Controller and circuit board support

Abstract

A controller includes a plurality of circuit boards and a support configured to support each circuit board. The support includes a plurality of loading surfaces axially spaced from each other and a plurality of fingers extending obliquely relative to the loading surfaces. Each circuit board is disposed between a respective loading surface and a respective finger.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 346,356 filed on May 27, 2022 and U.S. Non-Provisional Patent Application No. 18 / 201,413 filed on May 24, 2023, the entire disclosures of which are incorporated herein by reference. Technical Field

[0003] The present disclosure relates generally to controllers for actuators, and more particularly to a controller having a support configured to support and axially space a plurality of circuit boards. Background Art

[0004] The actuator may include a controller for controlling the angular position of the output shaft. The controller may include a plurality of circuit boards including, for example, a power electronics circuit board and one or more circuit boards supporting a sensor for detecting the angular position of the output shaft. Since space within the housing of the actuator is limited, alternative designs and configurations are desirable in order to fit all necessary components within the housing while still meeting performance requirements. Summary of the invention

[0005] According to one embodiment, a controller includes a plurality of circuit boards and a support configured to support each circuit board. The support includes a plurality of loading surfaces axially spaced apart from each other and a plurality of fingers extending obliquely relative to the loading surfaces. Each circuit board is disposed between a corresponding loading surface and a corresponding finger.

[0006] In an embodiment, the plurality of circuit boards may include a circuit board supporting a sensor and a power electronic circuit board spaced apart from the circuit board. The plurality of loading surfaces may include: a first loading surface configured to support the circuit board; and a second loading surface axially spaced apart from the first loading surface and configured to support the power electronic circuit board. The plurality of fingers may include: a first finger disposed between the first loading surface and the second loading surface and extending toward the first loading surface; and a second finger spaced apart from the second loading surface and extending toward the second loading surface. The first finger may be configured to axially bias the circuit board against the first loading surface. The first finger may be configured to elastically deform during installation of the circuit board between the first finger and the first loading surface.

[0007] The second finger can be configured to prevent installation of the power electronics circuit board when a component of the circuit board is not seated with a mating component of the power electronics circuit board. The second finger can be configured to allow installation of the other circuit board when a component of one circuit board is seated with a mating component of the other circuit board. The second finger can be configured to allow axial movement of the power electronics circuit board relative to the second loading surface.

[0008] The plurality of circuit boards may include an additional circuit board supporting an additional sensor. The plurality of loading surfaces may include a third loading surface configured to support an additional circuit board. The second loading surface may be disposed between the first loading surface and the third loading surface. The plurality of fingers may include a third finger spaced apart from the third loading surface and extending toward the third loading surface. The third finger may be configured to axially bias the additional circuit board against the third loading surface. The third finger may be configured to elastically deform during installation of the additional circuit board between the third finger and the third loading surface. The second finger may be disposed between the second loading surface and the third loading surface. The third finger may be disposed at an end of the support.

[0009] According to another embodiment, a circuit board support includes first and second loading surfaces and first and second fingers. The first loading surface is configured to support one circuit board. The second loading surface is axially spaced from the first loading surface and configured to support another circuit board. The first finger is disposed between the first loading surface and the second loading surface and extends toward the first loading surface. The first finger is configured to axially bias one circuit board against the first loading surface. The second finger is spaced from the second loading surface and extends toward the second loading surface. The second finger is configured to prevent installation of another circuit board when a component of one circuit board is not seated with a mating component of the other circuit board.

[0010] In an embodiment, the first finger-shaped portion may be configured to elastically deform during installation of a circuit board between the first finger-shaped portion and the first loading surface. The second finger-shaped portion may be configured to allow another circuit board to move axially relative to the second loading surface. The circuit board support may include a third loading surface configured to support another circuit board. The circuit board support may include a third finger-shaped portion spaced apart from the third loading surface and extending toward the third loading surface. The third finger-shaped portion may be configured to axially bias the other circuit board against the third loading surface. The second loading surface may be disposed between the first loading surface and the third loading surface. The second finger-shaped portion may be disposed between the second loading surface and the third loading surface. The third finger-shaped portion may be configured to elastically deform during installation of another circuit board between the third finger-shaped portion and the third loading surface. The third finger-shaped portion may be disposed at an end of the support.

