Integrated motor control device

Abstract

The utility model discloses an integrated motor control device, which comprises a main controller, a driving controller in electric signal communication with the main controller, a DI / DO terminal connection module in electric signal communication with the main controller, and a motor control output interface in electric signal connection with the driving controller, the main controller, the driving controllers and the DI / DO terminal connecting module are all arranged on a circuit board in an integrated mode, the number of the driving controllers corresponds to that of the motor control output interfaces, the number of the driving controllers is at least two, and the DI / DO terminal connecting module comprises a plurality of wiring terminal sets. According to the utility model, the connection convenience of all wire harnesses outside the integrated motor controller is improved, and multi-shaft motor or servo drive control is realized.

Description

[Technical Field]

[0001] This utility model belongs to the field of motor control technology, and in particular relates to an integrated motor control device. [Background Technology]

[0002] In the field of automated manufacturing, automated production equipment is indispensable. Among these, motors are essential and frequently used power sources for automated operation. For example, in photovoltaic module production equipment, automated conveyor lines are used to automatically transport the modules. Each independently controlled conveyor line has multiple motors, which require controllers and drivers for operation. Therefore, on existing photovoltaic module conveyor lines, each independently controlled conveyor line frame or side frame has at least one control cabinet. Inside typical motor control cabinets, each component is installed individually, and the connections between them must be made one by one. Generally, the motor control circuit draws single-phase power (one live and one neutral) from the main circuit, adding selector switches, buttons, indicator lights, relays, auxiliary contacts, terminals, cables, etc., to form a secondary circuit, i.e., the control circuit. Its wiring and installation are quite complex.

[0003] To improve wiring and installation efficiency, some integrated motor controllers are disclosed in the prior art. For example, patent CN219446912U discloses a control device, drive control system, and operating machinery. The device includes a first circuit board and a second circuit board. The first circuit board integrates a main controller, a first motor controller, and a second motor controller, while the second circuit board integrates a drive controller. The first and second circuit boards are electrically connected via wiring harnesses, reducing wiring work and improving hardware integration. However, in order to monitor position information in the conveyor line, several sensors are also installed. The conveyor line needs to cooperate with the sensor's sensing signals for start-stop control. Therefore, the motor controller also needs to connect multiple digital signal acquisition devices, such as photoelectric sensors, relays, and proximity switches. Wiring these harnesses still consumes a lot of time and effort for installers, and the control device described in the aforementioned patent does not consider the ease of installation of peripheral wiring harnesses.

[0004] Therefore, it is necessary to provide a new integrated motor control device to solve the above-mentioned technical problems. [Utility Model Content]

[0005] The main purpose of this utility model is to provide an integrated motor control device that improves the ease of connecting all external wiring harnesses of the integrated motor controller and realizes multi-axis motor or servo drive control.

[0006] This utility model achieves the above-mentioned objective through the following technical solution: an integrated motor control device, comprising a main controller and a drive controller electrically connected to the main controller, further comprising a DI / DO terminal connection module electrically connected to the main controller and a motor control output interface electrically connected to the drive controller, wherein the main controller, the drive controller and the DI / DO terminal connection module are all integrated on a circuit board, the number of the drive controller and the number of the motor control output interface correspond to each other and are at least two, and the DI / DO terminal connection module comprises a plurality of terminal blocks.

[0007] Furthermore, the motor control output interface is one or more combinations of a servo motor control output interface, a stepper motor control output interface, or a general motor control output interface.

[0008] Furthermore, the terminal block assembly includes several first terminal blocks, each first terminal block including a first power supply terminal, a second power supply terminal, and a signal terminal. The first power supply terminal supplies DC 0V voltage, and the second power supply terminal supplies DC 10-30V voltage.

[0009] Furthermore, the terminal block assembly includes several second terminal blocks, each of which includes a third power supply terminal and a signal terminal. The third power supply terminal supplies 0V or 10-30V voltage.

[0010] Furthermore, the terminal block assembly is a pluggable terminal connector.

[0011] Furthermore, the terminal block is electrically connected to one or more of the following: a photoelectric sensor, a proximity switch sensor, a relay, a reed sensor, a button, or a servo encoder.

[0012] Furthermore, the circuit board includes a first circuit board and a second circuit board, with the first circuit board disposed above the second circuit board; wherein, the main controller and the DI / DO terminal connection module are integrated on the first circuit board, and the drive controller is integrated on the second circuit board.

