Phase commutation module for intelligent controller of multi-turn electric actuator

Abstract

The utility model discloses a kind of intelligent controller's commutation module of multi-rotation electric actuator, comprising first thyristor, second thyristor, first relay, second relay, third relay, fourth relay and the device composition solid-state composite switch circuit, including relay drive interlock circuit, thyristor drive circuit, relay enable signal interface, thyristor enable signal interface, three-phase alternating current arbitrary two-phase interface, three-phase motor arbitrary two-phase interface simultaneously.This utility model is in combination application of relay thyristor, ensure electrical safety, electromagnetic compatibility performance is better;Through the above-mentioned circuit and signal interface, power input / output interface, realize electrical topology on self-contained system, physical structure is separable module, and then realize the flexible installation of wide position of commutation module, while effectively avoid the series problem caused by driving and control integration together.

Description

Technical Field

[0001] This utility model relates to a commutation module, and more particularly to a commutation module of an intelligent controller for a multi-rotation electric actuator. Background Technology

[0002] In the application of intelligent controllers for multi-turn electric actuators, most controllers with a drive power of around 2kW and below currently use a solid-state composite switch combining onboard integrated relays and thyristors to drive 380V motors, meaning that the power drive circuit and control circuit of the intelligent controller are integrated into one unit; controllers with a drive power of around 2kW and above mostly use two contactors to drive 380V motors.

[0003] The design of integrating the drive circuit and the control circuit has the following problems: the limited planar space restricts the power increase and upgrade; the integration of multiple components and the concentration of heat dissipation affect the life of the whole machine; the need for overall disassembly makes maintenance and replacement inconvenient; and the insufficient decoupling design makes it difficult to develop the control part and the power drive part in parallel, resulting in low R&D efficiency.

[0004] The application of contactors has the following drawbacks: 1) Large size, making it unsuitable for compact installation conditions; high material costs due to its large size; and material waste due to the large-capacity housing. 2) Complex wiring, requiring numerous connecting wires for power drive, self-locking, and interlocking functions, leading to reduced electrical safety performance due to potential hazards such as loose connections and short circuits caused by multi-wire, multi-contact connections. 3) High interference, with significant electromagnetic pulse interference generated by the large current surge corresponding to the contactor's mechanical contact spark. Summary of the Invention

[0005] In view of the above situation and in order to solve the technical problems of the prior art, this utility model provides a commutation module of an intelligent controller for a multi-rotation electric actuator.

[0006] This utility model solves the above-mentioned technical problems through the following technical solution: a commutation module of an intelligent controller for a multi-turn electric actuator, characterized in that the commutation module of the intelligent controller for the multi-turn electric actuator includes a first thyristor, a second thyristor, a first relay, a second relay, a third relay, a fourth relay, a relay drive interlock circuit, a thyristor drive circuit, a relay enable signal interface, a thyristor enable signal interface, an interface for any two phases of three-phase AC power, and an interface for any two phases of three-phase motor power. The circuit design of the commutation module is on one or more circuit boards, and the whole can be modularly and independently packaged, forming a self-contained system in electrical topology and a separable module in physical structure. One end of the second thyristor is connected to the common terminal of the first relay, the normally closed terminal of the first relay is connected to one end of the fourth relay, and the other end of the fourth relay is connected to the normally open terminal of the second relay; one end of the first thyristor is connected to the common terminal of the second relay, the normally closed terminal of the second relay is connected to one end of the third relay, and the other end of the third relay is connected to the normally open terminal of the first relay.

[0007] The first, second, third, and fourth relays are each connected to their respective relay drive interlock circuits; the relay drive interlock circuits are connected to the relay enable signal interface.

[0008] The other end of the first thyristor and the other end of the second thyristor are respectively connected to any two phase interfaces of the three-phase motor;

[0009] The first and second thyristors are connected to the thyristor drive circuit, and the thyristor drive circuit is connected to the thyristor enable signal interface.

[0010] The normally open terminal of the first relay is connected to any two phases of the three-phase AC power supply, and the normally open terminal of the second relay is connected to any two phases of the three-phase AC power supply.

[0011] Preferably, the first relay, the second relay, the third relay, and the fourth relay are all connected to any two phases of a three-phase AC power supply interface, the any two phases of the three-phase AC power supply interface are connected to a power source, and the any two phases of the three-phase motor interface are connected to a three-phase motor.

[0012] Preferably, the circuit consisting of the first, second, third, and fourth relays can interchange electrical positions with the circuit consisting of two thyristors. That is, any two phase terminals of the three-phase AC power supply can be directly connected to the thyristors, the thyristors can be directly connected to the relays, and the relays can be connected to any two phase interfaces of the three-phase motor.