[0011] Embodiments according to the present disclosure provide a circuit board support configured to support a plurality of circuit boards with an axially constrained housing. In addition, the circuit board support axially constrains the circuit boards, which increases the likelihood of proper installation of the circuit boards. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1 A cross-sectional view along the axis of an exemplary rotary actuator is shown.

[0013] Figure 2 An enlarged cross-sectional view of another portion of the rotary actuator is shown.

[0014] Figure 3 An enlarged cross-sectional view of another portion of the rotary actuator is shown. DETAILED DESCRIPTION

[0015] Embodiments of the present disclosure are described herein. It should be understood that similar reference numerals appearing in different figures identify identical or functionally similar structural elements. In addition, it should be understood that the disclosed embodiments are examples only, and other embodiments may take various forms and alternative forms. The drawings are not necessarily to scale; some features may be enlarged or minimized to show the details of a particular component. Therefore, the specific structural details and functional details disclosed herein should not be interpreted as being restrictive, but only as a representative basis for teaching those skilled in the art to utilize the embodiments in various ways. As will be understood by those of ordinary skill in the art, the various features shown and described with reference to any of the drawings in the drawings may be combined with the features shown in one or more other drawings to produce embodiments that are not explicitly shown or described. The combination of the features shown provides representative embodiments for typical applications. However, various combinations and modifications of features consistent with the teachings of the present disclosure may be desired for specific applications or implementations.

[0016] The terms used herein are only for the purpose of describing specific aspects and are not intended to limit the scope of the present disclosure. Unless otherwise specified, all technical terms and scientific terms used herein have the same meaning as those generally understood by those of ordinary skill in the art to which the present disclosure belongs. Although any method, device or material similar or equivalent to those described herein can be used in the practice or testing of the present disclosure, the following example methods, devices and materials will now be described.

[0017] Referring to the drawings, a rotary actuator 100 is generally shown. The rotary actuator 100 includes a housing 102 and a plurality of components. The housing 102 houses the plurality of components of the rotary actuator 100. For example, each component of the rotary actuator 100 may be at least partially housed in the housing 102.

[0018] Reference Figure 1 , the housing 102 includes a first end 104 and a second end 106 spaced apart from the first end 104 along the axis A. The housing 102 includes a wall 108 extending from the first end 104 to the second end 106 along the axis A. Additionally, the wall 108 extends annularly around the axis A. That is, the housing 102 has a tubular shape. The wall 108 defines a cavity 110 extending circumferentially around the axis A and extending axially along the axis A. The wall 108 may be elongated, i.e., having a longest linear dimension from the first end 104 to the second end 106. The wall 108 is open at the first end 104 and the second end 106. That is, the cavity 110 extends through the first end 104 of the housing 102 along the axis A and through the second end 106 of the housing 102. During assembly of the rotary actuator 100, components of the rotary actuator 100 are inserted through one of the ends 104, 106.

[0019] Now go to Figure 2 , the drive system 300 is engaged with the gearbox 200. The drive system 300 is disposed in the cavity 110. The gearbox 200 is disposed between the output shaft 134 and the drive system 300. The drive system 300 includes a motor 302. The motor 302 includes a fixed stator 304 and a rotatable rotor 306. The drive system 300 includes a rotor shaft 308 arranged coaxially with the axis A. The rotor 306 is non-rotatably connected to the rotor shaft 308, for example, via a press-fit connection, an adhesive, etc.

[0020] Now go to Figure 3 The rotation controller 400 is disposed between the drive system 300 and the second end 106 of the housing 102. That is, the rotation controller 400 is disposed in the cavity 110. The rotation controller 400 includes a computer 416 and a sensor 414 supported by a plurality of circuit boards 412.

[0021] The first circuit board 412a includes a first sensor 414a. Additionally, the first circuit board 412a may include a computer 416. Additionally or alternatively, the first circuit board 412a may include some of the devices represented as the computer 416, where the computer 416 actually includes multiple devices.

