Controller

Abstract

The purpose of the present invention is to improve the assemblability of a controller and reduce the workload during maintenance. In a controller (1), substrates and electronic components housed in a housing (2) are divided into a plurality of groups, and are assembled on different base members (11) for each group to be unitized. The plurality of electrical units (10) are detachably fixed to the bottom panel (21) via the base member (11). Each of the electrical units (10) is arranged so as not to hinder attachment and detachment of the other electrical units (10) to and from the bottom panel (21). Therefore, the fixing parts (the parts provided with the fixing holes) of the base part (11) relative to the bottom surface panel (21) are arranged in a manner of not overlapping with each other. The electrical unit (10) comprises at least part of a driver unit (3), a main circuit unit (5), a power supply circuit unit (4), an interface unit (6), an output unit (7) and a power supply input unit (8).

Description

Technical Field

[0001] The invention relates to a controller in which various substrates and electronic components are accommodated. Background Art

[0002] Patent Document 1 describes a controller that provides a driving current to an actuator (motor) of a robot and that houses various electronic components, a substrate, a cooling fan, and the like in a metal casing.

[0003] In the controller of patent document 1, various electronic components and substrates are fixed to the housing, respectively. For example, the control circuit substrate is directly fixed to the bottom surface of the housing, and the fan is directly fixed to the back panel of the housing. In addition, electronic components such as noise filters and relay modules are also directly fixed to the housing. Moreover, other components and units are assembled in an overlapping manner with respect to the components fixed to the housing. For example, a driver unit in which a plurality of driver substrates are assembled on a frame (substrate holder) is assembled in an overlapping manner on the control circuit substrate. On a power supply substrate equipped with a plurality of capacitors, a reinforcement frame is assembled in an overlapping manner, and the wiring for outputting the driving current from the driver unit passes through the wiring hole provided in the reinforcement frame, and is pulled around in a manner crossing over components of the power supply system such as the noise filter. Prior art literature Patent Literature

[0004] Patent Document 1: Japanese Patent Application Publication No. 2023-28305 Summary of the invention

[0005] As in Patent Document 1, when a structure is adopted in which a fan and electronic components are fixed to a housing separately and other units and components are assembled in a superimposed manner, assembly cannot be performed if the assembly is not performed in the correct order. In addition, when replacing or maintaining a component, it is necessary not only to remove the component but also to remove multiple components, which takes time. Moreover, since there are many wirings connected after assembly to the housing, the wiring length is long and the work load is heavy. In addition, it is difficult to concentrate the substrate and electronic components, making it difficult to save space.

[0006] In view of the above problems, an object of the present invention is to improve the ease of assembly of a controller and reduce the workload during maintenance.

[0007] In order to solve the above-mentioned problems, the controller of the present invention comprises: a housing, which comprises a housing body opened at one side and a cover that is detachable from the housing body from the one side; and a plurality of electric units housed in the housing, wherein the plurality of electric units are unitized electric units by dividing substrates and electronic components housed in the housing into a plurality of groups and assembling the substrates and electronic components in each group on different base members, the housing body comprises a unit fixing surface opposite to the cover, the plurality of electric units are respectively detachably fixed from the cover side via the base member with respect to the unit fixing surface, and are arranged in a manner that fixing portions of the base member with respect to the unit fixing surface do not overlap with each other, and the plurality of electric units include at least a part of the following units: A driver unit, comprising a plurality of driver substrates for generating a driving current for driving an actuator; a main circuit unit, which generates a DC voltage from an AC voltage and provides it to the driver substrate; a power circuit unit, which generates a DC voltage of a voltage different from the DC voltage provided by the main circuit unit from the AC voltage; an interface unit, comprising a substrate having a communication connector arranged in a hole of the shell; an output unit, comprising a plurality of connector components, the plurality of connector components including an external output connector for outputting the driving current to the outside and an encoder connector for inputting an encoder signal from the actuator; and a power input unit, comprising a terminal block for connecting a power supply line of an external AC power supply and a noise filter for inputting AC current via the terminal block.

[0008] According to the present invention, the substrate and electronic components stored in the housing of the controller are assembled on different base components in each group and unitized. In addition, all electrical units are fixed to the same unit fixing surface provided on the housing body so that they do not overlap each other. In this way, by unitizing the electronic components and the substrate in advance, they can be easily assembled into the housing. In addition, since the wiring between the electronic components installed on the common substrate can be provided on the substrate, the wiring can be reduced and the number of substrates can also be reduced. In addition, by unitizing, the electronic components and the substrate can be concentrated, and there is no need to ensure the working space required for separate assembly, so space can be saved. In addition, since all the units are fixed on the same surface in a non-overlapping manner, there is no need to consider the order when assembling. Therefore, the assemblability can be improved. In addition, since all the units are fixed so as not to hinder the loading and unloading of other units, the unit containing the target electronic components and the substrate can be taken out without removing other components during maintenance. Therefore, the workload can be reduced.

[0009] In the present invention, the plurality of electrical units preferably include all of the driver unit, the power circuit unit, the main circuit unit, the interface unit, the output unit, and the power input unit. In this way, all substrates and electronic components required for the controller are unitized according to their functions, thereby improving the assembly of the controller, reducing wiring and substrates, saving space, and reducing the maintenance load.

[0010] In the present invention, it is preferred that the housing body comprises: a front panel rising from one edge of the unit fixing surface; and a back panel rising from the other edge of the unit fixing surface, the power input unit, the output unit and the interface unit are arranged in a first direction along the front panel on the inner side of the front panel, the driver unit, the power circuit unit and the main circuit unit are arranged in this order in the first direction on the inner side of the back panel, the driver unit comprises a fan, which is opposite to the vent provided on the back panel in a second direction intersecting the first direction, the plurality of driver substrates are arranged parallel to the first direction on the side of the fan opposite to the vent, and the power circuit unit comprises a first voltage substrate, which is arranged parallel to the driver substrate at a position adjacent to the driver unit in the first direction. In this way, by arranging the power circuit unit in the center, it is easy to connect the power wiring of each unit and the wiring length can be shortened. In addition, in such a configuration, the airflow from the fan of the driver unit is not easily blocked, and part of it flows to the interface unit and the main circuit unit through the gap between the power circuit unit and the driver unit, which was confirmed by airflow analysis using a three-dimensional model. Therefore, the inside of the controller can be effectively cooled by a single fan.

[0011] In the present invention, the driver unit preferably includes: a first base frame as the base component; and a fan fixed to the first base frame, the first base frame maintaining the plurality of driver substrates in a state of being arranged in parallel in a posture perpendicular to the unit fixing surface, the fan being arranged between the vent provided in the housing and the plurality of driver substrates, and blowing air in a direction orthogonal to the arrangement direction of the plurality of driver substrates. In this way, by including the fan in the driver unit, the work of fixing the electrical components separately to the housing is reduced, and the assemblability can be improved. In addition, the positional accuracy of the fan relative to the driver substrate can be improved.

[0012] In the present invention, the first base frame preferably includes: a first base plate along the unit fixing surface; a plurality of first substrate mounting plates erected in parallel from the first base plate; and a frame top plate fixed to the front ends of the plurality of first substrate mounting plates, the plurality of driver substrates are respectively fixed to the first substrate mounting plates, and the fan is fixed to the edge of the first base plate on the vent side and the edge of the frame top plate on the vent side. In this way, the gap between the fan and the driver substrate can be made opposite.

[0013] In the present invention, the driver unit preferably has a connector for connecting between units arranged at the edge of the first base plate. In this way, by attaching and detaching the connector, wiring work for the circuit or electronic components of the driver unit can be centralized. Therefore, wiring can be centralized, and wiring work between units is easy.

[0014] In the present invention, the power supply circuit unit preferably includes: a first voltage substrate for generating a DC voltage of a first voltage; a second voltage substrate for generating a DC voltage of a second voltage different from the first voltage; and a first base member as the base member. In this way, a plurality of power supply circuits for generating DC voltages of different voltages can be unitized. Therefore, it is not necessary to assemble each power supply circuit individually to the housing, thereby improving assemblability.

[0015] In the present invention, the first base member preferably includes: a first fixing plate along the unit fixing surface; and a first mounting plate bent from the first fixing plate in a direction perpendicular to the unit fixing surface, and the first voltage substrate and the second voltage substrate are fixed to the first mounting plate from the same direction in a non-overlapping manner in a posture parallel to the first mounting plate. In this way, the power circuit unit becomes a thin and longitudinal shape with a small plane size. Therefore, the installation space on the unit fixing surface can be reduced, and the plane size of the entire device can be reduced.

[0016] In the present invention, the main circuit unit preferably comprises: a first substrate, which is provided with a main circuit relay, a rectifier circuit for inputting an AC voltage via the main circuit relay, and a pre-driver power supply; a second substrate, which is provided with a plurality of main circuit capacitors connected to the rectifier circuit; and a second base frame as the base component, the second base frame maintaining the first substrate and the second substrate in a stacked state. In this way, since the number of electronic components and substrates respectively fixed to the housing is reduced, the assemblability can be improved. In addition, since the electronic components mounted on the common substrate can be connected through the circuit pattern on the substrate, the wiring can be reduced, and the substrate can also be reduced. In addition, the wiring space can be reduced, and the working space for separate assembly is not required, so space saving can be achieved.

