Multi-axis servo driver IPM module welding and assembling method

Abstract

The invention discloses a multi-axis servo driver IPM module welding and assembling method which comprises the following steps: S1, preparing components: preparing a capacitor board, a power board, an IPM module board, a control board and an aluminum alloy base, preprocessing and testing the capacitor board, the power board, the IPM module board, the control board and the aluminum alloy base, and completing welding and testing of an IPM tube on the IPM module board; s2, a capacitor plate is fixed, specifically, the capacitor plate is fixed to the aluminum alloy base, and the capacitor plate is arranged on the side portion of the aluminum alloy base; s3, fixing a power panel: fixing the power panel on the aluminum alloy base, wherein the power panel is arranged on one side, far away from the capacitor plate, of the aluminum alloy base; s4, fixing the IPM module board: fixing the IPM module board on the aluminum alloy base, and arranging the IPM module board above the capacitor board; and S5, the control panel is fixed, specifically, the control panel is fixed to the aluminum alloy base, and the control panel is arranged above the IPM module board.

Description

Technical Field

[0001] The present invention relates to the technical field of multi-axis servo drivers, and in particular to a welding and assembling method of an IPM module of a multi-axis servo driver. Background Art

[0002] In the industrial automation equipment and robotics industry, as the number of servo applications increases rapidly, multi-axis drives have become the main drive units. Multi-axis drives have the advantages of low cost, compact structure, and easy installation. At present, the structure of multi-axis drives is to assemble multiple IPM modules on an aluminum alloy heat sink and then weld them to a large PCB board. The assembly steps are as follows: first, install 5 IPM modules on the aluminum alloy base with screws; then cover the large PCB board on the IPM module, insert the IPM pins from the corresponding PCB pads, and tighten the PCB screws; weld the IPM to the PCB; this process ensures that there is no internal stress on the IIPM module pins.

[0003] In the prior art, the IPM module assembly and welding process is complicated, and a screwdriver and a soldering iron are needed in the process, resulting in low assembly efficiency, troublesome function testing after assembly, low reliability, and the need to remove all modules and reassemble them if problems occur. If a module fails during later use, all modules need to be removed for repair and after-sales service. Therefore, a multi-axis servo drive IPM module welding and assembly method is proposed. Summary of the invention

[0004] The purpose of the present invention is to solve the shortcomings in the prior art that the IPM module assembly and welding process is complicated, a screwdriver and a soldering iron are required in the process, the assembly efficiency is low, the functional testing after assembly is troublesome, the reliability is low, all modules need to be dismantled and reassembled when problems occur, and all modules need to be dismantled for maintenance and after-sales when modules fail during later use, and a multi-axis servo drive IPM module welding and assembly method is proposed.

[0005] In order to achieve the above object, the present invention adopts the following technical solutions: A multi-axis servo drive IPM module welding and assembly method comprises the following steps: S1: Prepare components: prepare capacitor plates, power supply plates, IPM module plates, control plates and aluminum alloy bases, the capacitor plates, power supply plates, control plates and aluminum alloy bases are pre-processed and tested, the IPM module plates include IPM tubes, isolated current sampling parts and PWM control parts, the IPM module plates are welded and tested in advance; S2: Fixing the capacitor plate: Fixing the capacitor plate on the aluminum alloy base. The capacitor plate is arranged on the side of the aluminum alloy base. Since the aluminum alloy base contains a large capacitor and has a large volume, it is independently arranged, and the corresponding aluminum alloy base is selected according to different power requirements; S3: Fix the power board: fix the power board on the aluminum alloy base, the power board is arranged on the side of the aluminum alloy base away from the capacitor plate, and the power board is responsible for generating all the voltages required by the entire system, including IPM drive voltage, current sensor voltage, control board operating voltage (3.3V and 5V) and 24V input and output voltage; S4: Fix the IPM module board: fix the welded IPM module board on the aluminum alloy base, the IPM module board is arranged above the capacitor board, a multi-axis servo drive requires multiple IPM module boards, for example, the control board axis drive requires five IPM module boards, each IPM module board includes an IPM tube, an isolated current sampling part and a PWM control part; S5: Fix the control board: fix the control board on the aluminum alloy base, the control board is arranged above the IPM module board, the control board completes the core control function of the multi-axis drive, the working voltage is low voltage (3.3V and 5V), the control board is connected to the power board and the IPM module board through a flexible connection to reduce mechanical stress.

