation elements which thermally connect the base body to the outside of the circuit board and are provided for dissipating the thermal energy generated by the electronic unit in operation and, in particular, absorbed by the base body, in particular to the surroundings of the circuit board, in particular an especially efficient heat dissipation and / or an advantageous control of the heat dissipation can be achieved. Here, the dissipation elements are preferably arranged on the circuit board in such a distribution that the thermal energy generated by the electronic unit in operation is dissipated through at least two, advantageously at least three and particularly preferably at least four sides and / or surfaces of the circuit board.

[0024] It is further proposed that the control device comprises an electronics housing, in particular the aforementioned electronics housing, which comprises a base housing and a housing cover, in particular the aforementioned housing cover, which adjoin to a bearing end cap of the electric motor, in particular the aforementioned bearing end cap. Here, the base housing in particular delimits at least one receiving region for the electronics unit and the circuit board, while the housing cover is provided at least in the assembled state for covering the receiving region. It is furthermore advantageous if the base housing is coupled directly to the electric motor and in particular is connected in a materially, form- and / or force-locked manner to the electric motor, in particular to the electric motor housing and / or the bearing end cap, in particular by means of a riveting and / or adhesive connection. Thereby, in particular a control device and / or actuator assembly which is advantageously compactly configured can be provided.

[0025] It is advantageous if the circuit board is matched to the receiving region of the base housing in particular by means of a 3D printing method in such a way that the circuit board is in direct thermal contact with the electronics housing and the thermal energy generated in operation by the electronics unit, in particular the power electronics, is dissipated directly and in particular at least predominantly or completely via the bearing end cap of the electric motor, the side wall of the base housing which is arranged in particular parallel to the motor shaft and / or the housing cover. Thereby, in particular a further improved heat dissipation can be achieved.

[0026] Furthermore, the invention relates to an actuator assembly having at least one electric motor with at least one motor shaft and having the aforementioned control device. It is advantageous here if the control device and the electric motor are part of a steering actuator. It is therefore particularly preferred if the control device and the electric motor are part of a steering system which is in particular provided for use in a vehicle and preferably in a motor vehicle.

[0027] Furthermore, a method for producing a control device, in particular a steering control device, is proposed, in which at least one circuit board is produced by means of a 3D printing method and an electronics unit for operating at least one electric motor and / or for detecting at least one operating variable of an electric motor is arranged at least partially, preferably at least mostly and particularly preferably completely on the circuit board. Here, at least one carrier substrate and at least one conductor track are advantageously printed by means of a 3D printing method for producing the circuit board. Furthermore, at least one electronic component and / or at least one cooling element of the electronics unit is integrated and / or embedded into the circuit board, preferably in a 3D printing method. The electronic component and / or cooling element can also be printed by means of a 3D printing method, in particular. Furthermore, at least one motor contact for electrically connecting an electric motor can be printed by means of a 3D printing method and more precisely in particular printed onto the carrier substrate and preferably onto an equipable surface of the circuit board. Thereby, in particular the advantages already mentioned above can be achieved, wherein in particular a control device with an advantageous structure can be provided.

[0028] Here, the control device, actuator assembly, steering system and method should not be restricted to the above-mentioned applications and embodiments. The control device, actuator assembly, steering system and method can in particular have a different number of the elements, components and units mentioned here in order to achieve the principles of action described here. BRIEF DESCRIPTION OF DRAWINGS

[0029] Further advantages result from the following description of the figures. In the figures, various embodiments of the application are shown. Therein:

[0030] Figure 1 A part of an exemplary steering system with an actuator assembly configured as a steering actuator, which comprises an electric motor and a control device, is shown in a perspective view;

[0031] Figure 2 A part of the control device and the electric motor is shown in a schematic sectional view;

[0032] Figure 3 A circuit board of the control device is shown in a top view;

[0033] Figure 4 An exemplary flow chart with main method steps of a method for producing the control device is shown;

[0034] Figure 5 Another embodiment of another control device is shown in a schematic sectional view;

[0035] Figure 6a further embodiment of a further control device is shown in a schematic sectional view;

[0036] Figure 7 a further embodiment of a further control device is shown in a schematic sectional view; and

[0037] Figure 8 a further embodiment of a further control device is shown in a schematic sectional view. DETAILED DESCRIPTION

[0038] The following embodiments purely exemplarily relate to a steering system. However, in principle the present application is not limited to use in a steering system and can for example also be used in other areas of a vehicle, for example in a wiper device, a window lifter system and / or a drive system, and / or in other electronic systems, for example in the field of household appliances and / or machine tools.

[0039] Figure 1 At least a part of an exemplary steering system 70a is shown in a perspective view. The steering system 70a is configured as an electrically assisted steering system in the present case. The steering system 70a is exemplarily configured as a conventional steering system and comprises an electric power steering comprising a servo steering. Furthermore, the steering system 70a is provided for use in a vehicle (not shown), in particular a motor vehicle. The steering system 70a has an active connection to a wheel (not shown) of the vehicle in the installed state and is provided for influencing the driving direction of the vehicle. However, as an alternative it is also conceivable to configure a steering system with an electric superimposed steering and / or an active steering. Furthermore, the steering system can in principle also be configured as a steer-by-wire steering system.

