A high-voltage high-power compact intelligent driver

Abstract

The utility model relates to industrial automation technical field, and disclose a kind of high-voltage high-power compact intelligent driver, including semi-finished product drive module, the driver is high-voltage range and high-power range, can adapt to 400VDC~800VDC voltage input, and provide 2KW~10KW output power;Programmable intelligent control unit is used to realize flexible programming and intelligent control to drive operating parameter;The interface circuit board of self-development is welded on the semi-finished product drive module foundation.Optimized power topology structure and heat dissipation design, stable output kilowatt level power under the condition of 600V above high-voltage input, perfect adaptation large motor drive scene, break through traditional equipment size and power bottleneck, significantly improve industrial production line space utilization;Second, integrated programmable control unit and modular communication interface, support mainstream industrial protocol such as EtherCAT, Modbus-TCP plug and play, realize drive parameter self-adaptive setting and host computer seamless docking.

Description

Technical Field

[0001] This utility model relates to the field of industrial automation technology, and more specifically, to a high-voltage, high-power, compact intelligent driver. Background Technology

[0002] This product features high voltage, high power, compact design, and intelligent control, playing a crucial role in multiple key scenarios. It is particularly suitable for industrial automation, where the operation of heavy machinery on large production lines and the driving of equipment in automated logistics systems rely on its powerful performance and precise control. In the robotics field, industrial robots handling heavy objects and special robots performing hazardous tasks require this drive to provide stable power and flexible control. It is also indispensable for precision parts manufacturing in high-end CNC machine tool processing equipment and for the fine operations of laser processing equipment. In the energy industry, the pitch and yaw control of wind power generation equipment and the continuous and stable operation of petrochemical equipment also rely on the support of the G-MOLTRO series drives. Against the backdrop of rapid development in industrial automation and intelligent equipment, drives, as core execution components, are facing an urgent need for multi-dimensional performance upgrades. The limitations of traditional drives in high-voltage, high-power industrial scenarios are becoming increasingly apparent: their power modules are prone to dynamic response lag and increased output ripple under high-voltage input, leading to decreased motor drive stability; the increased size and complex wiring required to meet heat dissipation requirements directly limit the space utilization of compact production lines. More seriously, a single communication interface is insufficient to meet the demands of multi-protocol integration in the Industry 4.0 era. Traditional RS485 / CAN bus architectures are incompatible with real-time industrial Ethernet protocols such as EtherCAT and Profinet, leading to high networking costs for equipment. At the intelligent control level, drivers lacking edge computing capabilities struggle to implement advanced functions such as predictive maintenance and adaptive parameter tuning, still relying on dedicated programmers and complex manual parameter configuration for debugging. Encoder compatibility bottlenecks in motor feedback are equally prominent; existing drivers lack sufficient support for advanced absolute encoders such as BiSS-C and EnDat2.2, hindering the expansion of high-precision position control applications. Furthermore, rigid I / O interface configurations and missing safety protection functions create safety hazards in drive systems when dealing with emergency shutdowns and overload protection. These technological shortcomings are forcing drivers to evolve towards higher power density, modular communication, and intelligent diagnostics to meet the new requirements of intelligent manufacturing for equipment flexibility, networking, and safety. Utility Model Content

[0003] To overcome the shortcomings of existing technologies, this utility model provides a high-voltage, high-power, compact intelligent driver with the advantage of smooth driver operation.

[0004] To achieve the above objectives, this utility model provides the following technical solution: a high-voltage, high-power, compact intelligent driver, comprising a semi-finished driver module, wherein the driver has a high voltage and high power range, capable of adapting to voltage inputs of 400VDC to 800VDC, and providing output power of 2KW to 10KW; a programmable intelligent control unit, used to realize flexible programming and intelligent control of the driver's operating parameters; and an independently developed interface circuit board is soldered onto the semi-finished driver module.