[0013] Preferably, both the first and second thyristors are bidirectional thyristors, and either of the thyristors can be replaced by two antiparallel unidirectional controllable semiconductor devices.

[0014] Preferably, the first and second relays are both single-pole double-throw relays, which can be replaced by double-pole double-throw relays, and the third and fourth relays are both single-pole single-throw relays, which can be replaced by double-pole single-throw relays.

[0015] Preferably, the commutation module of the intelligent controller of the multi-turn electric actuator is connected to the main board of the intelligent controller of the multi-turn electric actuator via a relay enable signal interface and a thyristor enable signal interface.

[0016] Preferably, the commutation module of the intelligent controller for the multi-turn electric actuator further includes a relay drive interlock circuit and a relay enable signal interface. The first, second, third, and fourth relays are all connected to the relay drive interlock circuit, which is connected to the relay enable signal interface. The relay drive interlock circuit includes two sets of relay drive interlock sub-circuits, which operate on the same principle. These sub-circuits are respectively the drive interlock circuits for the first and fourth relays, and the drive interlock circuits for the second and third relays. The drive interlock circuits for the first and fourth relays include diode D1, transistor Q1, transistor Q41, capacitor C1, resistors R1, R2, and R41, and the first relay's lead wire. The first component is coil Y1. Diode D1 and coil Y1 are connected in parallel. Diode D1 and coil Y1 are both connected to the collector of transistor Q1. Resistor R1, the collector of transistor Q41, capacitor C1, and resistor R2 are all connected to the base of transistor Q1. Capacitor C1 and resistor R2 are connected in parallel. Resistor R41 is connected to the base of transistor Q41. The second component also includes diode D4, transistor Q4, transistor Q14, capacitor C4, resistor R4, resistor R5, resistor R14, and the fourth relay coil Y4. Diode D4 and coil Y4 are connected in parallel. Diode D4 and coil Y4 are both connected to the collector of transistor Q4. Resistor R4, the collector of transistor Q14, capacitor C4, and resistor R5 are all connected to the base of transistor Q4. Capacitor C4 and resistor R5 are connected in parallel. Resistor R14 is connected to the base of transistor Q14.

[0017] Preferably, the thyristor driving circuit includes a first thyristor driving circuit and a second thyristor driving circuit. The principle of the first thyristor driving circuit is the same as that of the second thyristor driving circuit. The first thyristor driving circuit includes resistors R10, R11, R12, and R13, and an optocoupler. Resistors R10, R11, and R12 are all connected to the optocoupler, and resistors R12 and R13 are connected in series.

[0018] Preferably, the optocoupler is a zero-crossing detection optocoupler, and resistors R10, R11, R12, and R13 are all current-limiting power resistors.

[0019] The positive and progressive effects of this utility model are as follows:

[0020] First, the commutation module of this utility model uses a solid-state composite switching circuit that combines relays and thyristors, ensuring superior electrical safety and electromagnetic compatibility performance.

[0021] Second, this utility model is equipped with a single-pole double-throw relay, which utilizes the electrical interlocking function determined by its physical state attributes. Combined with the application of a relay drive interlocking circuit, the following technical effects are achieved: On the one hand, when the relay enable signal is affected by interference, short circuits, or other factors in the transmission path, it can prevent multiple relays from operating simultaneously and causing circuit conflicts, thereby avoiding dangerous situations such as phase-to-phase short circuits and improving the fault tolerance capability when the relay enable signal is abnormal. On the other hand, when abnormal connection occurs such as relay contact sticking, there is no loop for AC phase-to-phase conduction. The above combined application jointly improves the electrical reliability of the commutation module and also enhances the fault tolerance capability of the commutation module when receiving abnormal signals.

[0022] Third, this utility model features a power input interface (any two phases of three-phase AC power), a power output interface (any two phases of three-phase motor power), a relay enable signal interface, and a thyristor enable signal interface. These interfaces serve as expandable connection nodes. Combined with the aforementioned solid-state composite switch circuit, relay drive interlock circuit, and thyristor drive circuit, they achieve a self-contained electrical topology and a physically modular structure. The entire circuit can be modularly and independently packaged, enabling flexible installation of the commutation module in a wide range of locations. This overcomes the power upgrade limitations imposed by the common integrated drive and control system on a fixed planar space. Specifically, on the one hand, the power drive capability of the commutation module can be upgraded independently without modifying the control section; on the other hand, the commutation module can be installed independently and flexibly, resulting in high spatial freedom, minimal volume constraints, and high feasibility for independently upgrading the power drive capability of the commutation module. Regarding heat dissipation optimization, the independent structure allows for specialized heat dissipation design for power devices (such as large heat sinks and independent air ducts). Heat dissipation optimization reduces the node temperature of the thyristor, thereby increasing the thyristor's drive power. Furthermore, heat is concentrated within the drive module for dissipation, avoiding impact on sensitive control circuits and improving system thermal reliability.