[0040] The steering system 70a comprises a steering transmission 72a which is exemplarily configured as a rack-and-pinion steering transmission and is provided for converting a steering specification into a steering movement of the wheel. To this end, the steering transmission 72a comprises at least one steering adjustment element 74a which is configured as a rack in the present case in particular.

[0041] Furthermore, the steering system 70a comprises at least one actuator assembly 68a. The actuator assembly 68a is configured as a steering actuator and has an active connection to the steering adjustment element 74a. The actuator assembly 68a is provided for providing a steering torque. In the present case, the actuator assembly 68a is provided for providing a steering torque in the form of an assist torque and / or a servo torque and for introducing it into the steering transmission 72a, in particular in order to carry out a steering support. However, as an alternative, the actuator assembly can also be part of an electric superposition steering and / or an active steering and be provided, in particular, for providing an additional steering angle and / or a variable transmission ratio. Furthermore, the actuator assembly can be part of a steer-by-wire steering system. In this case, the actuator assembly can be provided, in particular, for use in a wheel steering angle regulator and for providing a steering torque for directly controlling the driving direction of the vehicle. Furthermore, in this case, the actuator assembly can also be provided for use in an operating unit of a steer-by-wire steering system and for providing a feedback torque and / or a restoring torque acting on a steering handle. Furthermore, as mentioned at the outset, the actuator assembly can also be used independently of a steering system.

[0042] The actuator assembly 68a comprises an electric motor 14a which is known per se. The electric motor 14a is configured as a synchronous motor, in particular a permanent-magnet-excited synchronous motor. Furthermore, the electric motor 14a is configured as a multiphase electric motor. The electric motor 14a is provided for generating a steering torque. The electric motor 14a comprises a motor housing 76a which is configured, in particular, as an outer housing, a stator (not shown) arranged in the motor housing 76a, a rotor (not shown) arranged in the motor housing 76a, a motor shaft 20a arranged in the motor housing 76a and at least one bearing end cap 58a which, in the present case, is in the form of a B-type bearing end cap (see Figure 2 ). Here, the motor shaft 20a defines an axis of rotation 78a of the electric motor 14a.

[0043] Furthermore, the actuator assembly 68a has a control device 10a (see also Figure 2). The control device 10a is configured as a steering control device in the present case. The control device 10a comprises an electronics housing 56a. The electronics housing 56a is configured as an outer housing. The electronics housing 56a is configured as a receiving housing. The electronics housing 56a is coupled with the electric motor 14a, in particular with the motor housing 76a, and directly adjoins to the bearing end cap 58a. Thus, the electronics housing 56a is arranged axially with respect to the motor shaft 20a. Furthermore, the electronics housing 56a is configured in multiple pieces. The electronics housing 56a comprises a base housing 60a and a housing cover 62a, wherein the base housing in particular provides a receiving area 64a and the housing cover serves to cover the receiving area 64a in particular in the direction of the motor shaft 20a and / or the rotational axis 78a. In the present case, the base housing 60a is furthermore at least partially configured integrally with the motor housing 76a and the bearing end cap 58a. Here, the base housing 60a and / or the housing cover 62a are preferably made of metal, such as aluminum, and / or made of a material having a high heat conduction capacity. Furthermore, the housing cover 62a can comprise at least one plug connector 80a for electrical contacting of the outside of the control device 10a. In principle, the electronics housing and in particular the base housing can of course also be configured separately from the motor housing and / or the bearing end cap. Furthermore, the base housing and / or the housing cover can in principle also be made of plastic.

[0044] Furthermore, the control device 10a comprises an electronics unit 12a. The electronics unit 12a is arranged in the electronics housing 56a, in particular in the receiving area 64a.

[0045] The electronics unit 12a comprises actuating electronics 82a for actuating the electric motor 14a. The actuating electronics 82a comprises a control logic having at least one computing unit 84a and power electronics having at least one power electronic component 24a, 26a. The at least one power electronic component 24a, 26a is configured as a discrete switching element, advantageously as a MOSFET or a B6 power module. Furthermore, the actuating electronics 82a can comprise at least one intermediate circuit capacitor and / or at least one current measurement resistor. In the present case, the actuating electronics 82a is provided for providing a phase current for the electric motor 14a, in particular for all phases of the electric motor 14a. However, in principle, the electronics unit can also be free of actuating electronics. Furthermore, the electronics unit can have actuating electronics in the form of a control logic or actuating electronics in the form of power electronics.

[0046] Furthermore, the electronics unit 12a comprises, in the present case, detection electronics 86a for detecting at least one operating variable of the electric motor 14a. In the present case, the detection electronics 86a comprises at least one position sensor 88a for detecting the rotor position of the electric motor 14a and in particular of the motor shaft 20a. As an alternative or in addition, the detection electronics can also comprise at least one temperature sensor for detecting the temperature of the electric motor 14a. Furthermore, it is conceivable to dispense with the detection electronics altogether.