[0022] The first sensor 414a is axially aligned with the first encoder magnet 368a. The first sensor 414a is an angular position sensor. Specifically, the first sensor 414a is configured to detect the angular position of the first encoder magnet 368a relative to the axis A. The first sensor 414a can be any suitable type of angular position sensor. For example, the first sensor 414a can be a Hall effect sensor configured to output a unique angular position within a 360° rotation around the axis A. In such an example, the Hall effect sensor can determine the angular position of the first encoder magnet 368a based on the position of the detected pole relative to the axis A, for example, according to known techniques.

[0023] The computer 416 includes a processor and a memory such as is known. The memory includes one or more forms of computer-readable media and stores instructions that can be executed by the processor to perform various operations, including the operations disclosed herein. The computer 416, that is, its components, can be supported by one or more of the circuit boards 412.

[0024] The computer 416 is generally arranged to communicate over a communication network 418 via known wired and / or wireless mechanisms. Via the communication network 418, the computer 416 can send messages to and / or receive messages from various components in the rotary actuator 100, such as sensors 414, motors 302, etc. Additionally or alternatively, where the computer 416 actually includes multiple devices, the communication network 418 can be used for communication between the devices represented as the computer 416. Furthermore, as mentioned above, the various controllers and / or sensors 414 can provide data to the computer 416 via the communication network 418. In addition, the computer 416 can be configured to communicate with devices external to the rotary actuator 100 via a wired connection.

[0025] The second circuit board 412b may be referred to as a power electronics circuit board. That is, the second circuit board 412b may include one or more devices, such as semiconductor switching devices such as diodes, thyristors, power transistors, etc., current converter devices, etc., for controlling and converting the power provided to the rotation controller 400, which enables the computer 416 to control the motor 302. Additionally or alternatively, in the case where the computer 416 actually includes multiple devices, the second circuit board 412b may include some of the devices represented as the computer 416.

[0026] The third circuit board 412c includes a second sensor 414b. The second sensor 414b may be substantially the same as the first sensor 414a. The third circuit board 412c may have a smaller surface area than the first circuit board 412a and / or the second circuit board 412b. Additionally or alternatively, in the case where the computer 416 actually includes multiple devices, the third circuit board 412c may include some of the devices represented as the computer 416.

[0027] A plurality of supports 402 support a circuit board 412 within the cavity 110. The plurality of supports 402 are circumferentially spaced apart from one another about an axis A. Each support 402 includes a first end 404 and a second end 406 axially spaced apart from the first end 404. The first end 404 is mounted to a component configured to support the controller 400, such as via a press-fit connection. The supports 402 can be spaced apart from one another such that the supports 402 radially and circumferentially constrain the circuit board 412. The supports 402 can be any suitable material, such as plastic.

[0028] Each support 402 may include a plurality of loading surfaces 408 spaced apart from one another along the axis A. Each loading surface 408 may be configured to axially support a corresponding circuit board 412. For example, each support 402 may include the same number of loading surfaces 408 as circuit boards 412. Each loading surface 408 may extend radially relative to the axis A. Each support 402 may include a plurality of fingers 410 spaced apart from one another axially along the axis A. Each finger 410 may extend obliquely toward the axis A. For example, each finger 410 may extend radially inward and axially toward a corresponding loading surface 408. Each support 402 may include the same number of fingers 410 as the loading surfaces 408.

[0029] For example, each support member 402 may include a first loading surface 408a spaced apart from the first end 404 and a first finger 410a spaced apart from the first loading surface 408a in the first direction. The first finger 410a extends toward the first loading surface 408a in the second direction and extends radially inward toward the axis A. The first circuit board 412a may be disposed between the first loading surface 408a and the first finger 410a. Specifically, the first finger 410a may bias the first circuit board 412a to abut against the first loading surface 408a. For example, the first finger 410a may be designed to be elastically deformed so that the first circuit board 412a may be inserted between the first loading surface 408a and the first finger 410a. After installation, the first finger 410a may rebound and axially bias the first circuit board 412a in the second direction to contact the first loading surface 408a.