[0023] Based on the modular design of the physical structure of the commutation module, this utility model provides a single-pole single-throw relay and a single-pole double-throw relay. Their common feature is that each relay is equipped with only one set of contact switches instead of multiple sets of contact switches. Therefore, the contact capacity determined by its physical structure has a significant advantage. In summary, the commutation module described in this utility model has better scalability for upgrading the drive power.

[0024] In summary, compared to designs that integrate the drive and control circuits, this invention, based on the combined application of relay electrical interlocking and relay drive interlocking circuits, ensures electrical reliability and fault tolerance for abnormal signals. Furthermore, it overcomes the limitation on power increase in intelligent controllers within a given planar space. Simultaneously, it avoids the problems of concentrated heat dissipation from integrated components affecting the overall lifespan of the device, and avoids the inconvenience of complete disassembly for maintenance and replacement.

[0025] Furthermore, compared to intelligent controller-connected contactor applications, this invention reduces interference caused by sudden current changes by using the zero-crossing point of the AC sinusoidal wave of the thyristor for switching on and off with a small current, thus avoiding strong electromagnetic interference caused by mechanical contact sparks. Simultaneously, the power drive interface of this invention does not have external wiring related to commutation and interlocking, avoiding safety hazards caused by complex wiring. Moreover, under current electronic component technology standards, for applications with a drive power of approximately 3.5kW and below, compared to intelligent controller-connected contactor applications, this solution effectively reduces the cost waste caused by large size. Attached Figure Description

[0026] Figure 1 This is a schematic diagram of the structure of this utility model.

[0027] Figure 2 This is a schematic diagram of the drive interlock sub-circuit of the first relay and the fourth relay in this utility model.

[0028] Figure 3 This is a schematic diagram of the thyristor drive circuit in this utility model. Detailed Implementation

[0029] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present utility model. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments.

[0030] Examples of the embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain the present invention, and should not be construed as limiting the present invention.

[0031] In the description of this utility model, it should be understood that the terms "upper", "lower", "front", "rear", "left", "right", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model.

[0032] like Figure 1 As shown, the commutation module of the intelligent controller for the multi-turn electric actuator of this utility model includes a first thyristor 1, a second thyristor 2, a first relay 3, a second relay 4, a third relay 5, a fourth relay 6, a thyristor enable signal interface 7, a relay enable signal interface 8, an interface for any two phases of the three-phase motor 9, an interface for any two phases of the three-phase AC power 10, a relay drive interlock circuit 11, and a thyristor drive circuit 12.

[0033] The circuit design of the commutation module is on one or more circuit boards, and the whole can be modularly and independently packaged. It is an independent system in electrical topology and a separable module in physical structure.

[0034] One end of the second thyristor 2 is connected to the common terminal of the first relay 3, the normally closed terminal of the first relay 3 is connected to one end of the fourth relay 6, and the other end of the fourth relay 6 is connected to the normally open terminal of the second relay 4; one end of the first thyristor 1 is connected to the common terminal of the second relay 4, the normally closed terminal of the second relay 4 is connected to one end of the third relay 5, and the other end of the third relay 5 is connected to the normally open terminal of the first relay 3.

[0035] The first relay 3, the second relay 4, the third relay 5, and the fourth relay 6 are respectively connected to the corresponding relay drive interlock circuit 11; the relay drive interlock circuit 11 is connected to the relay enable signal interface 8.

[0036] The other end of the first thyristor 1 and the other end of the second thyristor 2 are respectively connected to any two phase interfaces of the three-phase motor;

[0037] The first thyristor 1 and the second thyristor 2 are connected to the thyristor drive circuit 12, and the thyristor drive circuit 12 is connected to the thyristor enable signal interface 7.

[0038] The normally open terminal of the first relay 3 is connected to any two phases of the three-phase AC power interface 10, and the normally open terminal of the second relay 4 is connected to any two phases of the three-phase AC power interface 10.

[0039] The first relay 3, the second relay 4, the third relay 5, and the fourth relay 6 are all connected to a three-phase AC power interface 10. The three-phase AC power interface 10 is connected to an external power supply to realize the access of motor drive current. Any two phase interfaces 9 of the three-phase motor are connected to a three-phase motor to realize the output of commutation drive current.