[0047] In order to accommodate the electronics unit 12a, the control device 10a furthermore comprises at least one circuit board 16a. In the present embodiment, the control device 10a comprises exactly one circuit board 16a. Thus, all of the actuating electronics 82a and all of the detection electronics 86a are arranged on the circuit board 16a. The circuit board 16a is integrally configured. Furthermore, the circuit board 16a is rigidly and / or shape-stably configured. As an alternative, the control device can also comprise a plurality of circuit boards, in particular at least two or at least three circuit boards, wherein in particular the actuating electronics and / or the detection electronics can be distributed to the circuit boards and / or the detection electronics can be arranged on a separate circuit board. Furthermore, the circuit board can in principle also be configured as a flexible circuit board or a rigid-flexible combined circuit board.

[0048] In the present case, the circuit board 16a is manufactured by means of a 3D printing method. The circuit board 16a comprises a carrier substrate 28a which is printed by means of a 3D printing method and in particular is shape-stable, and a plurality of conductor tracks 30a, 32a, 34a which are printed by means of a 3D printing method and are arranged on the carrier substrate 28a (see also Figure 3 ). Exemplarily, the 3D printing method used is an inkjet printing method or a material jetting method, in particular a material jetting method in the form of a Multi-Jet-Modeling-Verfahren and / or a Poly-Jet Modeling-Verfahren. In principle, of course, a 3D printing method which differs from the inkjet printing method or the material jetting method can also be used to manufacture the circuit board 16a. Furthermore, it is conceivable to print at least one active or passive electronic component, for example a resistor, advantageously in the form of a current measuring resistor, a capacitor, an inductance and / or a sensor element, by means of a 3D printing method and advantageously simultaneously with the carrier substrate and to arrange it on and / or in the carrier substrate.

[0049] Furthermore, the circuit board 16a has a first circuit board section 18a. The first circuit board section 18a is configured as a bottom plate. The first circuit board section 18a is arranged perpendicular to the motor shaft 20a and / or perpendicular to the axis of rotation 78a of the electric motor 14a. Here, the first circuit board section 18a is arranged such that the axis of rotation 78a intersects a geometric center point 90a of the first circuit board section 18a. Thus, the first circuit board section 18a is arranged parallel to the bearing end cap 58a of the electric motor 14a and directly adjoins the bearing end cap 58a, in particular. Furthermore, the shape of the first circuit board section 18a matches the shape of the electronics housing 56a. Furthermore, the first circuit board section 18a is provided for receiving at least one electronic component of the electronics unit 12a. In the present case, the first circuit board section 18a is provided at least for receiving a computing unit 84a of the control electronics 82a and for receiving a position sensor 88a of the detection electronics 86a. As an alternative, it is conceivable that the computing unit and / or the position sensor are not arranged on the first circuit board section, but instead, for example, power electronics or at least one power electronic component are arranged on the first circuit board section. Furthermore, it is conceivable that the first circuit board section is arranged such that the geometric center point of the first circuit board section is arranged offset with respect to the axis of rotation of the electric motor.

[0050] Furthermore, the circuit board 16a comprises at least one second circuit board section 22a, 23a which is connected to the first circuit board section 18a. In the present case, the circuit board 16a has two second circuit board sections 22a, 23a. However, in principle the circuit board can also have exactly one second circuit board section. The second circuit board sections 22a, 23a are rigidly connected to the first circuit board section 18a. The second circuit board sections 22a, 23a have the same material thickness as the first circuit board section 18a. The second circuit board sections 22a, 23a are configured as side plates. Furthermore, the second circuit board sections 22a, 23a are arranged on different sides, in particular opposite sides, of the first circuit board section 18a. Here, the second circuit board sections 22a, 23a are arranged at an angle with respect to the first circuit board section 18a. The angle a1, in particular an obtuse angle, between the first circuit board section 18a and the second circuit board section 22a and the angle a2, in particular an obtuse angle, between the first circuit board section 18a and the other second circuit board section 23a are identical in the present case and in particular lie between 120° and 150°. Furthermore, at least when viewed perpendicularly to the motor axis 20a and / or perpendicularly to the rotational axis 78a, the second circuit board sections 22a, 23a respectively extend from the first circuit board section 18a in a direction opposite to the electric motor 14a, in particular in the direction of the housing cover 62a. Thus, viewed in the direction perpendicular to the motor axis 20a and / or perpendicular to the rotational axis 78a of the electric motor 14a, the circuit board 16a has an at least substantially U-shaped or at least substantially C-shaped cross section.

[0051] However, as an alternative, at least one second circuit board section can also extend from the first circuit board section in a direction facing the electric motor. Furthermore, at least one second circuit board section can also be movably connected to the first circuit board section, in particular so that the first circuit board section and the second circuit board section can be moved and in particular can be pivoted with respect to one another. Here, for example material cutouts and / or cross-sectional taperings in the circuit board can be used for the movable connection of the second circuit board section and the first circuit board section. Furthermore, it is conceivable for the second circuit board sections to be configured differently from one another, for example in the case of an asymmetrical configuration of the electronics housing, in order to make the most of the available installation volume. Furthermore, the circuit board can also comprise at least three or at least four second circuit board sections which are advantageously configured in the same way and are in particular arranged on different sides of the first circuit board section.