[0017] In the present invention, it is preferred that the first substrate is provided with the main circuit relay, the rectifier circuit and the pre-driver power supply on the substrate surface on the opposite side to the second substrate, the second substrate is provided with the plurality of main circuit capacitors on the substrate surface on the opposite side to the first substrate, and has a metal spacer between the first substrate and the second substrate, the spacer also serving as a power wiring connecting the first substrate and the second substrate. In this way, since no electronic components are arranged between the two substrates, the distance between the substrates can be reduced. In addition, since the surface where no electronic components are mounted has parts protruding from the substrate surface such as the feet of the mounted components, it is necessary to be separated from other components. Therefore, by making the surface where no electronic components are mounted not facing outward but facing each other, a space-saving configuration can be achieved. Moreover, since there is no need to set the power wiring separately from the spacer, the wiring and terminal components can be reduced, and the substrate can be miniaturized.

[0018] In the present invention, the main circuit unit preferably includes: a safety relay module for emergency stopping the actuator; and a third substrate on which a signal relay and a connector for connecting to the signal relay are mounted, and the safety relay module and the third substrate are fixed to the second base frame. In this way, since the number of electronic components and substrates separately fixed to the housing is further reduced, the assemblability can be further improved. In addition, the wiring can be further reduced, and space saving can be further achieved.

[0019] In the present invention, the main circuit unit preferably includes a regenerative resistor fixed to the second base frame. In this way, since the number of electronic components and substrates separately fixed to the housing is further reduced, the assembly performance can be further improved.

[0020] In the present invention, it is preferred that the first substrate and the second substrate are stacked on top of each other in a posture parallel to the unit fixing surface, the second substrate has a substrate end portion that does not overlap with the first substrate, a power wiring connector for connecting a power wiring that provides a DC voltage to the driver substrate is arranged on the substrate surface on the first substrate side of the substrate end portion, a heat sink is fixed to the edge of the substrate end side of the first substrate, and a diode bridge of the rectifier circuit is fixed to the heat sink. In this way, the operability when connecting the power wiring between the driver substrate is good. In addition, by arranging the power wiring connector and the heat sink on the same side, it is easy to arrange them on the driver substrate side at the same time. Therefore, it is easy to shorten the wiring length of the power wiring, and it is easy to cool the heat sink by air supply from a fan provided in the driver unit.

[0021] In the present invention, it is preferred that the housing has a front panel, the interface unit has a second base member as the base member, and has a communication substrate and a control circuit substrate on which the communication connector is mounted as the substrate, the communication substrate and the control circuit substrate are fixed to the second base member in a stacked state with a spacer interposed therebetween, and are arranged on the inner side of the front panel. In this way, compared with fixing each substrate to the housing separately, the assemblability can be improved. In addition, the control circuit substrate on the lower side can be easily removed from the housing.

[0022] In the present invention, it is preferred that the housing has a front panel, the output unit has a third base component as the base component, the third base component has: a third fixing plate along the unit fixing surface; and a connector mounting plate bent from the third fixing plate and along the inner side surface of the front panel, the plurality of connector components are respectively fixed to the connector mounting plate and arranged in the opening of the front panel. In this way, compared with fixing each connector component to the housing separately, the assembly performance can be improved.

[0023] In the present invention, the plurality of connector components preferably include a monitoring signal connector for outputting a monitoring signal to the outside. In this way, since the number of connector components that are separately fixed to the housing is further reduced, the ease of assembly can be further improved.

[0024] In the present invention, it is preferred that the housing has a front panel, the power input unit has a fourth base member as the base member, the fourth base member has: a fourth fixing plate along the unit fixing surface; and a fourth mounting plate bent from the fourth fixing plate, the terminal block is fixed to the fourth fixing plate, and the noise filter is fixed to the fourth mounting plate. In this way, since the number of electronic components individually fixed to the housing is reduced, the assemblability can be improved. In addition, since the planar size of the power input unit is reduced, the installation space on the unit fixing surface is reduced, and thus the overall planar size of the device can be reduced.

[0025] According to the present invention, by unitizing the electronic components and substrate of the controller in advance, they can be easily assembled into a housing. In addition, since the wiring between the electronic components mounted on a common substrate can be arranged on the substrate, the wiring can be reduced and the number of substrates can be reduced. Moreover, by unitizing, the electronic components and substrates can be concentrated, and there is no need to ensure the working space required for separate assembly, so space can be saved. In addition, since all the units are fixed on the same surface in a non-overlapping manner, there is no need to consider the order during assembly. Therefore, the assemblability can be improved. In addition, since all the units are fixed so as not to hinder the loading and unloading of other units, the unit containing the target electronic components and substrates can be taken out without removing other components during maintenance. Therefore, the workload can be reduced. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 It is a perspective view of the appearance of a controller to which the present invention is applied. Figure 2 yes Figure 1 Exploded perspective view of the controller. Figure 3 This is a perspective view of a plurality of electric units housed in a casing as viewed from the front panel side. Figure 4 This is a perspective view of a plurality of electric units housed in a housing as viewed from the rear panel side. Figure 5 This is a top view of the controller with the cover removed. Figure 6 It is a plan view showing the fixing position of the base member of each electric unit with respect to the bottom panel. Figure 7 This is an exploded perspective view of the driver unit. Figure 8 This is an exploded perspective view of the power supply circuit unit. Fig. 9 This is an exploded perspective view of the main circuit unit. Fig.10 This is a side view of the main circuit unit viewed from the Y1 direction. Fig.11 It is an exploded perspective view of the first substrate, the second substrate and the second base frame of the main circuit unit. Fig.12 It is an explanatory diagram showing a part of the assembling process of the electric unit (an explanatory diagram of the process of assembling the power circuit unit). Fig.13 It is an explanatory diagram showing a part of the assembly process of the electric unit (an explanatory diagram of the process of assembling the main circuit unit). Fig.14 It is an explanatory diagram showing a part of the assembly process of the electric unit (an explanatory diagram of the process of assembling the driver unit). Fig.15 It is a top view of the driver unit, power supply circuit unit, and main circuit unit. Fig.16 This is a perspective view of the driver unit, power supply circuit unit, and main circuit unit as viewed from the rear panel side. DETAILED DESCRIPTION

[0027] Hereinafter, an embodiment of a controller to which the present invention is applied will be described with reference to the drawings. A controller 1 of the present embodiment is a device that supplies power to a robot (manipulator) having an actuator such as a motor.

[0028] Figure 1 It is a perspective view of the appearance of a controller 1 to which the present invention is applied. Figure 2 yes Figure 1 An exploded perspective view of the controller 1. Figure 3 This is a perspective view of the plurality of electric units 10 housed in the housing 2 as viewed from the front panel 23 side. Figure 4 This is a perspective view of the plurality of electric units 10 housed in the housing 2 as viewed from the rear panel 24 side. Figure 5 It is a top view of the controller 1 with the cover 2B removed.

[0029] In this specification, the three directions XYZ are mutually orthogonal directions. In this specification, for convenience, the Z direction is set as the up and down direction of the controller 1. The Z1 direction is downward, and the Z2 direction is upward. The X direction is the front and back direction of the controller 1. The X1 direction is the front, and the X2 direction is the back. The Y direction is the width direction of the controller 1. The Y1 direction and the Y2 direction are one side and the other side of the Y direction. The Y direction is the first direction. The X direction is the second direction. In addition, in the actual use of the controller 1, the Z direction may not be consistent with the up and down direction (vertical direction). For example, it can also be set to use the Y direction as the up and down direction.

[0030] (Overall structure) like Figure 1 , Figure 2 As shown, the controller 1 includes a metal housing 2. The housing 2 is a rectangular parallelepiped, and includes a bottom panel 21 facing the Z1 direction, a top panel 22 facing the Z2 direction, a front panel 23 facing the X1 direction, and a back panel 24 facing the X2 direction. The housing 2 is formed by assembling two parts, namely, a housing body 2A including the bottom panel 21 and a cover 2B including the top panel 22. The housing body 2A has a box shape that opens in the Z2 direction. The cover 2B is assembled to the housing body 2A from the Z2 direction to close the opening of the housing body 2A.

[0031] The housing body 2A includes: a front panel 23 and a back panel 24, which stand up along the Z2 direction from the edges of the bottom panel 21 in the X1 direction and the X2 direction; a side panel 25, which stands up along the Z2 direction from the edge of the bottom panel 21 in the Y1 direction and connects the ends of the front panel 23 and the back panel 24 in the Y1 direction; and a side panel 26, which stands up along the Z2 direction from the edge of the bottom panel 21 in the Y2 direction and connects the ends of the front panel 23 and the back panel 24 in the Y2 direction. The height of the side panels 25 and 26 in the Z direction is lower than that of the front panel 23 and the back panel 24.

[0032] The cover 2B includes a side panel 27 extending from the edge of the top panel 22 in the Y1 direction to the Z1 direction, and a side panel 28 extending from the edge of the top panel 22 in the Y2 direction to the Z1 direction. The side panels 27 and 28 are provided at their front ends with stepped portions 27a and 28a inserted into the inner sides of the side panels 25 and 26 of the housing body 2A.

[0033] like Figure 2 , Figure 3 , Figure 4 , Figure 5 As shown, a plurality of electric units 10 are housed in the housing 2. In the present embodiment, all the electric units 10 are arranged on the same surface and fixed on the same surface. The housing body 2A includes a bottom panel 21 opposite to the top panel 22 of the cover 2B. The bottom panel 21 is used as a unit fixing surface for fixing all the electric units 10.