[0005] As a preferred embodiment of this invention, the driver employs a high-voltage-range and high-power drive module capable of handling voltage inputs from 400VDC to 800VDC. By utilizing advanced power semiconductor devices and optimized circuit topologies, such as IGBT (Insulated Gate Bipolar Transistor) modules working in conjunction with fast recovery diodes, combined with a three-phase full-bridge inverter circuit and PWM modulation technology, and employing filter capacitors and inductors to improve power quality, and with the aid of overcurrent and overvoltage protection circuits, it achieves the conversion, precise regulation, and safe and stable power output of high-voltage, high-power electrical energy. It can provide output power from 2KW to 10KW, meeting the driving requirements of large-scale motor equipment.

[0006] As a preferred embodiment of this invention, the driver is designed with a programmable intelligent control unit: equipped with a high-performance ARM microcontroller combined with advanced vector control algorithms. This control unit can be programmed to flexibly set the driver's operating parameters, including motor speed, torque, acceleration / deceleration time, etc. Users can configure the control unit parameters according to actual application needs through host computer software or a local operating interface to achieve intelligent control of the driver.

[0007] As a preferred technical solution of this utility model, the driver can be flexibly selected by the customer using either EtherCAT bus or CAN bus. In the EtherCAT communication link of the G-MOLTRO series driver, the EtherCAT communication transformer 11FB-05NL plays a crucial role, primarily for achieving electrical isolation. It isolates the electrical signals of the EtherCAT bus from the internal circuitry of the driver, preventing external electrical interference from entering the driver and avoiding feedback of internal electrical noise from the driver to the bus, thus ensuring communication stability and reliability. However, in some industrial environments where real-time communication requirements are relatively low but reliability and anti-interference capabilities are high, the CAN bus can be selected. In the CAN communication link, the NUP2105L is a high-efficiency electrostatic protection diode used to protect the CAN transceiver from ESD and other transient voltages. It has a peak pulse power of 400W, a response time of less than 1ns, an operating voltage of 24V, a low clamping voltage, and is packaged in an SOT-23 package. It offers long communication distances, high reliability, and effectively avoids communication interruptions.

[0008] As a preferred embodiment of this invention, the driver is designed with two types of USB debugging interfaces: the USB interface offers advantages such as high transmission speed and plug-and-play functionality, facilitating parameter setting and debugging of the driver using devices such as laptops. Users can read, modify, and monitor various parameters of the driver simply through the corresponding debugging software and the USB interface, greatly improving the convenience and efficiency of debugging.

[0009] As a preferred embodiment of this invention, the driver is designed with an encoder main feedback interface supporting multiple protocols, adaptable to various encoders such as HALL sensors, differential incremental encoders, Tamagawa absolute encoders, BISS protocol absolute encoders, and Nikon encoders. For example, for incremental encoders, the interface circuit can accurately identify their A, B, and Z phase pulse signals, and precisely calculate the motor's speed and position through pulse counting and phase analysis. For absolute encoders, the interface can receive their parallel or serial output position encoding signals, directly obtaining the motor's absolute position information, achieving precise feedback of the motor's operating status, and providing data support for the driver's precise control.

[0010] As a preferred technical solution of this utility model, the driver is designed with an encoder auxiliary feedback interface that supports multiple protocols, which can be adapted to HALL sensors, differential incremental encoders, resolvers, Hiperface encoders, etc., and can be combined with main feedback to realize dual feedback applications;

[0011] As a preferred technical solution of this utility model, the driver is designed with a PortC simulation output interface for outputting and simulating specific signals. For example, in multi-axis linkage or complex motion control processes, the PortC interface may participate in the synchronous coordination between axes. It can output synchronization signals related to axis motion to ensure that multiple motors maintain precise synchronization in terms of speed, position, etc. during operation. This is crucial for ensuring the stable operation of multi-axis systems such as robotic arms and high-precision machining equipment.

