Modular, robust, and cooled actuator control system

Abstract

The modular actuator control system includes a first actuator control module and a second actuator control module configured to control a first actuator and a second actuator, each having a housing, control electronics and power electronics, power and communication connections, actuator power connections, and a flow path within each housing between an inlet port and an outlet port configured to provide liquid coolant to the power electronics within the housing, an attachment connecting the first and second housings of the first actuator control module and the second actuator control module, a coolant inlet port of the first actuator control module configured to connect to a fluid coolant source, and a coolant outlet port of the first actuator control module connected to the coolant inlet port of the second actuator control module, wherein the first actuator control module and the second actuator control module are stacked in coolant fluid communication with each other.

Description

Technical Field

[0001] The present invention generally relates to an actuator control system, and more particularly to a modular actuator control system.

Background Art

[0002] Electric motors that provide operation on at least one axis of motion are well known in the art and are used in a wide range of industries. Such motors can directly or indirectly drive a linear actuator or a rotary actuator, or can also drive a pump to provide electro-hydraulic linear operation or electro-hydraulic rotary operation. It is also known that such an operating system can include drive control electronics and power electronics to control and manage the operation of the actuator.

Summary of the Invention

Means for Solving the Problems

[0003] With parenthetical references to corresponding parts, sections or surfaces of embodiments of the disclosure, a first controller module (18) configured to control a first actuator (22) having at least one operating axis and being electrically powered, comprising a first housing (30a), a first control electronics (32a) located within the first housing (30a), a first power electronics (31a) located within the first housing (30a), and a first power connection (36a) configured to connect to a power supply (67), and A first communication connection (37a) configured to connect to a star controller electronic device (61), a first actuator power connection (39a) configured to connect a first power electronic device (31a) to a first actuator (22), a first coolant inlet port (80a, 82a), a first coolant outlet port (81a, 83a), and a first flow path within the first housing (30a) between the first coolant inlet port (80a, 82a) and the first coolant outlet port (81a, 83a) configured to supply liquid coolant to the first power electronic device (31a). A first controller module (18) comprising (87a), and a second controller module (19) configured to control a second actuator (23) having at least one operating axis and being electrically powered, comprising a second housing (30b), a second control electronics (32b) within the second housing (30b), a second power electronics (31b) within the second housing (30b), a second power connection (36b) configured to connect to a power supply (67), and a second controller module (19) configured to connect to a master controller electronics (61). A second controller module (19) comprising: two communication connections (37b); a second actuator power connection (39b) configured to connect a second power electronic device (31b) to a second actuator (23); a second coolant inlet port (80b, 82b); a second coolant outlet port (81b, 83b); and a second flow path (87b) within a second housing (30b) between the second coolant inlet port (80b, 82b) and the second coolant outlet port (81b, 83b), configured to supply liquid coolant to the second power electronic device (31b);A modular actuator control system (15) is provided, comprising attachments (28a-28d) connecting the first housing (30a) of the first controller module (18) and the second housing (30b) of the second controller module (19), wherein the first coolant inlet ports (80a, 82a) of the first controller module are configured to connect to a fluid coolant source (45), and the first coolant outlet ports (81a, 83a) of the first controller module (18) are connected to the second coolant inlet ports (80b, 82b) of the second controller module (19), and the first controller module (18) and the second controller module (19) are stacked to communicate with each other via coolant fluid.

[0004] The first controller module (18) may include a first secondary coolant outlet port (81a) and a first secondary flow path (85a) within the first housing (30a) between the first coolant inlet port (80a) and the first secondary coolant outlet port (81a), and the first flow path (87a) may be separated from the first secondary flow path (85a). The second controller module (19) may include a second secondary coolant inlet port (80b), and the first secondary coolant outlet port (81a) of the first controller module (18) may be connected to the second secondary coolant inlet port (80b) of the second controller module (19). The first controller module (18) and the second controller module (19) may be stacked in a parallel flow path coolant configuration (Figure 8).

[0005] The first controller module (18) may include a first actuator communication connection (40a) configured to connect a first control electronic device (32a) to a first actuator (22), and the second controller module (19) may include a second actuator communication connection (40b) configured to connect a second control electronic device (32b) to a second actuator (23). The first actuator (22) may be equipped with a first sensor (43a) for sensing the operating parameters of the first actuator (22), and the first actuator communication connection (40a) may be configured to connect a first control electronic device (32a) to the first sensor (43a) of the first actuator (22). The second actuator (23) may be equipped with a second sensor (43b) for sensing the operating parameters of the second actuator (23), and the second actuator communication connection (40b) may be configured to connect a second control electronic device (32b) to the second sensor (43b) of the second actuator (23).

[0006] The modular actuator control system may include a common power bus (50) that supplies power to the first power connection (36a) and the second power connection (36b). The modular actuator control system may also include a common serial bus (60a) that communicates with the first communication connection (37a) and the second communication connection (37b).

[0007] The first housing (30a) may include a first sealed electronic housing compartment defining a first electronic equipment chamber (98a) substantially isolated from the external environment, and the first control electronic equipment (32a) and the first power electronic equipment (31a) may be disposed within the first chamber (98a). The second housing (30b) may include a second sealed electronic housing compartment defining a second electronic equipment chamber (98b) substantially isolated from the external environment, and the second control electronic equipment (32b) and the second power electronic equipment (31b) may be disposed within the second chamber (98b). The first housing (30a) may include a first connection compartment defining a first connection chamber (99a) that is substantially isolated from the external environment, and a first power connection (36a) and a first communication connection (37a) may be located within the first connection chamber (99a). The second housing (30b) may include a second connection compartment defining a second connection chamber (99b) that is substantially isolated from the external environment, and a second power connection (36b) and a second communication connection (37b) may be located within the second connection chamber (99b). The modular actuator control system may include a power bus (50) that supplies power to a first power connection (36a) and a second power connection (36b), and a serial bus (60a) that communicates with a first communication connection (37a) and a second communication connection (37b). The common power bus (50) may extend within a first connection chamber (99a) and a second connection chamber (99b), and the common serial bus (60a) may extend within a first connection chamber (99a) and a second connection chamber (99b).

[0008] The modular actuator control system may include a master controller housing (30f), a master controller electronic equipment (61) disposed within the master controller housing (30f), a master communication connection (37f) configured to connect a first communication connection (37a) of a first controller module (18) and a second communication connection (37b) of a second controller module (19), and attachments (28a-28d) connecting the first housing (30a) of the first controller module (18), the second housing (30b) of the second controller module (19), and the master controller housing (30f) of the master controller module (16). The modular actuator control system may also include a serial bus (60a) for communication between the master communication connection (37f), the first communication connection (37a), and the second communication connection (37b).

[0009] The modular actuator control system comprises a power management housing (30e), power management electronics (51) located within the power management housing (30e), an input power connection (66) configured to connect to a power supply (67), an output control power connection (37e) configured to connect a first control electronics (32a) and a second control electronics (32b), power coolant inlet ports (80e, 82e), power coolant outlet ports (81e, 83e), and a power coolant inlet port configured to supply liquid coolant to the power management electronics (51). The power management module (17) may include a power channel (87e) within a power management housing (30e) between ports (80e, 82e) and power coolant outlet ports (81e, 83e), and attachments (28a~28d) connecting the first housing (30a) of the first controller module (18), the second housing (30b) of the second controller module (19), the master controller housing (30f) of the master controller module (16), and the power management housing (30e) of the power management module (17). The master controller module (16) may include an input control power connection (37f) configured to connect to the output control power connection (37e) of the power management module (17).

[0010] The modular actuator control system may include a pump (45) connected to the first coolant inlet ports (80a, 82a) of the first controller module (18) and configured to operate to pump liquid coolant through the first flow path (87a) of the first housing (30a) and the second flow path (87b) of the second housing (30b). The modular actuator control system may also include a heat exchanger (46) connected between the second coolant outlet ports (81b, 83b) of the second controller module (19) and the first coolant inlet ports (80a, 82a) of the first controller module (18). The heat exchanger (46) may be connected between the second coolant outlet ports (81b, 83b) of the second controller module (19) and the pump (45). The modular actuator control system may include a seal between the first housing (30a) of the first controller module (18) and the second housing (30b) of the second controller module (19).

[0011] The power management module (17) may be stacked between the second controller module (19) and the master controller module (16), and the second coolant outlet ports (81b, 83b) of the second controller module (19) may be connected to the power coolant inlet ports (80e, 82e) of the power management module (17).The modular actuator control system comprises a third controller module (20, 21) configured to control a third actuator (24, 25, 26, 27) having at least one operating axis and being electrically powered, the third controller module (20, 21) comprising a third housing (30c, 30d), a third control electronics (32c, 32d) within the third housing (30c, 30d), a third power electronics (31c, 31d, 31e, 31f) within the third housing (30c, 30d), and a third controller module (20, 21) configured to connect to a power supply (67). Power connections (36c, 36d), third communication connections (37c, 37d) configured to connect to master controller electronics (61), third actuator power connections (39c, 39d, 39e, 39f) configured to connect third power electronics (31c, 31d, 31e, 31f) to third actuators (24, 25, 26, 27), third coolant inlet ports (80c, 80d, 82c, 82d), third coolant outlet ports (81c, 81d, 83c, 83d), and third power electronics (31c, 31 A third controller module (20, 21) comprising a third flow path (87c, 87d) in a third housing (30c, 30d) between a third coolant inlet port (80c, 80d, 82c, 82d) and a third coolant outlet port (81c, 81d, 83c, 83d), configured to supply liquid coolant to d, 31e, 31f), and a first housing (30a) of the first controller module (18), a second housing (30b) of the second controller module (19), and a third controller module (20 The first controller module (18), the second controller module (19), and the third controller modules (20, 21) are stacked so as to be in communication with each other via coolant fluid. The first controller module (18), the second controller module (19), and the third controller modules (20, 21) are stacked so as to be in communication with each other via coolant fluid.The second controller module (19) may include a second secondary coolant outlet port (83b) and a second secondary flow path (86b) in the second housing (30b) between the second coolant inlet port (82b) and the second secondary coolant outlet port (83b), and the second flow path (87b) may be separated from the second secondary flow path (86b). The third controller module (21) may include a third secondary coolant inlet port (82d), and the second secondary coolant outlet port (83b) of the second controller module (19) may be connected to the third secondary coolant inlet port (82d) of the third controller module (21). The first controller module (18) and the second controller module (19) may be stacked in a series flow path coolant configuration, and the second controller module (19) and the third controller module (21) may be stacked in a parallel flow path coolant configuration.

