Mining motor controller

Abstract

The utility model discloses a mining motor controller, which comprises a mounting bottom plate, a shell connected with the mounting bottom plate, a capacitor module mounted in a mounting cavity defined by the shell and the mounting bottom plate, an inverter control panel, an IGBT (Insulated Gate Bipolar Translator) module and a control circuit board, the IGBT module is integrally packaged, and the control circuit board integrates the power supply module, the voltage sampling module, the current sampling module, the temperature sampling module, the hardware protection module, the PWM output module, the CAN communication module, the encoder decoding module and the MCU processing module on the same circuit board and is arranged around the IGBT module. The inverter control panel is installed above the IGBT module through an arch-shaped installation support, and the two ends of the arch-shaped installation support are fixedly connected with the installation bottom plate. According to the mining motor controller, miniaturization, high reliability and low cost of the mining motor controller are realized through modularized, integrated and highly integrated design.

Description

Technical Field

[0001] This utility model relates to the field of electric locomotive technology, specifically a mining motor controller. Background Technology

[0002] Mining motor controllers, as key components in mining machinery, directly affect the safety and efficiency of mining operations through their structural design and performance characteristics. They typically consist of multiple independent components, including capacitors, IGBT modules, control circuit boards, connecting busbars, and heat sinks. Existing mining motor controllers are structurally fragmented, exhibiting the following shortcomings:

[0003] 1) Large component size and scattered layout: Existing mining motor controllers mostly use electrolytic capacitors, which are relatively large due to their capacitance and voltage requirements. IGBT modules also use large package sizes, making the overall controller bulky. In addition, due to a lack of integration, the control circuit board is divided into multiple functional modules and scattered inside the controller, further increasing the overall size;

[0004] 2) Difficult maintenance and high failure rate: The control circuit boards are scattered in multiple locations inside the controller, which means that each module needs to be located one by one during maintenance. This poses a great challenge to maintenance personnel with limited technical skills in the mining environment. In addition, the internal wiring of the system is numerous and complex, which can easily lead to loose connections or disconnections, thereby increasing the equipment failure rate, maintenance difficulty and system instability.

[0005] 3) High heat dissipation requirements and increased size: Due to the high losses in existing control systems, the heat dissipation requirements are increased. Current solutions can only meet these requirements by increasing the area of ​​the heat sink, which further increases the overall size of the controller, making it difficult to achieve a simplified design and increasing the inconvenience of equipment installation and use.

[0006] 4) Low overall integration and poor anti-interference: The control module, power supply module, sampling module and other components of traditional motor controllers are scattered and lack effective electromagnetic compatibility design. They are easily affected by the complex electromagnetic environment of mines, which affects the control accuracy and stability.

[0007] In summary, existing mining motor controllers have significant shortcomings in terms of electronic component size, layout design, ease of maintenance, wiring complexity, failure rate, heat dissipation performance, and anti-interference capability. These problems not only increase the difficulty of equipment maintenance and operation but also seriously threaten the safety and efficiency of mining operations. Summary of the Invention

[0008] The purpose of this utility model is to provide a new type of mining motor controller, which overcomes the problems existing in the prior art through modular and integrated design, and improves the reliability and ease of maintenance of the equipment.

[0009] The technical solution adopted by this utility model is as follows: A mining motor controller includes a mounting base plate and a housing connected to the mounting base plate. The housing and the mounting base plate enclose a mounting cavity, in which a capacitor module, an inverter control board, an IGBT module, and a control circuit board are installed. The capacitor module includes three thin-film capacitors integrated within the same housing, and the output terminal of the capacitor module is connected to the input terminal of the IGBT module. The IGBT module is integrated into a single package. The control circuit board integrates a power supply module, a voltage sampling module, a current sampling module, a temperature sampling module, a hardware protection module, a PWM output module, a CAN communication module, an encoder decoding module, and an MCU processing module onto the same circuit board, which are closely arranged around the IGBT module. The inverter control board is mounted directly above the IGBT module via an arched mounting bracket, and both ends of the arched mounting bracket are fixedly connected to the mounting base plate.