[0052] Furthermore, in the present case the second circuit board sections 22a, 23a are constructed at least substantially mirror-symmetrical with reference to a center plane 92a which is oriented perpendicular to the first circuit board section 18a and which intersects the geometric center point 90a of the first circuit board section 18a. Here, the second circuit board sections 22a, 23a are arranged in such a way that an edge and / or a bend 94a between the first circuit board section 18a and the second circuit board section 22a and a further edge and / or bend 96a between the first circuit board section 18a and the further second circuit board section 23a are arranged parallel to one another and perpendicular to the motor shaft 20a and / or perpendicular to the rotational axis 78a (see in particular Figure 3 ].

[0053] Furthermore, the first circuit board section 18a and the second circuit board sections 22a, 23a are arranged relative to one another in such a way that the first circuit board section 18a and the second circuit board sections 22a, 23a are free of overlap and thus in particular do not have intersection and / or overlap regions when viewed in the direction of the motor shaft 20a and / or the rotational axis 78a. As an alternative, at least one second circuit board section can at least partially cover the first circuit board section when viewed in the direction of the motor shaft and / or the rotational axis.

[0054] Furthermore, at least one power electronics component 24a, 26a of the power electronics is arranged on each second circuit board section 22a, 23a. Advantageously, all power electronics components 24a, 26a can also be arranged on the second circuit board sections 22a, 23a. Here, the power electronics components 24a, 26a are arranged on a side of the respective second circuit board section 22a, 23a which faces the electric motor 14a, in particular the bearing end cap 58a. In the present case, the electronics unit 12a is arranged on the circuit board 16a in such a way that the electronics unit 12a is distributed over at least three sides 38a, 40a, 42a of the circuit board 16a.

[0055] Furthermore, at least one of the conductor tracks 30a, 32a, 34a, in particular printed by means of a 3D printing method, extends at least partially on the first circuit board section 18a and on the second circuit board section 22a and thus is arranged not only on the first circuit board section 18a but also on the second circuit board section 22a. In the present case, at least a first conductor track 30a and a second conductor track 32a of the conductor tracks 30a, 32a, 34a are exemplarily guided directly through the edge and / or bend 94a which is located between the first circuit board section 18a and the second circuit board section 22a.

[0056] Furthermore, the carrier substrate 28a, which is printed, inter alia, by means of a 3D printing method, can be made of at least two different materials. In the present case, the first circuit board section 18a and the second circuit board sections 22a, 23a are exemplarily made of different materials. Here, the first circuit board section 18a, on which, inter alia, control logic and detection electronics are arranged, is made of a less heat-resistant material, whereas the second circuit board sections 22a, 23a, on which, inter alia, power electronics are arranged, are made of a heat-resistant material. However, as an alternative or in addition, the inner circuit board sections of the circuit board can also have a different material than the outer circuit board sections of the circuit board. Furthermore, the carrier substrate manufactured by means of a 3D printing method can in principle also be shaped from a single material.

[0057] Furthermore, the at least two conductor tracks 30a, 32a, 34a, which are printed, inter alia, by means of a 3D printing method, can be made of different materials. In the present case, the first conductor track 30a and the third conductor track 34a are exemplarily made of different materials. Here, the first conductor track 30a is provided for the electrical connection of power electronics and is made of a material having a high electrical conductivity, whereas the third conductor track 34a is provided for the electrical connection of control logic and / or detection electronics 86a and is made of a material having a lower electrical conductivity. However, as an alternative or in addition, the inner conductor tracks can also have a different material than the outer conductor tracks. Furthermore, the conductor tracks manufactured by means of a 3D printing method can in principle also be shaped from a single material.

[0058] Moreover, the at least one conductor track 30a, 32a, 34a, which is printed, inter alia, by means of a 3D printing method, can be made of a plurality of different materials. In the present case, the second conductor track 32a has, by way of example, at least two conductor track sections 44a, 46a made of different materials. A first conductor track section 44a of the conductor track sections 44a, 46a is arranged in the region of the power electronics, in particular the power electronics component 24a. A second conductor track section 46a of the conductor track sections 44a, 46a is arranged in a further region which is offset and spaced apart from the region of the power electronics, for example in the region of the control logic and / or detection electronics 86a and / or in the connecting region of the first and second circuit board sections 18a, 22a. In this case, the first conductor track section 44a can be made, for example, of a material having a high electrical conductivity and the second conductor track section 46a of a material having a lower electrical conductivity. As an alternative or in addition, different components can also be integrated directly into the conductor track by using different materials for the individual conductor tracks, for example a resistor which is advantageously printed by means of a 3D printing method, a sensor element which is advantageously printed by means of a 3D printing method and / or a circuit board fuse which is advantageously printed by means of a 3D printing method.

[0059] Moreover, in the present case, at least one electronic component 48a of the electronics unit 12a is integrated and / or embedded in the circuit board 16a. In the present case, the electronic component 48a is, by way of example, a capacitor which is completely surrounded by the carrier substrate 28a and integrated and / or embedded in the carrier substrate 28a in a 3D printing method. However, it is also conceivable in principle to integrate and / or embed electronic components which are different from capacitors in the circuit board 16a, for example a position sensor 88a of the detection electronics 86a, a temperature sensor of the detection electronics and / or other active or passive electronic components.