[0034] like Figure 3 , Figure 4 As shown, a plurality of electrical units 10 are respectively provided with a metal base member 11 and a substrate or an electronic component fixed on the base member 11. Each electrical unit 10 is a unit in which substrates or electronic components of related functions are concentrated and fixed on the same base member 11. In this specification, an electronic component includes a component in which an electronic component or a substrate is modularized. The electrical unit 10 is fixed to the bottom panel 21 via the base member 11. In the present embodiment, each electrical unit 10 is arranged in a manner that does not hinder the loading and unloading of other electrical units 10 relative to the bottom panel 21. That is, each electrical unit 10 is arranged in a manner that the fixing portion where the base member 11 is fixed to the bottom panel 21 does not overlap with other electrical units 10 in the Z direction.

[0035] Figure 6 2 is a top view showing the fixing position of the base member 11 of each electric unit 10 relative to the bottom panel 21. Figure 2 As shown in FIG. 2 , a boss portion 29 protruding in the Z2 direction is provided on the inner surface (top surface) of the bottom panel 21. Figure 5 , Figure 6As shown, each electric unit 10 is fixed to a different boss portion 29 via a fixing hole 29a of the base member 11, and the fixing portion (fixing hole 29a) does not overlap with other electric units 10. Therefore, during maintenance, it is not necessary to remove other electric units 10, and only the electric unit 10 including the maintenance target portion can be installed and removed relative to the housing body 2A.

[0036] like Figure 2 , Figure 5 As shown, six electrical units 10, namely, a driver unit 3, a power circuit unit 4, a main circuit unit 5, an interface unit 6, an output unit 7, and a power input unit 8, are accommodated in the housing 2. The three electrical units 10, namely, the driver unit 3, the power circuit unit 4, and the main circuit unit 5, are arranged in this order toward the Y1 direction and are arranged on the inner side of the rear panel 24. The three electrical units 10, namely, the interface unit 6, the output unit 7, and the power input unit 8, are arranged in this order toward the Y2 direction and are arranged on the inner side of the front panel 23. The details of each electrical unit 10 are described below.

[0037] (Driver unit) like Figure 2 As shown, the driver unit 3 is a unit including a driver substrate unit 3A that holds a plurality of driver substrates 31 on a first base frame 30 as a base member 11, and a cooling fan 32 is integrated with the driver substrate unit 3A.

[0038] Figure 7 3 is an exploded perspective view of the driver unit 3. Figure 7 As shown, the first base frame 30 includes a first base plate 301, a plurality of first substrate mounting plates 302, and a frame top plate 303. The first base plate 301 is in the shape of a plate along the XY plane and is fixed to the bottom panel 21 (see FIG. Figure 2 ). The first substrate mounting plates 302 are arranged in parallel in a posture vertically standing from the first base plate 301. In this embodiment, three first substrate mounting plates 302 along the XZ plane are arranged in parallel with the Y direction. The frame top plate 303 is fixed to the upper ends of the plurality of first substrate mounting plates 302 in a posture along the XY plane. Two openings 304 extending in the X direction are provided on the frame top plate 303.

[0039] The driver unit 3 includes a plurality of driver substrates 31 and a fan 32 fixed to the first base frame 30. The driver unit 3 includes three driver substrates 31. Each driver substrate 31 is arranged in parallel with the first substrate mounting plate 302 and is fixed to the first substrate mounting plate 302 from the Y2 direction. Each driver substrate 31 has a heat sink 33 fixed to the substrate surface in the Y1 direction, and an electronic component 34 such as an IGBT module is mounted on the substrate surface in the Y2 direction.

[0040] A connector 35 for connecting a power line is disposed at the end of each driver substrate 31 in the Z2 direction. Figure 3 , Figure 4 As shown, the connectors 35 of the two driver substrates 31 on the Y1 side and the center are arranged in the opening 304 of the frame top plate 303. The connector 35 of the driver substrate 31 on the Y2 side is located closer to the Y2 direction than the end of the frame top plate 303 in the Y2 direction. Therefore, the connector 35 of the driver unit 3 is not covered by the frame top plate 303, and the power wiring can be connected from the Z2 direction.

[0041] like Figure 7 As shown, at the end of the Z1 direction of each driver substrate 31, a wiring substrate 36 is arranged along the XY plane. The driver substrate 31 is connected to the wiring substrate 36 via a connector 37 that is fitted in the Z direction. The end of the driver substrate 31 in the Z1 direction is held by the first base frame 30 via the connector 37 and the wiring substrate 36. In addition, at the end of the first base frame 30 in the X1 direction, a unit-to-unit connection connector 38 for connecting wiring from other electric units 10 is arranged.

[0042] The fan 32 is provided in a posture capable of blowing air in a direction (X direction) orthogonal to the arrangement direction (Y direction) of the driver substrates 31, and is arranged in the X2 direction of the driver substrate 31. The end of the fan 32 in the Z2 direction is fixed to the end of the frame top plate 303 in the X2 direction. The end of the fan 32 in the Z1 direction is fixed to the end of the first base plate 301 in the X2 direction.

[0043] like Figure 2 As shown in FIG. 1 , a circular vent 24a is provided at one location on the back panel 24. The vent 24a is located in the area on the Y2 side of the back panel 24. Figure 2 , Figure 5 As shown in the figure, when the driver unit 3 is assembled inside the corner where the side panel 26 and the back panel 24 in the Y2 direction of the housing body 2A are connected, the fan 32 arranged at the end of the driver unit 3 in the X2 direction is opposite to the vent 24a in the X direction. In this state, when the fan 32 is driven, air is sucked from the vent 24a, and the air flows in the gap between the adjacent driver substrates 31. The cooling effect of the airflow of the fan 32 will be described later.

[0044] (Power supply circuit unit) Figure 8 4 is an exploded perspective view of the power supply circuit unit 4. Figure 3 , Figure 4 , Figure 8As shown, the power circuit unit 4 includes a first base member 40 as a base member 11. The first base member 40 includes: a first mounting plate 401 along the XZ plane; and a first fixing plate 402 bent from the end of the first mounting plate 401 on the Z1 side to the Y2 direction. The first fixing plate 402 is provided at two locations separated in the X direction. The first base member 40 is fixed to the bottom panel 21 (see FIG. 2 ) as the unit fixing surface by fixing the first fixing plates 402 at two locations to the boss portions 29. Figure 2 ).

[0045] The first mounting plate 401 is provided with a rectangular notch 403 formed by cutting away the Z2 direction portion (upper end portion) of the X2 direction end portion (end portion on the back panel 24 side), and a rectangular opening 404 formed by cutting away a larger area in the X1 direction of the notch 403. The first fixing plate 402 is configured in a frame shape surrounding the opening 404.

[0046] The power supply circuit unit 4 includes a first voltage substrate 41 and a second voltage substrate 42. A first power supply circuit for generating a DC voltage of a first voltage from an AC voltage is provided on the first voltage substrate 41. A second power supply circuit for generating a DC voltage of a second voltage different from the first voltage from an AC voltage is provided on the second voltage substrate 42. For example, the first voltage is 24V and the second voltage is 5V. Both the first voltage and the second voltage are voltages different from the DC voltage (15V) supplied to the driver substrate 31. The power supply circuit unit 4 supplies DC voltages of 24V and 5V to other electrical units 10. For example, a DC voltage of 24V for driving the fan 32 is supplied to the driver unit 3, and a DC voltage of 5V is supplied to the control circuit substrate 64 described below.

[0047] The first voltage substrate 41 and the second voltage substrate 42 are fixed to the first mounting plate 401 from the Y2 direction (driver unit 3 side) and are arranged on the same surface. The first voltage substrate 41 and the second voltage substrate 42 are fixed to the front end of the spacer 405 protruding from the first mounting plate 401 in the Y2 direction. As a result, the first voltage substrate 41 and the second voltage substrate 42 are in a posture parallel to the XZ plane like the driver substrate 31, and are opposite to the driver unit 3 in the Y direction. The first voltage substrate 41 and the second voltage substrate 42 are mounted with electronic components 43 constituting a power supply circuit such as a power module on the substrate surface in the Y2 direction opposite to the driver unit 3. The first voltage substrate 41 and the second voltage substrate 42 face the opening 404 of the first mounting plate 401, so it is a structure that can also dissipate heat from the surface on the side where the electronic components are not mounted.

[0048] The first voltage substrate 41 and the second voltage substrate 42 are both rectangular substrates that are longer in the X direction and are arranged side by side in the Z direction. In the present embodiment, the first voltage substrate 41 for 24V is located in the Z2 direction, and the second voltage substrate 42 for 5V is located in the Z1 direction. The length of the second voltage substrate 42 in the X direction is longer than that of the first voltage substrate 41. The first voltage substrate 41 and the second voltage substrate 42 both overlap with the opening 404 of the first mounting plate 401, but do not overlap with the notch 403. The notch 403 of the first mounting plate 401 is shaped in such a way that the first mounting plate 401 is notched in accordance with the difference in length between the first voltage substrate 41 and the second voltage substrate 42 in the X direction.

