Modular Actuator Control Base Mount System

Abstract

The modular actuator control system includes a modular mounting base having first and second base attachments, first and second base coolant ports, a power bus, and a signal bus; and first and second drive modules each having a drive attachment operably configured to connect to the first and second base attachments, respectively, a power connection operably configured to connect to the power bus, a signal connection operably configured to connect to the signal bus, an actuator drive connection operably configured to connect to an actuator, and a coolant port operably configured to connect to the first and second base coolant ports, respectively, the first and second drive modules being removably mounted to the modular mounting base and operably configured to be in power communication with the power bus, in signal communication with the signal bus, and in coolant fluid communication with a coolant inlet of the modular mounting base.

Description

[Technical Field]

[0001] The present invention relates generally to actuator control systems, and more particularly to a modular actuator control base mount system. [Background technology]

[0002] Electric motors that provide actuation in at least one axis of motion are well known in the art and are used in a wide variety of industries. It is known that such motors can directly or indirectly drive linear or rotary actuators, or may drive pumps to provide electrohydraulic linear or rotary actuation. It is also known that such actuation systems may include drive controls and power electronics for controlling and monitoring the operation of the actuators.

[0003] International Patent Publication WO 2022 / 187066, entitled "Modular Rugged Cooled Actuator Control System," discloses a modular actuator control system comprising a control module, a power module, and multiple actuator control modules stacked together to provide a compact, rugged, and cooled controller system for controlling multiple actuators. The entire contents of International Patent Publication WO 2022 / 187066 are incorporated herein by reference.

[0004] A mobile machine is generally a land vehicle that is self-propelled or mobile, and that, unlike an automobile, has attached to it machinery or equipment that provides a function beyond transporting people from one point to another. Mobile machines are known to include, but are not limited to, forklifts, skid steers, excavators, tractors, bulldozers, agricultural machinery, dump trucks, garbage trucks, mobile cranes, and other mobile construction equipment. Summary of the Invention

[0005] For purposes of illustration only, and without limitation, with parenthetical references to corresponding parts, portions, or surfaces of the disclosed embodiments, a modular actuator control system (15, 215) is provided, the modular actuator control system (15, 215) comprising a modular mounting base (25, 225), a first drive module (18, 19, 20, 21, 22) operatively configured to control a motorized first actuator (52, 53, 54, 55, 56, 57) having at least one axis of motion, and a first drive module (18, 19, 20, 21, 22) operatively configured to control a motorized first actuator (52, 53, 54, 55, 56, 57) having at least one axis of motion. and a second drive module (18, 19, 20, 21, 22) operatively configured to control a second actuator (52, 53, 54, 55, 56, 57), and the module mounting base has a base housing (26, 27, 227), the base housing (26, 27, 227) having a coolant inlet (181), first base attachments (128, 158, 228, 258), first base coolant ports (188a, 188b, 189a, 189b, 190a, 190b, 191a, 191b, 192a, 192b), and a second base attachment (188b, 188c, 188d, 189e, 189f, 190f, 190g, 191h, 191i, 191b, 192i, 192b). a first drive module having a first drive housing (30c, 30d), the first drive housing (30c, 30d) including a first drive attachment (91c, 93c, 91d, 93d, 293) operably configured to connect to the first base attachment, a second base coolant port (188a, 188b, 189a, 189b, 190a, 190b, 191a, 191b, 192a, 192b), a power bus (170), and a signal bus (160), a first power connection (36c, 36d) operably configured to connect to a first power bus, a first signal connection (37c, 37d) operably configured to connect to a signal bus, a first actuator drive connection (38c, 39c, 39d) operably configured to connect to a first actuator, and a first coolant port (81c, 82c, 81d, 82d) operably configured to connect to a first base coolant port, and the second drive module has a second drive housing (30c, 30d),a second drive attachment (91c, 93c, 91d, 93d, 293) operably configured to connect to the second base attachment; a second power connection (36c, 36d) operably configured to connect to the power bus; a second signal connection (37c, 37d) operably configured to connect to the signal bus; a second actuator drive connection (38c, 39c, 39d) operably configured to connect to the second actuator; and a second coolant port (81c, 82c, 81d, 82d) operably configured to connect to the second base coolant port, wherein the first drive module and the second drive module are removably mounted to the module mounting base and are operably configured to be in power communication with the power bus, in signal communication with the signal bus, and in coolant fluid communication with the coolant inlet.

[0006] The first base coolant port may comprise a first supply port (188a, 189a, 190a, 191a, 192a) and a first return port (188b, 189b, 190b, 191b, 192b), the second base coolant port may comprise a second supply port (188a, 189a, 190a, 191a, 192a) and a second return port (188b, 189b, 190b, 191b, 192b), the first coolant port may comprise a first inlet port (81c, 81d) and a first outlet port (82c, 82d), and the second coolant port may comprise a second inlet port (81c, 81d) and a second outlet port (82c, 82d). The first drive housing may comprise a first coolant fluid flow path (87) between the first inlet port and the first outlet port, the second drive housing may comprise a second coolant fluid flow path (87) between the second inlet port and the second outlet port, the first supply port may be operably configured to connect to the first inlet port, the first return port may be operably configured to connect to the first outlet port, the second supply port may be operably configured to connect to the second inlet port, and the second return port may be operably configured to connect to the second outlet port. The base housing may comprise a first base coolant passage (183b, 183c, 183d, 183e) between the first return port and the second supply port.

[0007] The base housing may include a control base attachment (128a, 128b), the system may include a master controller module (16), the master controller module (16) may have a controller housing (30a), the controller housing (30a) may include controller attachments (91a, 93a) operably configured to connect to the control base attachment, a controller signal connection (37a) operably configured to connect to a signal bus, and a system controller connection (64) operably configured to communicate with a system controller (60), and the master controller module may be removably mounted to the module mounting base and operably configured to be in signal communication with the signal bus.

[0008] The base housing may include a power base attachment (128b, 158b) and a power base coolant port (187a, 187b), and the system may include a master power module (17), the master power module (17) having a power housing (30b), the power housing (30b) including power attachments (91b, 93b) operably configured to connect to the power base attachment, a master power connection (36b) operably configured to connect to the power bus, a system power connection (66) operably configured to connect to the system power source (70), and power module coolant ports (81b, 82b) operably configured to connect to the power base coolant port, and the master power module may be removably mounted to the module mounting base and operably configured to be in power communication with the power bus and in coolant fluid communication with the coolant inlet.

[0009] The power housing may include a power signal connection (37b) operably configured to connect to the signal bus. The first base coolant port may include a first supply port and a first return port, the second base coolant port may include a second supply port and a second return port, the power base coolant port may include a power supply port (187a) and a power return port (187b), the first coolant port may include a first inlet port and a first outlet port, the second coolant port may include a second inlet port and a second outlet port, the power module coolant port may include a power inlet port (81b) and a power outlet port (82b), the first drive housing may include a first coolant fluid flow path between the first inlet port and the first outlet port, The housing may include a second coolant fluid flow path between the second inlet port and the second outlet port, and the power housing may include a power-coolant fluid flow path (87) between the power inlet port and the power outlet port, where the first supply port is operably configured to connect to the first inlet port, the first return port is operably configured to connect to the first outlet port, the second supply port is operably configured to connect to the second inlet port, the second return port is operably configured to connect to the second outlet port, the power supply port is operably configured to connect to the power inlet port, and the power return port is operably configured to connect to the power outlet port. The modular actuator control system may include a pump (45) connected to the coolant inlet of the base housing and operably configured to pump fluid coolant through the first coolant fluid flow path of the first drive housing, the second coolant fluid flow path of the second drive housing, and the power-coolant fluid flow path.