[0010] Furthermore, the mounting base plate is divided into a first mounting area and a second mounting area arranged on the left and right sides. The capacitor module is fixedly mounted in the first mounting area, and the IGBT module, control circuit board, and inverter control board are fixedly mounted in the second mounting area.

[0011] Furthermore, the first installation area is provided with a positioning slot for fixing the capacitor module.

[0012] Furthermore, the input stud connected to the input terminal of the capacitor module, the output bolt connected to the three-phase AC output terminal of the IGBT module, and the inverter control board connector all extend through the upper surface of the housing to form a mounting cavity.

[0013] Furthermore, the mounting base plate is a one-piece molded structure made of aluminum alloy.

[0014] Furthermore, a water cooling system is connected to the bottom of the mounting base plate.

[0015] The advantages of this invention are as follows: By integrating the capacitor, IGBT module, and control circuit board, the overall size of the controller is significantly reduced; the number of drive boards and the complexity of overall wiring are reduced, thereby lowering manufacturing and maintenance costs; the highly integrated design allows all functional modules to be concentrated in one unit, simplifying the system maintenance process. When a system failure occurs, the integrated control board can be easily replaced, reducing maintenance time, making it particularly suitable for rapid maintenance needs in mining environments; the application of film capacitors and integrated IGBT modules makes the overall layout of the equipment more compact, reducing space occupation and facilitating installation and use in mining environments; by integrating the traditionally dispersed control circuit board functional modules onto the same board and closely arranging them around the IGBT module, the number of internal connecting cables is reduced, lowering the risk of failure due to disconnection and improving the reliability and stability of the system.

[0016] This utility model achieves miniaturization, high reliability, and low cost of mining motor controller through modular, integrated, and highly integrated design, making it more suitable for use in mining environments and improving the system's practicality and economic value. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the overall structure of this utility model.

[0018] Figure 2 This is a schematic diagram of the internal structure of the mounting cavity of this utility model.

[0019] Figure 3 This is an exploded view of this utility model. Detailed Implementation

[0020] To facilitate understanding of this utility model, the following description will be more comprehensive and detailed in conjunction with the accompanying drawings and preferred embodiments. However, the scope of protection of this utility model is not limited to the following specific embodiments.

[0021] like Figures 1-3 As shown, this embodiment provides a mining motor controller, including a mounting base plate 1, a housing 2 connected to the mounting base plate 1, and a functional module installed in the mounting cavity formed by the housing 2 and the mounting base plate 1.

[0022] The mounting base plate 1 is divided into a first mounting area and a second mounting area arranged on the left and right. The first mounting area independently mounts the capacitor module 3, while the second mounting area centrally mounts the inverter control board 4, IGBT module 6, and control circuit board.

[0023] Capacitor module 3 uses film capacitors instead of traditional electrolytic capacitors. Film capacitors offer higher performance, and through customized housing design, the capacitance and size of the capacitors can be flexibly adjusted according to module requirements. While achieving the same function, film capacitors have a smaller size and better layout compared to electrolytic capacitors. Traditional inverters typically consist of three discrete capacitor modules, which are scattered and relatively large. This invention integrates the three capacitor modules tightly within a single housing through an integrated design, reducing installation space and wiring complexity, and improving the overall reliability and compactness of the system. For convenient positioning and installation of capacitor module 3, a positioning slot is provided in the first installation area.

[0024] This invention employs an integrated IGBT module 6, whose input terminal is connected to the output terminal of the capacitor module. A customized IGBT driver board tightly integrates the drive circuit with the IGBT module 6, reducing the number of internal connecting cables, thereby lowering the probability of line failures and improving system reliability.

[0025] Traditional control units consist of multiple independent modules, including a power supply module, a voltage sampling module, a current sampling module, a temperature sampling module, a hardware protection module, a PWM output module, a CAN communication module, an encoder decoding module, and an MCU processing module. These modules are scattered in different locations of the mining motor controller, resulting in a complex structure and difficult maintenance.