[0049] (Main circuit unit) Fig. 9 It is an exploded perspective view of the main circuit unit 5 . Fig.10 This is a side view of the main circuit unit 5 as viewed from the Y1 direction. Fig.11 FIG. 5 is an exploded perspective view of the first substrate 51, the second substrate 52 and the second base frame 50 of the main circuit unit 5. Figure 3 , Figure 4 , Fig. 9 As shown, the main circuit unit 5 includes a second base frame 50 as the base member 11. Fig. 9 , Fig.10 As shown, the second base frame 50 includes a second base plate 501, a pair of second substrate mounting plates 502 and a connecting plate 503. The pair of second substrate mounting plates 502 stand vertically from the second base plate 501 and are arranged in the X direction. In the present embodiment, from the second base plate 501 along the XY plane, a pair of second substrate mounting plates 502 along the YZ plane stand in the Z2 direction. The second substrate mounting plate 502 on the X2 side is formed integrally with the second base plate 501. The connecting plate 503 is fixed to the upper ends of the pair of second substrate mounting plates 502 in a posture along the XY plane. In addition, the pair of second substrate mounting plates 502 may also be inclined relative to the direction vertically standing from the second base plate 501.

[0050] The main circuit unit 5 includes a first substrate 51, a second substrate 52, and a third substrate 53. The first substrate 51 and the second substrate 52 are in a posture parallel to the second base plate 501 and overlap in the Z direction. The first substrate 51 is located on the upper side (Z2 side) of the second substrate 52. The four corners of the first substrate 51 and the second substrate 52 are connected by spacers 54, and are connected by two spacers 55 at a position close to the center of the substrate. The two spacers 55 are electrically connected to the circuit on the first substrate 51 and the circuit on the second substrate 52. The spacer 55 is a spacer for power wiring that also serves as a power wiring that supplies the voltage from the rectifier circuit mounted on the first substrate 51 to the power wiring of the second substrate 52.

[0051] The first substrate 51 and the second substrate 52 are mounted between a pair of second substrate mounting plates 502. Both ends of the second substrate 52 in the X direction located on the Z1 side are supported by arm portions 504 bent from both ends of the pair of second substrate mounting plates 502 in the Y direction. The first substrate 51 is supported by the pair of second substrate mounting plates 502 via the second substrate 52.

[0052] The third substrate 53 is arranged in a vertical position extending in the Z direction and is disposed on the side of the main circuit unit 5 in the X1 direction. The third substrate 53 is fixed to the second substrate mounting plate 502 on the X1 side from the side opposite to the first substrate 51 and the second substrate 52 (X1 side). Figure 8 As shown, the second substrate mounting plate 502 on the X1 side is provided with a rectangular opening 505 in the center and is formed in a frame shape.

[0053] The first substrate 51 and the second substrate 52 are assembled in such a manner that the substrate surfaces on which the circuits and components are mounted are opposite to each other, and components are not mounted on the portions of the substrates facing each other. The first substrate 51 has a rectifier circuit and various components described below mounted on the substrate surface on the Z2 side opposite to the second substrate 52, and no components are mounted on the substrate surface on the Z1 side opposite to the second substrate 52. The second substrate 52 has a plurality of main circuit capacitors 520 mounted on the substrate surface on the Z1 side opposite to the first substrate 51, and no components are mounted on the area of ​​the substrate surface on the Z2 side opposite to the first substrate 51 that faces the first substrate 51. The second substrate 52 is longer in the Y direction than the first substrate 51, and has a substrate end 52a on the Y2 side that does not face the first substrate 51. The second substrate 52 has a power wiring connector 521 and an LED lamp 522 mounted on the substrate surface on the Z2 side of the substrate end 52a. The main circuit unit 5 supplies a 15V DC voltage to the driver substrate 31 from the power wiring connector 521 of the second substrate 52.

[0054] like Fig. 9 As shown, the components mounted on the first substrate 51 include: two main circuit relays 510 arranged at the end of the first substrate 51 in the X2 direction; an anti-surge resistor 511 and an anti-surge relay 512 arranged in the Y2 direction of the main circuit relay 510; a 15V pre-driver power supply 513 and a 24V brake power supply 514 arranged on the X1 side of the main circuit relay 510; a diode bridge 515 constituting a rectifier circuit; and connectors 516, 517, 518 for connecting to other electric units 10. The connectors 516, 517, 518 are arranged at the end of the first substrate 51 in the Y1 direction. The diode bridge 515 is fixed to a heat sink 519, and the heat sink 512 is fixed to the end of the first substrate 51 in the Y2 direction. The spacer 55 for power wiring between the first substrate 51 and the second substrate 52 is arranged on the back side of the pre-driver power supply 513 and the brake power supply 514.

[0055] The main circuit unit 5 further includes a safety relay module 56 for emergency stopping the motor and a regenerative resistor 57. The safety relay module 56 is fixed to the second base plate 501 on the Y1 side of the first substrate 51 and the second substrate 52. The regenerative resistor 57 is fixed to the top surface of the connecting plate 503. The regenerative resistor 57 is connected to the connector on the first substrate 51.

[0056] like Figure 3 As shown in FIG. 1 , a signal relay 531 is mounted on the third substrate 53 as an element for emergency stop control, and a connector 532 is mounted for connection with the signal relay 531. The signal relay 531 is arranged in the area on the Z1 side of the third substrate 53, and the connector 532 is arranged in the area on the Z2 side of the third substrate 53. Therefore, the connector 532 is arranged on the upper part of the main circuit unit 5, so it is easy to access when the main circuit unit 5 is assembled in the housing body 2A, and is arranged at a position where the wiring cable can be easily connected.

[0057] like Figure 2 , Figure 5 As shown, the main circuit unit 5 is assembled on the inner side of the corner where the side panel 25 and the back panel 24 of the housing body 2A are connected in the Y1 direction. As described above, on the inner side of the back panel 24, the driver unit 3, the power circuit unit 4 and the main circuit unit 5 are arranged in this order in the Y direction. The main circuit unit 5 is arranged in the following posture: the end where the safety relay module 56 is arranged is the Y1 side (side panel 25 side), and the end where the heat dissipation component 519 on the first substrate 51 and the power wiring connector 521 on the second substrate 52 are arranged is the Y2 side (power circuit unit 4 and driver unit 3 side). As described later, the heat dissipation component 519 is opposite to the notch 403 of the power circuit unit 4.

[0058] (Interface Unit) like Figure 3 , Figure 4 As shown, the interface unit 6 includes a second base member 60 as the base member 11. The second base member 60 includes: a rectangular plate 601 along the XY plane; and two boss fixing portions 602 provided at the ends of the plate 601 in the X2 direction. Figure 5 , Figure 6 As shown, the two boss fixing portions 602 of the second base member 60 are fixed to the boss portions 29 of the bottom panel 21 .

[0059] The interface unit 6 includes a first communication substrate 61, a second communication substrate 62, a third communication substrate 63, and a control circuit substrate 64. The board 601, the control circuit substrate 64, the third communication substrate 63, the second communication substrate 62, and the first communication substrate 61 are stacked in sequence in the Z1 direction and connected via spacers. A communication connector 65 is arranged at the end of each substrate in the X1 direction.

[0060] Among the first communication substrate 61, the second communication substrate 62, the third communication substrate 63 and the control circuit substrate 64, the substrate located on the upper side (Z2 side) is shorter in the X direction than the substrate located on the lower side (Z1 side). These four substrates are offset in such a manner that the positions of the ends on the X1 side are aligned. Therefore, the interface unit 6 as a whole is configured to be stepped on the X2 side, and the end of the substrate on the lower side in the X2 direction is configured to be visible from the upper side (Z2 side). At the ends of the control circuit substrate 64 and the third communication substrate 63 in the X2 direction, an inter-unit connection connector 66 (refer to Figure 4 ).

[0061] like Figure 2 and Figure 5 As shown, the interface unit 6 is assembled inside the corner where the side panel 25 and the front panel 23 of the housing body 2A in the Y1 direction are connected. The front panel 23 is provided with a plurality of openings 23a in the area on the Y1 side (see Figure 2 ).like Figure 1 As shown, a plurality of communication connectors 65 are respectively arranged in the openings 23a of the front panel 23, and can be connected from the front of the housing.

[0062] The connector 532 mounted on the third substrate 53 of the main circuit unit 5 is arranged on the X2 side of the interface unit 6. As described above, the X2 side of the interface unit 6 is stepped, and is formed in a shape that recedes toward the X1 side as it goes upward (Z2 side). Therefore, a space is ensured on the X1 side of the connector 532 of the main circuit unit 5, and a space required for the installation and removal work to the connector 532 is ensured.

[0063] (Output unit) like Figure 3 , Figure 4 As shown, the output unit 7 includes a third base member 70 as the base member 11. The third base member 70 includes: a rectangular connector mounting plate 701 along the YZ plane; and a third fixing plate 702 bent in the X2 direction from the end of the connector mounting plate 701 in the Z1 direction. The third fixing plate 702 is provided with fixing holes 29a for fixing to the boss portion 29 of the bottom panel 21 at two locations.

[0064] The output unit 7 includes: an external output connector 71 for outputting a driving current to the outside; a monitoring signal connector 72 for outputting a monitoring signal to the outside; two emergency stop connectors 73 and 74 for inputting an emergency stop signal from the outside; an encoder connector 75 for inputting an encoder signal from an actuator (motor); and a circuit breaker 76. The monitoring signal connector 72 is, for example, a connector for connecting to a teaching box. Figure 4 As shown, an external output connector 71 , a monitoring signal connector 72 , emergency stop connectors 73 and 74 , an encoder connector 75 , and a circuit breaker 76 are mounted in an opening 70 a provided in a connector mounting plate 701 .

[0065] like Figure 2 and Figure 5 As shown, the output unit 7 is assembled inside the front panel 23 of the housing body 2A and is located adjacent to the interface unit 6. On the front panel 23, a plurality of openings 23b are provided on the Y2 side of the region where the opening 23a for the communication connector 65 is provided (see Figure 2 ).like Figure 1 As shown, the external output connector 71, the monitoring signal connector 72, the emergency stop connectors 73 and 74, the encoder connector 75, and the circuit breaker 76 are arranged in the opening 23b of the front panel 23 and can be connected from the front of the housing.