[0010] The base housing may include a control base attachment, and the system may include a master controller module, the master controller module having a controller housing, the controller housing including a controller attachment operably configured to connect to the control base attachment, a controller signal connection operably configured to connect to a signal bus, and a controller system connection operably configured to communicate with a system controller, and the master controller module may be removably mounted to the module mounting base and operably configured to be in signal communication with the signal bus. A master power module may be supported by the module mounting base between the master controller module and the first drive module. The system power source may include an electric vehicle battery (70).

[0011] The first base attachment may comprise a first base bolt hole (128, 158, 228, 258), the first drive attachment may comprise a first module bolt hole (91c, 93c, 91d, 93d, 293), and the first drive attachment may be operatively configured to connect to the first base attachment via a first bolt (129, 159, 229, 259) extending through the first base bolt hole and the first module bolt hole and between the first base bolt hole and the first module bolt hole.

[0012] The base housing may include a base plate (26) and a back plate (27), and the power bus and signal bus may be housed in the back plate. The first base attachment may include a base plate attachment (128) and a back plate attachment (158). The coolant inlet may include an inlet port in the back plate, and the back plate may include an outlet port (182). The base plate may include first base keyways (118, 119, 120, 121, 122) configured to mate with corresponding keys of the first drive module and second base keyways (118, 119, 120, 121, 122) configured to mate with corresponding keys of the second drive module.

[0013] The base housing may include a back plate (227), and the power bus and signal bus may be housed in the back plate. The first base attachment may include a first back plate attachment (228) and a second back plate attachment (258). The back plate may include a first key (216) configured to mate with a corresponding key on the first drive module and a second key configured to mate with a corresponding key on the second drive module.

[0014] The accompanying drawings are incorporated herein as part of this specification. The drawings described herein illustrate examples of the disclosed subject matter and illustrate selected principles and teachings of the present disclosure. However, the drawings do not illustrate every possible implementation of the disclosed subject matter and are not intended to limit the scope of the present disclosure in any way. [Brief explanation of the drawings]

[0015] [Figure 1] FIG. 1 is a front isometric view of an embodiment of an improved modular actuator control system. [Figure 2] FIG. 2 is a front isometric view of the modular actuator control support structure shown in Figure 1. [Figure 3]FIG. 3 is a partial rear isometric exploded view of the back plate of the modular actuator control support structure shown in Figure 2. [Figure 4] FIG. 3 is a front view of the back plate of the modular actuator control support structure shown in FIG. 2. [Figure 5] FIG. 5 is a rear view of the back plate of the modular actuator control support structure shown in Figure 4. [Figure 6] FIG. 3 is a front isometric view of the base plate of the modular actuator control support structure shown in Figure 2. [Figure 7] FIG. 3 is a front isometric view of the control bus and power bus embodiment shown in FIG. 2. [Figure 8] FIG. 3 is a front schematic view of the control bus, power bus, and cooling bus of the backplane shown in FIG. 2. [Figure 9] FIG. 2 is a front isometric view of the master controller module shown in Figure 1. [Figure 10] Figure 10 is a rear view of the master controller module shown in Figure 9. [Figure 11] FIG. 2 is a front isometric view of the master power module shown in FIG. 1. [Figure 12] FIG. 12 is a rear view of the master power module shown in FIG. 11. [Figure 13] FIG. 2 is a front isometric view of one of the two-axis actuator drive modules shown in FIG. 1. [Figure 14] FIG. 14 is a rear view of the two-axis actuator drive module shown in FIG. [Figure 15] FIG. 2 is a front isometric view of one of the single axis actuator drive modules shown in FIG. 1. [Figure 16] FIG. 16 is a rear view of the single-axis actuator drive module shown in FIG. [Figure 17A] 2 is an isometric view illustrating the mounting of modules in the modular actuator control support structure shown in FIG. 1 mounted on an embodiment of a mobile machine. FIG. [Figure 17B]2 is an isometric view illustrating the mounting of modules in the modular actuator control support structure shown in FIG. 1 mounted on an embodiment of a mobile machine. FIG. [Figure 17C] 2 is an isometric view illustrating the mounting of modules in the modular actuator control support structure shown in FIG. 1 mounted on an embodiment of a mobile machine. FIG. [Figure 17D] 2 is an isometric view illustrating the mounting of modules in the modular actuator control support structure shown in FIG. 1 mounted on an embodiment of a mobile machine. FIG. [Figure 17E] 2 is an isometric view illustrating the mounting of modules in the modular actuator control support structure shown in FIG. 1 mounted on an embodiment of a mobile machine. FIG. [Figure 17F] 2 is an isometric view illustrating the mounting of modules in the modular actuator control support structure shown in FIG. 1 mounted on an embodiment of a mobile machine. FIG. [Figure 18A] FIG. 17B is an isometric view illustrating removal of a module from the modular actuator control support structure shown in FIG. 17F. [Figure 18B] FIG. 17B is an isometric view illustrating removal of a module from the modular actuator control support structure shown in FIG. 17F. [Figure 19] 2 is a vertical cross-sectional schematic view of a cooling conduit profile of the embodiment of the module shown in FIG. 1. [Figure 20] FIG. 2 is a schematic diagram of an embodiment of four drive modules of the modular actuator control system shown in FIG. 1 operably coupled to an exemplary vehicle having a liquid cooling system and a plurality of exemplary actuators. [Figure 21] FIG. 3 is a front isometric view of an alternative embodiment of the modular actuator control support structure shown in FIG. 2. [Figure 22] 22 is a front isometric view of an embodiment of an improved modular actuator control system having a modular actuator control support structure as shown in FIG. 21. FIG. DETAILED DESCRIPTION OF THE INVENTION

[0016] First, it should be clearly understood that like reference numerals are intended to identify identical structural elements, portions, or surfaces consistently throughout the several depicted views, as such elements, portions, or surfaces may be further described or explained by the entire written specification, of which this detailed description is an integral part. Unless otherwise indicated, the drawings are intended to be read in conjunction with the specification (e.g., cross-hatching, arrangement of parts, proportions, degrees, etc.) and should be considered part of the entire written description of the invention. As used in the following description, the terms "horizontal," "vertical," "left," "right," "upper," and "lower," as well as their adjectival and adverbial derivatives (e.g., "horizontally," "to the right," "above," etc.), simply refer to the orientation of the depicted structure when a particular depicted view faces the reader. Similarly, the terms "in" and "out" generally refer to the orientation of a surface relative to its axis of elongation or rotation, as appropriate.