[0060] Furthermore, the circuit board 16a has a plurality of motor contacts 98a, 100a, in particular configured in the same way, for electrically connecting the electric motor 14a. In the present case, the control device 10a has, by way of example, six motor contacts 98a, 100a, wherein each motor contact 98a, 100a is provided for connecting a motor lead 102a (indicated only diagrammatically) of the electric motor 14a, in particular of a multi-phase electric motor. The motor leads 102a are guided here through recesses in the bearing end cap 58a. The motor contacts 98a, 100a are provided for electrically connecting the control electronics 82a with the electric motor 14a. The motor contacts 98a, 100a are arranged on the first circuit board section 18a. Here, the motor contacts 98a, 100a are, by way of example, configured as solder points which are soldered to the first circuit board section 18a. Furthermore, the motor contacts 98a, 100a are divided into two, in particular equally large, groups of motor contacts 98a, 100a, wherein a first group of motor contacts 98a and a second group of motor contacts 100a are arranged at least substantially mirror-symmetrically with respect to the center plane 92a. However, as an alternative, at least one motor contact can also be arranged on the second circuit board section. Furthermore, the circuit board can have a number of motor contacts which differs from six. Furthermore, at least one motor contact can be printed by means of a 3D printing method.

[0061] In order to dissipate and / or cool the power electronics 24a, 26a, the control device 10a furthermore comprises a plurality of cooling bodies 104a, 106a, in the present case in particular two cooling bodies 104a, 106a, wherein one of the cooling bodies 104a, 106a is assigned to each of the second circuit board sections 22a, 23a. The cooling bodies 104a, 106a are at least substantially mirror-symmetrically configured with respect to the center plane 92a. The cooling bodies 104a, 106a are respectively in direct contact and / or direct thermal connection with the electronics housing 56a, in particular with the base housing 60a. Furthermore, the cooling bodies 104a, 106a each have a cooling surface which is assigned to the respective power electronics 24a, 26a and which extends parallel to the respective second circuit board section 22a, 23a. The cooling bodies 104a, 106a are respectively provided for dissipating the thermal energy generated by the respective power electronics 24a, 26a in operation via the side walls 66a, 67a of the base housing 60a which are in particular adjacent to the respective cooling body 104a, 106a and / or the bearing end cap 58a. However, it is also conceivable in principle to dispense with an additional cooling body and to dissipate the thermal energy generated in operation directly and in particular at least predominantly or completely via the bearing end cap of the electric motor, the side walls of the base housing which are arranged in particular parallel to the motor shaft and / or the housing cover.

[0062] Figure 4 An exemplary flow chart is shown, which has the main method steps of the method for manufacturing the control device 10a.

[0063] In method step 110a, the circuit board 16a is manufactured by means of a 3D printing method. Here, in particular a shape-stable carrier substrate 28a and a plurality of conductor tracks 30a, 32a, 34a are printed by means of a 3D printing method. Here, the conductor tracks 30a, 32a, 34a are printed onto the carrier substrate 28a and preferably onto the mountable surface of the circuit board 16a. Furthermore, the electronic components 48a of the electronics unit 12a can be integrated and / or embedded into the circuit board 16a. The 3D printing method used is exemplarily an inkjet printing method or a material jetting method, in particular a material jetting method in the form of a multi-material jetting method and / or a polymer jetting method. Thereby, the circuit board 16a can be produced in a very cost-effective manner and in almost any shape.

[0064] In method step 112a, the circuit board 16a is equipped by arranging and fixing the electronics unit 12a on the circuit board 16a. Here, for the fixing, in particular an adhesive process, a melting process, a soldering process and / or preferably a soldering process can be used. Furthermore, the electronics unit 12a is electrically connected with the conductor tracks 30a, 32a, 34a.

[0065] In method step 114a, the circuit board 16a together with the electronics unit 12a is installed into the electronics housing 56a. Here, the circuit board 16a together with the arranged electronics unit 12a is put into the receiving area 64a of the base housing 60a and fixed therein. Subsequently, the circuit board 16a and thus the electronics unit 12a is electrically coupled with the electric motor 14a. Finally, the receiving area 64a is closed by means of the housing cover 62a.

[0066] Here, Figure 4 The exemplary flow chart in Fig. 1 should exemplarily illustrate the method for manufacturing the control device 10a only. The individual method steps can also be varied or supplemented by additional method steps. Thus, for example in the 3D printing method, at least one additional cooling element can also be integrated and / or embedded into the circuit board 16a. Furthermore, at least one electronic component, at least one cooling element and / or at least one motor contact for electrically connecting the electric motor can be printed by means of the 3D printing method and in particular together with the carrier substrate 28a and the conductor tracks 30a, 32a, 34a.

[0067] InFigures 5 to 8 Further embodiments of the application are shown in the following. The following description and the drawings are essentially limited to the differences between the embodiments, wherein with regard to identically labeled components, in particular components having the same reference numerals, reference is made in principle also to the other embodiments, in particular to the drawings and / or the description of the Figures 1 to 4 embodiments. In order to distinguish the embodiments, reference numerals of the drawings of the embodiments are supplemented by the letter a. In the Figures 1 to 4 embodiments, the letter a is replaced by the letters b to e. Figures 5 to 8

[0068] Figure 5 Another embodiment of the application is shown. Reference numerals of the Figure 5 embodiments are supplemented by the letter b. Figure 5 Another embodiment of the application differs at least essentially from the preceding embodiments in the configuration and arrangement of the circuit board 16b of the control device 10b.