[0006] The above further includes: Further, the IPM module board is pre-welded including SMT reflow soldering and wave soldering; The specific steps of the SMT reflow soldering are: the IPM module board is first bent in advance, and then SMT reflow soldering is performed. This method is suitable for IPM module boards with special requirements for pin shape. The bending process can better meet the process requirements of reflow soldering. The specific steps of the wave soldering are: the IPM module board is pre-pinned, and then wave soldering is performed in the SMT factory. This method is suitable for IPM module boards with a large number of pins and dense arrangement. Wave soldering can ensure that all pins are well soldered.

[0007] Furthermore, the pretreatment and testing of the aluminum alloy base include surface treatment (cleaning, degreasing, and rust removal of the aluminum alloy base to ensure that the surface is clean and flawless), size and shape inspection (using measuring tools to check whether the size and shape of the aluminum alloy base meet the design requirements) and strength testing (pressure testing, tension testing, etc. of the aluminum alloy base to ensure that its strength meets the use requirements); the pretreatment and testing of the capacitor plate include capacitance value testing (using a capacitance tester to measure the capacitance value of each capacitor on the capacitor plate to ensure that it meets the design requirements), leakage current testing (under a specified voltage, measuring the leakage current of the capacitor to ensure that it is within the allowable range) and temperature characteristic testing (placing the capacitor plate in different temperature environments to test the changes in its capacitance value, leakage current and other parameters to ensure that its performance is stable within the operating temperature range); the pretreatment and testing of the power board include insulation testing (using an insulation resistance tester to detect the insulation resistance between the components on the power board and between the components and the ground The insulation resistance of the IPM module board is ensured to meet the safety standards), withstand voltage test (apply a voltage higher than the normal working voltage to the power board for a certain period of time to check whether there is breakdown or leakage) and load test (connect the power board to a simulated load to test its output voltage, current stability and efficiency under different loads); the pretreatment and testing of the IPM module board include welding and appearance inspection (ensure that after the IPM tube is welded at the SMT outsourcing factory, an appearance inspection is carried out to confirm that the welding quality is good and there is no cold solder joint or continuous solder joint), static test (without power, use a multimeter or other tools to check the resistance, capacitance and other parameters between the pins on the IPM module board to ensure that they meet the design requirements) and dynamic test (connect the IPM module board to the test system to simulate the actual working scene to test whether its protection function (such as overcurrent, overvoltage, undervoltage protection) is normal and whether the output waveform is stable); the pretreatment and testing of the control board include cleaning, drying, visual inspection and functional testing.

[0008] Furthermore, the capacitor board is electrically connected to the power board, and the DC voltage generated by the power board is filtered through the capacitor board to reduce voltage fluctuations and ensure stable operation of subsequent circuits. The power board provides the operating voltage (such as 3.3V, 5V, etc.) required by the control board, and the operating voltage is directly connected to the control board through a power line to ensure that the control board can work normally. The power board provides the required driving voltage and current sensor voltage for the IPM module board, and the driving voltage and current sensor voltage are connected to the IPM module board through a dedicated power line to drive the IPM tube and monitor the current. The IPM module board is connected to the control board through a PWM (pulse width modulation) signal line and a current feedback signal line. The control board controls the switching state of the IPM tube through a PWM signal, thereby achieving precise control of the motor. At the same time, the current sensor on the IPM module board will feed back the current signal to the control board for current protection and closed-loop control.