[0012] The first flow path (87a, 287) within the first housing (30a) between the first coolant inlet port (82a, 282) and the first coolant outlet port (81a) may comprise a plurality of separate coolant passages (90, 290) that are thermally close to the first power electronic equipment (31a). The first flow path (187) within the first housing (30a) between the first coolant inlet port (180) and the first coolant outlet port may comprise a meandering coolant passage that is thermally close to the first power electronic equipment (31a).

[0013] The master controller housing (30f) of the master controller module (16) may include a braking resistor (53) and a DC capacitor (54). The power supply (67) may include an electric vehicle battery. [Brief explanation of the drawing]

[0014] [Figure 1] This is a front isometric view of one embodiment of an improved modular actuator control system. [Figure 2] Figure 1 is a rearward isometric view of the modular actuator control system shown. [Figure 3] Figure 1 is a schematic diagram of a modular actuator control system shown, operably coupled to one example of a liquid cooling system and multiple examples of actuators. [Figure 4] Figure 1 is a schematic top view of the modular actuator control system. [Figure 5] Figure 1 is a left-side isometric view of the left-side actuator control system. [Figure 6] Figure 5 shows a partial vertical side cross-sectional view of the actuator control module, illustrating the external shape of the internal cooling conduit in the first embodiment. [Figure 7] Figure 1 is a schematic vertical cross-sectional view of the actuator control system shown in the series cooling stack configuration. [Figure 8] Figure 1 is a schematic vertical cross-sectional view of the actuator control system in a parallel cooling stack configuration. [Figure 9] Figure 1 is a schematic vertical cross-sectional view of the actuator control system in a cooling stack configuration that combines series and parallel connections. [Figure 10] Figure 1 is a left-side isometric view of the power management module shown. [Figure 11] Figure 6 shows the external shape of the internal cooling conduit of an alternative second embodiment to the first embodiment shown. [Figure 12] Figure 6 shows the external shape of the internal cooling conduit of an alternative second embodiment to the first embodiment shown. [Modes for carrying out the invention]

[0015] First, it should be clearly understood that similar reference numerals are intended to consistently identify the same structural element, part, or surface through multiple drawings, such element, part, or surface may be further described or illustrated by the entire written specification, in which this detailed description is an essential part. Unless otherwise noted, drawings are intended to be read in conjunction with the specification (e.g., shading, part placement, proportions, degree, etc.) and should be considered as part of the entire written description of the invention. When used in the following description, the terms “horizontally,” “vertically,” “left,” “right,” “up,” and “down,” and their adjective and adverbial derivatives (e.g., “horizontally,” “right,” “upwards,” etc.) simply refer to the orientation of the illustrated structure when a particular drawing is facing the reader. Similarly, the terms “inward” and “outward” generally refer to the orientation of a surface relative to its axis of extension or axis of rotation, as necessary.

[0016] Referring to the drawings, and more specifically to Figures 1 to 4, a modular actuator control system is provided, the first embodiment of which is shown overall in 15. As shown, system 15 comprises a central control module 16, a central power module 17, a first actuator control module 18, a second actuator control module 19, a third actuator control module 20, and a fourth actuator control module 21, all of which are stacked together to provide a compact, robust, and cooled controller system 15 for controlling a plurality of actuators 22 to 27.

[0017] As shown, the first actuator control module 18 controls the linear electromechanical actuator 22, the second actuator control module 19 controls the rotary electrohydraulic actuator 23, the third actuator control module 20 is a dual drive controller that controls both the rotary electromechanical actuator 24 and the rotary electromechanical actuator 25, and the fourth actuator control module 21 is a dual drive controller that controls both the linear electrohydraulic actuator 26 and the rotary electromechanical actuator 27. This embodiment includes four actuator control modules 18 - 21 that control six actuators 22 - 27, but other configurations may be employed depending on the desired application. For example, and without limitation, three or fewer, or five or more actuator control modules may be stacked together as desired. Additionally, and without limitation, the 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 desired number of actuators and functionality.

[0018] As shown in FIGS. 1 - 4, in this embodiment, the actuator control module 18 is a single-axis controller that generally includes power electronics 31a, controller electronics 32a, and an internal coolant conduit 87a in a front portion and a housing 30a in a rear portion that includes an actuator power connection 36a operably connected to a DC bus 50 and a communication connection 37a operably connected to communication buses and control power buses 60a and 60b.

[0019] As shown, the housing 30a is a robust enclosure that generally comprises a front panel 100a, a left panel 102a with a rear end opening cover 106a, a right panel 103a with a rear end opening 106b, a bottom panel 105a, a top panel 104a, and a rear panel 101a with a rear end opening cover 107a. As described above, the housing 30a generally comprises a front compartment 98a that generally accommodates control electronics 32a, power electronics 31a, and internal cooling conduits 87a, and a rear compartment 99a that generally accommodates connections to other modules. The front compartment 98 and the rear compartment 99 are separated by internal panels with appropriately sized openings for power bus connections and communication bus connections. The housing panels are perforated by various connections and by various openings that may be closed when not in use. As shown in Figure 1, the front panel 100a of the housing 30a includes actuator power connections 39a, actuator sensor feedback connections 40a, and in this embodiment, an auxiliary interface 41a. The actuator power connection 39a provides drive power to the actuator 22. The actuator sensor feedback connection 40a interfaces with the feedback sensor 43a of the actuator 22. The auxiliary interface 41a allows connection of module 18 to other external auxiliary sensors and functions, if desired. The housing 30a of module 18 protects the internal electronics from the external environment when stacked with modules 16, 17 and 19-21 as shown. In this embodiment, the rear panel 101a is shown to have a rear access opening that is covered by a rear opening cover 107a after the modular stack is assembled, but alternatively, and without limitation, the rear panel 101a may be a solid panel.

[0020] As shown, the power electronics device 31a provides operating power to the terminals of the electric motor 22a via the actuator power connection 39a. The power electronics device 31a converts DC power from the connection 36a to the DC bus 50 into a controlled pulse-width modulation (PWM) current to drive the motor 22a. The operation of the power electronics device 31a is managed by a PWM control signal from the power control interface 35a of the motor control electronics device 32a.

[0021] The motor control electronics device 32a controls, monitors, and manages the operation of the actuator 22, including the control of power to the motor 22a via the power control interface 35a. The motor control electronics device 32a includes a communication interface 33a, a processor 34a, and a power control interface 35a. The communication interface 33a provides communication with the central control module 16 via the communication connection 37a and, if desired, with other actuator control modules 19, 20, and 21. The communication interface 33a transmits data, commands, and status. The processor 34a provides internal control and monitoring. The processor 34a receives commands from the central controller module 16 and feedback from the sensor 43a that reads the operating parameters of the actuator 22 via the actuator sensor connection 40a, and controls the actuator 22 accordingly. In this embodiment, such sensors are coupled to the control electronics device 32a via a wired connection 40a. In other embodiments, they may be coupled via a wireless connection. The processor 34a is configured to perform various computer-implemented functions such as executing method steps, calculations, etc., and storing relevant data. The processor 34a may be any digital device having output lines that are logical functions of its input lines, examples of which include microprocessors, microcontrollers, field-programmable gate arrays (FPGAs), programmable logic devices (PLDs), application-specific integrated circuits, or other similar devices.

[0022] In this embodiment, the actuator 22 is a linear electromechanical actuator having a three-phase permanent magnet DC electric motor 22a that drives an output shaft 22b. The linear magnetic motor 22a includes a fixed stator and a sliding shaft that is driven to move linearly (i.e., linearly translate) relative to the stator. The shaft is at least partially enclosed by the stator and held in place relative to the stator by bearings. The shaft generates a magnetic field thanks to having a series of built-in permanent magnets. The stator generates a magnetic field through an annular magnetic coil. By adjusting the time of current flow in the coil relative to the position and / or momentum of the shaft, the interaction of the magnetic force from the shaft and the magnetic force from the stator acts to drive the shaft to move linearly in either direction. Other motors may be used as alternatives. A position sensor 43a provides position feedback via connection 40a to monitor the shaft position used for closed-loop operation control in the motor control electronics 32a. A position sensor may be any electrical device for measuring a position or a derivative of a position, or distance from an object, examples of which include encoders, resolvers, linear variable differential transformers, variable resistors, variable capacitors, laser rangefinders, ultrasonic area detectors, infrared area detectors, or other similar devices.