[0069] In this case, the circuit board 16b is configured integrally and rigidly and / or shape-stably by means of a 3D printing method. Furthermore, the entire electronics unit 12b is arranged on the circuit board 16b and more precisely so that the electronics unit 12b is distributed over at least three sides 38b, 40b, 42b of the circuit board 16b.

[0070] The circuit board 16b comprises a first circuit board section 18b and two second circuit board sections 22b, 23b connected to the first circuit board section 18b, which are arranged at an angle with respect to the first circuit board section 18b. In the present case, the first circuit board section 18b and the second circuit board sections 22b, 23b are arranged at an angle with respect to one another such that the angle a1 between the first circuit board section 18b and the second circuit board section 22b and the angle a2 between the first circuit board section 18b and the other second circuit board section 23b are each 90°. Thus, viewed in the direction perpendicular to the motor axis 20b of the electric motor 14b, the circuit board 16b has a U-shaped cross section.

[0071] Furthermore, the first circuit board section 18b is directly adjoined to a housing cover 62b of an electronics housing 56b. Here, the second circuit board sections 22b, 23b each extend from the first circuit board section 18b at least when viewed perpendicularly to the motor axis 20b in the direction facing the electric motor 14b. In this case, the circuit board 16b and in particular the first circuit board section 18b can advantageously be arranged, in particular fixed, at the housing cover 62b, whereby the circuit board 16b can advantageously be assembled together with the housing cover 62b and in particular in one work step. ​

[0072] Furthermore, the control device 10b does not have a cooling body and / or cooling elements which can be present. In this case, the circuit board 16b is so matched to the receiving region 64b of the base housing 60b of the electronics housing 56b that the circuit board 16b is in direct thermal contact with the electronics housing 56b and the thermal energy generated in operation by the electronics unit 12b, in particular the power electronics, is directly dissipated through the side wall 66b of the base housing 60b arranged parallel to the motor shaft 20b and the housing cover 62b. In this case, the base housing 60b and the housing cover 62b are made of metal, in particular aluminum.

[0073] Furthermore, motor contacts 98b, 100b for electrically connecting the electric motor 14b are arranged on the second circuit board sections 22b, 23b. Each motor contact 98b, 100b is provided for connecting a motor lead 102b (only indicated schematically) of the electric motor, in particular a multi-phase electric motor 14b. Furthermore, the motor contacts 98b, 100b are divided into two, in particular equally large, groups of motor contacts 98b, 100b, wherein a first group of motor contacts 98b is arranged on the second circuit board section 22b and a second group of motor contacts 100b is arranged on the further second circuit board section 23b.

[0074] In Figure 6 A further embodiment of the application is shown in Figure 6 The embodiment is supplemented by the letter c. Figure 6 A further embodiment of the application differs at least substantially from the aforementioned embodiments in the configuration and arrangement of the circuit board 16c of the control device 10c.

[0075] In this case, the circuit board 16c is integrally and rigidly and / or stably configured by means of a 3D printing method. Here, the circuit board 16c has a quaderförmig cross section, viewed in the direction perpendicular to the motor shaft 20c of the electric motor 14c, and extends from the bearing end cap 58c of the electric motor 14c to the housing cover 62c of the electronics housing 56c on the one hand and from the side wall 66c of the base housing 60c of the electronics housing 56c to the other side wall 67c of the base housing 60c of the electronics housing 56c, which is opposite the side wall 66c, on the other hand. Furthermore, the entire electronics unit 12c is arranged on the circuit board 16c and precisely so arranged that the electronics unit 12c is distributed over at least four side portions 36c, 38c, 40c, 42c of the circuit board 16c and preferably over at least six side portions 36c, 38c, 40c, 42c of the circuit board 16c.

[0076] Furthermore, the control device 10c does not have a cooling body and / or cooling elements which can be present. In this case, the circuit board 16c is so matched to the receiving region 64c of the base housing 60c that the circuit board 16c is in direct thermal contact with the electronics housing 56c and the thermal energy generated by the electronics unit 12c, in particular the power electronics, in operation is directly dissipated through the bearing end cap 58c, the side wall 66c and / or the further side wall 67c of the base housing 60c and the housing cover 62c.

[0077] Figure 7 Another embodiment of the application is shown. The Figure 7 The embodiment is supplemented by the letter d. Figure 7 Another embodiment of the application differs at least substantially from the aforementioned embodiments in that an additional cooling element 50d is integrated into the circuit board 16d of the control device 10d.

[0078] The circuit board 16d of the control device 10d corresponds at least substantially to the circuit board 16b of the aforementioned embodiments and thus comprises a first circuit board section 18d and two second circuit board sections 22d, 23d which are connected to the first circuit board section 18d. Thus, viewed in the direction perpendicular to the motor axis 20d of the electric motor 14d, the circuit board 16d has a U-shaped cross section. In this case, however, the second circuit board sections 22d, 23d each extend from the first circuit board section 18d, viewed perpendicularly to the motor axis 20d, in the direction opposite to the electric motor 14d, in particular in the direction of the housing cover 62d of the electronics housing 56d. In this case, however, as an alternative, the circuit board can also have other shapes and / or cross-sectional shapes.