[0012] As a preferred embodiment of this invention, the driver is designed with an I / O interface, including two output interfaces supporting 2A DO output, four DI input interfaces, and one AI analog input interface. The DO output interfaces use MURS260 diodes as the output driving element, enabling high-load output of 2A, and can directly drive small relays, solenoid valves, and other devices. The DI input interfaces use ITS724G optocoupler isolation circuits, which can accurately detect externally input switching signals and convert them into digital signals recognizable by the driver. The AI ​​input interface can accurately acquire ±10V analog signals, used to acquire analog output signals from sensors such as temperature and pressure sensors.

[0013] As a preferred technical solution of this utility model, the driver is designed with an STO protection interface using a Zener diode KDZ6.2V-Y-RTK / P. This interface can realize the safe torque shutdown protection function. When the system detects abnormal conditions, such as motor overload, short circuit, over-temperature, etc., the output torque of the driver can be quickly cut off through the STO interface to protect the motor and equipment from damage, while ensuring the safety of the operator.

[0014] As a preferred embodiment of this invention, the driver is designed with an integrated interface for both main power supply and motor power, using MKDS1.5 / 2-5.08 and MKDS1.5 / 3-5.08 connectors. This interface integrates the main power supply line and the motor power line into a single interface. This integrated interface design greatly simplifies the wiring and installation process, reduces the number of cables and connection points, lowers the probability of line faults, and makes the overall structure of the driver more compact, saving installation space.

[0015] Compared with the prior art, the beneficial effects of this utility model are as follows:

[0016] 1. This utility model, through optimized power topology and heat dissipation design, stably outputs kilowatt-level power under high voltage input conditions above 600V, perfectly adapting to large motor drive scenarios. It breaks through the traditional equipment's size and power bottlenecks, significantly improving the space utilization of industrial production lines. Secondly, it integrates a programmable control unit and modular communication interface, supporting plug-and-play functionality for mainstream industrial protocols such as EtherCAT and Modbus-TCP, enabling adaptive tuning of drive parameters and seamless integration with the host computer, meeting the needs of multi-device collaborative control in smart factories. Finally, it innovatively adopts a USB direct-connection debugging architecture, combined with graphical configuration software, allowing parameter setting and fault diagnosis to be completed without specialized tools, improving debugging efficiency by over 60%. This technical solution effectively solves the drive challenges in high-voltage, high-power scenarios, providing a highly reliable and flexible core drive solution for high-end equipment manufacturing.

[0017] 2. This utility model integrates a multi-protocol encoder feedback interface, compatible with incremental, absolute, and emerging BiSS-C / EnDat2.2 digital encoders, to construct a fully closed-loop control link, achieving micron-level motor position feedback accuracy and reducing speed fluctuation to within 0.01%. Secondly, the innovative interface matrix integrates a PortC high-speed simulation interface, 16 programmable I / O channels, and a dual-channel STO safety interface, supporting peripheral expansion such as industrial cameras while also enabling a safe torque shutdown function, reducing equipment failure rate by 40%. Finally, the three-in-one integrated terminal design highly integrates the power supply, motor winding, and braking resistor interfaces, reducing equipment size by 35% and wiring complexity by 50%, making it particularly suitable for space-sensitive applications such as CNC machine tools and robot joints. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the overall structure of this utility model;

[0019] Figure 2 This is a schematic diagram of the layout of the various interfaces of this utility model;

[0020] Figure 3 This is a schematic diagram showing the external dimensions of the present invention.

[0021] Figure 4 This is a partial circuit design diagram of this utility model.