[0013] Furthermore, the first circuit board is provided with a communication interface that is connected to the main controller via electrical signals, and the communication interface is connected to the PLC control device via a communication line; the second circuit board is provided with a power input interface that supplies power to the main controller and the drive controller, and the power input interface is electrically connected to the power supply protection module via a power line.

[0014] Furthermore, the motor control output interface is disposed on the second circuit board; the communication interface is disposed near the lower edge of the first circuit board, and the motor control output interface and the power input interface are disposed near the lower edge of the second circuit board.

[0015] Furthermore, the power supply protection module and the circuit board are housed in the same housing.

[0016] Furthermore, it also includes a housing that encloses the circuit board, the horizontal cross-section of the housing being rectangular; both the second circuit board and the first circuit board are L-shaped structures, and the L-shaped circuit board is installed inside the rectangular housing, forming a wire harness entry and exit space between the L-shaped circuit board and the housing.

[0017] Furthermore, the external wiring harness enters the wiring harness entry / exit space from the back or bottom of the housing.

[0018] Furthermore, both the first circuit board and the second circuit board include a first extension plate and a second extension plate located in the same horizontal plane and perpendicular to each other; the first extension plate extends in a front-to-back direction, and the second extension plate extends from the left edge of the first extension plate to the left; the DI / DO terminal connection module is disposed on the second extension plate; the length of the second extension plate of the first circuit board is less than the length of the second extension plate of the second circuit board, so that there is an extended area in the space above the second circuit board that is not covered by the first circuit board.

[0019] Furthermore, an expansion circuit board can be selectively installed on the expansion area as needed. The expansion circuit board integrates the DI / DO terminal connection module. A female adapter that is electrically connected to the main controller is provided on the second extension surface of the first circuit board. A male adapter that is plugged into the female adapter to achieve electrical connection is provided on the expansion circuit board.

[0020] Compared with existing technologies, the advantages of this integrated motor control device are as follows: The main controller and motor drive controller are integrated on a circuit board, realizing an integrated control device design. A centralized DI / DO terminal connection module is designed on the integrated circuit board, using this module to handle the connection of all external digital signal harnesses, enabling digital signal input and output and improving the convenience of harness wiring operations. The DI / DO terminal connection module uses a plug-in terminal block structure, further enhancing the convenience of harness connection. The circuit board employs a two-board design, with the main controller and DI / DO terminal connection module integrated on the upper first circuit board, controlling the motor drive. The device is integrated on the lower second circuit board, thereby reducing the overall planar size of the control device. The DI / DO terminal connection module is located in the second extension area of ​​the first circuit board, and the motor control output interface and power input interface are also located on the lower edge of the second extension area of ​​the second circuit board. The first and second circuit boards are designed in an L-shape, so that the circuit boards form a notch in the horizontal plane. This notch forms a space for the wire harness to enter and exit, so that all incoming or outgoing wire harnesses can pass through the notch from the back of the housing to the front of the circuit board and be connected to the corresponding terminal group, motor control output interface and power input interface. This provides sufficient space for wiring operations and improves the neatness of the wire harness inside the control device. [Attached Image Description]

[0021] Figure 1 This is a schematic diagram of the frame structure of an embodiment of the present utility model;

[0022] Figure 2 This is a schematic diagram of the frame structure of the drive controller in an embodiment of this utility model;

[0023] Figure 3 This is a schematic diagram of the structure of an embodiment of the present utility model;

[0024] Figure 4 This is a schematic diagram of the structure of an embodiment of the present invention with an expansion circuit board;

[0025] The numbers in the image represent:

[0026] 100 - Integrated motor control device; 20 - Motor; 30 - Power supply protection module; 40 - PLC control device;

[0027] 1-Main controller; 2-Drive controller; 21-Rectifier module; 22-Bus electrolytic capacitor module; 23-Switching power supply module; 24-Control circuit module; 25-Inverter module; 3-DI / DO terminal connection module; 4-Circuit board; 41-First circuit board; 411-First extension board; 412-Second extension board; 42-Second circuit board; 43-Wire harness entry / exit space; 44-Extension area; 45-Extension circuit board; 46-Adaptor female connector; 47-Adaptor male connector; 5-Communication interface; 6-Motor control output interface; 7-Power input interface; 8-Program download and debugging interface; 9-Display module; 10-Third circuit board.