[0023] As shown in Figures 1 to 4, in this embodiment, the actuator control module 19 is a single-axis controller and is similar to module 18, and generally comprises a housing 30b in the rear portion that includes power electronics 31b, controller electronics 32b and internal coolant conduits 87b in the front portion, and an actuator power connection 36b operably connected to a DC bus 50 and a communication connection 37b operably connected to a communication and control power bus 60.

[0024] As shown, the housing 30b is a robust enclosure generally comprising a front panel 100b, a left panel 102b with a rear end opening 106c aligned with a rear end opening 106b in the right panel 103a of module 18, a right panel 103b with a rear end opening 106d, a bottom panel 105b, a top panel 104b, and a rear panel 101b with a rear opening cover 107b. As described above, the housing 30b generally comprises a front compartment 98b that generally houses the control electronics 32b, power electronics 31b, and internal cooling conduits 87b, and a rear compartment 99b that generally houses connections to other modules. The front compartment 98b and the rear compartment 99b are separated by internal panels with appropriately sized openings for power bus connections and communication bus connections. The housing panels are perforated by various connections and by various openings that may be closed when not in use. As shown in Figure 1, the front panel 100b of the housing 30b includes an actuator power connection 39b, an actuator sensor feedback connection 40b, and in this embodiment, an auxiliary interface 41b. The actuator power connection 39b provides drive power to the actuator 23. The actuator sensor feedback connection 40b interfaces with the feedback sensor 43b of the actuator 23. The auxiliary interface 41b allows for connection of module 19 to other external auxiliary sensors and functions, if desired. The housing 30b of module 19 protects the internal electronics from the external environment when stacked with modules 16, 17, and 18 and 20 and 21, as shown. In this embodiment, the rear panel 101b is shown to have a rear access opening that is covered by a rear opening cover 107b after the modular stack is assembled, but alternatively, and without limitation, the rear panel 101b may be a solid panel.

[0025] As shown, the power electronics 31b provides operating power to the terminals of the electric motor 23a via the actuator power connection 39b. The power electronics 31b converts the DC power from connection 36b to the DC bus 50 into a controlled PWM current that drives the motor 23a. The operation of the power electronics 31b is controlled by a PWM control signal from the power control interface 35b of the motor control electronics 32b.

[0026] The motor control electronics 32b controls, monitors, and manages the operation of the actuator 23, including controlling the power to the motor 23a via the power control interface 35b. The motor control electronics 32b includes a communication interface 33b, a processor 34b, and the power control interface 35b. The communication interface 33b provides communication with the central control module 16 via a communication connection 37b, and, if desired, communication with other actuator control modules 18, 20, and 21. The communication interface 33b transmits data, commands, and status. The processor 34b provides internal control and monitoring. The processor 34b receives commands from the central controller module 16 and feedback from sensors 43b that read the operating parameters of the actuator 23 via actuator sensor connections 40b, and controls the actuator 23 accordingly. In this embodiment, such sensors are coupled to the control electronics 32a via wired connections 40a.

[0027] In this embodiment, the actuator 23 is a rotary electro-hydraulic actuator generally comprising a variable-speed bidirectional electric servo motor 23a and a bidirectional or reversible pump 23b driven by the motor 23a. In this embodiment, the motor 23a is a brushless DC variable-speed servo motor supplied with current. The motor 23a has an internal rotor with permanent magnets and a fixed, non-rotating stator with coil windings. A magnetic field is induced when current is appropriately applied through the coils of the stator via power electronics 31b and power connection 39b. The interaction of the magnetic fields between the stator and rotor generates a torque, which may rotate the output shaft of the motor 23a. Based on position feedback via connection 40b, the control electronics 32b generates and rectifies the stator field via power electronics 31b to change the speed and direction of the motor 23a. Accordingly, the motor 23a selectively applies torque to its output shaft in either direction around the output shaft axis at a varying speed. Other motors may be used as alternatives. For example, a variable-speed stepper motor, a brush motor, or an induction motor may be used. In this embodiment, pump 23b is a constant-displacement bidirectional internal two-port gear pump. The pumping element, i.e., the meshed gears, is capable of rotating in either direction, thereby allowing the hydraulic fluid to flow in either direction. This allows oil to be added to or removed from the system when the controller 32b closes the position or pressure control loop. At least one gear of pump 23b is connected to the output shaft of motor 23a, with the other pump gears following behind. The direction of flow in pump 23b depends on the direction of rotation of the rotor and the output shaft of motor 23a. The speed and output of pump 23b are variable with variations in the speed of motor 23a. Other bidirectional pumps may be used as alternatives. For example, a variable-displacement pump may be used.

[0028] As shown in Figures 1 to 4, in this embodiment, the actuator control module 20 is a dual-axis controller and generally comprises a housing 30c in the rear portion, which includes power electronics 31c, power electronics 31d, controller electronics 32c and internal coolant conduits 87c, and an actuator power connection 36c operably connected to a DC bus 50 and a communication connection 37c operably connected to a communication and control power bus 60.

[0029] As shown, the housing 30c is a robust enclosure generally comprising a front panel 100c, a left panel 102c with a rear end opening 106e aligned with a rear end opening 106d in the right panel 103b of module 19, a right panel 103c with a rear end opening 106f, a bottom panel 105c, a top panel 104c, and a rear panel 101c with a rear opening cover 107c. As described above, the housing 30c generally comprises a front compartment 98c that generally accommodates control electronics 32c, power electronics 31c, power electronics 31d, and internal cooling conduits 87c, and a rear compartment 99c that generally accommodates connections to other modules. The front compartment 98c and the rear compartment 99c are separated by internal panels with appropriately sized openings for power bus connections and communication bus connections. The housing panels are perforated by various connections and by various openings that may be closed when not in use. As shown in Figure 1, the front panel 100c of the housing 30c includes a first actuator power connection 39c, a second actuator power connection 39d, a first actuator sensor feedback connection 40c, a second actuator sensor feedback connection 40d, and in this embodiment, an auxiliary interface 41c. The actuator power connection 39c provides drive power to the actuator 24. The actuator sensor feedback connection 40c interfaces with the feedback sensor 43c of the actuator 24. The actuator power connection 39d provides drive power to the actuator 25. The actuator sensor feedback connection 40d interfaces with the feedback sensor 43d of the actuator 25. The auxiliary interface 41c allows for connection of module 20 to other external auxiliary sensors and functions, if desired. The housing 30c of module 20 protects the internal electronics from the external environment when stacked with modules 16, 17, 18, 19, and 21 as shown. In this embodiment, the rear panel 101c is shown to have a rear access opening that is covered by a rear opening cover 107c after the modular stack is assembled, but alternatively and without limitation, the rear panel 100c may be a solid panel.

[0030] As shown, the power electronics 31c provides operating power to the terminals of the electric motor 24a via the actuator power connection 39c. The power electronics 31c converts the DC power from connection 36c to the DC bus 50 into a controlled PWM current that drives the motor 24a. The operation of the power electronics 31c is controlled by a PWM control signal from the power control interface 35c of the motor control electronics 32c. As shown, the power electronics 31d provides operating power to the terminals of the electric motor 25a via the actuator power connection 39d. The power electronics 31d converts the DC power from connection 36c to the DC bus 50 into a controlled PWM current that drives the motor 25a. The operation of the power electronics 31d is controlled by a PWM control signal from the power control interface 35c of the motor control electronics 32c.

[0031] The motor control electronics 32c controls, monitors, and manages the operation of actuators 24 and 25, including controlling power to motor 24a and motor 25a via the power control interface 35c. The motor control electronics 32c includes a communication interface 33c, a processor 34c, and a power control interface 35c. The communication interface 33c provides communication with the central control module 16 via a communication connection 37c, and, if desired, communication with other actuator control modules 18, 19, and 21. The communication interface 33c transmits data, commands, and status. The processor 34c provides internal control and monitoring. The processor 34c receives commands from the central controller module 16 and feedback from sensors 43c that read the operating parameters of actuator 24 via actuator sensor connection 40c, and controls actuator 24 accordingly. The processor 34c also receives commands from the central controller module 16 and feedback from the sensor 43d, which reads the operating parameters of the actuator 25 via the actuator sensor connection 40d, and controls the actuator 25 accordingly.

[0032] In this embodiment, actuators 24 and 25 are rotary electromechanical actuators, each typically comprising variable-speed bidirectional electric servo motors 24a and 25a, respectively. In this embodiment, motors 24a and 25a are brushless DC variable-speed servo motors, each having an electronically controlled rectification system that includes resolver feedback for monitoring the rotor angle, to which current is supplied and used for closed-loop operation control in actuator control electronics 32c. Motor 24a has an internal rotor with permanent magnets and a fixed, non-rotating stator with coil windings. A magnetic field is induced when current is appropriately applied through the coils of the stator via power electronics 31c and power connection 39c. The interaction of the magnetic fields between the stator and rotor generates a torque, which may rotate the output shaft of motor 24a. Based on position feedback via connection 40c, control electronics 32c generates and rectifies a stator field via power electronics 31c to change the speed and direction of motor 24a. Similarly, motor 25a has an internal rotor with permanent magnets and a fixed, non-rotating stator with coil windings. A magnetic field is induced when current is appropriately applied through the coils of the stator via power electronics 31d and power connection 39d. The interaction of the magnetic fields between the stator and rotor generates a torque, which may rotate the output shaft of motor 25a. Based on position feedback via connection 40d, control electronics 32c generates and rectifies a stator field via power electronics 31d to change the speed and direction of motor 25a. Accordingly, motors 24a and 25a selectively apply torque to their output shaft in either direction around the output shaft axis at a varying speed. Other motors may be used as alternatives. For example, a variable-speed stepper motor, a brushed motor, or an induction motor may be used.