[0017] The specific assemblies and systems illustrated in the accompanying drawings, and described in the following specification, should be understood to be merely exemplary embodiments. Accordingly, specific dimensions, orientations, or other physical characteristics relating to the disclosed embodiments are not to be considered limiting, unless expressly stated otherwise. Also, although not necessarily, similar elements in the various embodiments described herein may be commonly referred to with similar reference numerals within this section of the application.

[0018] It should be recognized that the present teachings are illustrative only and not limiting. The concepts herein are not limited to use or application in any particular system or method. Thus, the implementations described herein are shown and described with reference to exemplary embodiments, but it will be recognized that the principles herein may be equally applied to other types of systems and methods.

[0019] As used herein, the terms "first," "second," etc. do not necessarily imply any order, sequence, or priority relationship, but are merely used to more clearly distinguish one element or set of elements from another element or set of elements unless otherwise specified.

[0020] Referring now to the drawings, a modular actuator control module base mount system is provided, a first embodiment of which is generally designated by the numeral 15. As shown, system 15 generally includes a base 25 configured to support and couple one or more actuator control modules 16-22 such that the actuator control modules are keyed and plugged into base 25 for connection to associated power, command, and cooling. As described further below, individual modules 16-22 may be removably mounted and plugged into base 25 such that drive modules 18-22 may connect to and control one or more actuators 52-57 on the mobile machine, and base 25 is configured to be mounted on a mobile machine such as a skid steer 29. In this embodiment, module 16 is a master controller module, module 17 is a master power module, modules 18-20 are each dual-axis actuator drive modules, and modules 21 and 22 are each single-axis actuator drive modules. In this embodiment, the base 25 generally comprises a horizontally extending base plate 26 and an attached vertically extending back plate 27 .

[0021] 2 and 6, base plate 26 is generally bounded by a horizontal upper surface 110, a horizontal lower surface 111, a vertical front surface 112, a vertical rear surface 113, a vertical left side surface 114, and a vertical right side surface 115. A plurality of vehicle mounting holes, each designated 126, extend through base plate 26 from upper surface 110 to lower surface 111 and are configured to receive corresponding mounting bolts or screws 127 so that base plate 26 may be mounted to a vehicle, such as a skid steer 29, as shown in FIGS.

[0022] Top surface 110 and front surface 112 include specially configured recessed keyways 116-122 that correspond to matching keys on the base of modules 16-22, respectively, so that modules 16-22 can be properly positioned on base 25 during installation, as shown in FIG. 17D. Thus, in this embodiment, keyway system 123 is provided in base plate 26 such that keyway 116 matches module 16, keyway 117 matches module 17, keyway 118 matches module 18, keyway 119 matches module 19, keyway 120 matches module 20, keyway 121 matches module 21, and keyway 22 matches module 22. Different types of modules may have different keys and corresponding keyways in base plate 26, as needed, to ensure that each type of module is properly aligned along backplane 28 of base 25, as desired. Thus, modules 16-22 are keyed into position along backplane 28 of base 25 to prevent installation of the wrong type of module in a particular location along backplane 27 of base 25. Thus, for example, keyway 116 may be configured to accept only master control module 16, keyway 117 may be configured to accept only master power module 17, keyways 118-120 may each be configured to accept only dual-axis actuator drive modules 18, 19, or 20, and / or keyways 121 and 122 may be configured to accept only single-axis actuator drive modules 21 or 22.

[0023] Front surface 112 includes a pair of horizontally spaced threaded module mounting bolt holes, each indicated at 128, configured to receive corresponding module mounting bolts, each indicated at 129, so that each of modules 16-22 may be removably mounted to base plate 26 as shown in Figures 17E-17F. Back surface 113 includes a plurality of threaded back plate mounting bolt holes (not shown) configured to receive corresponding mounting bolts (not shown) so that back plate 27 may be removably mounted to base plate 26 as shown in Figures 1 and 2. Base plate 26 may be a solid, unitary member.

[0024] As shown in FIGS. 2-5 , back plate 27 is configured to house control bus 160, power bus 170, and cooling bus 180 of backplane 28 of base 25. Back plate 27 is a sturdy enclosure generally comprising a horizontal top surface 140, a horizontal bottom surface 141, a vertical front panel 142, a vertical rear panel 143, a vertical right surface 145, and a vertical left surface 144. The upper end of back plate 27 includes pairs of horizontally spaced module mounting bolt holes, each indicated by 158, configured to receive corresponding module mounting bolts, each indicated by 159, so that each of modules 16-22 may be removably mounted to back plate 27 as shown in FIGS. 17E-17F. The lower end of back plate 27 includes a plurality of base plate mounting bolt holes 153 configured to receive corresponding mounting bolts (not shown) so that back plate 27 may be removably mounted to base plate 26 as shown in FIGS. 1 and 2.

[0025] One or more of the modules 16-22 can be easily removed from the base 25 for replacement by removing the appropriate bolts 159 from the appropriate mounting holes 158 in the back plate 27, removing the appropriate bolts 129 from the appropriate mounting holes 128 in the base plate 26, and unplugging the coolant, signal, and power connections from the base 25. 18A and 18B, the master power module 17 may be removed from the base 25 by removing bolts 129 from module bolt holes 93b and corresponding base plate bolt holes 128b to disconnect the housing 30b from the base plate 26, by removing bolts 159 from module bolt holes 91b and corresponding back plate bolt holes 158b to disconnect the housing 30b from the back plate 27, by disconnecting power connection 136b from power connection 172a of bus 170, by disconnecting signal connection 37b from connection 162b of signal bus 160, and by disconnecting ports 81b and 82b from ports 187a and 187b of the back plate 27, respectively, so that the module 17 may be completely disconnected and disconnected from the base 25 and removed and replaced as needed.

[0026] As shown in FIG. 4 , front panel 142 includes electronic connection openings 146-152. Opening 146 aligns with keyway 116 to provide a passage through backplate 27 for connecting connection 162a of control signal bus 160 to connection 37a and master control electronics 61 of master control module 16, and the rear panel of control module 16 has connection opening 50a of corresponding position and size when module 16 is properly positioned in keyway 116. Opening 147 aligns with keyway 117 to provide a passage through backplate 27 for connecting connection 162b of control bus 160 to connection 37b and control power electronics 62 of master power module 17 and for connecting connection 172a of power bus 170 to connection 36b and master power electronics 63 of master power module 17, and the rear panel of power module 17 has opening 50b of corresponding position and size when module 17 is properly positioned in keyway 117. Opening 148 is aligned with keyway 118 to provide passage through back plate 27 for connecting connection 162c of control bus 160 to connection 37c and control electronics 32c of dual-axis actuator drive module 18, and connection 172b of power bus 170 to connection 36c and power electronics 31c of dual-axis actuator drive module 18, and the back panel of dual-axis actuator drive module 18 has opening 50c of corresponding position and size when module 18 is properly positioned in keyway 118. Opening 149 is aligned with keyway 119 to provide passage through back plate 27 for connecting connection 162d of control bus 160 to connection 37c and control electronics 32c of dual-axis actuator drive module 19, and connection 172c of power bus 170 to connection 36c and power electronics 31c of dual-axis actuator drive module 19, and the back panel of dual-axis actuator drive module 19 has opening 50c of corresponding position and size when module 19 is properly positioned in keyway 119.Opening 150 is aligned with keyway 120 to provide passage through back plate 27 for connecting connection 162e of control bus 160 to connection 37c and control electronics 32c of dual-axis actuator drive module 20, and connection 172d of power bus 170 to connection 36c and power electronics 31c of dual-axis actuator drive module 20, and the back panel of dual-axis actuator drive module 20 has opening 50c of corresponding position and size when module 20 is properly positioned in keyway 120. Opening 151 is aligned with keyway 121 to provide passage through back plate 27 for connecting connection 162f of control bus 160 to connection 37d and control electronics 32d of single-axis actuator drive module 21, and connection 172e of power bus 170 to connection 36d and power electronics 31d of single-axis actuator drive module 21, and the back panel of single-axis actuator drive module 21 has opening 50d of a corresponding position and size when module 21 is properly positioned in keyway 121. Opening 152 is aligned with keyway 122 to provide passage through back plate 27 for connecting connection 162g of control bus 160 to connection 37d and control electronics 32d of single-axis actuator drive module 22, and connection 172f of power bus 170 to connection 36d and power electronics 31d of single-axis actuator drive module 22, and the back panel of single-axis actuator drive module 22 has opening 50d of a corresponding position and size when module 22 is properly positioned in keyway 122.