[0040] Both the first thyristor 1 and the second thyristor 2 are bidirectional thyristors.

[0041] The first relay 3 and the second relay 4 are both single-pole double-throw relays, while the third relay 5 and the fourth relay 6 are both single-pole single-throw relays.

[0042] The commutation module of the intelligent controller for the multi-turn electric actuator of this utility model is connected to the main board of the intelligent controller for the multi-turn electric actuator, and receives relay enable signals, thyristor enable signals, etc. from the main board.

[0043] The working principle of this utility model is as follows:

[0044] In scenario one, the enable signals for driving the third relay 5 and the fourth relay 6, issued by the functional motherboard and received through the relay enable signal interface 8, are valid. After being driven by the relay drive interlock circuit 11, the contacts of the third relay 5 and the fourth relay 6 are engaged. After an effective delay, the enable signals for driving the first thyristor 1 and the second thyristor 2, issued by the functional motherboard and received through the thyristor enable signal interface 7, are valid. After being driven by the thyristor drive circuit 12, the first thyristor 1 and the second thyristor 2 are turned on, and power supply phase A is connected to the three-phase motor U phase, and power supply phase B is connected to the three-phase motor V phase. After the functional motherboard successively removes the thyristor and relay enable signals, power supply phase A is disconnected from the three-phase motor U phase, and power supply phase B is disconnected from the three-phase motor V phase.

[0045] In scenario two, the enable signals for driving the first relay 3 and the second relay 4, issued by the functional motherboard and received through the relay enable signal interface 8, are valid. After being driven by the relay drive interlock circuit 11, the normally open contacts of the first relay 3 and the second relay 4 are closed. After an effective delay, the enable signals for driving the first thyristor 1 and the second thyristor 2, issued by the functional motherboard and received through the thyristor enable signal interface 7, are valid. After being driven by the thyristor drive circuit 12, the first thyristor 1 and the second thyristor 2 are turned on, and power supply phase A is connected to the three-phase motor V phase, and power supply phase B is connected to the three-phase motor U phase. After the functional motherboard successively removes the thyristor and relay enable signals, power supply phase A is disconnected from motor V phase, and power supply phase B is disconnected from three-phase motor U phase.

[0046] The above two scenarios enable phase commutation of any two phases of the three-phase motor. Combined with the connection of the third phase of the three-phase motor (i.e., phase W in this example) to the third phase of AC power (i.e., phase C in this example) (default connection by direct short circuit or on-demand connection via switch), the motor is driven in both forward and reverse directions, thereby enabling the opening and closing of valves linked by the multi-turn electric actuator.

[0047] like Figure 2 As shown, the commutation module of the intelligent controller for the multi-turn electric actuator of this utility model also includes a relay drive interlock circuit 11 and a relay enable signal interface 8. The relay drive interlock circuit 11 includes two sets of relay drive interlock sub-circuits, which respectively realize the interlock between the first relay 3 and the fourth relay 6 and the driving of their corresponding relays, as well as the interlock between the second relay 4 and the third relay 5 and the driving of their corresponding relays. The two relay-driven interlocking sub-circuits operate on the same principle. Each sub-circuit includes a first diode D1, a first transistor Q1, a forty-first transistor Q41, a first capacitor C1, a first resistor R1, a second resistor R2, a forty-first resistor R41, and the coil of the first relay, i.e., the first coil Y1. The first diode D1 and the first coil Y1 are connected in parallel. Both the first diode D1 and the first coil Y1 are connected to the collector of the first transistor Q1. The first resistor R1, the collector of the forty-first transistor Q41, the first capacitor C1, and the second resistor R2 are all connected to the base of the first transistor Q1. The first capacitor C1 and the second resistor R2 are connected in parallel. The forty-first resistor R41 is connected in parallel with... The base connection of the forty-first transistor Q41; also includes the fourth diode D4, the fourth transistor Q4, the fourteenth transistor Q14, the fourth capacitor C4, the fourth resistor R4, the fifth resistor R5, the fourteenth resistor R14, the coil of the fourth relay, i.e., the fourth coil Y4, the fourth diode D4 and the fourth coil Y4 are connected in parallel, the fourth diode D4 and the fourth coil Y4 are both connected to the collector of the fourth transistor Q4, the fourth resistor R4, the collector of the fourteenth transistor Q14, the fourth capacitor C4, the fifth resistor R5 are all connected to the base of the fourth transistor Q4, the fourth capacitor C4 and the fifth resistor R5 are connected in parallel, and the fourteenth resistor R14 is connected to the base of the fourteenth transistor Q14.