[0022] In the diagram: J0 / 1, Driver main power supply port; J0 / 2, Motor power line interface; J0, Main power supply and motor power integrated interface; J1, Self-developed interface circuit board; J2, Semi-finished driver module; J3, IO interface; J4, Main feedback interface; J5, Auxiliary feedback interface; J6, PortC simulation output interface; J7, EtherCATIN interface; J8, EtherCATOUT interface; J9, USB debugging interface; J12, Auxiliary power supply interface; J22, CAN bus interface; J23, CANOUT interface; J26, STO protection interface. Detailed Implementation

[0023] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0024] like Figures 1 to 4As shown, this utility model provides a high-voltage, high-power, compact intelligent driver, including a semi-finished driver module J2. The driver has a high voltage and high power range, capable of adapting to voltage inputs of 400VDC to 800VDC and providing output power of 2KW to 10KW. A programmable intelligent control unit is provided for flexible programming and intelligent control of the driver's operating parameters. An independently developed interface circuit board J1 is soldered onto the semi-finished driver module J2. The circuit board includes selectable EtherCAT bus interfaces J7 (EtherCATIN), J8 (EtherCATOUT), J22 (CAN), J23 (CANOUT), J23 (CAN), an auxiliary power supply interface J12, and a USB debugging interface J9 to meet different bus communication requirements. The USB debugging interface J9 with different plug-in types is used for setting and debugging the driver's parameters. It supports multiple... The encoder main feedback interface J4 supports multiple protocols and is compatible with Hall sensors, differential incremental encoders, Tamagawa absolute encoders, BISS protocol absolute encoders, and Nikon encoders, enabling accurate feedback of motor operating status. The encoder auxiliary feedback interface J5 supports multiple protocols and is compatible with Hall sensors, differential incremental encoders, resolvers, Hiperface encoders, etc., and can be used in conjunction with main feedback to achieve dual feedback applications. The PortC simulation output interface J6 is used for the output and simulation of specific signals. The IO interface J3 includes two output interfaces supporting 2A DO output, four DI input interfaces, and one AI input interface to meet the input and output requirements of different signals. The STO protection interface J26 is used to implement safe torque shutdown protection. The main power supply and motor power integrated interface J0 integrates the main power supply line and the motor power line into the same interface.

[0025] The driver has an independently developed interface circuit board J1, on which a semi-finished driver module J2 is soldered. The independently developed interface circuit board J1 is designed with an integrated main feedback interface J4, an auxiliary feedback interface J5, a PortC simulation output interface J6, an integrated IO interface J3 including 2 DO digital output interfaces, 4 DI digital input interfaces, 1 AI analog input interface, an auxiliary power supply interface J12, a driver main power supply port J0 / 1, a motor power line interface J0 / 2, an EtherCATIN interface J7, an EtherCATOUT interface J8, a CANIN interface J22, a CANOUT interface J23, a USB debugging interface J9, and an STO interface J26.

[0026] The semi-finished product drive module J2 works by using an IGBT module in conjunction with a fast recovery diode, and adopts a three-phase full-bridge inverter circuit topology and PWM modulation technology.

[0027] The driver's circuit design employs advanced integrated circuit technology and a modular design concept. The driver module is responsible for the control logic and signal processing of the entire driver, communicating with other upper-level systems via a high-speed data bus. When soldering the driver, the microcontroller chip of the programmable intelligent control unit and peripheral circuit components are first soldered onto the independently developed interface circuit board J1. Then, the independently developed interface circuit board J1 is soldered onto the high-voltage, high-power driver module according to production requirements.

[0028] The programmable intelligent control unit of the driver is based on high-performance ARM microcontrollers such as the STM32 series and algorithms such as vector control, adaptive control, and fault diagnosis to achieve precise control and intelligent management of the driver's operation.

[0029] The independently developed interface circuit board J1 is also designed with EtherCAT high-speed bus interfaces EtherCATIN interface J7 and EtherCATOUT interface J8. The specific implementation is as follows: EtherCAT high-speed bus signals from the host system, such as those from Elmo controllers, Beckhoff controllers, Omron, etc., are input to the EtherCATIN communication transformer 11FB-05NL via the EtherCATIN interface J7, and then input to the corresponding driver module EtherCATIN. The signals are then output to the corresponding driver module EtherCATOUT via the EtherCATOUT communication transformer 11FB-05NL, and then output to the corresponding EtherCATOUT interface J8. The EtherCATOUT interface J8 outputs to other external devices or is left unconnected, thereby realizing real-time network communication.