[0033] As shown in Figures 1 to 4, in this embodiment, the actuator control module 21 is a dual-axis controller and is similar to module 20, and generally comprises a housing 30d in the rear portion, which includes power electronics 31e, power electronics 31f, controller electronics 32d and internal coolant conduits 87d in the front portion, and an actuator power connection 36d operably connected to a DC bus 50 and a communication connection 37d operably connected to a communication and control power bus 60.

[0034] As shown, the housing 30d is a robust enclosure generally comprising a front panel 100d, a left panel 102d with a rear end opening 106g aligned with a rear end opening 106f in the right panel 103c of module 20, a right panel 103d with a rear end opening 106h, a bottom panel 105d, a top panel 104d, and a rear panel 101d with a rear opening cover 107d. As described above, the housing 30d generally comprises a front compartment 98d that generally accommodates control electronics 32d, power electronics 31e, power electronics 31f, and internal cooling conduits 87d, and a rear compartment 99d that generally accommodates connections to other modules. The front compartment 98d and the rear compartment 99d are separated by internal panels with appropriately sized openings for power and communication bus connections. The housing panels are perforated by various connections and by various openings that may be closed when not in use. As shown in Figure 1, the front panel 100d of the housing 30d includes a first actuator power connection 39e, a second actuator power connection 39f, a first actuator sensor feedback connection 40e, a second actuator sensor feedback connection 40f, and in this embodiment, an auxiliary interface 41d. The actuator power connection 39e provides drive power to the actuator 26. The actuator sensor feedback connection 40e interfaces with the feedback sensor 43e of the actuator 26. The actuator power connection 39f provides drive power to the actuator 27. The actuator sensor feedback connection 40f interfaces with the feedback sensor 43f of the actuator 27. The auxiliary interface 41d allows for connection of module 21 to other external auxiliary sensors and functions, if desired. The housing 30d of module 21 protects the internal electronics from the external environment when stacked with modules 16, 17, 18, 19, and 20 as shown. In this embodiment, the rear panel 101d is shown to have a rear access opening that is covered by a rear opening cover 107d after the modular stack is assembled, but alternatively and without limitation, the rear panel 101d may be a solid panel.

[0035] As shown, the power electronics 31e provides operating power to the terminals of the electric motor 26a via the actuator power connection 39e. The power electronics 31e converts the DC power from connection 36d to the DC bus 50 into a controlled PWM current that drives the motor 26a. The operation of the power electronics 31e is controlled by a PWM control signal from the power control interface 35d of the motor control electronics 32d. As shown, the power electronics 31f provides operating power to the terminals of the electric motor 27a via the actuator power connection 39f. The power electronics 31f converts the DC power from connection 36d to the DC bus 50 into a controlled PWM current that drives the motor 27a. The operation of the power electronics 31f is controlled by a PWM control signal from the power control interface 35d of the motor control electronics 32d.

[0036] The motor control electronics 32d controls, monitors, and manages the operation of actuators 26 and 27, including controlling the power to motor 26a and motor 27a via the power control interface 35d. The motor control electronics 32d includes a communication interface 33d, a processor 34d, and a power control interface 35d. The communication interface 33d provides communication with the central control module 16 via a communication connection 37d, and, if desired, communication with other actuator control modules 18, 19, and 20. The communication interface 33d transmits data, commands, and status. The processor 34d provides internal control and monitoring. The processor 34d receives commands from the central controller module 16 and feedback from sensors 43e that read the operating parameters of actuator 26 via actuator sensor connection 40e, and controls actuator 26 accordingly. The processor 34d also receives commands from the central controller module 16 and feedback from the sensor 43f, which reads the operating parameters of the actuator 27 via the actuator sensor connection 40f, and controls the actuator 27 accordingly.

[0037] In this embodiment, the actuator 26 is a linear electro-hydraulic actuator having an electric motor 26a that drives a hydraulic pump 26b in a closed-loop hydraulic circuit to extend or retract a hydraulic cylinder drive mechanism 26c. In this embodiment, a servo motor 26a is used to drive a reversible pump 26b so that the pump 26b pressurizes a working fluid, typically hydraulic oil, and directly increases the pressure in the hydraulic pump on one side of the hydraulic piston 26d, thereby extending or retracting a piston 26d in the cylinder 26c. In this embodiment, the motor 26a is a brushless DC variable-speed servo motor supplied with current. The motor 26a has an internal rotor with permanent magnets and a fixed, non-rotating stator with coil windings. A magnetic field is induced when current is appropriately applied through the coils of the stator via power electronics 31e and power connections 39e. The interaction of the magnetic fields between the stator and rotor generates a torque, which may rotate the output shaft of the motor 26a. Based on position feedback via connection 40e, control electronics 32d generates and rectifies a stator field via power electronics 31e to change the speed and direction of motor 26a. Accordingly, motor 26a selectively applies torque to its output shaft in either direction around the output shaft axis at a varying speed. In this embodiment, pump 26b is a fixed displacement bidirectional internal two-port gear pump. The pumping element, i.e., the meshed gears, is capable of rotating in either direction, thereby allowing the hydraulic fluid to flow in either direction. This allows oil to be added to or removed from the system when controller 32d closes the position or pressure control loop. At least one gear of pump 26b is connected to the output shaft of motor 26a, with the other pump gear following behind. The direction of flow of pump 26b depends on the direction of rotation of the rotor and the output shaft of motor 26a. The speed and output of pump 26b are variable with the variation in the speed of motor 26a.

[0038] In this embodiment, the actuator 27 is a rotary electromechanical actuator, typically comprising a variable-speed bidirectional electric servo motor 27a. In this embodiment, the motor 27a is a brushless DC variable-speed servo motor, comprising an electronically controlled rectification system that includes resolver feedback for monitoring the rotor angle, to which current is supplied and used for closed-loop operation control in the actuator control electronics 32d. The motor 27a has an internal rotor with permanent magnets and a fixed, non-rotating stator with coil windings. A magnetic field is induced when current is appropriately applied through the coils of the stator via the power electronics 31f and power connection 39f. The interaction of the magnetic fields between the stator and rotor generates a torque, which may rotate the output shaft of the motor 27a. Based on position feedback via connection 40f, the control electronics 32d generates and rectifies the stator field via the power electronics 31f to change the speed and direction of the motor 27a. Accordingly, the motor 27a selectively applies torque to its output shaft in any direction around the output shaft axis at a varying speed.

[0039] As shown in Figures 1 to 4, in this embodiment, the central power management module 17 generally comprises a housing 30e in the rear portion that includes control power electronics 55, auxiliary battery electronics 52 and internal coolant conduits 87e in the front portion, and actuator supply power connection 36e operably connected to the DC bus 50 and control power connection 37e operably connected to the control power bus 60b.

[0040] As shown, the housing 30e is a robust enclosure generally comprising a front panel 100e, a left panel 102e with a rear end opening 106i aligned with a rear end opening 106h in the right panel 103d of module 21, a right panel 103e with a rear end opening 106j, a bottom panel 105e, a top panel 104e, and a rear panel 101e with a rear opening cover 107e. As described above, the housing 30e generally comprises a front compartment 98e that generally houses the control power electronics 55, auxiliary battery electronics 52, and internal coolant conduits 87e, and a rear compartment 99e that generally houses connections to other modules. The front compartment 98e and the rear compartment 99e are separated by an internal panel 58 with appropriately sized openings for power and control bus connections. The housing panels are perforated by various connections and by various openings that may be closed when not in use. As shown in Figure 1, the front panel 100e of the housing 30e includes a DC bus power input connection 66, an auxiliary battery connection 71, and in this embodiment, an auxiliary low-power connection 72. The DC bus power input connection 66 is configured to connect to a power supply 67, which in this embodiment comprises an electric vehicle main battery pack. The auxiliary battery connection 71 is configured to connect to an auxiliary battery 70, which in this embodiment comprises a low-voltage battery such as a 12-volt battery. The low-power connection 72 allows for connection of module 17 to other external low-voltage devices, if desired. The housing 30e of module 17 protects the internal electronics from the external environment when stacked with modules 16, 18-21 as shown. In this embodiment, the rear panel 101e is shown to have a rear access opening that is covered by a rear opening cover 107e after the modular stack is assembled, but alternatively, and without limitation, the rear panel 101e may be a solid panel.

[0041] As shown, the control power electronics 55 provides lower voltage operating power to the actuator control electronics 32a, 32b, 32c, and 32d of modules 18, 19, 20, and 21, as well as the master control electronics 61 of module 16, via connection 37e and the control power bus 60b. The auxiliary battery electronics 52 is connected to an external auxiliary battery 70 via auxiliary battery connection 71 to supply power to the system logic before the main power supply 67 becomes active.

[0042] As shown in Figures 1 to 4, in this embodiment, the central control module 16 generally comprises a housing 30f in the rear portion, which includes a master control electronics 61, regenerative braking electronics 53 and DC capacitor 54 in the front portion, and a power connection 36f operably connected to the DC bus 50 and a communication connection 37f operably connected to the communication bus and control power buses 60a and 60b.