[0066] (Power input unit) like Figure 3 , Figure 4 As shown, the power input unit 8 includes a fourth base member 80 as the base member 11. The fourth base member 80 includes: a fourth mounting plate 801 having a rectangular shape along the XZ plane; and a fourth fixing plate 802 bent in the Y1 direction from the end of the fourth mounting plate 801 in the Z1 direction. The fourth fixing plate 802 is provided with fixing holes 29a for fixing to the boss portion 29 of the bottom panel 21 at three locations.

[0067] The power input unit 8 includes: a power input terminal block 81 to which a power supply line from an external power source is connected; a noise filter 82; and a grounding plate 83. The power input terminal block 81 is fixed to the fourth fixing plate 802. In this embodiment, the power input terminal block 81 is fixed to the fourth fixing plate 802 via a plate separate from the fourth base member 80. The noise filter 82 is fixed to the fourth mounting plate 801. Figure 3 As shown, the grounding piece 83 is formed integrally with the fourth base member 80. The grounding piece 83 is bent from the edge of the fourth mounting plate 801 in the X1 direction toward the Z2 direction.

[0068] like Figure 2 and Figure 5As shown, the power input unit 8 is assembled inside the corner where the side panel 26 and the front panel 23 of the housing body 2A are connected in the Y2 direction. Figure 1 As shown in FIG. 2 , an opening 23c is provided at the end of the front panel 23 on the Y2 side, which is opposite to the power input terminal block 81 and the grounding plate 83. Figure 1 Although not shown in the figure, a plate that blocks the opening 23c is mounted on the front panel 23, and a power supply cable from an external power source is introduced into the housing 2 via a sleeve held on the plate. The power supply cable includes: a power supply line connected to the power input terminal block 81; and a grounding line connected to the grounding plate 83.

[0069] For example, a single-phase AC voltage for control power and a three-phase AC voltage for drive power are input from a power supply cable to the power input unit 8. A circuit breaker 76 provided on the output unit 7 is connected to a voltage supply path connecting the power input terminal block 81 and the noise filter 82. The noise filter 82 includes a filter circuit for removing noise superimposed on the AC voltage supplied to the main circuit unit 5.

[0070] (Electric unit assembly process) Fig.12 , Fig.13 , Fig.14 It is an explanatory diagram showing a part of the assembly process of the electric unit 10 . Fig.12 It is an explanatory diagram of the process of assembling the power circuit unit 4. Fig.13 It is an explanatory diagram of the process of assembling the main circuit unit 5. Fig.14 1 is an explanatory diagram of a process of assembling the driver unit 3. When assembling the controller 1, for example, the assembly process described below can be performed. In addition, the assembly process described below is an example, and is not limited to this order.

[0071] For example, Fig.12 As shown, the three electrical units 10 (power input unit 8, output unit 7 and interface unit 6) on the front panel 23 side are assembled to the housing body 2A. Figure 5 and Figure 6 As shown, since each electric unit 10 is arranged in a manner that does not hinder the loading and unloading of other electric units 10, the three electric units 10 can be installed in any order.

[0072] Next, the power circuit unit 4 and the main circuit unit 5 arranged in the center of the three electrical units 10 on the back panel 24 side are assembled. Fig.12 , Fig.13 As shown in FIG. 1 , first assemble the power circuit unit 4. Then, as shown in FIG. Fig.13 As shown, the main circuit unit 5 is assembled on the Y1 side of the power circuit unit 4.

[0073] like Fig.14 As shown, it is necessary to draw the power distribution cable 12 between the main circuit unit 5 and the power input unit 8. Figure 5 As shown, in this embodiment, the power circuit unit 4 is arranged at a position retreated from the back panel 24 compared to the two electrical units 10 (main circuit unit 5, driver unit 3) on both sides. Fig.14 As shown, the power distribution cable 12 extends along the X2 direction inside the side panel 26, and then extends along the Y1 direction inside the back panel 24, from the gap S between the power circuit unit 4 and the back panel 24 toward the main circuit unit 5. Fig.14 Although not shown in the figure, the power distribution cable 12 is drawn around the end portion on the Y1 side of the first substrate 51 and connected to the connector on the first substrate 51 .

[0074] After the driver unit 3 is assembled, the power distribution cable 12 is passed through the gap between the driver unit 3 and the housing body 2A. When the main circuit unit 5 is installed or removed, the power distribution cable 12 is disconnected from the connector on the first substrate 51 to remove only the main circuit unit 5.

[0075] (Cooling effect of the drive unit fan) Fig.15 FIG. 4 is a top view of the driver unit 3, the power supply circuit unit 4 and the main circuit unit 5. Fig.15 In the figure, the frame top plate 303 of the driver unit 3 is omitted, and the regeneration resistor 57 and the connection plate 503 of the main circuit unit 5 are omitted. Fig.16 This is a perspective view of the driver unit 3, the power circuit unit 4, and the main circuit unit 5 as viewed from the rear panel 24 side. Fig.16 In FIG. 5 , the regenerative resistor 57 and the connection plate 503 are omitted from the main circuit unit 5 , and the second base plate 501 is shown in a disassembled state.

[0076] like Fig.15 As shown in FIG. 1 , in the driver unit 3, the driver substrates 31 extending in the X direction are arranged in the Y direction. Gaps S1 and S2 for air to pass through are provided between adjacent driver substrates 31. Figure 5 ) is consistent with the X direction. The fan 32 is arranged at a position opposite to the two gaps S1 and S2. Therefore, when the fan 32 is driven, air flows through the gaps S1 and S2.

[0077] A power circuit unit 4 is arranged on the Y1 side of the driver unit 3, and is assembled as a whole into a thin shape parallel to the driver substrate 31. In the power circuit unit 4, the first voltage substrate 41 and the second voltage substrate 42 are arranged on the side facing the driver unit 3, and extend in parallel with the driver substrate 31. In the present embodiment, the end of the fan 32 of the driver unit 3 in the Y1 direction extends to a position facing a part of the gap S3 between the driver unit 3 and the power circuit unit 4. Therefore, when the fan 32 is driven, air flows not only through the gaps S1 and S2 of the adjacent driver substrates 31, but also through the gap S3 between the driver unit 3 and the power circuit unit 4.

[0078] Since the three driver substrates 31 are all provided with heat sinks 33 fixed on the surfaces on the Y1 side, the airflow from the fan 32 cools the three heat sinks 33. In addition, the power circuit unit 4 has electronic components 43 constituting the power circuit mounted on the substrate surfaces of the first voltage substrate 41 and the second voltage substrate 42 on the driver unit 3 side (Y2 side), so the air from the fan 32 flows through the portion generating more heat.

[0079] like Fig.13 , Fig.16 As shown, a notch 403 is formed at the end of the power circuit unit 4 on the back panel 24 side (X2 side). As described above, the power circuit unit 4 is retracted toward the X1 side until a gap S is formed between it and the back panel 24 (see FIG. Figure 5 ) position, so that the notch portion 403 faces the gap S3 through which the air from the fan 32 passes. Fig.16 It can be seen that the notch 403 faces the heat dissipation component 519 of the main circuit unit 5. Fig.16 As shown by the arrow in , the airflow from the fan 32 flows toward the heat sink 519 via the notch 403. Therefore, the heat sink 519 is cooled.

[0080] like Figure 2 As shown in FIG. 1 , the housing 2 is provided with vents 23d and 23e on the front panel 23, and air is exhausted to the front side, but there is no vent in the central portion of the front panel 23 located on the X1 side of the power circuit unit 4. The three-dimensional model of this embodiment is used to perform fluid analysis, and the results confirm that when the fan 32 is driven, an airflow ( 23d, 23e ) is generated from the airflow along the power circuit unit 4 and returns to the main circuit unit 5 side via the output unit 7 and the interface unit 6. Figure 5 In addition, the flow velocity of the airflow in each part of the housing 2 was determined by fluid analysis, and it was confirmed that the air flows throughout the entire interior of the housing 2, and the difference in flow velocity due to different positions is small.

[0081] As a different arrangement from the present embodiment, a fluid analysis was also performed using a three-dimensional model for an arrangement in which the configurations of the driver unit 3 and the power circuit unit 4 were swapped. However, it was confirmed that in this case, compared with the present embodiment, it was difficult for air to bypass the power circuit unit 4 side, and the flow rate near the power circuit unit 4 became lower, making it impossible to cool effectively.

[0082] In addition, in the present embodiment, an air intake fan that draws air from the vent 24a into the housing 2 is used as the fan 32, but an exhaust fan that exhausts air from the vent 24a to the outside of the housing 2 may be used. Even if the airflow directions are opposite, the power supply circuit unit 4 and the heat dissipation component 519 of the main circuit unit 5 can be cooled by one fan 32.