[0009] Further, in S2, a performance test is performed before the capacitor plate is fixed to ensure that parameters such as the capacitance value and the withstand voltage level of the capacitor plate meet the design requirements; Specific steps to fix the capacitor plate on the aluminum alloy base: Position the capacitor plate: Use a marker pen to draw the outline of the capacitor plate on the aluminum alloy base, place the capacitor plate on the outline of the aluminum alloy base, and ensure that the alignment and gap between the capacitor plate and the aluminum alloy base meet the requirements; Install the fixings: according to the size and shape of the capacitor plate, drill the mounting holes on the aluminum alloy base and install the fixings such as bolts or nuts. During the fixing process, ensure that the bolts or nuts are tightened with moderate force to avoid deformation or damage of the capacitor plate due to over-tightening, or loosening of the capacitor plate due to over-loosening; Add insulating material: Add insulating material, such as insulating sheet or insulating pad, between the capacitor plate and the aluminum alloy base to ensure electrical isolation between the capacitor plate and the aluminum alloy base. The thickness and specification of the insulating material should be selected according to the rated voltage and working environment of the capacitor plate.

[0010] Further, in S3, before fixing the power board, voltage output stability, ripple factor, and over-current and over-voltage protection function tests are performed; Specific steps to fix the power board on the aluminum alloy base: Positioning and marking: Use a marking pen to make positioning marks on the aluminum alloy base, and determine the installation position on the aluminum alloy base according to the size and installation requirements of the power board; Install the bracket or fixture: Install the bracket or fixture (such as screw holes, buckles, etc.) on the aluminum alloy base according to the positioning marks, and ensure that the bracket or fixture is firmly installed and matches the installation hole of the power board; Fix the power board: Place the power board on the bracket or fixture, align it with the positioning mark, and use screws, nuts and other fasteners to fix the power board on the aluminum alloy base. Apply a thin layer of thermal conductive silicone grease on the contact surface between the power board and the aluminum alloy base. Pay attention to the tightening force to avoid over-tightening to damage the components or over-loosening to cause unstable fixation. Inspection and testing: After fixing, check whether the power board is firmly installed without shaking or tilting, and perform a functional test to ensure that the power board can work normally without abnormal sound or heat.

[0011] Furthermore, in S4, the specific steps of fixing the IPM module board are: IPM module board placement: Place the radiator horizontally with the fin side facing downward and the smooth side facing upward, and place the IPM module board on the radiator to ensure accurate positioning; Use gaskets or thermal conductive silicone: If you use a special gasket for the IPM module board, lay the gasket flat on the installation position of the IPM module board on the radiator, and ensure that the gasket hole is aligned with the IPM module board fixing hole on the radiator; if you use thermal conductive silicone, first apply the thermal conductive silicone evenly on the IPM module board, and then place the IPM module board accurately on the radiator. The use of thermal conductive silicone helps improve heat dissipation efficiency; Fix the IPM module board: Use an electric screwdriver to fix the IPM module board on the radiator according to the torque requirements (usually 1.1 N·m~1.1N·m); During the fixing process, the principle of "left-right-left" should be followed, that is, first use an electric screwdriver to pre-fix the left side of the IPM module board with screws, then tighten the screws on the right side according to the specified torque, and finally tighten the screws on the left side according to the specified torque. This helps to ensure the stability and uniform force of the IPM module board on the radiator; Inspection and testing: Carefully check the contact between the IPM module board and the radiator to ensure that there is no foreign matter. Use the electric screwdriver calibration tool to calibrate the electric screwdriver and record the calibration. After the fixation is completed, test the IPM module board to ensure that it functions normally.

[0012] Furthermore, the radiator is arranged inside the aluminum alloy base, a cooling fan is arranged on the aluminum alloy base away from the radiator, and the fins of the radiator are perpendicular to the surface of the aluminum alloy base.