[0027] As shown in FIG. 2, the right side 145 of the back plate 27 includes a coolant system inlet port 181, and the left side 144 of the back plate 27 includes a coolant system outlet port 182. As shown in FIG. 20, the coolant inlet port 181 and outlet port 182 are connected to a coolant system on the vehicle 29, including the coolant circulation pump 45 and the heat exchanger 46. As shown in FIGS. 2, 4, and 8, the front panel 142 includes module coolant supply ports 187a, 188a, 189a, 190a, 191a, and 192a. The front panel 142 also includes module coolant return ports 187b, 188b, 189b, 190b, 191b, and 192b. Passage 183a in lower back plate 27 extends between inlet 181 and supply port 192a, passage 183b in lower back plate 27 extends between return port 192b and supply port 191a, passage 183c in lower back plate 27 extends between return port 191b and supply port 190a, passage 183d in lower back plate 27 extends between return port 190b and supply port 189a, passage 183e in lower back plate 27 extends between return port 189b and supply port 188a, passage 183f in lower back plate 27 extends between return port 188b and supply port 187a, and passage 183g in lower back plate 27 extends between return port 187b and outlet port 182.

[0028] Supply port 187a aligns with keyway 117 to provide a coolant fluid passageway from backplate 27 to fluid coolant inlet 81b of master power module 17, and the rear panel of power module 17 has correspondingly positioned and sized coolant inlet 81b that mates with port 187a when module 17 is properly positioned in keyway 117. Return port 187b similarly aligns with keyway 117 to provide a coolant fluid passageway from fluid coolant outlet 82b of master power module 17 to backplate 27, and the rear panel of power module 17 has correspondingly positioned and sized coolant outlet 82b that mates with return port 187b when module 17 is properly positioned in keyway 117. The supply port 188a is aligned with the keyway 118 to provide a coolant fluid passageway from the back plate 27 to the fluid coolant inlet 81c of the dual-axis actuator drive module 18, and the rear panel of the dual-axis actuator drive module 18 has a correspondingly positioned and sized coolant inlet 81c that mates with the port 188a when the module 18 is properly positioned in the keyway 118. The return port 188b is similarly aligned with the keyway 118 to provide a coolant fluid passageway from the fluid coolant outlet 82c of the dual-axis actuator drive module 18 to the back plate 27, and the rear panel of the dual-axis actuator drive module 18 has a correspondingly positioned and sized coolant outlet 82c that mates with the return port 188b when the module 18 is properly positioned in the keyway 118. The supply port 189a is aligned with the keyway 119 to provide a coolant fluid passage from the back plate 27 to the fluid coolant inlet 81c of the dual-axis actuator drive module 19, and the back panel of the dual-axis actuator drive module 19 has a correspondingly positioned and sized coolant inlet 81c that mates with the port 189a when the module 19 is properly positioned in the keyway 119.Return port 189b similarly aligns with keyway 119 to provide a coolant fluid passageway from fluid coolant outlet 82c of dual-axis actuator drive module 19 to back plate 27, and the rear panel of dual-axis actuator drive module 19 has correspondingly positioned and sized coolant outlet 82c that mates with return port 189b when module 19 is properly positioned in keyway 119. Supply port 190a aligns with keyway 120 to provide a coolant fluid passageway from back plate 27 to fluid coolant inlet 81c of dual-axis actuator drive module 20, and the rear panel of dual-axis actuator drive module 20 has correspondingly positioned and sized coolant inlet 81c that mates with port 190a when module 20 is properly positioned in keyway 120. Return port 190b is similarly aligned with keyway 120 to provide a coolant fluid passageway from fluid coolant outlet 82c of dual-axis actuator drive module 20 to back plate 27, and the rear panel of dual-axis actuator drive module 20 has correspondingly positioned and sized coolant outlet 82c that mates with return port 190b when module 20 is properly positioned in keyway 120. Supply port 191a is aligned with keyway 121 to provide a coolant fluid passageway from back plate 27 to fluid coolant inlet 81d of single-axis actuator drive module 21, and the rear panel of single-axis actuator drive module 21 has correspondingly positioned and sized coolant inlet 81d that mates with port 191a when module 21 is properly positioned in keyway 121. The return port 191b is similarly aligned with the keyway 121 to provide a coolant fluid passage from the fluid coolant outlet 82d of the single-axis actuator drive module 21 to the back plate 27, and the back panel of the single-axis actuator drive module 21 has a correspondingly positioned and sized coolant outlet 82d that mates with the return port 191b when the module 21 is properly positioned in the keyway 121.The supply port 192a is aligned with the keyway 122 to provide a coolant fluid passageway from the back plate 27 to the fluid coolant inlet 81d of the single-axis actuator drive module 22, and the rear panel of the single-axis actuator drive module 22 has a correspondingly positioned and sized coolant inlet 81d that mates with the port 192a when the module 22 is properly positioned in the keyway 122. The return port 192b is similarly aligned with the keyway 122 to provide a coolant fluid passageway from the fluid coolant outlet 82d of the single-axis actuator drive module 22 to the back plate 27, and the rear panel of the single-axis actuator drive module 22 has a correspondingly positioned and sized coolant outlet 82d that mates with the return port 192b when the module 22 is properly positioned in the keyway 122.

[0029] Thus, with base 25 connected to modules 16-22 and pump 45 circulating coolant fluid, coolant flow path 184 flows in the following order: inlet 181, through passage 183a, out supply port 192a, through module 22, into return port 192b, through passage 183b, out supply port 191a, through module 21, into return port 191b, through passage 183c, out supply port 190a. , through module 20, into return port 190b, through passage 183d, out supply port 189a, through module 19, into return port 189b, through passage 183e, out supply port 188a, through module 18, into return port 188b, through passage 183f, out supply port 187a, through module 17, into return port 187b, through passage 183g, and out exit 182.