[0026] This invention features a highly integrated control circuit board design, integrating all the aforementioned functional modules onto a single circuit board and closely arranging them around the IGBT module 6. This not only reduces the size of the control system but also significantly reduces the length of connecting cables, minimizing potential failure points and improving system reliability and ease of maintenance. The inverter control board 4 is mounted directly above the IGBT module 6 via an arched mounting bracket 5, with both ends of the arched mounting bracket 5 fixedly connected to the mounting base plate 1. This utilizes vertical space to increase layout density while enhancing structural stability.

[0027] The input studs connected to the input terminal of capacitor module 3, the output bolts connected to the three-phase AC output terminal of IGBT module 6, and the connectors of inverter control board 4 all extend through the upper surface of the housing 2 into the mounting cavity, which conforms to the explosion-proof wiring specifications for mining equipment and facilitates on-site maintenance.

[0028] Mounting base plate 1 adopts an integrated aluminum alloy heat dissipation base plate. The bottom of mounting base plate 1 can be connected to a water cooling system, which allows the heat dissipation system to switch from air cooling to water cooling when needed, realizing the flexibility of heat dissipation method and supporting the operation requirements of higher power.

[0029] This invention achieves miniaturization, integration, and high reliability of the mining motor controller through comprehensive optimization and integration of the capacitor, IGBT module, control circuit board, and heat dissipation system. It meets the requirements for stable and reliable operation of equipment in the mining environment, and also facilitates maintenance and management.

[0030] With the aid of the teachings present in the foregoing description and related drawings, those skilled in the art will conceive of many modifications and other embodiments of the present invention. Therefore, it is to be understood that the present invention is not limited to the specific embodiments disclosed, and modifications and other embodiments are considered to be included within the scope of the appended claims. Although specific terms are used herein, they are used in a general and descriptive sense only and are not intended to be limiting.

Claims

1. A mining motor controller, characterized in that: The system includes a mounting base plate (1) and a housing (2) connected to the mounting base plate (1). The housing (2) and the mounting base plate (1) enclose a mounting cavity, in which a capacitor module (3), an inverter control board (4), an IGBT module (6), and a control circuit board are installed. The capacitor module (3) includes three thin-film capacitors integrated in the same housing. The output end of the capacitor module (3) is connected to the input end of the IGBT module (6). The IGBT module (6) is encapsulated in an integrated manner. The control circuit board integrates a power supply module, a voltage sampling module, a current sampling module, a temperature sampling module, a hardware protection module, a PWM output module, a CAN communication module, an encoder decoding module, and an MCU processing module on the same circuit board and is arranged closely around the IGBT module (6). The inverter control board (4) is mounted directly above the IGBT module (6) via an arched mounting bracket (5). The two ends of the arched mounting bracket (5) are fixedly connected to the mounting base plate (1).

2. A mining motor controller as described in claim 1, characterized in that: The mounting base plate (1) is divided into a first mounting area and a second mounting area arranged on the left and right. The capacitor module (3) is fixedly installed in the first mounting area, and the IGBT module (6), control circuit board, and inverter control board (4) are fixedly installed in the second mounting area.

3. A mining motor controller as described in claim 2, characterized in that: The first installation area is provided with a positioning slot for fixing the capacitor module (3).

4. A mining motor controller as described in claim 1, characterized in that: The input stud connected to the input terminal of the capacitor module (3), the output bolt connected to the three-phase AC output terminal of the IGBT module (6), and the connector of the inverter control board (4) all extend through the upper surface of the housing (2) to form a mounting cavity.

5. A mining motor controller as described in claim 1, characterized in that: The mounting base plate (1) is an integrally formed structure made of aluminum alloy.

6. A mining motor controller as described in claim 1, characterized in that: The bottom of the mounting base plate (1) is connected to a water cooling system.

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