[0013] Further, for the above S5, in S5, the specific steps of fixing the control board are: Positioning and marking: Use positioning pins or positioning blocks to position the control panel on the aluminum alloy base to ensure that the position of the control panel is accurate; Install the fixings: pass the screws through the mounting holes on the control panel and screw them into the screw holes on the aluminum alloy base. Install washers on the screws (if necessary) to increase the gap between the control panel and the aluminum alloy base to prevent heat conduction or mechanical stress caused by close contact with the aluminum alloy base. Use a torque wrench to tighten the screws according to the specified torque value to ensure that the control panel is firmly fixed on the base; Connection and testing: Connect all interfaces on the control board to the corresponding cables, such as PWM signal line, current feedback signal line, etc. During the connection process, pay attention to check the polarity of the cables and whether the pins correspond correctly to avoid wrong connection causing short circuit or damage to components. After the connection is completed, perform a functional test to ensure that the control board can receive and process signals normally and drive the motor to run; Arrangement and protection: Arrange excess cables and use cable ties or wire clips to secure them in place to avoid interference or damage. Apply thermal grease or insulating glue to the gap between the control board and the aluminum alloy base to improve heat dissipation or prevent dust from entering.

[0014] The present invention has the following beneficial effects: In the present invention, all functional sub-boards are tested independently, and the functional test after the general assembly is simple and reliable. If a problem occurs, only the problematic part needs to be removed, which simplifies the subsequent maintenance and after-sales work.

[0015] In the present invention, the assembly process is simplified and the assembly efficiency is improved. The IPM module board is prepared and welded as an independent module, which greatly simplifies the assembly process. Only an electric-controlled screwdriver is needed during the assembly process, and the assembly efficiency is improved. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 A step diagram of a multi-axis servo drive IPM module welding and assembly method proposed by the present invention; Figure 2 It is a schematic diagram of the structure of S2 in the present invention; Figure 3 It is a structural schematic diagram of S3 in the present invention; Figure 4 It is a schematic diagram of the structure of S4 in the present invention; Figure 5 It is a structural schematic diagram of S5 in the present invention; Figure 6 This is a schematic diagram of the external structure after the present invention is assembled; Figure 7 It is a structural schematic diagram of the capacitor plate in the present invention; Figure 8 It is a structural schematic diagram of the power board in the present invention; Fig. 9 It is a structural schematic diagram of the IPM module board in the present invention; Fig.10 It is a structural schematic diagram of the control board in the present invention.

[0017] In the figure: 1. Aluminum alloy base; 2. Capacitor board; 3. Power board; 4. IPM module board; 5. Control board. DETAILED DESCRIPTION

[0018] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0019] See also Figure 1 As shown, the present invention is a multi-axis servo drive IPM module welding and assembly method, comprising the following steps: S1: preparing components: preparing a capacitor plate (2), a power supply plate (3), an IPM module plate (4), a control plate (5) and an aluminum alloy base (1); the capacitor plate (2), the power supply plate (3), the control plate (5) and the aluminum alloy base (1) are pre-processed and tested; the IPM module plate (4) includes an IPM tube, an isolated current sampling part and a PWM control part; the IPM module plate (4) is welded and tested in advance; S2: Fixing the capacitor plate 2: Fixing the capacitor plate 2 on the aluminum alloy base 1. The capacitor plate 2 is arranged on the side of the aluminum alloy base 1. Since the aluminum alloy base 1 contains a large capacitor and has a large volume, it is independently arranged, and the corresponding aluminum alloy base 1 is selected according to different power requirements; S3: Fix the power board 3: fix the power board 3 on the aluminum alloy base 1, the power board 3 is arranged on the side of the aluminum alloy base 1 away from the capacitor plate 2, and the power board 3 is responsible for generating all voltages required by the entire system, including the IPM drive voltage, the current sensor voltage, the control board working voltage (3.3V and (5)V) and the 24V input and output voltage; S4: Fixing the IPM module board 4: Fixing the welded IPM module board 4 on the aluminum alloy base 1, wherein the IPM module board 4 is arranged above the capacitor board 2. A multi-axis servo drive requires multiple IPM module boards 4, for example, a control board 5-axis drive requires five IPM module boards 4, and each IPM module board 4 includes an IPM tube, an isolated current sampling part, and a PWM control part; S5: Fix the control board 5: fix the control board 5 on the aluminum alloy base 1, the control board 5 is arranged above the IPM module board 4, the control board 5 completes the core control function of the multi-axis drive, the working voltage is a low voltage (3.3V and (5)V), the control board 5 is connected to the power board 3 and the IPM module board 4 through a flexible connection to reduce mechanical stress; Functional testing and debugging: Since all functional sub-boards (control board, power board, IPM module board, capacitor board) are tested independently, the functional test after the final assembly will be simpler and more reliable. If a problem occurs, only the problematic part needs to be removed for replacement or repair without removing the entire module.