[0030] In this embodiment, no ports are provided in the master control module 16, and the master control module is not cooled via the pump 45, heat exchanger 46, and coolant fluid path 184; instead, ports and passages may be added in sequence to the back plate 27 such that the flow path 184 extends through the module 16, cools the module 16, and then exits the back plate 27 via the outlet port 182.

[0031] As shown in FIG. 5, rear panel 143 includes a module power and command access opening 154 that is covered and sealed by a removable cover 155, and a separate cooling access opening 156 that is covered and sealed by a removable cover 157.

[0032] As shown in FIG. 7, in this embodiment, control bus 160 generally comprises two connected printed circuit boards 161a and 161b supporting mounted control bus connectors 162a, 162b, 162c, 162d, 162e, 162f, and 162g. Control bus connectors 162a, 162b, 162c, 162d, 162e, 162f, and 162g are spaced on substrates 161a and 162b to align with keyways 116, 117, 118, 119, 120, 121, and 122, respectively, and to provide signal and low-voltage control power connections through openings 146, 147, 148, 149, 150, 151, and 152 to connectors 37a, 37b, 37c, and 37d and control electronics 61, 62, 32c, and 32d, respectively, of modules 16, 17, 18, 19, 20, 21, and 22. Control bus 160 may have, for example, without limitation, four high current circuits, 24 signal circuits, and eight spare signal circuits. In this embodiment, control bus connectors 162a, 162b, 162c, 162d, 162e, 162f, and 162g and module connectors 37a, 37b, 37c, and 37d are multi-pin mating connectors that provide low voltage power 160a in addition to communication signals, although alternative bus circuits and configurations may be used depending on the application.

[0033] In this embodiment, power bus 170 is a DC bus generally comprising two copper bus bars 171 and 173, one for power positive and one for power negative, supported by a plurality of spaced apart insulators each designated 174 and having DC connectors 172a, 172b, 172c, 172d, 172e, and 172f press-fit thereto, respectively. DC connectors 172a, 172b, 172c, 172d, 172e, and 172f are spaced on each of bus bars 171 and 173 to align with keyways 117, 118, 119, 120, 121, and 122, respectively, and to provide electrical connections through openings 147, 148, 149, 150, 151, and 152 to connectors 36b, 36c, and 36d and power electronics 63, 31c, and 31d, respectively, of modules 17, 18, 19, 20, 21, and 22. In this embodiment, power bus connectors 172a, 172b, 172c, 172d, 172e, and 172f and module connectors 36b, 36c, and 36d are single pin mating connectors.

[0034] 9-16 , various different types of modules may be supported by base 25. In this example, exemplary modules include master control module 16, master power module 17, dual-axis actuator drive modules 18-20, and single-axis actuator drive modules 21 and 22, all configured to be stacked together on base 25 to provide a compact, rugged, cooled controller system 15 for controlling multiple actuators. Each of modules 16-22 seals to base 25 via, for example, gaskets, O-rings, or face seals to prevent ingress of dust and water from the surrounding environment. For example, without limitation, dual drive modules 18, 19, and 20 may each control both a linear electro-hydraulic actuator 56 and a rotary electro-mechanical actuator 57 on mobile machine 29, or two rotary electro-mechanical actuators 54 and 55. Actuator drive module 21 may control linear electro-mechanical actuator 52 on mobile machine 29, and actuator drive module 22 may control rotary electro-hydraulic actuator 53 on mobile machine 29.

[0035] While the embodiment 15 shown in FIG. 1 includes five actuator drive modules 18-22 capable of controlling eight actuators, other configurations may be used depending on the desired application. For example, without limitation, as shown in FIG. 20, fewer than five actuator drive modules may be supported together on base 25 as needed, or more than five actuator drive modules may be supported together on base 25 as needed. Additionally, without limitation, actuator control modules may be configured to control alternative types of actuators. Thus, the modular system is easily adaptable and expandable and may include different stacked actuator control modules depending on the total number and functionality of actuators desired.

[0036] While in the embodiment 15 shown in Figure 2, the base 25 is formed from a horizontal base plate 26 with a vertical back plate 27, alternatively, as shown in Figures 21 and 22, the backplane 28 may be formed only from a vertical back plate 227 without the horizontal base plate. In such an alternative embodiment 215, the upper end of the back plate 227 of the base 225 includes pairs of horizontally spaced module mounting bolt holes, each indicated at 258, configured to receive corresponding module mounting bolts, each indicated at 259, so that the upper rear flange portion 90 of each of the modules 16-22 may be removably mounted to the back plate 227, as shown in Figure 21. However, in this embodiment, the lower rear edge portions of each of the modules 16-22 are also provided with mounting flanges, each indicated at 292, having bolt holes, each indicated at 293, and the lower edge of the back plate 227 includes horizontally spaced module mounting bolt holes, each indicated at 228, that are also configured to receive corresponding module mounting bolts, each indicated at 229, so that the lower rear edge portions of each of the modules 16-22 may be removably mounted directly to the back plate 227 as shown in FIG.

[0037] In such an alternative embodiment 215, the vertical back plate 227 may also include specially configured keys, each indicated at 216, that correspond to matching keyholes in the rear panels of the modules 16-22 so that the modules 16-22 are properly positioned along the vertical back plate 227 forming the backplane 28. Thus, different types of modules may include different keys in the back plate 227 as needed to ensure that each type of module is properly aligned along the module mounting base 225. Thus, the modules 16-22 may be keyed into position along the vertical back plate 227 of the backplane 28 of the module mounting base 225, rather than to the horizontal base plate, to prevent installation of the wrong type of module in a particular position along the back plate of the module mounting base. Also, in such an alternative embodiment 215, the upper front edge portion of each of the modules 16-22 may be provided with a handle 260 configured to enable the modules 16-22 to be more easily lifted and maneuvered into place by a user.

[0038] In the exemplary embodiment, master controller module 16 generally comprises a housing 30a that houses master control electronics 61 and back-end communication control bus connections 37a. Housing 30a protects the electronics within the module from the external environment and provides front-end actuator connections, back-end base connections, and mounting connections when mounted to base 25 as shown and described.

[0039] 9, the front panel of housing 30a includes an external wired communication bus connection 64, an external wireless antenna interface 65, a general-purpose auxiliary analog and digital interface 67, an Ethernet port 69, and a USB port 42a. A lower front edge portion of housing 30a also includes a mounting flange 92a having at least two horizontally spaced base plate mounting bolt holes, each designated 93a, configured to receive corresponding module mounting bolts 129 so that module 16 may be removably mounted to base plate 26 as shown in FIGS. 17E-17F.

[0040] 10, the rear panel of the housing 30a includes an opening 50a through which the communication connection 37a is operably connected to the communication and control bus 160 of the base 25. The upper rear edge portion of the housing 30a also includes a mounting flange 90a having at least two horizontally spaced base mounting bolt holes, each designated 91a, configured to receive corresponding module mounting bolts 159 so that the module 16 may be removably mounted to the back plate 27 as shown in FIGS.