Detailed Implementation Methods

[0028] Example 1:

[0029] Please refer to Figures 1-4 This embodiment is an integrated motor control device 100, which includes a main controller 1, a plurality of drive controllers 2 that are electrically connected to the main controller 1, and a DI / DO terminal connection module 3 that is electrically connected to the main controller 1. The main controller 1, drive controllers 2 and DI / DO terminal connection module 3 are all integrated on a circuit board 4.

[0030] The circuit board 4 is provided with a communication interface 5 that is connected to the main controller 1 via electrical signals. The communication interface 5 is connected to the PLC control device 40 via a communication line.

[0031] The circuit board 4 is also provided with a motor control output interface 6 electrically connected to the drive controller 2. In this embodiment, the number of drive controllers 2 and motor control output interfaces 6 corresponds, and at least two are provided. The motor control output interface 6 is electrically connected to the controlled motor 20 via a power line. The motor control output interface 6 is one or both of a three-phase power output interface and a single-phase power output interface; or it is one or a combination of a servo motor control output interface, a stepper motor control output interface, or a general motor control output interface. The motor 20 includes motors, servo motors, stepper motors, etc. By setting multiple drive controllers 2 and cooperating with multiple types of motor control output interfaces 6, multi-axis control and control of different types of motors can be realized.

[0032] The circuit board 4 is also provided with a power input interface 7 that supplies power to the main controller 1 and the drive controller 2. The power input interface 7 is electrically connected to the power supply protection module 30 through a power cord. The power supply protection module 30 converts the mains power into a stable DC / AC voltage and then inputs it into the integrated motor control device 100.

[0033] The DI / DO terminal connection module 3 is equipped with several terminal blocks, which are pluggable terminal connectors. Single-layer or double-layer pluggable terminals can also be configured as needed. In this embodiment, the integrated motor control device 100 is used for the drive control of the motor on the conveyor line. The control of the conveyor line also requires the use of components such as photoelectric sensors, proximity switch sensors, relays, reed sensors, buttons, or servo encoders. These components need to be installed at designated locations outside the circuit board. Therefore, wiring harnesses are needed to connect these components to the PLC control device 40 to obtain digital signals for program control. To improve the ease of wiring these components, this embodiment provides a centrally distributed DI / DO terminal connection module 3 on the circuit board 4. The terminal blocks in the DI / DO terminal connection module 3 enable the acquisition of digital signals or the output of control signals from various external components.

[0034] In addition, to improve convenience when wiring or disconnecting the above-mentioned components, this embodiment has optimized the design of the terminal block group. The terminal block group is used to realize quick plugging and unplugging of individual components. That is, the two or three wires from a single component are directly integrated into a single connector, and then the connector is inserted into the same terminal block group. When a fault occurs and it needs to be removed, the connector can be directly pulled out from the terminal block group without having to pull out each wire one by one, saving time.

[0035] In this embodiment, the terminal block assembly includes a first terminal block assembly, which includes a first power supply terminal, a second power supply terminal, and a signal terminal. The first power supply terminal supplies DC 0V, and the second power supply terminal supplies DC 10-30V, for example, DC 10V, 12V, 24V, or 30V. For example, a photoelectric sensor has three lead wires, the free ends of which are integrated into a connector. This connector is then plugged into the first terminal block assembly, where two power supply wires are electrically connected to the first and second power supply terminals, and the other signal wire is electrically connected to the signal terminal. If the component has only two lead wires, such as a servo encoder, one power supply wire can be electrically connected to either the first or second power supply terminal according to the required voltage value, and the other signal wire can be electrically connected to the signal terminal.

[0036] The terminal block assembly further includes a second terminal block assembly, which includes a third power supply terminal and a signal terminal. The third power supply terminal supplies 0V or 10-30V voltage, for example, 0V, 10V, 12V, 24V, or 30V. For example, in a servo encoder, one power supply harness is electrically connected to the third power supply terminal, and the other signal harness is electrically connected to the signal terminal.

[0037] The terminal block assembly can be designed entirely as the first terminal block assembly, or it can include both the first terminal block assembly and the second terminal block assembly.

[0038] To reduce the overall size of the control device, two circuit boards 4 are designed: a first circuit board 41 and a second circuit board 42. The first circuit board 41 is positioned above the second circuit board 42, making full use of the height space and thus reducing the planar size of the control device. The main controller 1 and the DI / DO terminal connection module 3 are integrated on the first circuit board 41, while the drive controller 2 is integrated on the second circuit board 42. The communication interface 5 is located on the first circuit board 41, near its lower edge. The motor control output interface 6 and the power input interface 7 are located on the second circuit board 42, near its lower edge.