[0020] In one embodiment, for the above-mentioned IPM module board 4, the advance soldering of the IPM module board 4 includes SMT reflow soldering and wave soldering; The specific steps of SMT reflow soldering are: the IPM module board 4 is bent in advance, and then SMT reflow soldering is performed. This method is suitable for IPM module boards with special requirements for pin shape. The bending process can better meet the process requirements of reflow soldering. The specific steps of wave soldering are: the IPM module board 4 is pre-aligned, and then wave soldering is performed in the SMT factory. This method is suitable for IPM module boards with a large number of pins and dense arrangement. Wave soldering can ensure that all pins are well soldered.

[0021] In one embodiment, for the above-mentioned aluminum alloy base 1, the pretreatment and testing of the aluminum alloy base 1 include surface treatment (cleaning, degreasing, rust removal, etc. of the aluminum alloy base to ensure that the surface is clean and flawless), size and shape inspection (using measuring tools to check whether the size and shape of the aluminum alloy base meet the design requirements) and strength test (pressure test, tension test, etc. are performed on the aluminum alloy base to ensure that its strength meets the use requirements); the pretreatment and testing of the capacitor plate 2 include capacitance value test (using a capacitance tester to measure the capacitance value of each capacitor on the capacitor plate to ensure that it meets the design requirements), leakage current test (under a specified voltage, measuring the leakage current of the capacitor to ensure that it is within the allowable range) and temperature characteristic test (placing the capacitor plate in different temperature environments to test the changes in its capacitance value, leakage current and other parameters to ensure that its performance is stable within the operating temperature range); the pretreatment and testing of the power supply board 3 include insulation test (using an insulation resistance tester to detect the insulation resistance of each component on the power supply board). The pretreatment and testing of the IPM module board 4 include welding and appearance inspection (ensure that the IPM tube is welded in the SMT outsourcing factory, and then the appearance inspection is carried out to confirm that the welding quality is good, and there is no cold welding or continuous welding), static testing (without power, use tools such as a multimeter to check the resistance, capacitance and other parameters between the pins on the IPM module board to ensure that they meet the design requirements) and dynamic testing (connect the IPM module board to the test system to simulate the actual working scene, and test whether its protection function (such as overcurrent, overvoltage, undervoltage protection) is normal, and whether the output waveform is stable); the pretreatment and testing of the control board 5 include cleaning, drying, visual inspection and functional testing.

[0022] In one embodiment, for the above-mentioned capacitor plate 2, the capacitor plate 2 is electrically connected to the power supply plate 3, and the DC voltage generated by the power supply plate 3 is filtered through the capacitor plate 2 to reduce voltage fluctuations and ensure stable operation of subsequent circuits. The power supply plate 3 provides the operating voltage (such as 3.3V, 5V, etc.) required by the control board 5, and the operating voltage is directly connected to the control board 5 through a power line to ensure that the control board can work normally. The power supply board 3 provides the required driving voltage and current sensor voltage for the IPM module board 4, and the driving voltage and current sensor voltage are connected to the IPM module board 4 through a dedicated power line to drive the IPM tube and monitor the current. The IPM module board 4 is connected to the control board 5 through a PWM (pulse width modulation) signal line and a current feedback signal line. The control board 5 controls the switching state of the IPM tube through a PWM signal, thereby realizing precise control of the motor. At the same time, the current sensor on the IPM module board 4 will feed back the current signal to the control board 5 for current protection and closed-loop control.