[0048] The first diode D1 is the freewheeling diode for the first coil Y1, and the fourth diode D4 is the freewheeling diode for the fourth coil Y4. The Y1 enable signal is used for the first coil Y1, and the Y4 enable signal is used for the fourth coil Y4. Both the Y1 and Y4 enable signals are connected through the relay enable signal interface 8.

[0049] The relay drive interlock circuit 11 operates under the following conditions: Condition 1: When the normally open contact of the first relay 3 needs to be closed, the Y1 enable signal is valid (high level), the Y4 enable signal is invalid (low level), the forty-first transistor Q41 is cut off, the Y1 enable signal provides base current to the first transistor Q1 through the first resistor R1, the first transistor Q1 is saturated and conducting, the first coil Y1 of the first relay 3 is energized, and the normally open contact of the first relay 3 is closed; In addition, at this time, the Y1 enable signal provides base current to the fourteenth transistor Q14 through the fourteenth resistor R14, the fourteenth transistor Q14 is saturated and conducting, the base voltage of the fourth transistor Q4 is forced to low, the fourth transistor Q4 cannot conduct, the Y4 coil of the fourth relay 6 cannot be energized, and the contact of the fourth relay 6 cannot be closed. That is, once the Y1 enable signal is valid, the contact of the fourth relay 6 will inevitably not be closed. In scenario two, when the normally open contact of the fourth relay 6 needs to be activated, the Y4 enable signal is valid (high level), the Y1 enable signal is invalid (low level), the fourteenth transistor Q14 is cut off, the Y4 enable signal provides base current to the fourth transistor Q4 through the fourth resistor R4, the fourth transistor Q4 is saturated and conducting, the Y4 coil of the fourth relay 6 is energized, and the normally open contact of the fourth relay 6 is closed. Meanwhile, at this time, the Y4 enable signal provides base current to the forty-first transistor Q41 through the forty-first resistor R41, the forty-first transistor Q41 is saturated and conducting, the base voltage of the first transistor Q1 is forced low, the first transistor Q1 cannot conduct, the Y1 coil of the first relay 3 cannot be energized, and the normally open contact of the first relay 3 cannot be closed. That is, once the Y4 enable signal is valid, the normally open contact of the first relay 3 will inevitably not be closed. Scenario 3: When it is necessary to simultaneously disconnect the normally open contacts of the first relay 3 and the fourth relay 6, both the Y1 enable signal and the Y4 enable signal are invalid (low level). The first transistor Q1, the forty-first transistor Q41, the fourth transistor Q4, and the fourteenth transistor Q14 are all cut off, and neither the first relay 3 nor the fourth relay 6 operates. Scenario 4: When factors such as abnormal input or electromagnetic interference cause the Y1 enable signal and the Y4 enable signal to be valid (high level) simultaneously, the forty-first transistor Q41 and the fourteenth transistor Q14 are saturated and conduct, forcibly pulling down the base voltages of the first transistor Q1 and the fourth transistor Q4, respectively. The first transistor Q1 and the fourth transistor Q4 are cut off, and neither the Y1 coil nor the Y4 coil can be energized. At this time, neither the normally open contact of the first relay 3 nor the fourth relay 6 can be energized.

[0050] When the relay enable signal is affected by interference, short circuit or other factors in the transmission path, the relay drive interlock circuit 11 can prevent the normally open contacts of the first relay 3 and the fourth relay 6 from closing at the same time, which would cause circuit conflict, thereby avoiding dangerous situations such as phase-to-phase short circuit. The relay drive interlock circuit 11 improves the fault tolerance capability when the relay enable signal is abnormal, and at the same time improves the electrical reliability of the commutation module.

[0051] like Figure 3 As shown, the thyristor driving circuit 12 includes a first thyristor driving circuit and a second thyristor driving circuit. The structures of the first and second thyristor driving circuits are the same. The first thyristor driving circuit includes a tenth resistor R10, an eleventh resistor R11, a twelfth resistor R12, a thirteenth resistor R13, and an optocoupler G1. The tenth resistor R10, the eleventh resistor R11, and the twelfth resistor R12 are all connected to the optocoupler G1, and the twelfth resistor R12 and the thirteenth resistor R13 are connected in series. The optocoupler G1 can be a zero-crossing detection optocoupler, and the tenth resistor R10, the eleventh resistor R11, the twelfth resistor R12, and the thirteenth resistor R13 can all be current-limiting power resistors.