[0083] (Main effects of this embodiment) As described above, the controller 1 of the present embodiment includes: a housing 2 having a housing body 2A opened on the Z2 side (one side) and a cover 2B detachable from the housing body 2A from the Z2 side; and a plurality of electric units 10 housed in the housing 2. The plurality of electric units 10 are components that are unitized by dividing the substrates and electronic components housed in the housing 2 into a plurality of groups and assembling them on different base members 11 for each group. The housing body 2A includes a bottom panel 21 that is a unit fixing surface facing the cover 2B. The plurality of electric units 10 are detachably fixed to the bottom panel 21 from the cover 2B side via the base member 11, and the fixing portions of the base member 11 with respect to the bottom panel 21 (in the present embodiment, the portions where the fixing holes 29a are provided) are arranged so as not to overlap with each other. The plurality of electrical units 10 include at least a portion of the following units: a driver unit 3 having a plurality of driver substrates 31 for generating a driving current for driving an actuator such as a motor; a main circuit unit 5 for generating a DC voltage from an AC voltage and providing it to the driver substrate 31; a power circuit unit 4 for generating a DC voltage having a voltage different from the DC voltage provided by the main circuit unit 5 from an AC voltage; an interface unit 6 having a substrate having a communication connector 65 arranged in a hole of the housing 2; an output unit 7 having a plurality of connector components including an external output connector 71 for outputting a driving current to the outside and an encoder connector 75 for inputting an encoder signal from a motor; and a power input unit 8 having a power input terminal block 81 for connecting a power supply line of an external AC power source and a noise filter 82 for inputting an AC current via the power input terminal block 81.

[0084] According to the present embodiment, the substrates and electronic components (including the components after the substrates and electronic components are modularized) stored in the housing 2 of the controller 1 are assembled on different base components 11 for each group and unitized. Then, all the electrical units 10 are fixed to the bottom panel 21 which is the same unit fixing surface set on the housing body 2A so that their fixing parts do not overlap each other. In this way, by unitizing the electronic components and the substrate in advance, they can be easily assembled into the housing 2. In addition, since the wiring between the electronic components installed on the common substrate can be set on the substrate, the wiring can be reduced and the number of substrates can be reduced. Moreover, by unitizing, the electronic components and the substrate can be concentrated, and there is no need to ensure the working space required for separate assembly, so space can be saved. In addition, since all the units are fixed on the same surface in a non-overlapping manner, there is no need to consider the order when assembling. Therefore, the assemblability can be improved. In addition, since all the units are fixed so as not to hinder the loading and unloading of other units, the unit containing the target electronic components and substrates can be taken out without removing other components during maintenance. Therefore, the workload can be reduced.

[0085] In the present embodiment, the plurality of electrical units 10 include all of the driver unit 3, the power circuit unit 4, the main circuit unit 5, the interface unit 6, the output unit 7, and the power input unit 8. Therefore, all the substrates and electronic components required for the controller 1 are unitized according to their functions, thereby improving the assemblability of the controller 1, reducing wiring and substrates, saving space, and reducing the maintenance load.

[0086] In this embodiment, the housing body 2A includes: a front panel 23 rising from one edge of the bottom panel 21; and a back panel 24 rising from the other edge of the bottom panel 21. The power input unit 8, the output unit 7, and the interface unit 6 are arranged in this order in the Y direction (first direction) along the front panel 23 inside the front panel 23. The driver unit 3, the power circuit unit 4, and the main circuit unit 5 are arranged in this order in the Y direction (first direction) inside the back panel 24. The driver unit 3 includes a fan 32, which is opposite to the vent 24a provided on the back panel 24 in the X direction (second direction) intersecting the Y direction (first direction). A plurality of driver substrates 31 are arranged parallel to the Y direction (first direction) on the side opposite to the vent 24a with respect to the fan 32. The power circuit unit 4 includes a first voltage substrate 41, which is arranged parallel to the driver substrate 31 at a position adjacent to the driver unit 3 in the Y direction (first direction). Thus, by placing the power circuit unit 4 in the center, it is easy to connect the power wiring of each unit, and the wiring length can be shortened. In addition, in such a configuration, the airflow from the fan 32 of the driver unit 3 is not easily blocked, and a part of it flows to the interface unit 6 and the main circuit unit 5 side through the gap S3 between the power circuit unit 4 and the driver unit 3, which has been confirmed by the airflow analysis using the three-dimensional model. Therefore, the inside of the controller 1 can be effectively cooled by a single fan 32.

[0087] In addition, the three electric units 10 (the power input unit 8 , the output unit 7 , and the interface unit 6 ) disposed inside the front panel 23 may be arranged in an order different from this order.

[0088] In the present embodiment, the driver unit 3 includes: a first base frame 30 as a base member 11; and a fan 32 fixed to the first base frame 30. The first base frame 30 holds a plurality of driver substrates 31 in a state of being arranged in parallel in a posture perpendicular to the bottom panel 21. The fan 32 is arranged between the vent 24a provided in the housing 2 and the plurality of driver substrates 31, and blows air in a direction orthogonal to the arrangement direction of the plurality of driver substrates 31. In this way, by including the fan 32 in the driver unit 3, the work of fixing the electrical components separately to the housing 2 is reduced, and the assemblability can be improved. In addition, the positional accuracy of the fan 32 relative to the driver substrate 31 can be improved.

[0089] In this embodiment, the first base frame 30 includes: a first base plate 301 along the bottom panel 21; a plurality of first substrate mounting plates 302 rising in parallel from the first base plate 301; and a frame top plate 303 fixed to the front ends of the plurality of first substrate mounting plates 302. The plurality of driver substrates 31 are respectively fixed to the first substrate mounting plates 302. The fan 32 is fixed to the edge of the first base plate 301 on the side of the vent 24a and the edge of the frame top plate 303 on the side of the vent 24a. With such a frame structure, the fan 32 can face the gap between the driver substrates 31.

[0090] In this embodiment, the driver unit 3 is provided with a connector 38 for connecting between units arranged at the edge of the first base plate 301. Therefore, by attaching and detaching the connector at one position, wiring between the circuits and electronic components of the driver unit 3 and other units can be performed in a centralized manner. Therefore, wiring can be centralized, and wiring work between units is easy.

[0091] In this embodiment, the power circuit unit 4 includes: a first voltage substrate 41 for generating a DC voltage of a first voltage (24V); a second voltage substrate 42 for generating a DC voltage of a second voltage (5V) different from the first voltage; and a first base member 40 as the base member 11. Thus, a plurality of power circuits for generating DC voltages of different voltages can be unitized. Therefore, it is not necessary to separately assemble each power circuit to the housing 2, so that the assemblability can be improved and the wiring can be centralized.

[0092] In this embodiment, the first base member 40 includes: a first fixing plate 402 along the bottom panel 21; and a first mounting plate 401 bent from the first fixing plate 402 in a direction perpendicular to the bottom panel 21 (Z2 direction). The first voltage substrate 41 and the second voltage substrate 42 are parallel to the first mounting plate 401 and fixed to the first mounting plate 401 from the same direction (Y2 direction) in a non-overlapping manner. As a result, the power circuit unit 4 becomes a thin and longitudinally long shape, and becomes a unit with a small plane size, so the installation space on the bottom panel 21 is small. Therefore, the plane size of the entire device can be reduced.

[0093] In the present embodiment, the main circuit unit 5 comprises: a first substrate 51, which is provided with a main circuit relay 510, a rectifier circuit for inputting an AC voltage via the main circuit relay 510, and pre-driver power supplies 513 and 514; a second substrate 52, which is provided with a plurality of main circuit capacitors 520 connected to the rectifier circuit; and a second base frame 50 as a base member 11. The second base frame 50 holds the first substrate 51 and the second substrate 52 in a stacked state. Thus, since the number of electronic components and substrates separately fixed to the housing 2 is reduced, the assemblability can be improved. In addition, since the electronic components mounted on the common substrate can be connected through the circuit pattern on the substrate, the wiring can be reduced, and the substrate can also be reduced. In addition, the wiring space can be reduced, and the working space for separate assembly is not required, so space saving can be achieved.

[0094] In the present embodiment, the first substrate 51 is provided with a main circuit relay 510, a rectifier circuit, and pre-driver power supplies 513 and 514 on the substrate surface opposite to the second substrate 52. The second substrate 52 is provided with a plurality of main circuit capacitors 520 on the substrate surface opposite to the first substrate 51. A metal spacer 55 is provided between the first substrate 51 and the second substrate 52. The spacer 55 is also used as a power wiring connecting the first substrate 51 and the second substrate 52. In this way, since no electronic components are arranged between the two substrates, the distance between the substrates can be reduced. In addition, since the surface where no electronic components are mounted has a portion protruding from the substrate surface such as the legs of the mounted components, it is necessary to be separated from other components. Therefore, by making the surface where no electronic components are mounted not facing outward but facing each other, a space-saving configuration can be achieved. Moreover, since there is no need to set the power wiring separately from the spacer 55, the wiring and terminal components can be reduced, and the substrate can be miniaturized.

[0095] In this embodiment, the main circuit unit 5 includes: a safety relay module 56 for emergency stopping the motor; and a third substrate 53 on which a signal relay 531 and a connector 532 for connecting to the signal relay 531 are mounted. The safety relay module 56 and the third substrate 53 are fixed to the second base frame 50. In this way, by including the safety relay module 56 and the third substrate 53 in the main circuit unit 5, the number of electronic components and substrates separately fixed to the housing 2 can be further reduced, so that the assemblability can be further improved. In addition, the wiring can be further reduced, and the space saving can be further achieved.

[0096] In the present embodiment, the main circuit unit 5 includes the regenerative resistor 57 fixed to the second base frame 50. Therefore, since the number of electronic components and substrates separately fixed to the housing 2 is further reduced, the assemblability can be further improved.