[0043] As shown, the housing 30f is a robust enclosure generally comprising a front panel 100f, a left panel 102f with a rear end opening 106k aligned with the rear end opening 106j in the right panel 103e of module 17, a right panel 103f, a bottom panel 105f, a top panel 104f, and a rear panel 101f with a rear opening cover 107f. As described above, the housing 30f generally comprises a front compartment 98f that generally houses the master control electronics 61, the regenerative braking electronics 53, and the DC capacitor 54, and a rear compartment 99f that generally houses the connections to other modules. The front compartment 98f and the rear compartment 99f are separated by internal panels with appropriately sized openings for power and communication bus connections. The housing panels are perforated by various connections and by various openings that may be closed when not in use. As shown in Figure 1, the front panel 100f of the housing 30f includes an external hardwired communications bus connection 64, an external wireless antenna interface 65, a USB port 68, an Ethernet® port 69, and in this embodiment, an auxiliary interface 41f. The housing 30f of module 16 protects the internal electronics from the external environment when stacked with modules 17-21 as shown. In this embodiment, the rear panel 101f is shown to have a rear access opening that is covered by a rear opening cover 107f after the modular stack is assembled, but alternatively and without limitation, the rear panel 101f may be a solid panel.

[0044] DC capacitor 54 smooths the power from the electronic high-frequency switching to the common bus 50, and damping resistor 53 dissipates the regenerative power from actuators 22-27. Master control electronics 361 controls, monitors, and manages the operation of individual actuator control modules 18-21. Central control electronics 61 includes an internal communication interface 62, a master processor 63, an external wired communication interface 64, and an external wireless interface 65. Communication interface 62 provides communication with each of the actuator control modules 18-21 via communication connection 37f. Communication interface 32 transmits data, commands, and status. Processor 63 provides control and monitoring of modules 18-21. Processor 63 receives commands and inputs via external communication interface 64, receives feedback from modules 18-21 via communication bus 60a, and accordingly provides command signals via communication bus 60a to control modules 18-21. Processor 61 is configured to perform various computer implementation functions such as performing method steps, calculations, etc., and storing related data. The processor 61 may be any digital device having output lines which are logical functions of its input lines, examples of which include microprocessors, microcontrollers, FPGAs, PLDs, application-specific integrated circuits, or other similar devices.

[0045] As shown, each of the four corners of the housings 30a–30f includes a longitudinally extending corner passage sized to receive four tie rods 28a, 28b, 28c, and 28d that pass through it and extend longitudinally. As shown, the complete assembly is completed by aligning the four longitudinally extending corner passages within the module housings 30a–30f and using the tie rods 28a, 28b, 28c, and 28d that pass through them to press the module housings 30a–30f together longitudinally with bolted end plates. The module housings 30a–30f are sealed to each other to provide a water-resistant and dustproof stacked assembly 15. When assembled with the rear covers 107a-107f in place, the rear compartments 99a-99f form a common area open from module to module, allowing communication bus connections and power bus connections to be created integrally with the assembly 15. In this embodiment, the assembly 15 may have at least an IP67K protection rating. The tie rods 28a, 28b, 28c, and 28d allow individual modules to be mounted together in a compact stack so that different modules may be interchangeable, and modules may be added to or removed from the stack as desired. The modular stack 15 is shown in this embodiment held together by tie rod attachments 28a, 28b, 28c, and 28d, but other attachment systems may be used as alternatives. For example, and not limited to, modules may be individually connected to one another by bolts between adjacent modules, or other clamping or tensioning devices may be used to mount modules within the coolant transfer stack.

[0046] As shown, the left side of the actuator module 18 includes two liquid coolant ports 80a and 82a, and the right side of the actuator module 18 includes two liquid coolant ports 81a and 83a. A horizontal internal coolant passage 85a extends directly between the opposing ports 80a and 81a. In this embodiment, ports 80a and 81a are located at the upper left and right rear corners of the module unit 18, and the coolant passage 85a extends horizontally between them in the longitudinal direction xx. A horizontal coolant passage 86a extends directly between the opposing ports 82a and 83a. In this embodiment, ports 82a and 83a are located at the lower left and right front corners of the module unit 18, and the coolant passage 86a extends horizontally between them in the longitudinal direction xx. An internal power electronics coolant passage 87a is provided between the upper coolant passage 85a and the lower coolant passage 86a. Referring to Figure 6, in this embodiment, the shape of the coolant passage 87a comprises a rear vertical chamber 88 extending downward from the passage 85 in the transverse direction yy, a front vertical chamber 89 extending upward from the passage 86 in the transverse direction yy, and a plurality of parallel coolant channels extending laterally and spaced apart vertically, each separately indicated by 90, which extend between the rear vertical chamber 88a and the front vertical chamber 89a and are positioned in close thermal proximity to the power electronic equipment 31a.

[0047] As will be further explained below, each of the ports 80a, 81a, 82a, and 83a within the housing 30a of module 18 is configured to be blocked to allow for alternative coolant configurations as desired. In addition, the housing 30a of module 18 includes several alternative coolant ports to allow for coolant supply from alternative faces or sides of the housing 30a of module 18 as desired. In particular, the front port 91a is provided in the internal coolant passage 86a from the front side 100a of module 18, the bottom port 92a is provided in the internal coolant passage 86a from the bottom side 105a of module 18, and the top port 93a is provided in the internal coolant passage 85a from the top side 104a of module 18. If no particular alternative cooling configuration is desired, ports 91a, 92a, and 93a are blocked as shown in Figure 1.

[0048] Similar to module 18, the left side of actuator module 19 includes two liquid coolant ports 80b and 82b, and the right side of actuator module 19 includes two liquid coolant ports 81b and 83b. A horizontal internal coolant passage 85b extends directly between the opposing ports 80b and 81b. In this embodiment, ports 80b and 81b are located at the upper left and right rear corners of module unit 19, and the coolant passage 85b extends horizontally between them in the longitudinal direction xx. A horizontal internal coolant passage 86b extends directly between the opposing ports 82b and 83b. In this embodiment, ports 82b and 83b are located at the lower left and right front corners of module unit 19, and the coolant passage 86b extends horizontally between them in the longitudinal direction xx. An internal power electronics coolant passage 87b is provided between the upper coolant passage 85b and the lower coolant passage 86b. In this embodiment, the external shape of the coolant passage 87b is the same as that of the coolant passage 87a of module 18, and comprises a rear vertical chamber 89 extending downward from passage 85b in the transverse direction yy, a front vertical chamber 89 extending upward from passage 86b in the transverse direction yy, and a plurality of parallel coolant channels 90 extending laterally, spaced apart vertically, extending between the rear vertical chamber 88 and the front vertical chamber 89, and positioned in close thermal proximity to the power electronic equipment 31b.

[0049] As will be further explained below, each of the ports 80b, 81b, 82b, and 83b within the housing 30b of module 19 is configured to be blocked to allow for alternative coolant configurations if desired. In addition, the housing 30b of module 19 includes several alternative coolant ports to allow for coolant supply from alternative faces or sides of the housing 30b of module 19 if desired. In particular, the front port 91b is provided in the internal coolant passage 86b from the front side 100b of module 19, the bottom port 92b is provided in the internal coolant passage 86b from the bottom side 105b of module 19, and the top port 93b is provided in the internal coolant passage 85b from the top side 104b of module 19. If no particular alternative cooling configuration is desired, ports 91b, 92b, and 93b are blocked as shown in Figure 1.

[0050] Similar to module 19, the left side of actuator module 20 includes two liquid coolant ports 80c and 82c, and the right side of actuator module 20 includes two liquid coolant ports 81c and 83c. A horizontal internal coolant passage 85c extends directly between the opposing ports 80c and 81c. In this embodiment, ports 80c and 81c are located at the upper left and right rear corners of module unit 20, and the coolant passage 85c extends horizontally between them in the longitudinal direction xx. A horizontal internal coolant passage 86c extends directly between the opposing ports 82c and 83c. In this embodiment, ports 82c and 83c are located at the lower left and right front corners of module unit 20, and the coolant passage 86c extends horizontally between them in the longitudinal direction xx. An internal power electronics coolant passage 87c is provided between the upper coolant passage 85c and the lower coolant passage 86c. In this embodiment, the external shape of the coolant passage 87c is the same as that of the coolant passage 87a of module 18, and comprises a rear vertical chamber 89 extending downward from passage 85c in the transverse direction yy, a front vertical chamber 89 extending upward from passage 86c in the transverse direction yy, and a plurality of parallel coolant channels 90 extending laterally, spaced apart vertically, extending between the rear vertical chamber 88 and the front vertical chamber 89, and positioned in close thermal proximity to the power electronic equipment 31c.

[0051] As will be further explained below, each of the ports 80c, 81c, 82c, and 83c within the housing 30c of module 20 is configured to be blocked to allow for alternative coolant configurations if desired. In addition, the housing 30c of module 20 includes several alternative coolant ports to allow for coolant supply from alternative faces or sides of the housing 30c of module 20 if desired. In particular, the front port 91c is located in the internal coolant passage 86c from the front side 100c of module 20, the bottom port 92c is located in the internal coolant passage 86c from the bottom side 105c of module 20, and the top port 93c is located in the internal coolant passage 85c from the top side 104c of module 20. If no particular alternative cooling configuration is desired, ports 91c, 92c, and 93c are blocked as shown in Figure 1.