[0052] The working principle of the first thyristor drive circuit is as follows: When the first thyristor 1 needs to be turned on, the thyristor enable signal is low, and there is a drive current between the + and - pins of the optocoupler G1. Near the zero-crossing point of the sine wave voltage at the first thyristor 1 terminal, the zero-crossing detection optocouplers M1 and M2 pins and their external circuitry form a drive loop, the trigger signal of the first thyristor 1 is valid, and the first thyristor 1 is turned on. When the thyristor needs to be turned off, the thyristor enable signal is high, there is no drive current in the optocoupler G1, and the first thyristor 1 is naturally turned off.

[0053] The “SCR drive circuit 12” ensures that the SCR is turned on near the zero-crossing point of the AC sine wave, reducing the impact of sudden current changes and electromagnetic interference generated by di / dt.

[0054] This utility model utilizes the electrical interlocking function determined by the physical state attributes of a single-pole double-throw relay and its corresponding application circuit. Combined with the comprehensive application of the relay-driven interlocking circuit, it enhances the fault tolerance capability of the commutation module when abnormal signals are received at the signal interface, and also further improves the overall electrical safety of the commutation module; the details are as follows.

[0055] This utility model utilizes an electrical topology combining two single-pole double-throw relays (first and second relays) and two single-pole single-throw relays (third and fourth relays) to achieve the following electrical interlocking functions: 1) Transient and steady-state interlocking under no-load conditions: When the relay contacts are under no-load conditions or only leakage current flows, no arcing occurs at any open / closed combination of relay contacts, and during relay contact tripping, preventing the formation of a phase-to-phase conducting circuit and effectively avoiding phase-to-phase short circuits. 2) Steady-state interlocking under load conditions: Under abnormal conditions such as contact sticking, the normally open and normally closed terminals of the single-pole double-throw relays cannot conduct, preventing the formation of a phase-to-phase conducting circuit.

[0056] The relay-driven interlock circuit prevents abnormal operation of multiple contacts caused by interference or short circuits in the relay enable signal transmission path, which could lead to phase-to-phase short circuits or other abnormal problems. Specifically, it implements the following electronic interlock function: Without the relay-driven interlock circuit, under the condition that the fourth relay 6 contact is closed and the first relay 3's normally closed contact is under load, if the first relay 3 coil is abnormally energized and its normally open contact closes, the normally closed contact of the first relay 3 will arc during the closing process. If its normally open contact closes during the arcing process, all three contacts of the first relay 3 are equivalent to being simultaneously connected. Two phases of the three-phase AC voltage will form a circuit through the contacts of the fourth relay 6 and the first relay 3, causing a short circuit fault. The relay-driven interlock circuit limits the simultaneous energization of relay coils in conflicting circuits, effectively preventing the first relay 3 from being simultaneously energized when the fourth relay coil is energized, thus effectively preventing the simultaneous closing of normally open contacts in conflicting circuits.

[0057] In summary, the aforementioned electrical interlocking function addresses transient and steady-state interlocking under no-load conditions, as well as steady-state interlocking under load. Building upon this, the electronic interlocking function further effectively improves the protection against phase-to-phase short circuits caused by relay contact arcing during transient switching under load. In conclusion, the combined application of electrical and electronic interlocking enhances the fault tolerance capability when the relay enable signal is abnormal. This circuit is particularly suitable for applications with long signal lines between the commutation module and the intelligent controller's mainboard in a separate design. Simultaneously, the organic and rational combination of the two interlocking circuits effectively improves the electrical safety of the commutation module.

[0058] This utility model uses the electrical interlocking function determined by the physical state attributes of a single-pole double-throw relay to improve electrical safety. At the same time, the contact capacity advantage determined by the physical structure of its contacts, combined with the separable modular design of the commutation module, jointly enhances the scalability of the commutation module's drive power upgrade.

[0059] The commutation module of the intelligent controller for multi-turn electric actuators is designed on a single circuit board. This independently structured power drive section is a physically self-contained modular unit that can be equipped with a dedicated housing. Internally, it integrates core power semiconductor devices, a matching cooling system (such as heat sinks and fans), power stage components such as relays, and may include the necessary drive circuitry. This module connects to the external environment through specially designed standardized electrical interfaces located on the housing (including control signal interfaces for receiving control commands, power input interfaces, and power output interfaces). Its core feature lies in the independence of this physical structure and the clear interface definition, allowing it to be easily physically separated and connected to the control section of the entire machine as a single unit, thereby enabling independent installation, testing, replacement, and maintenance.