[0030] The first loading surface 408a is spaced apart from the first end 404 such that the first sensor 414a is disposed within a predetermined range of the first encoder magnet 368a. As discussed herein, the components of the rotary actuator 100 are axially constrained to maintain the first sensor 414a within a predetermined range of the first encoder magnet 368a. The predetermined range may be specified by the manufacturer of the sensor, for example, based on empirical testing to determine a range in which the output of the sensor 414a meets a specified measurement accuracy and / or precision.

[0031] Each support 402 may include a second loading surface 408b axially spaced apart from the first finger 410a in the first direction. Additionally, each support 402 may include a second finger 410b axially spaced apart from the second loading surface 408b in the first direction. The second finger 410b may extend toward the second loading surface 408b in the second direction and extend radially inward toward the axis A. The second circuit board 412b may be disposed between the second loading surface 408b and the second finger 410b. The second finger 410b may be axially spaced apart from the second circuit board 412b. That is, the second finger 410b may allow the second circuit board 412b to move axially relative to the second loading surface 408b. For example, the second finger 410b may be an assembly aid that allows the second circuit board 412b to be inserted between the second loading surface 408b and the second finger 410b when components of the first circuit board 412a are properly seated with mating components of the second circuit board 412b. Additionally, the second finger 410b may be an assembly aid that prevents the second circuit board 412b from being inserted between the second loading surface 408b and the second finger 410b when components of the first circuit board 412a are not properly seated with mating components of the second circuit board 412b.

[0032] Each support 402 may include a third loading surface 408c axially spaced apart from the second finger 410b in the first direction. Additionally, each support 402 may include a third finger 410c axially spaced apart from the third loading surface 408c in the first direction. The third finger 410c may be disposed at the second end 406. The third finger 410c may extend toward the third loading surface 408c in the second direction and extend radially inward toward the axis A. The third circuit board 412c may be disposed between the third loading surface 408c and the third finger 410c. Specifically, the third finger 410c may bias the third circuit board 412c against the third loading surface 408c. The third finger 410c may be substantially the same as the first finger 410a. The third loading surface 408c may be spaced apart from the first end 404 so that the second sensor 414b is disposed within a predetermined range of the second encoder magnet 368b.

[0033] The housing of the controller 400 can be axially constrained by the encoder magnets 368a, 368b and the predetermined range. A support member 402 is provided that is axially spaced from the circuit board 412 and biases the circuit board 412 onto the corresponding loading surface 408, so that the controller 400 can be supported between the encoder magnets 368a, 368b while maintaining the sensor 414 within the predetermined range of the encoder magnets 368a, 368b.

[0034] Although exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms covered by the claims. The words used in the specification are descriptive rather than restrictive words, and it should be understood that various changes can be made without departing from the spirit and scope of the present disclosure. As previously described, the features of various embodiments can be combined to form other embodiments of the present disclosure that may not be clearly described or illustrated. Although various embodiments may have been described as providing advantages or being superior to other embodiments or prior art implementations in terms of one or more desired characteristics, it is recognized by those of ordinary skill in the art that one or more features or characteristics can be compromised to achieve the desired overall system properties, depending on the specific application and implementation. These properties may include, but are not limited to, cost, strength, durability, life cycle cost, marketability, appearance, packaging, size, applicability, weight, manufacturability, ease of assembly, etc. Therefore, to a certain extent, any embodiment is described as being less desirable than other embodiments or prior art implementations in terms of one or more characteristics, which are not outside the scope of the present disclosure and may be desirable for a particular application.