[0041] The master control electronics 61 within the housing 30a receives commands from the vehicle controller 60 via connection 64 and controls, monitors, and oversees the operation of the individual actuator control modules 17-22. The master control electronics 61 includes an internal communications board interface, a master processor, regenerative braking electronics, a DC capacitor, an external wired communications board interface, and an external wireless board interface. The communications interface provides communication with each of the actuator drive modules 18-22 via communications connections 37a and the bus 160 of the base 25 to communicate data, commands, and status. The processor provides control and monitoring of the modules 17-22. For example, the processor receives commands and inputs from the vehicle controller 60 via connection 64, receives feedback from the modules 17-22 via the communications bus 160 of the base 25, and provides command signals to control the modules 17-22 accordingly via the communications bus 160 of the base 25. A processor may be configured to perform various computer-implemented functions, such as performing method steps and calculations, and storing associated data, and may be a digital device having output lines that are logical functions of input lines, examples of which include a microprocessor, microcontroller, FPGA, PLD, application specific integrated circuit, or other similar device.

[0042] In this embodiment, the master power module 17 generally includes an enclosure 30b that houses the control power electronics 63, the low voltage power controller 62, the internal coolant conduits 87, the backside power high voltage DC supply connection 36b, and the backside communication and low voltage control bus connection 37b. The enclosure 30b protects the internal electronics of the module from the external environment and provides front end actuator connections, back end base connections, and mounting connections when mounted to the base 25 as shown and described.

[0043] 11, the front panel of housing 30b includes a high-voltage DC power input connection 66, an auxiliary battery connection 71, an auxiliary 12V power connection 72, three auxiliary high-voltage connections 73, a fuse access panel 74, and an auxiliary interface 42b. DC bus power input connection 66 is configured to connect to the mobile machine 29's main power source, which in this embodiment includes an electric vehicle main battery pack 70. Auxiliary battery connection 71 is configured to connect to an auxiliary battery, which in this embodiment includes a low-voltage battery such as a 12-volt battery. Connections 72 and 73 allow module 17 to connect to other external low-voltage and high-voltage devices as needed, and auxiliary interface 42b allows module 17 to connect to other external auxiliary sensors and functions as needed, which may be, for example, without limitation, a USB port. The lower front end portion of the housing 30b also includes a mounting flange 92b having at least two horizontally spaced base plate mounting bolt holes, each designated 93b, configured to receive corresponding module mounting bolts 129 so that the module 17 may be removably mounted to the base plate 26 as shown in Figures 17E-17F.

[0044] As shown in FIG. 12 , the rear panel of the enclosure 30 b includes an opening 50 b through which power connection 36 b is operably connected to the DC bus 170 of the base 25 and through which connection 37 b is operably connected to the communication and control bus 160 of the base 25. In this embodiment, rear power connection 36 b is connected to the power input connection 66 via a copper bus bar to provide a high-voltage power supply to the DC bus 170 of the base 25. The rear panel also includes a coolant inlet port 81 b and a coolant outlet port 82 b. As shown in FIG. 19 , the module coolant passage 87 extends between the inlet port 81 and the outlet port 82. The upper rear end portion of the enclosure 30 b also includes a mounting flange 90 b having at least two horizontally spaced base mounting bolt holes, each designated 91 b, configured to receive corresponding module mounting bolts 159 so that the module 17 can be removably mounted to the backplate 27 as shown in FIGS. 17E-17F .

[0045] Power electronics 63 in housing 30b includes a master power board and provides high-voltage operating power to the actuator power electronics of modules 18-22 via connection 36b and power bus 170 of base 25. Control power electronics 62 provides low-voltage operating power to the actuator control electronics of modules 18-22 and the master control electronics of module 16 via control power bus 160a of bus 160 of base 25. Auxiliary battery electronics connects to an internal or external auxiliary battery via auxiliary battery connection 71 for charging the auxiliary battery and powering the system logic before the main power source is active. Low-voltage control power bus 160a may be integrated with bus 160 and connections 162a, 162b, 162c, 162d, 162e, 162f, and 162g, or alternatively, may be a separate board in back plate 27 with separate connections to each of control electronics 32c and 32d and control power electronics 62.

[0046] In this embodiment, actuator control or servo drive modules 18, 19, and 20 are dual-axis controllers, each generally comprising an enclosure 30c that houses dual-axis power electronics 31c, control electronics 32c, internal coolant conduits 87, backside power high voltage DC link connections 36c, and backside communication control bus connections 37c. Enclosure 30c protects the internal electronics of the module from the external environment and provides front-end actuator connections, back-end base connections, and mounting connections when mounted to base 25 as shown and described.

[0047] As shown in FIG. 13 , the front panel of the housing 30c includes a first actuator power output connection 38c, a second actuator power connection 39c, a first actuator sensor feedback connection 40c, a second actuator sensor feedback connection 41c, and, in this example, an auxiliary interface 42c. The actuator power connection 38c provides drive power to a first connected actuator on the moveable machine 29, such as actuator 54 or 56, and the actuator sensor feedback connection 40c interfaces with the first connected actuator's feedback sensors, such as position sensors, temperature sensors, and current sensors. The actuator power connection 39c provides drive power to a second connected actuator on the moveable machine 29, such as actuator 55 or 57, and the actuator sensor feedback connection 41c interfaces with the second connected actuator's feedback sensors, such as position sensors, temperature sensors, and current sensors. The auxiliary interface 42c allows the module to connect to other external auxiliary sensors and functions, if desired. The lower front end portion of housing 30c also includes a mounting flange 92c having at least two horizontally spaced base plate mounting bolt holes, each indicated at 93c, configured to receive corresponding module mounting bolts, each indicated at 129, so that each of modules 18, 19, and 20 may be removably mounted to base plate 26 as shown in Figures 17E-17F.

[0048] As shown in FIG. 14, the rear panel of the enclosure 30c includes an opening 50c through which the power connection 36c is operably connected to the DC bus 170 of the base 25 and through which the communication connection 37c is operably connected to the communication and control bus 160 of the base 25. The rear panel also includes a coolant inlet port 81c and a coolant outlet port 82c. As shown in FIG. 19, the module coolant passage 87 extends between the inlet port 81 and the outlet port 82. The upper rear edge portion of the enclosure 30c also includes a mounting flange 90c having at least two horizontally spaced base mounting bolt holes, each indicated at 91c, configured to receive corresponding module mounting bolts, each indicated at 159, so that each of the modules 18, 19, and 20 may be removably mounted to the backplate 27 as shown in FIGS. 17E-17F.

[0049] The power electronics 31c within the housing 30c of each of modules 18, 19, and 20 may include a first axis power board and a second axis power board, which provide operating power to the terminals of connected electric motors, such as motors 54a, 55a, and 56a, 57a, via actuator power connections 38c and 39c, respectively. The power electronics convert DC power from connection 36c to the DC bus 170 of base 25 into a controlled pulse-width modulated (PWM) current that drives the connected motors. Operation of the power electronics is governed by PWM control signals from a power control interface of motor control electronics 32c. The motor control electronics 32c within housing 30c includes a control board to control, monitor, and supervise the operation of each connected actuator, such as actuators 54a-57, including controlling power to actuator motors 54a-57a, respectively. Motor control electronics 32c may include a communications interface, a processor, a power control interface, and brake circuitry for brake control and actuation. The communications interface may provide communication with central controller module 16 and, if necessary, other actuator control modules via communications connection 37c and signal bus 160 of base 25. The processor may provide internal control and monitoring and may receive commands from central controller module 16 and feedback from sensors recording operating parameters of connected actuators via actuator sensor connections 40c and 41c, respectively, and control the respective actuators accordingly. In this embodiment, such sensors are coupled to the control electronics via wired connections 40c and 41c, although in other embodiments they may be coupled via wireless connections.