[0052] Similar to module 20, the left side of actuator module 21 includes two liquid coolant ports 80d and 82d, and the right side of actuator module 21 includes two liquid coolant ports 81d and 83d. A horizontal internal coolant passage 85d extends directly between the opposing ports 80d and 81d. In this embodiment, ports 80d and 81d are located at the upper left and right rear corners of module unit 21, and the coolant passage 85d extends horizontally between them in the longitudinal direction xx. A horizontal coolant passage 86d extends directly between the opposing ports 82d and 83d. In this embodiment, ports 82d and 83d are located at the lower left and right front corners of module unit 21, and the coolant passage 86d extends horizontally between them in the longitudinal direction xx. An internal power electronics coolant passage 87d is provided between the upper coolant passage 85d and the lower coolant passage 86d. In this embodiment, the external shape of the coolant passage 87d is the same as that of the coolant passage 87a of module 18, and comprises a rear vertical chamber 89 extending downward from passage 85d in the transverse direction yy, a front vertical chamber 89 extending upward from passage 86d in the transverse direction yy, and a plurality of parallel coolant channels 90 extending laterally, spaced apart vertically, extending between the rear vertical chamber 88 and the front vertical chamber 89, and arranged in thermally close proximity to the power electronic equipment 31e and 31f.

[0053] As will be further explained below, each of the ports 80d, 81d, 82d, and 83d in the housing 30d of module 21 is configured to be blocked to allow for alternative coolant configurations if desired. In addition, the housing 30d of module 21 includes several alternative coolant ports to allow for coolant supply from alternative faces or sides of the housing 30d of module 21 if desired. In particular, the front port 91d is provided in the internal coolant passage 86d from the front side 100d of module 21, the bottom port 92d is provided in the internal coolant passage 86d from the bottom side 105d of module 21, and the top port 93d is provided in the internal coolant passage 85d from the top side 104d of module 21. If no particular alternative cooling configuration is desired, ports 91d, 92d, and 93d are blocked as shown in Figure 1.

[0054] Similar to module 20, the left side of the central power control module 17 includes two liquid coolant ports 80e and 82e, and the right side of the central power control module 17 includes two liquid coolant ports 81e and 83e. A horizontal internal coolant passage 85e extends directly between the opposing ports 80e and 81e. In this embodiment, ports 80e and 81e are located at the upper left and right rear corners of the module unit 17, and the coolant passage 85e extends horizontally between them in the longitudinal direction xx. A horizontal coolant passage 86e extends directly between the opposing ports 82e and 83e. In this embodiment, ports 82e and 83e are located at the lower left and right front corners of the module unit 17, and the coolant passage 86e extends horizontally between them in the longitudinal direction xx. An internal central power management electronics coolant passage 87e is provided between the upper coolant passage 85e and the lower coolant passage 86e. In this embodiment, the external shape of the coolant passage 87e is the same as that of the coolant passage 87a of module 18, and comprises a rear vertical chamber 89 extending downward from passage 85e in the transverse direction yy, a front vertical chamber 89 extending upward from passage 86e in the transverse direction yy, and a plurality of parallel coolant channels 90 extending laterally, spaced apart vertically, extending between the rear vertical chamber 88 and the front vertical chamber 89, and positioned in close thermal proximity to the central power management electronic equipment 51.

[0055] As will be further explained below, each of the ports 80e, 81e, 82e, and 83d in the housing 30e of module unit 17 is configured to be blocked to allow for alternative coolant configurations if desired. In addition, the housing 30e of module unit 17 includes several alternative coolant ports to allow for the supply or discharge of coolant from alternative faces or sides of the housing 30e of module unit 17 if desired. In particular, the front port 91e is provided in the internal coolant passage 86e from the front side 100e of module 17, the bottom port 92e is provided in the internal coolant passage 86e from the bottom side 105e of module 17, and the top port 93e is provided in the internal coolant passage 85e from the top side 104e of module 17. If no particular alternative cooling configuration is desired, ports 92e and 93e are blocked. As will be further explained below, in a specific cooling configuration combining series and parallel connections, with the central control module 16 stacked to the right of module 17, the alternative port 91e may not be blocked and may be used as an outlet port, as shown in Figure 1.

[0056] The porting and cooling passage designs of modules 17-21 allow the cooling passages of assembly 15 to be adapted to achieve flow and pressure drop requirements for specific applications simply by positioning plugs. Thus, using the same modules, the passages may be in series, parallel, or a combination of both series and parallel, and may be adjusted to specific requirements. Figure 7 shows a series passage cooling configuration. In the series cooling configuration shown in Figure 7, the upper left port 80a is blocked by a plug 95a, and the lower right port 83a is blocked by a plug 96b. Coolant is supplied to passage 86a via the lower left port 82a and the circulation pump 45, and is supplied into the vertical chamber 89 of the coolant passage 87a because the plug 96b blocks port 83a. The coolant is then guided into each of the horizontally extending parallel channels 90 of the coolant flow path 87a, flowing from front to back of module 18 at different heights in the channels 90, thereby cooling the power electronics 31a, which is positioned in close thermal proximity to the cooling channels 90. The fluid coolant exits from the rear of the channels 90 and enters the rear vertical chamber 88 of the coolant flow path 87a. Due to a plug 95a in port 80a, the coolant is guided to exit module 18 through the upper right port 81a. Thus, in this series flow cooling configuration, module 18 receives coolant through a single inlet port 82a and discharges coolant through a single outlet port 81a.

[0057] With modules 18 and 19 stacked side by side, the upper right port 81a of module 18 is aligned with the upper left port 80b of module 19, creating a sealed fluid communication between them. The coolant then exits the upper right port 81a of module 18 and enters the upper left port 80b of module 19. The lower left port 82b is blocked by a plug 96b, and the upper right port 81b is blocked by a plug 95c. The coolant is supplied to passage 85b via the upper left port 80b and the circulation pump 45, and because the plug 95c blocks port 81b, it is supplied into the rear vertical chamber 88 of the coolant flow path 87b. The coolant is then guided to enter each of the horizontally extending parallel channels 90 of the coolant flow path 87b, flowing from rear to front of module 19 at different heights of the channels 90, thereby cooling the power electronics 31b, which is positioned in close thermal proximity to the cooling channels 90. The fluid coolant exits from the front of the channels 90 and enters the front vertical chamber 89 of the coolant flow path 87b. Due to the plug 96b in port 82b, the coolant is guided to exit module 19 through the lower right port 83b. Thus, in this series flow cooling configuration, module 19 receives coolant through a single inlet port 80b and discharges coolant through a single outlet port 83b.

[0058] With modules 19 and 20 stacked side by side, the lower right port 83b of module 19 is aligned with the lower left port 82c of module 20, creating a sealed fluid communication with the lower left port 82c of module 20. The coolant then exits the lower right port 83b of module 19 and enters the lower left port 82c of module 20. The upper left port 80c is blocked by a plug 95c, and the lower right port 83c is blocked by a plug 96d. The coolant is supplied to the passage 86c via the lower left port 82c and the circulation pump 45, and because the plug 96d blocks port 83c, it is supplied into the vertical forward chamber 89 of the coolant flow path 87c. The coolant is then guided to enter each of the horizontally extending parallel channels 90 of the coolant flow path 87c, flowing from front to back of module 20 at different heights in the channels 90, thereby cooling the power electronics 31c and 31d, which are positioned in close thermal proximity to the cooling channels 90. The fluid coolant exits from the rear of the channels 90 and enters the rear vertical chamber 88 of the coolant flow path 87b. Due to the plug 95c in port 80c, the coolant is guided to exit module 20 through the upper right port 81c. Thus, in this series flow cooling configuration, module 20 receives coolant through a single inlet port 82c and discharges coolant through a single outlet port 81c.

[0059] With modules 20 and 21 stacked side by side, the upper right port 81c of module 20 is aligned with the upper left port 80d of module 21, creating a sealed fluid communication between them. The coolant then exits the upper right port 81c of module 20 and enters the upper left port 80d of module 21. The lower left port 82d is blocked by a plug 96d, and the upper right port 81d is blocked by a plug 95e. The coolant is supplied to the passage 85d via the upper left port 80d and the circulation pump 45, and because the plug 95e blocks port 81d, it is supplied into the rear vertical chamber 88 of the coolant flow path 87d. The coolant is then guided to enter each of the horizontally extending parallel channels 90 of the coolant flow path 87d, flowing from rear to front of module 19 at different heights of the channels 90, thereby cooling the power electronics 31f and 31g, which are positioned in close thermal proximity to the cooling channels 90. The fluid coolant exits from the front of the channels 90 and enters the front vertical chamber 89 of the coolant flow path 87d. Due to the plug 96d in port 82d, the coolant is guided to exit module 21 through the lower right port 83d. Thus, in this series flow cooling configuration, module 21 receives coolant through a single inlet port 80d and discharges coolant through a single outlet port 83d.