[0035] Reference numerals list

[0036] 100 Rotary Actuators

[0037] 102 Shell

[0038] 104 first end

[0039] 106 second end

[0040] 108 wall

[0041] 110 chambers

[0042] 134 Output shaft

[0043] 200 Gear Box

[0044] 300 drive system

[0045] 302 Motor

[0046] 304 stator

[0047] 306 rotor

[0048] 308 rotor shaft

[0049] 400 Controller

[0050] 402 Support

[0051] 404 first end

[0052] 406 Second end

[0053] 408 loading surface

[0054] 410 finger

[0055] 412 Circuit Board

[0056] 414 Sensor

[0057] 416 Computer

[0058] 418 Communication Network

[0059] 368a First encoder magnet

[0060] 368b Second encoder magnet

[0061] 408a First loading surface

[0062] 408b Second loading surface

[0063] 408c Third loading surface

[0064] 410a First finger

[0065] 410b Second finger

[0066] 410c Third finger

[0067] 412a First circuit board

[0068] 412b Second circuit board

[0069] 412c Third Circuit Board

[0070] 414a First sensor

[0071] 414b Second sensor

[0072] A axis

Claims

1. A controller, comprising: Multiple circuit boards; as well as a support configured to support each circuit board, the support including a plurality of loading surfaces axially spaced apart from one another and a plurality of fingers extending obliquely relative to the loading surfaces; Each circuit board is arranged between a corresponding loading surface and a corresponding finger portion.

2. The controller according to claim 1, wherein: The plurality of circuit boards include a circuit board supporting a sensor and a power electronics circuit board spaced apart from the circuit board; The plurality of loading surfaces include: a first loading surface configured to support the circuit board; and a second loading surface axially spaced from the first loading surface and configured to support the power electronic circuit board; and The plurality of fingers include a first finger disposed between the first loading surface and the second loading surface and extending toward the first loading surface, and a second finger spaced apart from the second loading surface and extending toward the second loading surface.

3. The controller according to claim 2, wherein: The first finger is configured to axially bias the circuit board against the first loading surface.

4. The controller according to claim 3, wherein: The first finger is configured to elastically deform during mounting of the circuit board between the first finger and the first loading surface.

5. The controller according to claim 2, wherein: The second finger is configured to inhibit installation of the power electronics circuit board when a component of the circuit board is not seated with a mating component of the power electronics circuit board.

6. The controller according to claim 5, wherein: The second finger is configured to allow mounting of one circuit board when a component of the other circuit board is seated with a mating component of the other circuit board.

7. The controller according to claim 2, wherein: The second finger is configured to allow axial movement of the power electronics circuit board relative to the second loading surface.

8. The controller according to claim 2, wherein: The plurality of circuit boards includes an additional circuit board supporting an additional sensor; The plurality of loading surfaces include a third loading surface configured to support the additional circuit board, the second loading surface being disposed between the first loading surface and the third loading surface; and The plurality of fingers include a third finger spaced apart from and extending toward the third loading surface.

9. The controller according to claim 8, wherein: The third finger is configured to axially bias the additional circuit board against the third loading surface.

10. The controller according to claim 9, wherein: The third finger is configured to elastically deform during mounting of the additional circuit board between the third finger and the third loading surface.

11. The controller according to claim 8, wherein: The second finger is disposed between the second loading surface and the third loading surface.

12. The controller according to claim 8, wherein: The third finger is disposed at an end of the support.

13. A circuit board support, comprising: a first loading surface configured to support a circuit board; a second loading surface axially spaced from the first loading surface and configured to support another circuit board; a first finger disposed between the first loading surface and the second loading surface and extending toward the first loading surface, the first finger configured to axially bias the one circuit board against the first loading surface; as well as A second finger is spaced apart from and extends toward the second loading surface, the second finger being configured to prevent mounting of the other circuit board when a component of the one circuit board is not seated with a mating component of the other circuit board.

14. The circuit board support according to claim 13, wherein: The first finger is configured to elastically deform during mounting of the one circuit board between the first finger and the first loading surface.

15. The circuit board support according to claim 13, wherein: The second finger is configured to allow axial movement of the other circuit board relative to the second loading surface.

16. The circuit board support according to claim 13, further comprising: a third loading surface configured to support an additional circuit board; as well as A third finger is spaced apart from and extends toward the third loading surface, the third finger being configured to axially bias the additional circuit board against the third loading surface.

17. The circuit board support according to claim 16, wherein: The second loading surface is disposed between the first loading surface and the third loading surface.

18. The circuit board support according to claim 16, wherein: The second finger is disposed between the second loading surface and the third loading surface.

19. The circuit board support according to claim 16, wherein: The third finger is configured to elastically deform during mounting of the additional circuit board between the third finger and the third loading surface.

20. The circuit board support according to claim 16, wherein: The third finger is disposed at an end of the support.

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