[0060] The commutation module of the intelligent controller for multi-turn electric actuators is electrically self-contained and physically modular. The entire circuit can be modularly and independently packaged, enabling flexible installation in a wide range of locations. This overcomes the power upgrade limitations imposed by the common practice of integrating drive and control components in a fixed spatial plane. Specifically, the power drive capability of the commutation module can be upgraded independently without modifying the control section; and the commutation module can be installed independently and flexibly, resulting in high spatial freedom, minimal size constraints, and high feasibility for independent power drive upgrades. Regarding heat dissipation optimization, the independent structure allows for specialized heat dissipation designs for power devices (such as large heat sinks and independent air ducts). This optimization reduces the node temperature of the thyristor, thereby increasing its drive power. Furthermore, heat is concentrated within the drive module for dissipation, preventing interference with sensitive control circuits and improving system thermal reliability.

[0061] In addition to the thyristor, the power device of the commutation module of this utility model is a relay. Based on the modular design of the physical structure of the commutation module, the drive power of the thyristor has better expansion performance. At the same time, this technology uses a single-pole relay, which is characterized by a single relay being equipped with only one set of contact switches instead of multiple sets of contact switches. Therefore, the contact capacity determined by its physical structure has a significant advantage. In summary, the commutation module of this utility model has better expansion performance for upgrading drive power.

[0062] The following is an example: Under the premise that the overall size of the commutation module does not exceed that of a 3.5kW contactor, and according to current electronic component technical standards, the commutation module is particularly suitable for driving AC 380V motors ranging from 2kW to 3.5kW. Taking a 3kW AC asynchronous motor as an example, the motor's rated current is approximately 6A. Considering the motor's starting current and stall current (based on a 6-second stall time before power interruption), and meeting the requirements of an industrial operating environment temperature of 70℃ and a temperature rise not exceeding 40℃, the commutation module can be designed with a rated current of 16A. This includes four relays with a 16A contact capacity, and thyristors with an effective on-state current of 40A or 60A. It also features an aluminum heatsink with a volume four times that of the thyristors, 2mm wide double-sided power traces on the PCB, 2 ounces of copper plating, and 3.5mm line spacing. For harsh environments, the entire module can be potted for insulation, which also improves transient temperature rise suppression. With this design, the overall size of the commutation module is approximately two-thirds the size of two contactors of the same power, resulting in a smaller size and lower cost.

[0063] Both the first thyristor 1 and the second thyristor 2 are contactless semiconductor switches. In conventional applications, their drive circuits have zero-crossing detection capabilities. Therefore, the thyristors can conduct near the zero-crossing point of a sine wave. Their instantaneous conduction current and the turn-off current determined by their inherent properties are very small. As semiconductor power devices controlling the on-time and off-time currents, they can achieve a theoretically infinite lifespan for the entire switching circuit, while also minimizing switching interference. Using a relay in conjunction with thyristors can increase the visible mechanical switching breakpoint, avoiding electrical risks such as electric shock and single-phase operation in case of thyristor breakdown.

[0064] The relay drive interlock circuit 11 prevents the relay enable signal from being affected by interference, short circuits, or other factors during transmission, which could cause abnormal contact jumping of the relay. This avoids phase-to-phase short circuits or abnormal operation, thus improving the electrical reliability of the entire power drive circuit. Therefore, provided that electrical safety distance and electromagnetic compatibility performance requirements are met, it is preferable to place the relay drive interlock circuit close to the relay body.

[0065] The foregoing has shown and described the basic principles, main features, and advantages of this utility model. It will be apparent to those skilled in the art that this utility model is not limited to the details of the exemplary embodiments described above, and that it can be implemented in other specific forms without departing from the spirit or basic characteristics of this utility model. Therefore, the embodiments should be considered exemplary and non-limiting in all respects. The scope of this utility model is defined by the appended claims rather than the foregoing description, and thus all variations falling within the meaning and scope of equivalents of the claims are intended to be included within this utility model. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0066] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A commutation module of an intelligent controller for a multi-turn electric actuator, characterized in that, The commutation module of the intelligent controller for the multi-turn electric actuator includes a first thyristor, a second thyristor, a first relay, a second relay, a third relay, a fourth relay, a relay drive interlock circuit, a thyristor drive circuit, a relay enable signal interface, a thyristor enable signal interface, an interface for any two phases of three-phase AC power, and an interface for any two phases of three-phase motor power. The circuit design of the commutation module is on one or more circuit boards, and the whole can be modularly and independently packaged. It is an electrically self-contained system and a physically separable module. One end of the second thyristor is connected to the common terminal of the first relay, the normally closed terminal of the first relay is connected to one end of the fourth relay, and the other end of the fourth relay is connected to the normally open terminal of the second relay. One end of the first thyristor is connected to the common terminal of the second relay, the normally closed terminal of the second relay is connected to one end of the third relay, and the other end of the third relay is connected to the normally open terminal of the first relay. The first, second, third, and fourth relays are each connected to their respective relay drive interlock circuits; the relay drive interlock circuits are connected to the relay enable signal interface.