[0039] In this embodiment, while ensuring convenient wiring, the planar area occupied by the first circuit board 41 and the second circuit board 42 is minimized as much as possible. The shapes of the first circuit board 41 and the second circuit board 42 are optimized in this embodiment. Specifically, this embodiment also includes a housing (not shown in the figure) enclosing the circuit board 4, the horizontal cross-section of which is rectangular. Both the second circuit board 42 and the first circuit board 41 have an L-shaped structure and each includes a first extension plate surface 411 and a second extension plate surface 412 located in the same horizontal plane and perpendicular to each other. The first extension plate 411 extends in a front-to-back direction, and the second extension plate 412 extends to the left from the left edge of the first extension plate 411. The DI / DO terminal connection module 3, the motor control output interface 6, and the power input interface 7 are all disposed on the corresponding second extension plate 412. The L-shaped circuit board 4 is installed inside the rectangular housing, forming a wire harness entry / exit space 43 between it and the housing, so that the wire harness enters the housing from the back and then passes through the wire harness entry / exit space 43 to be plugged into the DI / DO terminal connection module 3, the motor control output interface 6, or the power input interface 7. The power supply protection module 30 can be disposed independently outside the housing or disposed together with the circuit board 4 inside the housing.

[0040] The first circuit board 41 is also provided with a program download and debugging interface 8, which is used to load computer control programs or debug control devices.

[0041] In this embodiment, the length of the second extension surface 412 of the first circuit board 41 is less than the length of the second extension surface 412 of the second circuit board 42, resulting in an extended area 44 in the space above the second circuit board 42 that is not covered by the first circuit board 41. An extended circuit board 45 can be installed in the extended area 44 as needed. The extended circuit board 45 integrates a DI / DO terminal connection module 3. The second extension surface 412 of the first circuit board 41 is provided with an adapter female connector 46 that is electrically connected to the main controller 1. The extended circuit board 45 is provided with an adapter male connector 47 that is plugged into the adapter female connector to achieve electrical connection. Electrical connection between the extended circuit board 45 and the main controller 1 is achieved by plugging the adapter male connector 47 into the adapter female connector 46.

[0042] This embodiment also includes a display module 9, which is independently integrated on a third circuit board 10. The third circuit board 10 is located above the first circuit board 41, specifically above the first extension surface 411 of the first circuit board 41. The display module 9, located above the third circuit board 10, is mainly used by the user to set control parameters. By placing the display module 9 and the third circuit board 10 above the first circuit board 41, the height space of the housing is further effectively utilized, reducing the overall planar area of ​​the control device.

[0043] The drive controller 2 includes a rectifier module 21, a bus electrolytic capacitor module 22, a switching power supply module 23, a control circuit module 24, and an inverter module 25.

[0044] The 220V AC mains input is rectified by the rectifier module 21 and then enters the bus electrolytic capacitor module 22. After that, it is output to the motor 20 by the inverter module 25. The switching power supply module 23 draws power from both ends of the bus electrolytic capacitor module 22 and converts it into drive and control power. The control chip in the control circuit module outputs relevant control signals according to the instructions given by the main controller 1 to control the motor output frequency, voltage, etc., and to perform some protection.

[0045] The working principle of the integrated motor control device 100 in this embodiment is as follows: The power supply protection module 30 inputs a stable DC / AC voltage to the power input interface 7 to power the entire control device; the main controller 1 connects to the communication interface 5 at one end and to the PLC control device 40 at the other end via a communication line to achieve communication with the PLC control device; the DI / DO terminal connection module 3 collects external digital signals and outputs digital control signals through a wiring harness; the drive controller 2 connects to the motor control output interface 6 at one end via a three-phase power line and to the controlled motor 20 at the other end to achieve electrical signal connection with the motor 20; the main controller 1 feeds back the digital signals collected by the DI / DO terminal connection module 3 to the PLC control device 40, the PLC control device 40 runs the control program and issues control commands to the main controller 1, the main controller 1 then outputs control commands to the drive controller 2, and the drive controller 2 controls the motor 20's speed, direction, start or stop actions or parameters according to the received control signals.