[0023] In one embodiment, for the above S2, in S2, a performance test is performed before fixing the capacitor plate 2 to ensure that the parameters such as the capacitance value and the withstand voltage level of the capacitor plate 2 meet the design requirements; Specific steps for fixing the capacitor plate 2 on the aluminum alloy base 1: Positioning the capacitor plate 2: Use a marking pen to draw the outline of the capacitor plate 2 on the aluminum alloy base 1, and place the capacitor plate 2 on the outline of the aluminum alloy base 1 to ensure that the alignment and gap between the capacitor plate 2 and the aluminum alloy base 1 meet the requirements; Install the fixings: according to the size and shape of the capacitor plate 2, drill the mounting holes on the aluminum alloy base 1 and install the fixings such as bolts or nuts. During the fixing process, ensure that the bolts or nuts are tightened with moderate force to avoid deformation or damage of the capacitor plate 2 due to over-tightening, or loosening of the capacitor plate 2 due to over-loosening; Adding insulating material: Add insulating material, such as an insulating sheet or insulating pad, between the capacitor plate 2 and the aluminum alloy base 1 to ensure electrical isolation between the capacitor plate 2 and the aluminum alloy base 1. The thickness and specification of the insulating material should be selected according to the rated voltage of the capacitor plate 2 and the working environment.

[0024] In one embodiment, for the above S3, in S3, before fixing the power board 3, voltage output stability, ripple factor and over-current and over-voltage protection function tests are performed; Specific steps for fixing the power board 3 on the aluminum alloy base 1: Positioning and marking: Use a marking pen to make positioning marks on the aluminum alloy base 1, and determine the installation position on the aluminum alloy base according to the size and installation requirements of the power board 3; Install the bracket or fixture: Install the bracket or fixture (such as screw holes, buckles, etc.) on the aluminum alloy base 1 according to the positioning marks, and ensure that the bracket or fixture is firmly installed and matches the installation hole of the power board 3; Fix the power board: Place the power board 3 on the bracket or fixture, align it with the positioning mark, and use screws, nuts and other fasteners to fix the power board 3 on the aluminum alloy base 1. Apply a thin layer of thermal conductive silicone grease on the contact surface between the power board 3 and the aluminum alloy base 1. Pay attention to the tightening force to avoid damage to the components due to over-tightening or unstable fixation due to over-loosening. Inspection and testing: After fixing, check whether the power board is firmly installed without shaking or tilting, and perform a functional test to ensure that the power board can work normally without abnormal sound or heat.

[0025] In one embodiment, for the above S4, in S4, the specific steps of fixing the IPM module board 4 are: Placement of IPM module board 4: Place the radiator horizontally with the fin side facing downward and the smooth side facing upward, and place the IPM module board 4 on the radiator to ensure accurate positioning; Use gaskets or thermal conductive silicone: If you use a special gasket for the IPM module board 4, lay the gasket flat on the installation position of the IPM module board 4 on the radiator, and ensure that the gasket hole is aligned with the IPM module board 4 fixing hole on the radiator; if you use thermal conductive silicone, first apply the thermal conductive silicone evenly on the IPM module board 4, and then accurately place the IPM module board 4 on the radiator. The use of thermal conductive silicone helps improve the heat dissipation efficiency; Fix the IPM module board 4: Use an electric screwdriver to fix the IPM module board 4 on the radiator with the screws according to the torque requirements (usually 1.1 N·m~1.1N·m); During the fixing process, the principle of "left-right-left" should be followed, that is, first use an electric screwdriver to pre-fix the left side of the IPM module board 4 with screws, then tighten the screws on the right side according to the specified torque, and finally tighten the screws on the left side according to the specified torque. This helps to ensure the stability and uniform force of the IPM module board 4 on the radiator; Inspection and testing: Carefully check the contact between the IPM module board 4 and the radiator to ensure that there is no foreign matter. Use the electric screwdriver calibration tool to calibrate the electric screwdriver and record the calibration. After the fixation is completed, test the IPM module board 4 to ensure that it functions normally.