[0060] With modules 21 and 17 stacked side by side, the lower right port 83d of module 21 is aligned with the lower left port 82e of module 17, creating a sealed fluid communication between them. The coolant then exits the lower right port 83d of module 21 and enters the lower left port 82e of module 17. The upper left port 80e is blocked by a plug 95e, and the lower right port 83e is blocked by a plug 96f. The coolant is supplied to the passage 86e via the lower left port 82e and the circulation pump 45, and because the plug 96f blocks port 83e, it is supplied into the vertical forward chamber 89 of the coolant flow path 87e. The coolant is then guided into each of the horizontally extending parallel channels 90 of the coolant flow path 87e, flowing from front to back of module 17 at different heights of the channels 90, thereby cooling the central power management electronics 51, including the control power electronics 55, which are located in close thermal proximity to the cooling channels 90. The fluid coolant exits from the rear of the channels 90 and enters the rear vertical chamber 88 of the coolant flow path 87c. Due to a plug 95e in port 80e, the coolant is guided to exit module 17 through the upper right port 81e. Thus, in this series flow cooling configuration, module 20 receives coolant through a single inlet port 82e and discharges coolant through a single outlet port 81e. In the embodiment shown in Figure 1, with the central control module 16 stacked to the right of module 17, and since the central control module 16 does not include any coolant channels in this embodiment, port 81e may be blocked, and an alternative port 93e may be left open and used as an outlet port. Therefore, in this series flow cooling configuration, module 17 receives coolant through a single inlet port 82e and discharges coolant through a single outlet port 81e or 93e.

[0061] Figure 8 shows a parallel flow channel cooling configuration. In the parallel cooling configuration shown in Figure 8, the lower left port 82a is blocked by a plug 96a. Neither the upper right port 81a nor the lower right port 83a of module 18 is blocked. Neither the upper left port 80b nor the lower left port 82b of module 19 is blocked. Coolant is supplied to passage 85a via the upper left port 80a and the circulation pump 45. The coolant flows through passage 85a to the upper right port 81a and is similarly guided to flow into the vertical rear chamber 88 of the coolant flow channel 87a. From the vertical rear chamber 88 of the coolant flow channel 87a, the coolant flows into each of the horizontally extending parallel channels 90 of the coolant flow channel 87a, flowing from rear to front of module 18 at different heights of the channels 90, thereby cooling the power electronics 31a, which is positioned in close thermal proximity to the cooling channels 90. The fluid coolant exits from the front of channel 90 and enters the forward vertical chamber 89 of the coolant flow path 87a. Due to the plug 96a in port 82a, the coolant is guided to exit module 18 through either the upper right port 81a or the lower right port 83a. Thus, in this parallel flow cooling configuration, module 18 receives coolant at least through the inlet port 80a and discharges coolant through the two parallel outlet ports 81a and 83a.

[0062] With modules 18 and 19 stacked side by side, the upper right port 81a of module 18 is aligned with the upper left port 80b of module 19, creating a sealed fluid communication between them. As a result, the coolant exits the upper right port 81a of module 18 and enters the upper left port 80b of module 19. Also, the lower right port 83a of module 18 is aligned with the lower left port 82b of module 19, creating a sealed fluid communication between them. As a result, the coolant exits the lower right port 83a of module 18 and enters the lower left port 82b of module 19. Neither the upper right port 81b nor the lower right port 83b of module 19 is blocked. Also, neither the upper left port 80c nor the lower left port 82c of module 20 is blocked. The coolant is supplied to passage 85b via the upper left port 80b and to passage 86b via the lower left port 82b. The coolant flows through passage 85b to the upper right port 81b, through passage 86b to the lower right port 83b, and is also guided to flow into channel 90 of the coolant flow path 87b, thereby cooling the power electronic equipment 31b. Thus, in this parallel flow cooling configuration, module 19 receives coolant through two parallel inlet ports 80b and 82b and discharges coolant through two parallel outlet ports 81b and 83b.

[0063] With modules 19 and 20 stacked side by side, the upper right port 81b of module 19 is aligned with the upper left port 80c of module 20, creating a sealed fluid communication between them. The coolant then exits the upper right port 81b of module 19 and enters the upper left port 80c of module 20. Additionally, the lower right port 83b of module 19 is aligned with the lower left port 82c of module 20, creating a sealed fluid communication between them. The coolant then exits the lower right port 83b of module 19 and enters the lower left port 82c of module 20. Neither the upper right port 81c nor the lower right port 83c of module 20 is blocked. Also, neither the upper left port 80c nor the lower left port 82d of module 21 is blocked. The coolant is supplied to passage 85c via the upper left port 80c and to passage 86c via the lower left port 82c. The coolant flows through passage 85c to the upper right port 81c, through passage 86c to the lower right port 83c, and similarly into channel 90 of the coolant flow path 87c, thereby cooling the power electronics 31c and 31d. Thus, in this parallel flow cooling configuration, module 20 receives coolant through two parallel inlet ports 80c and 82c and discharges coolant through two parallel outlet ports 81c and 83c.

[0064] With modules 20 and 21 stacked side by side, the upper right port 81c of module 20 is aligned with the upper left port 80d of module 21, creating a sealed fluid communication between them. The coolant then exits the upper right port 81c of module 20 and enters the upper left port 80d of module 21. Additionally, the lower right port 83c of module 20 is aligned with the lower left port 82d of module 21, creating a sealed fluid communication between them. The coolant then exits the lower right port 83c of module 20 and enters the lower left port 80d of module 21. Neither the upper right port 81d nor the lower right port 83d of module 21 is blocked. Furthermore, neither the upper left port 80e nor the lower left port 82e of module 17 is blocked. The coolant is supplied to passage 85d via the upper left port 80d and to passage 86d via the lower left port 82d. The coolant flows through passage 85d to the upper right port 81d, through passage 86d to the lower right port 83d, and similarly into channel 90 of the coolant flow path 87d, thereby cooling the power electronics 31e and 31f. Thus, in this parallel flow cooling configuration, module 21 receives coolant through two parallel inlet ports 80d and 82d and discharges coolant through two parallel outlet ports 81d and 83d.

[0065] With modules 21 and 17 stacked side by side, the upper right port 81d of module 21 is aligned with the upper left port 80e of module 17, creating a sealed fluid communication between them. The coolant then exits the upper right port 81d of module 21 and enters the upper left port 80e of module 17. Similarly, the lower right port 83d of module 21 is aligned with the lower left port 82e of module 17, creating a sealed fluid communication between them. The coolant then exits the lower right port 83d of module 21 and enters the lower left port 82e of module 17. The coolant is supplied to passage 85e via the upper left port 80e and to passage 86e via the lower left port 82e. The upper right port 81e is blocked by a plug 95f. The coolant is guided to flow through passage 86e to the lower right port 83e, and similarly through passage 85e into the vertical rear chamber 88 of the coolant flow path 87e. From the vertical rear chamber 88 of the coolant flow path 87e, the coolant flows into each of the horizontally extending parallel channels 90 of the coolant flow path 87e, flowing from rear to front of module 17 at different heights of the channels 90, thereby cooling the electronic equipment 51, which is positioned in close thermal proximity to the cooling channels 90. The fluid coolant exits from the front of the channels 90, enters the front vertical chamber 89 of the coolant flow path 87e, and exits module 17 through the lower right port 83e. In the embodiment shown in Figure 1, with the central control module 16 stacked to the right of module 17, and since the central control module 16 does not include any coolant channels in this embodiment, port 83e may be blocked, and an alternative port 91e may be left open and used as an exit port. Therefore, in this parallel flow cooling configuration, module 17 receives coolant through two parallel inlet ports 80e and 82e and discharges coolant through at least one outlet port 83e or 91e.

[0066] Figure 9 shows a series-parallel flow cooling configuration. In the series-parallel cooling configuration shown in Figure 9, the upper left port 80a is blocked by a plug 95a, and the lower right port 83a is blocked by a plug 96b. The coolant is supplied to the passage 86a via the lower left port 82a and the circulation pump 45, and is supplied into the vertical chamber 89 of the coolant flow path 87a because the plug 96b blocks port 83a. The coolant is then guided into each of the horizontally extending parallel channels 90 of the coolant flow path 87a, flowing from front to back of the module 18 at different heights in the channels 90, thereby cooling the power electronics 31a, which is positioned in close thermal proximity to the cooling channels 90. The fluid coolant exits the rear of the channels 90 and enters the rear vertical chamber 88 of the coolant flow path 87a. Due to the plug 95a in port 80a, the coolant is guided to exit module 18 through the upper right port 81a. Thus, module 18 is in a series flow cooling configuration, receiving coolant through a single inlet port 82a and discharging coolant through a single outlet port 81a.

[0067] With modules 18 and 19 stacked side by side, the upper right port 81a of module 18 is aligned with the upper left port 80b of module 19, creating a sealed fluid communication between them. The coolant then exits the upper right port 81a of module 18 and enters the upper left port 80b of module 19. The lower left port 82b is blocked by a plug 96b, and the upper right port 81b is blocked by a plug 95c. The coolant is supplied to passage 85b via the upper left port 80b and the circulation pump 45, and because the plug 95c blocks port 81b, it is supplied into the rear vertical chamber 88 of the coolant flow path 87b. The coolant is then guided into each of the horizontally extending parallel channels 90 of the coolant flow path 87b, flowing from rear to front of module 19 at different heights of the channels 90, thereby cooling the power electronics 31b, which is positioned in close thermal proximity to the cooling channels 90. The fluid coolant exits from the front of the channels 90 and enters the front vertical chamber 89 of the coolant flow path 87b. Due to the plug 96b in port 82b, the coolant is guided to exit module 19 through the lower right port 83b. Thus, modules 18 and 19 are in a series flow cooling configuration, with module 19 receiving coolant through a single inlet port 80b and discharging coolant through a single outlet port 83b.