[0050] One or more of the connected actuators may be rotary electromechanical actuators 54, 57, typically comprising variable-speed, bidirectional electric servo motors 54a, 57a, respectively, such as brushless DC variable-speed servo motors with an electronically controlled commutation system including resolver feedback for monitoring rotor angle, which are supplied with electrical current and used for closed-loop motion control in the actuator control electronics. Alternatively, one or more of the connected actuators may be a linear electrohydraulic actuator 56, having an electric motor 56a driving a hydraulic pump 56b in a closed-loop hydraulic circuit to extend or retract a hydraulic cylinder drive mechanism 56c. In this example, the servo motor 56a is used to drive a reversible pump 56b to extend or retract a piston 56d in a cylinder 56e, which pressurizes a hydraulic fluid, typically hydraulic oil, directly increasing the pressure in a hydraulic gap on one side or the other of the hydraulic piston 56d. In this example, the motor 56a is a brushless DC variable-speed servo motor supplied with electrical current. Other types of actuators or other motors may be used instead. For example, a variable speed stepper motor, a brush motor, or an induction motor may be used.

[0051] In this embodiment, actuator control or servo drive modules 21 and 22 are single-axis controllers, each generally comprising an enclosure 30d that houses power electronics 31d, controller electronics 32d, internal coolant conduits, backside power high voltage DC link connections 36d, and backside communication control bus connections 37d. Enclosure 30d protects the internal electronics of the module from the external environment and provides front-end actuator connections, back-end base connections, and mounting connections when mounted to base 25 as shown and described.

[0052] As shown in FIG. 15 , the front panel of the housing 30d includes an actuator power output connection 39d, an actuator sensor feedback connection 40d, and, in this embodiment, an auxiliary interface 42d. The actuator power connection 39d provides drive power to connected actuators, such as actuators 52 and 53, on the movable machine 29. The actuator sensor feedback connection 40d interfaces with feedback sensors of the connected actuators, such as position sensors, temperature sensors, and current sensors. The auxiliary interface 42d allows the module to connect to other external auxiliary sensors and functions, as needed, and may be, for example, without limitation, a USB port. The lower front end portion of the housing 30d also includes a mounting flange 92d having at least two horizontally spaced base plate mounting bolt holes, each indicated at 93d, configured to receive corresponding module mounting bolts, each indicated at 129, so that each of the modules 21 and 22 can be removably mounted to the base plate 26, as shown in FIGS. 17E-17F .

[0053] As shown in FIG. 16 , the rear panel of the enclosure 30d includes an opening 50d through which the power connection 36d is operably connected to the DC bus 170 of the base 25 and through which the communication connection 37d is operably connected to the communication and control bus 160 of the base 25. The rear panel also includes a coolant inlet port 81d and a coolant outlet port 82d. As shown in FIG. 19 , the module coolant passage 87 extends between the inlet port 81 and the outlet port 82. The upper rear edge portion of the enclosure 30d also includes a mounting flange 90d having at least two horizontally spaced base mounting bolt holes, each indicated at 91d, configured to receive corresponding module mounting bolts, each indicated at 159, so that each of the modules 21 and 22 may be removably mounted to the backplate 27 as shown in FIGS. 17E-17F .

[0054] The power electronics 31d within the housing 30d of each of modules 21 and 22 may include power boards and capacitor boards and provide operating power to the terminals of connected electric motors, such as motors 52a and 53a, via actuator power connections 39d. The power electronics convert DC power from connection 36d to DC bus 170 of base 25 into a controlled pulse-width modulated (PWM) current that drives the connected motors. Operation of the power electronics is governed by PWM control signals from a power control interface of motor control electronics 32d. The motor control electronics 32d within housing 30d includes a control board and controls, monitors, and oversees the operation of the connected actuators, including controlling power to the actuator motors. The motor control electronics 32d may include a communications interface, a processor, a power control interface, and brake circuitry for brake control and actuation. The communications interface may provide communication with the central control module 16 and, if necessary, other actuator control modules, via communications connections 37d and signal bus 160 of base 25. The processor may provide internal control and monitoring, and may receive commands from central controller module 16 and feedback from sensors that record operating parameters of connected actuators via actuator-sensor connections 40d, and may control the actuators accordingly. In this embodiment, such sensors are coupled to control electronics 32d via wired connections 40d, but in other embodiments may be coupled via wireless connections.

[0055] The connected actuator may be a linear electromechanical actuator 52 having a three-phase permanent magnet DC electric motor 52a driving an output shaft. The feedback sensor may include a position sensor providing position feedback via connection 40d to monitor shaft position for use in closed-loop motion control in the motor control electronics 32d. The position sensor may be any electrical device for measuring position, the derivative of position, or distance from an object, examples of which include an encoder, resolver, linear variable differential transformer, variable resistor, variable capacitor, laser range finder, ultrasonic distance detector, infrared distance detector, or other similar device. Alternatively, the connected actuator may be a rotary electrohydraulic actuator 53, typically comprising a variable-speed bidirectional electric servo motor 53a and a bidirectional or reversible pump 53b driven by the motor. The control electronics 32d may generate and commutate a stator field via power electronics 31d to vary the speed and direction of the motor 53a based on position feedback via connection 40d. Other types of actuators or other motors may be used as alternatives. For example, a variable speed stepper motor, a brushed motor, or an induction motor may be used.

[0056] 19, each of modules 17-22 may include a side portion between rear inlet port 81 and rear outlet port 82 with an internal coolant conduit 87 extending from the rear to the front of the module in thermal proximity to the power electronics of the module. A top fill port 83 with a plug and a bottom drain port 84 with a bleeder valve may also be provided so that the module can be filled to avoid significant air pockets and be completely drained. While coolant paths are shown, alternative passage shapes and ports may be used.

[0057] The modular control base-mounted systems 15 and 215 offer many advantages. Each system 15 and 215 provides a stack of individualized electronic modules that are liquid-cooled, highly compact, environmentally resistant, mechanically robust, and scalable, suitable for environments such as compact earthmoving equipment and mobile machinery. Each system 15 and 215 is highly scalable and customizable, minimizes cables and hoses, provides improved operating voltages, and is easy to maintain. Integrated cooling passages designed into the base 25 or 225 and each module eliminate the need for external interconnects between them. Integrated electrical bus connections between the base 25 or 225 and each module, both power and control, eliminate the need for external interconnects between them. Individual stacked modular units may be customized within the base 25 or 225 to provide the desired individualized control electronics. The number and configuration of modular units may be varied as desired for application and environmental conditions. Individual modular units may also be line replaceable units (LRUs). Individual modules may have an ingress protection rating of at least IP44 and may have an ingress protection rating of at least IP67K when mounted on a base 25. Systems 15 and 215 are scalable in size by adding base 25 or 225 and stacking lengths for modular units as needed.