[0079] Furthermore, the control device 10d comprises a cooling element 50d which is integrated and / or embedded into the circuit board 16d. Here, the cooling element 50d is directly integrated and / or embedded into the circuit board 16d in a 3D printing method and thus when manufacturing the circuit board 16d. In principle, the cooling element 50d can also be printed directly by means of a 3D printing method and in particular together with the circuit board 16d. The cooling element 50d is made of a thermally conductive material having a thermal conductivity of at least 200 W / mK. The cooling element 50d is integrally configured. Furthermore, the cooling element 50d is integrally connected with the circuit board 16d. Here, the cooling element 50d is at least largely surrounded by the carrier substrate 28d of the circuit board 16d. In the present case, the cooling element 50d is so surrounded by the carrier substrate 28d of the circuit board 16d that a side of the cooling element 50d facing the bearing end cap 58d and a side of the cooling element 50d facing the side wall 66d of the base housing 60d are completely covered by the circuit board 16d and / or the carrier substrate 28d. Furthermore, the cooling element 50d is so surrounded by the carrier substrate 28d of the circuit board 16d that a side of the cooling element 50d facing the housing cover 62d is not covered. The cooling element 50d is currently provided for cooling the electronic device unit 12d, in particular the power electronics, arranged on the circuit board 16d. In the present case, the cooling element 50d is provided for absorbing the thermal energy generated by the electronic device unit 12d in operation and dissipating it through the housing cover 62d. To this end, the housing cover 62d is preferably made of metal, in particular aluminum.

[0080] As an alternative, the cooling element can also be made of a thermally conductive material having a thermal conductivity of 200 W / mK or less and for example at least 15 W / mK or at least 100 W / mK. Furthermore, a side of the cooling element facing the bearing end cap and / or a side of the cooling element facing the side wall of the base housing can be uncovered. In this case, the cooling element can be provided for absorbing the thermal energy generated by the electronic device unit in operation and dissipating it through the bearing end cap and / or the side wall.

[0081] In Figure 8 another embodiment of the application is shown. The Figure 8 embodiment is supplemented by the letter e. Figure 8 Another embodiment of the application differs at least substantially from the aforementioned embodiments in the configuration and arrangement of an additional cooling element 50e integrated into the circuit board 16e of the control device 10e.

[0082] The circuit board 16e of the control device 10e at least substantially corresponds to the circuit board 16c of the aforementioned embodiment. Thus, viewed in the direction perpendicular to the motor axis 20e of the electric motor 14e, the circuit board 16e has a square cross section. However, in this case, as an alternative, the circuit board can also have other shapes and / or cross-sectional shapes.

[0083] Furthermore, the control device 10e comprises a cooling element 50e which is integrated and / or embedded in the circuit board 16e. Here, the cooling element 50e is integrated and / or embedded in the circuit board 16e directly in a 3D printing method and thus when manufacturing the circuit board 16e. In the present case, the cooling element 50e is printed directly by means of a 3D printing method and in particular together with the circuit board 16e. The cooling element 50e is at least mostly surrounded by the carrier substrate 28e of the circuit board 16e. Here, the cooling element 50e constitutes the inner core of the circuit board 16e.

[0084] In the present case, the cooling element 50e furthermore comprises a base body 52e which is located inside with respect to the circuit board 16e and in particular is assigned to the electronics unit 12e, and a plurality of dissipation elements 54e which thermally connect the base body 52e to the outside of the circuit board 16e. Here, the cooling element 50e comprises a plurality of dissipation elements 54e, in particular at least twelve dissipation elements 54e, which are arranged distributed on the circuit board 16e and connect the base body 52e in particular to at least four sides 36e, 38e, 40e, 42e and preferably to at least six sides 36e, 38e, 40e, 42e of the circuit board 16e. Currently, the dissipation elements 54e are configured in the same manner as one another. The dissipation elements 54e are provided for controlled heat dissipation. The dissipation elements 54e are provided for dissipating the thermal energy generated by the electronics unit 12e in operation and absorbed by the base body 52e outward, in particular to the surrounding area of the circuit board 16e. In the present case, the dissipation elements 54e are arranged distributed on the circuit board 16e in such a way that the thermal energy generated by the electronics unit 12e in operation is dissipated through at least three sides 36e, 38e, 40e, 42e and / or surfaces of the circuit board 16e.

[0085] However, it is also conceivable in principle to configure at least two dissipation elements having different shapes and / or different materials. For example, the dissipation elements in the region of the power electronics can have a greater diameter and / or be made of a material having a higher heat conduction capacity than the dissipation elements in the region of the control logic and / or detection electronics. Furthermore, it is conceivable to provide different dissipation elements for controlling the heat dissipation. For example, it is conceivable in this regard to arrange and / or configure the dissipation elements such that the heat dissipation and / or heat dissipation takes place at least predominantly through the bearing end cap of the electric motor, the side wall of the base housing or the housing cover.