[0030] The driver is based on a semi-finished driver module J2, on which an independently developed interface circuit board J1 is soldered.

[0031] The main feedback port J4 boasts strong compatibility, supporting encoder feedback from various protocols. It is compatible with Hall sensors, differential incremental encoders, Tamagawa absolute encoders, BISS protocol absolute encoders, Nikon encoders, and more, enabling precise feedback on motor operating status. An encoder auxiliary feedback interface J5, supporting multiple protocols, is also included, compatible with Hall sensors, differential incremental encoders, Resolvers, and Hiperface encoders, allowing for dual-feedback applications when used in conjunction with the main feedback. Additionally, a PortC simulation output interface is designed for outputting and simulating specific signals. For example, in multi-axis linkage or complex motion control processes, the PortC interface may participate in the synchronization and coordination between axes. It can output synchronization signals related to axis motion, ensuring that multiple motors maintain precise synchronization in speed, position, and other aspects during operation. This is crucial for ensuring the stable operation of multi-axis systems such as robotic arms and high-precision machining equipment.

[0032] The driver layout includes EtherCAT bus interfaces J7 (EtherCATIN), J8 (EtherCATOUT), J22 (CAN), and J23 (CANOUT), allowing customers to flexibly select EtherCAT bus interfaces. EtherCAT meets the communication needs of different buses.

[0033] The driver layout includes USB debugging interfaces J9 with different plug types, used for setting and debugging driver parameters.

[0034] The driver layout is used to support the encoder main feedback interface J4 of multiple protocols, which can be adapted to HALL sensors, differential incremental encoders, Tamagawa absolute encoders, BISS protocol absolute encoders, Nikon encoders, etc., to achieve accurate feedback of motor operating status.

[0035] The driver is equipped with an integrated interface J0 for main power supply and motor power, ensuring the stability and reliability of power supply and power transmission.

[0036] The servo motor connection port J0 / 2 and the driver power supply port J0 / 1 are connected to the servo motor, enabling the servo motor to be connected and driven. The driver power supply port J0 / 1 is configured to allow an external power supply to power the driver, enabling the driver to start normally. The driver enables direct driving and control of the servo motor, reducing intermediate links and allowing control signals to be transmitted directly and efficiently to the servo motor, thereby improving the system's response speed and control accuracy.

[0037] The logic signal interface J3 includes 4 DI channels and 2 DO channels that can be directly connected to photoelectric switches and relays to receive or send logic level signals without the need for additional conversion or adaptation equipment. This allows the driver to be easily integrated into various applications in industrial automation, robotics, medical equipment and other fields to meet the needs of different scenarios.

[0038] The driver layout is used to support the encoder auxiliary feedback interface J5 of multiple protocols, adapting to HALL sensors, differential incremental encoders, resolvers, and Hiperface encoders, and to achieve dual feedback applications in conjunction with the main feedback.

[0039] The driver is equipped with a PortC simulation output interface J6 for the output and simulation of specific signals.

[0040] The driver is equipped with an STO protection interface J26, which is used to implement the safe torque shutdown protection function.

[0041] Among them, by setting up the USB debugging interface J9, developers can connect the device to the computer to perform operations such as application debugging, data transfer, and performance analysis. This allows developers to run and debug applications directly on the device, greatly improving development efficiency.