[0097] In the present embodiment, the first substrate 51 and the second substrate 52 are stacked in a posture parallel to the bottom panel 21 with the first substrate 51 located above. The second substrate 52 has a substrate end 52a that does not overlap with the first substrate 51. A power wiring connector 521 for connecting a power wiring for supplying a DC voltage to the driver substrate 31 is arranged on the substrate surface on the first substrate 51 side (Z2 side) of the substrate end 52a. A heat sink 519 is fixed to the edge on the substrate end 52a side of the first substrate 51. A diode bridge 515 of a rectifier circuit is fixed to the heat sink 519. Thus, by arranging the power wiring connector 521 facing upward at the substrate end, the workability when connecting the power wiring between the main circuit unit 5 and the driver substrate 31 is improved. In addition, by arranging the power wiring connector 521 and the heat sink 519 on the same side, it is easy to arrange them simultaneously on the driver substrate 31 side. Therefore, it is easy to shorten the wiring length of the power wiring, and the airflow from the fan 32 provided on the driver unit 3 easily reaches the heat sink 519. Therefore, the heat sink 519 can be easily cooled.

[0098] In this embodiment, the housing 2 includes a front panel 23, the interface unit 6 includes a second base member 60 as a base member 11, and includes a first communication substrate 61, a second communication substrate 62, a third communication substrate 63, and a control circuit substrate 64 on which a communication connector 65 is mounted as substrates. The three communication substrates and the control circuit substrate 64 are fixed to the second base member 60 in a stacked state with a spacer 55 interposed therebetween, and are arranged on the inner side of the front panel 23. In this way, by concentrating the control circuit substrate 64 and the communication substrate in one unit, the assemblability can be improved compared to fixing each substrate separately to the housing 2. In addition, it is easy to remove the control circuit substrate 64 on the lower side from the housing 2.

[0099] In this embodiment, the housing 2 includes a front panel 23. The output unit 7 includes a third base member 70 as a base member 11. The third base member 70 includes: a third fixing plate 702 along the bottom panel 21; and a connector mounting plate 701 bent from the third fixing plate 702 and along the inner side of the front panel 23. A plurality of connector components are respectively fixed to the connector mounting plate 701 and arranged in the opening 23b of the front panel 23. In this way, by concentrating the connector components in one unit, the assemblability can be improved compared with the case where each connector component is separately fixed to the housing 2.

[0100] In the present embodiment, the plurality of connector components include the monitoring signal connector 72 for outputting the monitoring signal to the outside, and therefore the number of connector components that are separately fixed to the housing 2 is further reduced. Therefore, the assemblability can be further improved.

[0101] In the present embodiment, the housing 2 includes a front panel 23. The power input unit 8 includes a fourth base member 80 as a base member 11. The fourth base member 80 includes: a fourth fixing plate 802 along the bottom panel 21; and a fourth mounting plate 801 bent from the fourth fixing plate 802. The power input terminal block 81 is fixed to the fourth fixing plate 802, and the noise filter 82 is fixed to the fourth mounting plate 801. In this way, by unitizing the components of the power input part, the assemblability can be improved. In addition, since the noise filter 82 is fixed to the fourth mounting plate 801 rising from the bottom panel 21, the plane size of the power input unit 8 is small, and the installation space on the bottom panel 21 is small. Therefore, the plane size of the entire device can be reduced.

[0102] (Other embodiments) The present invention may take the following forms. (1) A controller having a housing and a plurality of electrical units, The housing includes a housing body opened at one side and a cover detachable from the housing body from the one side, and the plurality of electric units are accommodated in the housing. The plurality of electrical units are formed by dividing the substrate and the electronic components housed in the housing into a plurality of groups and assembling each group on a different base member. The housing body includes a unit fixing surface facing the cover, The plurality of electric units are respectively fixed to the unit fixing surface via the base member from the cover side in a detachable manner, and the fixing portions of the base member with respect to the unit fixing surface are arranged so as not to overlap each other. The plurality of electrical units include at least a portion of a driver unit, a main circuit unit, a power circuit unit, an interface unit, an output unit, and a power input unit, The driver unit includes a plurality of driver substrates for generating a drive current for driving the actuator. The main circuit unit generates a DC voltage from an AC voltage and supplies the DC voltage to the driver substrate. The power supply circuit unit generates a DC voltage having a voltage different from the DC voltage provided by the main circuit unit from the AC voltage, The interface unit includes a substrate provided with a communication connector, wherein the communication connector is arranged in a hole of the housing. The output unit includes a plurality of connector components, the plurality of connector components including an external output connector for outputting the drive current to the outside and an encoder connector for inputting an encoder signal from the actuator. The power input unit includes a terminal block to which a power supply line of an external AC power source is connected, and a noise filter that inputs an AC current through the terminal block.

[0103] (2) In the controller of (1) above, The plurality of electrical units include all of the driver unit, the power circuit unit, the main circuit unit, the interface unit, the output unit, and the power input unit.

[0104] (3) In the controller of (1) or (2) above, The housing body comprises: a front panel rising from one edge of the unit fixing surface; and a back panel rising from the other edge of the unit fixing surface. The power input unit, the output unit and the interface unit are arranged on the inner side of the front panel in a first direction along the front panel, The driver unit, the power circuit unit, and the main circuit unit are arranged in this order in the first direction on the inner side of the back panel, The driver unit includes a fan, the fan is opposite to the vent provided on the back panel in a second direction intersecting the first direction, and the plurality of driver substrates are arranged in parallel with the first direction on a side of the fan opposite to the vent. The power circuit unit includes a first voltage substrate disposed in parallel with the driver substrate at a position adjacent to the driver unit in the first direction.

[0105] (4) In the controller described in any one of (1) to (3) above, The driver unit includes: a first base frame as the base member; and a fan fixed to the first base frame. The first base frame holds the plurality of driver substrates in a state of being arranged in parallel in a posture perpendicular to the unit fixing surface. The fan is disposed between a vent provided in the housing and the plurality of drive substrates, and blows air in a direction perpendicular to an arrangement direction of the plurality of drive substrates.

[0106] (5) In the controller of (4) above, The first base frame comprises: a first base plate along the unit fixing surface; a plurality of first substrate mounting plates rising in parallel from the first base plate; and a frame top plate fixed to the front ends of the plurality of first substrate mounting plates. The plurality of driver substrates are respectively fixed to the first substrate mounting plate, The fan is fixed to an edge of the first base plate on the air vent side and an edge of the frame top plate on the air vent side.

[0107] (6) In the controller of (5) above, The driver unit includes an inter-unit connection connector disposed on an edge of the first base plate.

[0108] (7) In the controller described in any one of (1) to (6) above, The power circuit unit includes: a first voltage substrate that generates a DC voltage of a first voltage; a second voltage substrate that generates a DC voltage of a second voltage different from the first voltage; and a first base member as the base member.

[0109] (8) In the controller of (7) above, The first base member includes: a first fixing plate along the unit fixing surface; and a first mounting plate bent from the first fixing plate in a direction perpendicular to the unit fixing surface. The first voltage substrate and the second voltage substrate are fixed to the first mounting plate from the same direction in a posture parallel to the first mounting plate so as not to overlap.

[0110] (9) In the controller described in any one of (1) to (8) above, The main circuit unit comprises: A first substrate configured with a main circuit relay, a rectifier circuit inputting an AC voltage via the main circuit relay, and a pre-driver power supply; a second substrate provided with a plurality of main circuit capacitors connected to the rectifying circuit; and A second base frame as the base member, The second base frame holds the first substrate and the second substrate in a stacked state.

[0111] (10) In the controller of (9) above, The first substrate has the main circuit relay, the rectifier circuit, and the pre-driver power supply arranged on a substrate surface opposite to the second substrate. The second substrate has the plurality of main circuit capacitors arranged on a substrate surface opposite to the first substrate. A metal spacer is provided, which is interposed between the first substrate and the second substrate, The spacer also functions as a power wiring connecting the first substrate and the second substrate.

[0112] (11) In the controller of (9) or (10) above, The main circuit unit includes: a safety relay module for emergency stopping the actuator; and a third substrate on which a signal relay and a connector for connecting to the signal relay are mounted. The safety relay module and the third substrate are fixed on the second base frame.

[0113] (12) In the controller described in any one of (9) to (11) above, The main circuit unit includes a regenerative resistor fixed to the second base frame.

[0114] (13) In the controller described in any one of (9) to (12) above, The first substrate and the second substrate are stacked in a posture parallel to the unit fixing surface with the first substrate on top. The second substrate has a substrate end portion that does not overlap with the first substrate, and a power wiring connector for connecting a power wiring that supplies a DC voltage to the driver substrate is arranged on a substrate surface on the first substrate side of the substrate end portion. A heat dissipation member is fixed to an edge of the first substrate on the substrate end side, and a diode bridge of the rectifier circuit is fixed to the heat dissipation member.

[0115] (14) In the controller described in any one of (1) to (13) above, The housing includes a front panel. The interface unit has a second base member as the base member, and has a communication substrate on which the communication connector is mounted and a control circuit substrate as the substrate. The communication board and the control circuit board are fixed to the second base member in a stacked state with a spacer interposed therebetween, and are arranged inside the front panel.

[0116] (15) In the controller described in any one of (1) to (14) above, The housing includes a front panel. The output unit includes a third base member as the base member, the third base member including: a third fixing plate along the unit fixing surface; and a connector mounting plate bent from the third fixing plate and along the inner side surface of the front panel, The plurality of connector components are respectively fixed to the connector mounting plate and arranged in the opening of the front panel.