[0026] In one embodiment, for the above-mentioned radiator, the radiator is arranged inside the aluminum alloy base 1 , a cooling fan is arranged on the aluminum alloy base 1 away from the radiator, and the radiator fins are perpendicular to the surface of the aluminum alloy base 1 .

[0027] In one embodiment, for the above S5, in S5, the specific steps of fixing the control board 5 are: Positioning and marking: Use positioning pins or positioning blocks to position the control board 5 on the aluminum alloy base 1 to ensure that the position of the control board 5 is accurate; Install the fixings: pass the screws through the mounting holes on the control board 5 and screw them into the screw holes on the aluminum alloy base 1. Install washers on the screws (if necessary) to increase the gap between the control board 5 and the aluminum alloy base 1 to prevent heat conduction or mechanical stress caused by close contact with the aluminum alloy base 1. Use a torque wrench to tighten the screws according to the specified torque value to ensure that the control board is firmly fixed on the base; Connection and testing: Connect all interfaces on the control board 5 to the corresponding cables, such as PWM signal line, current feedback signal line, etc. During the connection process, pay attention to check whether the polarity of the cables and the pins are correct to avoid wrong connection causing short circuit or damage to components. After the connection is completed, perform a functional test to ensure that the control board 5 can normally receive and process signals and drive the motor to run; Arrangement and protection: Arrange the redundant cables and fix them in place with cable ties or wire clips to avoid interference or damage. Apply thermal grease or insulating glue to the gap between the control board 5 and the aluminum alloy base 1 to improve heat dissipation performance or prevent dust from entering.

[0028] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A multi-axis servo drive IPM module welding and assembly method, characterized in that: The following steps are involved: S1: preparing components: preparing a capacitor plate (2), a power supply plate (3), an IPM module plate (4), a control plate (5) and an aluminum alloy base (1); the capacitor plate (2), the power supply plate (3), the control plate (5) and the aluminum alloy base (1) are pre-processed and tested; the IPM module plate (4) includes an IPM tube, an isolated current sampling part and a PWM control part; the IPM module plate (4) is welded and tested in advance; S2: fixing the capacitor plate (2): fixing the capacitor plate (2) on the aluminum alloy base (1), wherein the capacitor plate (2) is arranged on the side of the aluminum alloy base (1); S3: fixing the power supply board (3): fixing the power supply board (3) on the aluminum alloy base (1), wherein the power supply board (3) is arranged on a side of the aluminum alloy base (1) away from the capacitor plate (2); S4: fixing the IPM module plate (4): fixing the welded IPM module plate (4) on the aluminum alloy base (1), wherein the IPM module plate (4) is arranged above the capacitor plate (2); S5: Fixing the control board (5): fixing the control board (5) on the aluminum alloy base (1), wherein the control board (5) is arranged above the IPM module board (4).

2. A multi-axis servo drive IPM module welding and assembly method according to claim 1, characterized in that: The IPM module board (4) is pre-welded including SMT reflow soldering and wave soldering; The specific steps of the SMT reflow soldering are as follows: the IPM module board (4) is first bent in advance, and then subjected to SMT reflow soldering; The specific steps of the wave soldering are as follows: the IPM module board (4) is pre-pinned, and then wave soldering is performed in an SMT factory.

3. A multi-axis servo drive IPM module welding and assembly method according to claim 1, characterized in that: The pretreatment and testing of the aluminum alloy base (1) include surface treatment, size and shape inspection, and strength test; the pretreatment and testing of the capacitor plate (2) include capacitance value test, leakage current test, and temperature characteristic test; the pretreatment and testing of the power supply board (3) include insulation test, withstand voltage test, and load test; the pretreatment and testing of the IPM module board (4) include welding and appearance inspection, static test, and dynamic test; the pretreatment and testing of the control board (5) include cleaning, drying, visual inspection, and functional test.