2. The commutation module of the intelligent controller for the multi-turn electric actuator as described in claim 1, characterized in that, The other end of the first thyristor and the other end of the second thyristor are respectively connected to any two phase interfaces of the three-phase motor; the first thyristor and the second thyristor are connected to the thyristor drive circuit, and the thyristor drive circuit is connected to the thyristor enable signal interface; the normally open terminal of the first relay is connected to any two phase interfaces of the three-phase AC power supply, and the normally open terminal of the second relay is connected to any two phase interfaces of the three-phase AC power supply.

3. The commutation module of the intelligent controller for the multi-turn electric actuator as described in claim 1, characterized in that: The circuit consisting of the first, second, third, and fourth relays can be electrically interchanged with the circuit consisting of two thyristors. That is, any two phase terminals of the three-phase AC power supply can be directly connected to the thyristors, the thyristors can be directly connected to the relays, and the relays can be connected to any two phase interfaces of the three-phase motor.

4. The commutation module of the intelligent controller for the multi-turn electric actuator as described in claim 1, characterized in that, Both the first and second thyristors are bidirectional thyristors, and either of the thyristors can be replaced by two antiparallel unidirectional thyristor devices.

5. The commutation module of the intelligent controller for the multi-turn electric actuator as described in claim 1, characterized in that, The first and second relays are both single-pole double-throw relays, which can be replaced by double-pole double-throw relays. The third and fourth relays are both single-pole single-throw relays, which can be replaced by double-pole single-throw relays.

6. The commutation module of the intelligent controller for the multi-turn electric actuator as described in claim 1, characterized in that, The commutation module of the intelligent controller of the multi-turn electric actuator is connected to the main board of the intelligent controller of the multi-turn electric actuator via the relay enable signal interface and the thyristor enable signal interface.

7. The commutation module of the intelligent controller for the multi-turn electric actuator as described in claim 1, characterized in that, The commutation module of the intelligent controller for the multi-turn electric actuator also includes a relay drive interlock circuit and a relay enable signal interface. The first, second, third, and fourth relays are all connected to the relay drive interlock circuit, which is connected to the relay enable signal interface. The relay drive interlock circuit includes two sets of relay drive interlock sub-circuits, which operate on the same principle. These sub-circuits are for the first and fourth relays, and for the second and third relays, respectively. The first and fourth relay drive interlock sub-circuits include diode D1, transistor Q1, transistor Q41, capacitor C1, resistors R1, R2, and R41, and the coil of the first relay. Coil Y1, diode D1 and coil Y1 are connected in parallel. Diode D1 and coil Y1 are both connected to the collector of transistor Q1. Resistor R1, collector of transistor Q41, capacitor C1, and resistor R2 are all connected to the base of transistor Q1. Capacitor C1 and resistor R2 are connected in parallel. Resistor R41 is connected to the base of transistor Q41. Also included are diode D4, transistor Q4, transistor Q14, capacitor C4, resistor R4, resistor R5, resistor R14, and the coil of the fourth relay, i.e., coil Y4. Diode D4 and coil Y4 are connected in parallel. Diode D4 and coil Y4 are both connected to the collector of transistor Q4. Resistor R4, collector of transistor Q14, capacitor C4, and resistor R5 are all connected to the base of transistor Q4. Capacitor C4 and resistor R5 are connected in parallel. Resistor R14 is connected to the base of transistor Q14.

8. The commutation module of the intelligent controller for the multi-turn electric actuator as described in claim 1, characterized in that, The thyristor driving circuit includes a first thyristor driving circuit and a second thyristor driving circuit. The principle of the first thyristor driving circuit is the same as that of the second thyristor driving circuit. The first thyristor driving circuit includes resistors R10, R11, R12, and R13, and an optocoupler. Resistors R10, R11, and R12 are all connected to the optocoupler, and resistors R12 and R13 are connected in series.

9. The commutation module of the intelligent controller for the multi-turn electric actuator as described in claim 8, characterized in that, The optocoupler is a zero-crossing detection optocoupler, and resistors R10, R11, R12, and R13 are all current-limiting power resistors.

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