[0046] In this embodiment, the integrated motor control device 100 only requires connecting the power supply line to the power input interface 7, the three-phase power supply line of the motor 20 to the motor control output interface 6, the communication line to the communication interface 5, and the external digital signal acquisition harness to the corresponding terminal group of the DI / DO terminal connection module 3 during installation. The number of harness connections is small, and all connections are made by plugging in, which is convenient, time-saving, and labor-saving. The connections of the harness are concentrated in the area of ​​the DI / DO terminal connection module 3, making the entire control device neat and easy to wire. It can also be expanded according to needs, making it highly adaptable.

[0047] For those skilled in the art, various modifications and improvements can be made without departing from the inventive concept of this utility model, and these all fall within the protection scope of this utility model.

Claims

1. An integrated motor control device, comprising a main controller and a drive controller electrically connected to the main controller, characterized in that: It also includes a DI / DO terminal connection module that is electrically connected to the main controller and a motor control output interface that is electrically connected to the drive controller. The main controller, the drive controller and the DI / DO terminal connection module are all integrated on the circuit board. The number of the drive controller and the number of the motor control output interfaces correspond to each other and are set to at least two. The DI / DO terminal connection module includes several terminal blocks.

2. The integrated motor control device as described in claim 1, characterized in that: The motor control output interface is one or more combinations of a servo motor control output interface, a stepper motor control output interface, or a general motor control output interface.

3. The integrated motor control device as described in claim 1, characterized in that: The terminal block assembly includes several first terminal blocks, each of which includes a first power supply terminal, a second power supply terminal, and a signal terminal. The first power supply terminal supplies DC 0V voltage, and the second power supply terminal supplies DC 10-30V voltage.

4. The integrated motor control device as described in claim 3, characterized in that: The terminal block assembly includes several second terminal blocks, each of which includes a third power supply terminal and a signal terminal. The third power supply terminal supplies 0V or 10-30V voltage.

5. The integrated motor control device as described in any one of claims 1 to 4, characterized in that: The terminal block assembly is a pluggable terminal connector.

6. The integrated motor control device as described in any one of claims 1 to 4, characterized in that: The terminal block is electrically connected to one or more of the following: a photoelectric sensor, a proximity switch sensor, a relay, a reed sensor, a button, or a servo encoder.

7. The integrated motor control device as described in claim 1, characterized in that: The circuit board includes a first circuit board and a second circuit board, with the first circuit board positioned above the second circuit board; wherein the main controller and the DI / DO terminal connection module are integrated on the first circuit board, and the drive controller is integrated on the second circuit board.

8. The integrated motor control device as described in claim 7, characterized in that: The first circuit board is provided with a communication interface that is connected to the main controller via electrical signals. The communication interface is connected to the PLC control device via a communication line. The second circuit board is provided with a power input interface that supplies power to the main controller and the drive controller. The power input interface is connected to the power supply protection module via a power line.

9. The integrated motor control device as described in claim 8, characterized in that: The motor control output interface is located on the second circuit board; the communication interface is located near the lower edge of the first circuit board, and the motor control output interface and the power input interface are located near the lower edge of the second circuit board.

10. The integrated motor control device as described in claim 8, characterized in that: The power supply protection module and the circuit board are housed in the same housing.

11. The integrated motor control device as described in claim 7, characterized in that: It also includes a housing that encloses the circuit board, the horizontal cross-section of the housing being rectangular; the second circuit board and the first circuit board are both L-shaped structures, the L-shaped circuit board being installed inside the rectangular housing and forming a wire harness entry and exit space between them.

12. The integrated motor control device as described in claim 11, characterized in that: The external wiring harness enters the wiring harness entry / exit space from the back or bottom of the housing.

13. The integrated motor control device as described in claim 7, characterized in that: Both the first circuit board and the second circuit board include a first extension plate and a second extension plate located in the same horizontal plane and perpendicular to each other; the first extension plate extends in a front-to-back direction, and the second extension plate extends from the left edge of the first extension plate to the left; the DI / DO terminal connection module is disposed on the second extension plate; the length of the second extension plate of the first circuit board is less than the length of the second extension plate of the second circuit board, so that there is an extended area in the space above the second circuit board that is not covered by the first circuit board.

14. The integrated motor control device as described in claim 13, characterized in that: An expansion circuit board is selectively installed on the expansion area as needed. The expansion circuit board integrates the DI / DO terminal connection module. A female adapter that is electrically connected to the main controller is provided on the second extension surface of the first circuit board. A male adapter that is plugged into the female adapter to achieve electrical connection is provided on the expansion circuit board.

Images