4. A multi-axis servo drive IPM module welding and assembly method according to claim 1, characterized in that: The capacitor plate (2) is electrically connected to the power supply plate (3); the DC voltage generated by the power supply plate (3) is filtered through the capacitor plate (2); the power supply plate (3) provides the operating voltage required by the control plate (5); the operating voltage is directly connected to the control plate (5) through a power line; the power supply plate (3) provides the required driving voltage and current sensor voltage for the IPM module plate (4); the driving voltage and current sensor voltage are connected to the IPM module plate (4) through a power line; the IPM module plate (4) and the control plate (5) are connected through a PWM signal line and a current feedback signal line; the control plate (5) controls the switch state of the IPM tube through a PWM signal; and at the same time, the current sensor on the IPM module plate (4) feeds back the current signal to the control plate (5).

5. A multi-axis servo drive IPM module welding and assembly method according to claim 1, characterized in that: In S2, a performance test is performed before fixing the capacitor plate (2) to ensure that the parameters of the capacitor plate (2) meet the design requirements; Specific steps for fixing the capacitor plate (2) on the aluminum alloy base (1): Positioning the capacitor plate (2): using a marker pen to draw the outline of the capacitor plate (2) on the aluminum alloy base (1), and placing the capacitor plate (2) on the outline of the aluminum alloy base (1); Install the fixings: according to the size and shape of the capacitor plate (2), drill a mounting hole on the aluminum alloy base (1) and install the fixings; Adding insulating material: Add insulating material between the capacitor plate (2) and the aluminum alloy base (1).

6. A multi-axis servo drive IPM module welding and assembly method according to claim 1, characterized in that: In S3, before fixing the power board (3), voltage output stability, ripple factor and over-current and over-voltage protection function tests are performed; Specific steps for fixing the power board (3) on the aluminum alloy base (1): Positioning and marking: Use a marking pen to make positioning marks on the aluminum alloy base (1), and determine the installation position on the aluminum alloy base according to the size and installation requirements of the power board (3); Install the bracket or fixing: Install the bracket or fixing on the aluminum alloy base (1) according to the positioning mark; Fixing the power board: Place the power board (3) on the bracket or fixture, align with the positioning mark, use fasteners to fix the power board (3) on the aluminum alloy base (1), and apply a thin layer of thermal conductive silicone grease on the contact surface between the power board (3) and the aluminum alloy base (1).

7. A multi-axis servo drive IPM module welding and assembly method according to claim 1, characterized in that: In S4, the specific steps of fixing the IPM module board (4) are: Place the IPM module board (4): Place the radiator horizontally with the fin side facing downward and the smooth side facing upward, and place the IPM module board (4) on the radiator to ensure that the position is accurate; Use a gasket or thermal conductive silicone: If a special gasket for the IPM module board (4) is used, lay the gasket evenly on the installation position of the IPM module board (4) on the radiator, ensuring that the gasket hole is aligned with the IPM module board (4) fixing hole on the radiator; if thermal conductive silicone is used, first apply the thermal conductive silicone evenly on the IPM module board (4), and then accurately place the IPM module board (4) on the radiator; Fix the IPM module board (4): Use an electric screwdriver to tighten the screws to the required torque to fix the IPM module board (4) on the heat sink.

8. A multi-axis servo drive IPM module welding and assembly method according to claim 7, characterized in that: The radiator is arranged inside the aluminum alloy base (1); a cooling fan is arranged on the aluminum alloy base (1) away from the radiator; and the fins of the radiator are perpendicular to the surface of the aluminum alloy base (1).

9. A multi-axis servo drive IPM module welding and assembly method according to claim 1, characterized in that: In S5, the specific steps of fixing the control board (5) are: Positioning and marking: Use positioning pins or positioning blocks to position the control board (5) on the aluminum alloy base (1); Install the fixings: Pass the screws through the mounting holes on the control board (5) and screw them into the screw holes on the aluminum alloy base (1); Connection and testing: Connect all interfaces on the control board (5) to the corresponding cables. After the connection is completed, perform a functional test to ensure that the control board (5) can normally receive and process signals and drive the motor to operate; Finishing and protection: Apply thermal grease or insulating glue to the gap between the control board (5) and the aluminum alloy base (1).

Images