Claims

1. A control device (10a-e) comprising an electronic device unit (12a-e) for operating at least one electric motor (14a-e) and / or for detecting at least one operating parameter of said electric motor (14a-e), and having at least one circuit board (16a-e), said electronic device unit (12a-e) being at least partially disposed on said circuit board, characterized in that, The circuit board (16a-e) is manufactured by means of a 3D printing method, wherein the circuit board (16a-e) includes at least two conductor lines (30a, 34a) printed by means of a 3D printing method and made of different materials, and / or includes at least one conductor line (32a) printed by means of a 3D printing method having at least two conductor line segments (44a, 46a) made of different materials.

2. The control device (10a-e) according to claim 1, characterized in that, The circuit board (16a-e) has at least one first circuit board segment (18a; 18b; 18d) arranged perpendicular to the motor shaft (20a-e) of the electric motor (14a-e), and at least one second circuit board segment (22a, 23a; 22b, 23b; 22d, 23d) connected to the first circuit board segment (18a; 18b; 18d), the second circuit board segment being arranged at an angle relative to the first circuit board segment (18a; 18b; 18d).

3. The control device (10a-e) according to claim 2, characterized in that, The electronic device unit (12a-e) includes at least one power electronic component (24a, 26a) arranged on the second circuit board segment (22a, 23a; 22b, 23b; 22d, 23d).

4. The control device (10a-e) according to claim 2 or 3, characterized in that, The circuit board (16a-e) includes at least one conductor line (30a, 32a) printed by means of a 3D printing method, the conductor line extending at least partially on the first circuit board segment (18a; 18b; 18d) and the second circuit board segment (22a, 23a; 22b, 23b; 22d, 23d).

5. The control device (10a-e) according to any one of claims 1 to 3, characterized in that, Viewed along the direction perpendicular to the motor shaft (20a-e) of the electric motor (14a-e), the circuit board (16a-e) has a cross-section that is at least substantially U-shaped, at least substantially C-shaped, or rectangular, and the electronic device units (12a-e) are distributed on at least three sides (38a, 40a, 42a; 38b, 40b, 42b; 36c, 38c, 40c, 42c; 36e, 38e, 40e, 42e) of the circuit board (16a-e).

6. The control device (10a-e) according to any one of claims 1 to 3, characterized in that, The electronic device unit (12a-e) includes at least one electronic component (48a) which is integrated and / or embedded in the circuit board (16a-e).

7. The control device (10d-e) according to any one of claims 1 to 3, characterized in that... At least one cooling element (50d-e) is integrated and / or embedded in the circuit board (16d-e).

8. The control device (10e) according to claim 7, characterized in that, The cooling element (50e) includes a substrate (52e) located inside the circuit board (16e) and a plurality of dissipation elements (54e) that thermally connect the substrate (52e) to the outside of the circuit board (16e) and are configured to dissipate the heat generated by the electronic device unit (12e) during operation.

9. The control device (10a-e) according to any one of claims 1 to 3, characterized in that... Electronic device housing (56a; 56b; 56c; 56d), the electronic device housing comprising a base housing (60a; 60b; 60c; 60d) and a housing cover (62a; 62b) adjacent to the bearing end cap (58a; 58c; 58d) of the electric motor (14a-e); 62c； 62d), wherein the base shell (60a; 60b; 60c； 60d) provides a receiving area (64a; 64b; 64c) for at least one circuit board (16a-e), and the housing cover (62a; 62b; 62c； 62d) is configured to cover the receiving area (64a; 64b; 64c), and wherein the circuit board (16a-e) is matched with the receiving area (64a; 64b; 64c) of the base housing (60a; 60b; 60c; 60d) such that the circuit board (16a-e) is in direct thermal contact with the electronic device housing (56a; 56b; 56c; 56d), and such that the heat generated by the electronic device unit (12a-e) during operation is dissipated directly through the bearing end cap (58a; 58c; 58d) of the electric motor (14a-e), the sidewalls (66a, 67a; 66b; 66c, 67c; 66d) of the base housing (60a; 60b; 60c; 60d), and / or the housing cover (62a; 62b; 62c; 62d).

10. The control device (10a-e) according to claim 1, characterized in that, The control device (10a-e) is a steering control device.

11. An actuator assembly (68a) having at least one electric motor (14a-e) with at least one motor shaft (20a-e) and at least one control device (10a-e) according to any one of claims 1 to 10.

12. The actuator assembly (68a) according to claim 11, characterized in that, The actuator component is a steering actuator.

13. A steering system (70a) having at least one actuator component (68a) according to claim 11 or 12.

14. A method for manufacturing a control device (10a-e) according to any one of claims 1 to 10, wherein at least one circuit board (16a-e) is manufactured by means of a 3D printing method and an electronic device unit (12a-e) for operating at least one electric motor (14a-e) and / or for detecting at least one operating parameter of said electric motor (14a-e) is arranged at least partially on said circuit board (16a-e).

15. The method according to claim 14, characterized in that, To manufacture the circuit boards (16a-e), a carrier substrate (28a; 28d; 28e) and at least one conductor line (30a, 32a, 34a) are printed using a 3D printing method.

16. The method according to claim 14 or 15, characterized in that, In the 3D printing method, at least one electronic component (48a) and / or at least one cooling element (50d; 50e) of the electronic device unit (12a-e) are integrated and / or embedded into the circuit board (16a-e).

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