[0042] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0043] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A high-voltage, high-power, compact intelligent driver, comprising a semi-finished driver module (J2), characterized in that: The driver features a high voltage and high power range, adapting to input voltages from 400VDC to 800VDC and providing output power from 2KW to 10KW. A self-developed interface circuit board (J1) is soldered onto the semi-finished driver module (J2). It includes EtherCAT bus interfaces (J7), EtherCATOUT (J8), CAN bus interfaces (J22), and CANOUT (J23) for flexible customer selection to meet different bus communication needs, an auxiliary power supply interface (J12), and a USB debugging interface (J9). Different types of USB debugging interfaces (J9) are used for setting and debugging the driver's parameters. Supports encoder main feedback interface (J4) with multiple protocols, compatible with HALL sensors, differential incremental encoders, Tamagawa absolute encoders, BISS protocol absolute encoders, and Nikon encoders; To achieve accurate feedback on the motor's operating status; The encoder auxiliary feedback interface (J5) supports multiple protocols and is compatible with HALL sensors, differential incremental encoders, resolvers, Hiperface encoders, etc., and can be used with the main feedback to realize dual feedback applications; the PortC simulation output interface (J6) is used for the output and simulation of specific signals; IO Interface (J3): Includes 2 output interfaces supporting DO output of 2A, 4 DI input interfaces and 1 AI input interface to meet the input and output requirements of different signals; STO protection interface (J26) is used to realize the safe torque shutdown protection function; main power supply and motor power integrated interface (J0) integrates the main power supply line and the motor power line into the same interface.

2. The high-voltage, high-power, compact intelligent driver according to claim 1, characterized in that: The semi-finished product drive module (J2) works by using an IGBT module in conjunction with a fast recovery diode, and adopts a three-phase full-bridge inverter circuit topology and PWM modulation technology.

3. The high-voltage, high-power, compact intelligent driver according to claim 1, characterized in that: The driver's programmable intelligent control unit is based on high-performance ARM microcontrollers such as the STM32 series and algorithms such as vector control, adaptive control, and fault diagnosis, to achieve precise control and intelligent management of the driver's operation.

4. The high-voltage, high-power, compact intelligent driver according to claim 1, characterized in that: The driver is based on a semi-finished driver module (J2) with an independently developed interface circuit board (J1) soldered on.

5. The high-voltage, high-power, compact intelligent driver according to claim 1, characterized in that: The driver layout is equipped with EtherCAT bus EtherCATIN interface (J7) and EtherCATOUT interface (J8) for customers to flexibly select, and CAN bus CANIN (J22) and CANOUT interface (J23) to meet different bus communication requirements.

6. The high-voltage, high-power, compact intelligent driver according to claim 1, characterized in that: The driver layout has USB debugging interfaces (J9) with different plug types for setting and debugging driver parameters.

7. The high-voltage, high-power, compact intelligent driver according to claim 1, characterized in that: The driver layout is used to support the encoder main feedback interface (J4) of multiple protocols, and is compatible with HALL sensors, differential incremental encoders, Tamagawa absolute encoders, BISS protocol absolute encoders, Nikon encoders, etc., to achieve accurate feedback of motor operating status. The driver is equipped with an integrated interface (J0) for main power supply and motor power, ensuring the stability and reliability of power supply and power transmission.

8. The high-voltage, high-power, compact intelligent driver according to claim 1, characterized in that: The driver layout is designed to support encoder auxiliary feedback interfaces (J5) for multiple protocols, adapting to HALL sensors, differential incremental encoders, resolvers, and Hiperface encoders, and enabling dual feedback applications in conjunction with main feedback.

9. A high-voltage, high-power, compact intelligent driver according to claim 1, characterized in that: The driver is equipped with a PortC simulation output interface (J6) for the output and simulation of specific signals.

10. A high-voltage, high-power, compact intelligent driver according to claim 1, characterized in that: The driver layout includes an I / O interface (J3): including two output interfaces that support 2A DO output, four DI input interfaces, and one AI input interface to meet the input and output requirements of different signals; 11. A high-voltage, high-power, compact intelligent driver according to claim 1, characterized in that: The driver is equipped with an STO protection interface (J26) for implementing a safe torque shutdown protection function.

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