[0058] It should be understood that some features of the system that are described for clarity in the context of separate embodiments may also be provided in combination in a single embodiment. Conversely, various features that are described for brevity in the context of a single embodiment may also be provided separately or in any suitable combination. While various embodiments have been described in detail above, it should be understood that they are presented by way of illustration and not limitation. While presently preferred forms of an improved modular actuator control module-mounted base have been shown and described, and several modifications thereof have been discussed, those skilled in the art will readily recognize that various additional changes and modifications may be made without departing from the scope of the invention, as defined and distinguished by the claims.

Claims

1. 1. A modular actuator control system comprising: A module mounting base; a first drive module operatively configured to control an electrically powered first actuator having at least one axis of motion; a second drive module operatively configured to control an electrically powered second actuator having at least one axis of motion; Equipped with The module mounting base has a base housing, and the base housing includes: a coolant inlet; a first base attachment; a first base coolant port; a second base attachment; and a second base coolant port; Electric buses and Signal bus and Equipped with The first drive module has a first drive housing, the first drive housing comprising: a first drive attachment operatively configured to connect to the first base attachment; a first power connection operatively configured to connect to the power bus; a first signal connection operatively configured to connect to the signal bus; a first actuator drive connection operatively configured to connect to the first actuator; a first coolant port operatively configured to connect to the first base coolant port; Equipped with The second drive module has a second drive housing, the second drive housing comprising: a second drive attachment operatively configured to connect to the second base attachment; a second power connection operatively configured to connect to the power bus; a second signal connection operatively configured to connect to the signal bus; a second actuator drive connection operatively configured to connect to the second actuator; a second coolant port operatively configured to connect to the second base coolant port; Equipped with a modular actuator control system, wherein the first drive module and the second drive module are removably mounted to the module mounting base and are configured to be operatively in power communication with the power bus, in signal communication with the signal bus, and in coolant fluid communication with the coolant inlet.

2. the first base coolant port comprises a first supply port and a first return port; the second base coolant port comprises a second supply port and a second return port; the first coolant port comprises a first inlet port and a first outlet port; the second coolant port comprises a second inlet port and a second outlet port; the first drive housing includes a first coolant fluid flow path between the first inlet port and the first outlet port; the second drive housing includes a second coolant fluid flow path between the second inlet port and the second outlet port; the first supply port is operatively configured to connect to the first inlet port, and the first return port is operatively configured to connect to the first outlet port; 2. The modular actuator control system of claim 1, wherein the second supply port is operably configured to connect to the second inlet port and the second return port is operably configured to connect to the second outlet port.

3. The modular actuator control system of claim 2 , wherein the base housing comprises a first base coolant passage between the first return port and the second supply port.

4. the base housing includes a control base attachment; The modular actuator control system includes a master controller module, the master controller module having a controller housing, the controller housing comprising: a controller attachment operatively configured to connect to said control base attachment; a controller signal connection operatively configured to connect to the signal bus; a system controller connection operatively configured to communicate with the system controller; Equipped with 2. The modular actuator control system of claim 1, wherein the master controller module is configured to be removably mounted to the module mounting base and operatively in signal communication with the signal bus.

5. The base housing includes: a power base attachment; Power base coolant port and Equipped with The modular actuator control system includes a master power module, the master power module having a power enclosure, the power enclosure comprising: a power attachment operatively configured to connect to the power base attachment; a master power connection operatively configured to connect to the power bus; a system power connection operatively configured to connect to a system power source; a power module coolant port operatively configured to connect to the power base coolant port; Equipped with 2. The modular actuator control system of claim 1, wherein the master power module is configured to be removably mounted to the module mounting base, in electrical power communication with the power bus, and in coolant fluid communication with the coolant inlet.

6. The modular actuator control system of claim 5 , wherein the power enclosure comprises a power signal connection operatively configured to connect to the signal bus.

7. the first base coolant port comprises a first supply port and a first return port; the second base coolant port comprises a second supply port and a second return port; the power-based coolant port comprises a power supply port and a power return port; the first coolant port comprises a first inlet port and a first outlet port; the second coolant port comprises a second inlet port and a second outlet port; the power module coolant port comprises a power inlet port and a power outlet port; the first drive housing includes a first coolant fluid flow path between the first inlet port and the first outlet port; the second drive housing includes a second coolant fluid flow path between the second inlet port and the second outlet port; the power enclosure includes a power coolant fluid flow path between the power inlet port and the power outlet port; the first supply port is operatively configured to connect to the first inlet port, and the first return port is operatively configured to connect to the first outlet port; the second supply port is operatively configured to connect to the second inlet port, and the second return port is operatively configured to connect to the second outlet port; 6. The modular actuator control system of claim 5, wherein the power supply port is operatively configured to connect to the power inlet port and the power return port is operatively configured to connect to the power outlet port.

8. 8. The modular actuator control system of claim 7, comprising a pump connected to the coolant inlet of the base housing and operatively configured to pump fluid coolant through the first coolant fluid flow path of the first drive housing, the second coolant fluid flow path of the second drive housing, and the power coolant fluid flow path.

9. the base housing includes a control base attachment; The modular actuator control system includes a master controller module, the master controller module having a controller housing, the controller housing comprising: a controller attachment operatively configured to connect to said control base attachment; a controller signal connection operatively configured to connect to the signal bus; a controller-system interface operatively configured to communicate with the system controller; Equipped with 6. The modular actuator control system of claim 5, wherein the master controller module is configured to be removably mounted to the module mounting base and operatively in signal communication with the signal bus.

10. 10. The modular actuator control system of claim 9, wherein the master power module is supported by the module mounting base between the master controller module and the first drive module.

11. The modular actuator control system of claim 5 , wherein the system power source comprises an electric vehicle battery.

12. the first base attachment includes a first base bolt hole; the first drive attachment includes a first modular bolt hole; 2. The modular actuator control system of claim 1, wherein the first drive attachment is operatively configured to connect to the first base attachment via a first bolt extending through the first base bolt hole and the first module bolt hole and between the first base bolt hole and the first module bolt hole.

13. 2. The modular actuator control system of claim 1, wherein the base housing comprises a base plate and a back plate, and the power bus and the signal bus are housed in the back plate.

14. The modular actuator control system of claim 13 , wherein the first base attachment comprises a base plate attachment and a back plate attachment.

15. The modular actuator control system of claim 13 , wherein the coolant inlet comprises an inlet port in the back plate and an outlet port in the back plate.

16. 14. The modular actuator control system of claim 13, wherein the base plate comprises a first base keyway configured to mate with a corresponding key of the first drive module and a second base keyway configured to mate with a corresponding key of the second drive module.

17. 2. The modular actuator control system of claim 1, wherein the base housing comprises a back plate, and the power bus and the signal bus are housed in the back plate.

18. 20. The modular actuator control system of claim 17, wherein the first base attachment comprises a first back plate attachment and a second back plate attachment.

19. 20. The modular actuator control system of claim 17, wherein the back plate comprises a first keyway configured to mate with a corresponding key of the first drive module and a second keyway configured to mate with a corresponding key of the second drive module.

Images