[0117] (16) In the controller of (15) above, The plurality of connector components include a monitoring signal connector for outputting a monitoring signal to the outside.

[0118] (17) In the controller of any one of (1) to (16) above, The housing includes a front panel. The power input unit includes a fourth base member as the base member, the fourth base member including: a fourth fixing plate along the unit fixing surface; and a fourth mounting plate bent from the fourth fixing plate. The terminal block is fixed to the fourth fixing plate, The noise filter is fixed on the fourth mounting plate. Explanation of symbols

[0119] 1…controller, 2…housing, 2A…housing body, 2B…cover, 3…driver unit, 3A…driver substrate unit, 4…power circuit unit, 5…main circuit unit, 6…interface unit, 7…output unit, 8…power input unit, 10…electrical unit, 11…base member, 12…power distribution cable, 21…bottom panel, 22…top panel, 23…front panel, 23a, 23b, 23c…opening, 23d, 23e…vent, 24…back panel, 24a…vent, 25, 26, 27, 28…side panels, 27a, 28a…stepped portion, 29…boss portion, 29a…fixing hole, 30…first base frame, 3 1…Driver board, 32…Fan, 33…Heat sink, 34…Electronic component, 35…Connector, 36…Wiring board, 37…Connector, 38…Connector for connecting between units, 40…First base member, 41…First voltage board, 42…Second voltage board, 43…Electronic component, 50…Second base frame, 51…First board, 52…Second board, 52a…Board end, 53…Third board, 54, 55…Spacer, 56…Safety relay module, 57…Regenerative resistor, 60…Second base member, 61…First communication board, 62…Second communication board, 63…Third communication board, 64…Control circuit board, 65…Communication connection , 66...Connector for connecting between units, 70...Third base component, 70a...Opening portion, 71...External output connector, 72...Monitoring signal connector, 73, 74...Emergency stop connector, 75...Encoder connector, 76...Circuit breaker, 80...Fourth base component, 81...Power input terminal block, 82...Noise filter, 83...Grounding plate, 301...First base plate, 302...First substrate mounting plate, 303...Frame top plate, 304...Opening portion, 401...First mounting plate, 402...First fixing plate, 403...Notch portion, 404...Opening portion, 405...Spacer, 501...Second base plate, 502...Second substrate mounting plate, 5 03…connecting plate, 504…arm, 505…opening, 510…main circuit relay, 511…anti-shock resistor, 512…anti-shock relay, 513…pre-driver power supply, 514…brake power supply, 515…diode bridge, 516, 517, 518…connector, 519…heat dissipation component, 520…main circuit capacitor, 521…connector for power wiring, 522…LED lamp, 531…signal relay, 532…connector, 601…plate, 602…boss fixing portion, 701…connector mounting plate, 702…third fixing plate, 801…fourth mounting plate, 802…fourth fixing plate, S, S1, S2, S3…gap.

Claims

1. A controller, characterized in that: A housing and a plurality of electric units are provided, wherein the housing includes a housing body opened at one side and a cover that is detachable from the housing body from the one side, and the plurality of electric units are accommodated in the housing. The plurality of electrical units are formed by dividing the substrate and the electronic components housed in the housing into a plurality of groups and assembling each group on a different base member. The housing body includes a unit fixing surface facing the cover, The plurality of electric units are detachably fixed to the unit fixing surface via the base member from the cover side, and are arranged so that the fixing portions of the base member to the unit fixing surface do not overlap with each other. The plurality of electrical units include at least a portion of a driver unit, a main circuit unit, a power circuit unit, an interface unit, an output unit, and a power input unit, The driver unit includes a plurality of driver substrates for generating a drive current for driving the actuator. The main circuit unit generates a DC voltage from an AC voltage and supplies the DC voltage to the driver substrate. The power supply circuit unit generates a DC voltage having a voltage different from the DC voltage provided by the main circuit unit from the AC voltage, The interface unit includes a substrate provided with a communication connector, wherein the communication connector is arranged in a hole of the housing. The output unit includes a plurality of connector components, the plurality of connector components including an external output connector for outputting the drive current to the outside and an encoder connector for inputting an encoder signal from the actuator. The power input unit includes a terminal block to which a power supply line of an external AC power source is connected, and a noise filter that inputs an AC current through the terminal block.

2. The controller according to claim 1, characterized in that: The plurality of electrical units include all of the driver unit, the power circuit unit, the main circuit unit, the interface unit, the output unit, and the power input unit.

3. The controller according to claim 2, characterized in that: The housing body comprises: a front panel rising from one edge of the unit fixing surface; and a back panel rising from the other edge of the unit fixing surface. The power input unit, the output unit and the interface unit are arranged on the inner side of the front panel in a first direction along the front panel, The driver unit, the power circuit unit, and the main circuit unit are arranged in this order in the first direction on the inner side of the back panel, The driver unit includes a fan, the fan is opposite to the vent provided on the back panel in a second direction intersecting the first direction, and the plurality of driver substrates are arranged in parallel with the first direction on a side of the fan opposite to the vent. The power circuit unit includes a first voltage substrate disposed in parallel with the driver substrate at a position adjacent to the driver unit in the first direction.

4. The controller according to any one of claims 1 to 3, characterized in that: The driver unit includes: a first base frame as the base member; and a fan fixed to the first base frame. The first base frame holds the plurality of driver substrates in a state of being arranged in parallel in a posture perpendicular to the unit fixing surface. The fan is disposed between a vent provided in the housing and the plurality of driver boards, and blows air in a direction perpendicular to an arrangement direction of the plurality of driver boards.

5. The controller according to claim 4, characterized in that: The first base frame comprises: a first base plate along the unit fixing surface; a plurality of first substrate mounting plates rising in parallel from the first base plate; and a frame top plate fixed to the front ends of the plurality of first substrate mounting plates. The plurality of driver substrates are respectively fixed to the first substrate mounting plate, The fan is fixed to an edge of the first base plate on the air vent side and an edge of the frame top plate on the air vent side.

6. The controller according to claim 5, characterized in that: The driver unit includes an inter-unit connection connector disposed on an edge of the first base plate.

7. The controller according to any one of claims 1 to 3, characterized in that: The power circuit unit includes: a first voltage substrate that generates a DC voltage of a first voltage; a second voltage substrate that generates a DC voltage of a second voltage different from the first voltage; and a first base member as the base member.

8. The controller according to claim 7, characterized in that: The first base member includes: a first fixing plate along the unit fixing surface; and a first mounting plate bent from the first fixing plate in a direction perpendicular to the unit fixing surface. The first voltage substrate and the second voltage substrate are fixed to the first mounting plate from the same direction in a posture parallel to the first mounting plate so as not to overlap.

9. The controller according to any one of claims 1 to 3, characterized in that: The main circuit unit comprises: a first substrate provided with a main circuit relay, a rectifier circuit for inputting an AC voltage via the main circuit relay, and a pre-driver power supply; a second substrate provided with a plurality of main circuit capacitors connected to the rectifier circuit; as well as a second base frame, the second base frame serving as the base member, The second base frame holds the first substrate and the second substrate in a stacked state.

10. The controller according to claim 9, characterized in that: The main circuit relay, the rectifier circuit, and the pre-driver power supply are arranged on a substrate surface of the first substrate opposite to the second substrate. The second substrate has the plurality of main circuit capacitors arranged on a substrate surface opposite to the first substrate. A metal spacer is provided, the spacer being interposed between the first substrate and the second substrate, The spacer also serves as a power wiring connecting the first substrate and the second substrate.

11. The controller according to claim 9, characterized in that: The main circuit unit includes: a safety relay module for emergency stopping the actuator; and a third substrate on which a signal relay and a connector for connecting to the signal relay are mounted. The safety relay module and the third substrate are fixed to the second base frame.

12. The controller according to claim 9, characterized in that: The main circuit unit includes a regenerative resistor fixed to the second base frame.

13. The controller according to claim 9, characterized in that: The first substrate and the second substrate are stacked in a posture parallel to the unit fixing surface with the first substrate on top. The second substrate has a substrate end portion that does not overlap with the first substrate, and a power wiring connector for connecting a power wiring that supplies a DC voltage to the driver substrate is arranged on a substrate surface on the first substrate side of the substrate end portion. A heat dissipation member is fixed to an edge of the first substrate on the substrate end side, and a diode bridge of the rectifier circuit is fixed to the heat dissipation member.

14. The controller according to any one of claims 1 to 3, characterized in that: The housing includes a front panel. The interface unit has a second base member as the base member, and has a communication substrate on which the communication connector is mounted and a control circuit substrate as the substrate. The communication board and the control circuit board are fixed to the second base member in a stacked state with a spacer interposed therebetween, and are arranged inside the front panel.

15. The controller according to any one of claims 1 to 3, characterized in that: The housing includes a front panel. The output unit includes a third base member as the base member, the third base member including: a third fixing plate along the unit fixing surface; and a connector mounting plate bent from the third fixing plate and along the inner side surface of the front panel, The plurality of connector components are respectively fixed to the connector mounting plate and arranged in the opening of the front panel.

16. The controller according to claim 15, characterized in that The plurality of connector components include monitoring signal connectors for outputting monitoring signals to the outside.

17. The controller according to any one of claims 1 to 3, characterized in that: The housing includes a front panel. The power input unit includes a fourth base member as the base member, the fourth base member including: a fourth fixing plate along the unit fixing surface; and a fourth mounting plate bent from the fourth fixing plate. The terminal block is fixed to the fourth fixing plate, The noise filter is fixed to the fourth mounting plate.

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