[0068] With modules 19 and 20 stacked side by side, the lower right port 83b of module 19 is aligned with the lower left port 82c of module 20, creating a sealed fluid communication with the lower left port 82c of module 20. The coolant then exits the lower right port 83b of module 19 and enters the lower left port 82c of module 20. The upper left port 80c is blocked by a plug 95c, and the lower right port 83c is blocked by a plug 96d. The coolant is supplied to the passage 86c via the lower left port 82c and the circulation pump 45, and because the plug 96d blocks port 83c, it is supplied into the vertical forward chamber 89 of the coolant flow path 87c. The coolant is then guided to enter each of the horizontally extending parallel channels 90 of the coolant flow path 87c, flowing from front to back of module 20 at different heights in the channels 90, thereby cooling the power electronics 31c and 31d, which are positioned in close thermal proximity to the cooling channels 90. The fluid coolant exits from the rear of the channels 90 and enters the rear vertical chamber 88 of the coolant flow path 87b. Due to a plug 95c in port 80c, the coolant is guided to exit module 20 through the upper right port 81c. Thus, modules 18, 19 and 20 are in a series flow cooling configuration, with module 20 receiving coolant through a single inlet port 82c and discharging coolant through a single outlet port 81c.

[0069] With modules 20 and 21 stacked side by side, the upper right port 81c of module 20 is aligned with the upper left port 80d of module 21, creating a sealed fluid communication with the upper left port 80d of module 21. The coolant then exits the upper right port 81c of module 20 and enters the upper left port 80d of module 21. The lower left port 82d is blocked by a plug 96d. Neither the upper right port 81d nor the lower right port 83d of module 21 is blocked. Neither the upper left port 80e nor the lower left port 82e of module 17 is blocked. The coolant is supplied to passage 85d via the upper left port 80d and the circulation pump 45. The coolant flows through passage 85d to the upper right port 81d and is similarly guided to flow into the vertical rear chamber 88 of the coolant flow path 87d. From the vertical rear chamber 88 of the coolant flow path 87d, the coolant flows into each of the horizontally extending parallel channels 90 of the coolant flow path 87d, flowing from rear to front of module 21 at different heights in the channels 90, thereby cooling the power electronics 31e and 31f, which are positioned in close thermal proximity to the cooling channels 90. The fluid coolant exits from the front of the channels 90 and enters the front vertical chamber 89 of the coolant flow path 87d. Due to the plug 96d in port 82d, the coolant is guided to exit module 21 through either the upper right port 81d or the lower right port 83d. Thus, module 18 is in a parallel flow cooling configuration, receiving coolant at least through the inlet port 80d and discharging coolant through the two parallel outlet ports 81d and 83d.

[0070] With modules 21 and 17 stacked side by side, the upper right port 81d of module 21 is aligned with the upper left port 80e of module 17, creating a sealed fluid communication between them. The coolant then exits the upper right port 81d of module 21 and enters the upper left port 80e of module 17. Similarly, the lower right port 83d of module 21 is aligned with the lower left port 82e of module 17, creating a sealed fluid communication between them. The coolant then exits the lower right port 83d of module 21 and enters the lower left port 82e of module 17. The coolant is supplied to passage 85e via the upper left port 80e and to passage 86e via the lower left port 82e. The upper right port 81e is blocked by a plug 95f. The coolant flows through passage 86e to the lower right port 83e, and similarly through passage 85e into the vertical rear chamber 88 of the coolant flow path 87e. From the vertical rear chamber 88 of the coolant flow path 87e, the coolant flows into each of the horizontally extending parallel channels 90 of the coolant flow path 87e, flowing from rear to front of module 17 at different heights of the channels 90, thereby cooling the electronic equipment 51, which is positioned in close thermal proximity to the cooling channels 90. The fluid coolant exits from the front of the channels 90, enters the front vertical chamber 89 of the coolant flow path 87e, and exits module 17 through the lower right port 83e. In the embodiment shown in Figure 1, with the central control module 16 stacked to the right of module 17, and since the central control module 16 does not include any coolant channels in this embodiment, port 83e may be blocked, and an alternative port 91e may be left open and used as an exit port. Therefore, modules 21 and 17 are in a parallel flow cooling configuration, with module 17 receiving coolant through two parallel inlet ports 80e and 82e and discharging the coolant through at least one outlet port 83e or 91e.

[0071] Figure 11 shows a first alternative cooling passage 187 to the cooling passage 87 shown in Figure 6. In this embodiment, the left side of the module also includes an upper liquid coolant port 180 and a lower liquid coolant port 182. The right side of the module includes a first liquid coolant port aligned opposite the coolant port 180, with a coolant passage 185 extending horizontally between them in the longitudinal direction xx. The right side of the module also includes a second liquid coolant port aligned opposite the coolant port 182, with a coolant passage 186 extending horizontally between them in the longitudinal direction xx. The cooling passage 185 is located at the upper left corner of the module unit 118. However, in this embodiment, the coolant passage 186 is located at the lower left corner of the module unit. As shown, in this embodiment, the internal power electronics coolant passage 187 extends as a single meandering passage between the upper coolant passage 185 and the lower coolant passage 186a.

[0072] Figure 12 shows a second alternative cooling passage 287 for the cooling passage 87 shown in Figure 6. In this embodiment, as in the embodiment shown in Figure 11, the left side of the module includes an upper liquid coolant port 280 and a lower liquid coolant port 282. The right side of the module includes a first liquid coolant port aligned opposite the coolant port 280, with a coolant passage 285 extending horizontally between them in the longitudinal direction xx. The right side of the module also includes a second liquid coolant port aligned opposite the coolant port 282, with a coolant passage 286 extending horizontally between them in the longitudinal direction xx. The cooling passage 285 is located in the upper left corner of the module unit, and the coolant passage 286 is located in the lower left corner of the module unit 118. As shown, in this embodiment, the shape of the coolant passage 287 comprises a coolant channel 291 extending laterally from passage 285 in direction zz, a forward vertical chamber 289 extending downward from passage 291 in the transverse direction yy, a rear vertical chamber 288 extending upward from passage 286 in the transverse direction yy, and a plurality of parallel coolant channels extending laterally and spaced vertically, each indicated separately by 290, which extend between the forward vertical chamber 289 and the rear vertical chamber 188.

[0073] The coolant passages are shown with various geometric shapes and conduit configurations, but alternative passage geometric shapes and porting may be used. For example, divided volumes inside the housing may be used to provide coolant passages, or input and output ports may be located in alternative locations through the housing, and the number of such ports may vary as desired.

[0074] The modular control system 15 offers several advantages. System 15 is liquid-cooled, extremely compact, environmentally robust, mechanically robust, expandable, and provides a stack of individualized electronics modules rated for various environments, such as compact earthmoving machinery. System 15 is easily expandable and contractible and customizable. Integrated cooling passages designed to enter within each module eliminate the need for external interconnects between them. Integrated electrical bus connections, both power and control, eliminate the need for external interconnects between them. Individual stacked modular units may be customized to provide individualized desired control electronics. The number and configuration of modular units may be modified as desired to suit application and environmental conditions. The system provides IoT data collection, storage, and transmission. The system has remote control capabilities and autonomous control capabilities. Individual modular units may also be line-replaceable units (LRUs). Individual modules may have a protection rating of at least IP44, and when arranged in a multi-module assembly, may have a protection rating of at least IP67K. System 15 can be scaled up or down by adding module units to the stack as needed.

[0075] While the currently preferred form of a modular actuator control system has been shown and described, and several modifications thereof have been considered, those skilled in the art will readily understand that various additional changes and modifications can be made without departing from the scope of the invention as defined and differentiated by the claims.

Claims

1. A first controller module configured to control a first actuator having at least one operating axis and being electrically powered, The first housing and The first control electronic equipment located within the first housing, The first power electronic equipment in the first housing, A first power connection configured to connect to the master power supply, A first communication connection configured to connect to a master controller electronic device, A first actuator power connection configured to connect the first power electronic equipment to the first actuator, The first coolant inlet port, The first coolant outlet port, A first coolant flow path within the first housing is provided between the first coolant inlet port and the first coolant outlet port, configured to supply liquid coolant to the first power electronic device, The first controller module and A second controller module configured to control a second actuator having at least one operating axis and being electrically powered, The second housing and The second control electronic device located within the second housing, The second power electronic equipment within the second housing, A second power connection configured to be connected to the master power supply, A second communication connection configured to connect to the master controller electronic device, A second actuator power connection configured to connect the second power electronic equipment to the second actuator, The second coolant inlet port, The second coolant outlet port, A second coolant flow path within the second housing is provided between the second coolant inlet port and the second coolant outlet port, configured to supply the liquid coolant to the second power electronic device, The second controller module, The first controller module comprises a first housing and an attachment connecting the second housing of the second controller module, The first coolant inlet port of the first controller module is configured to be connected to a fluid coolant source. A modular actuator control system in which the first coolant outlet port of the first controller module is connected to the second coolant inlet port of the second controller module, A modular actuator control system in which the first controller module and the second controller module are stacked so as to communicate with each other via a coolant fluid.

2. The first controller module comprises a first secondary coolant outlet port and a first secondary flow path within the first housing between the first coolant inlet port and the first secondary coolant outlet port. The first coolant flow path is separated from the first secondary flow path. The second controller module is equipped with a second secondary coolant inlet port, The first secondary coolant outlet port of the first controller module is connected to the second secondary coolant inlet port of the second controller module. The modular actuator control system according to claim 1, wherein the first controller module and the second controller module are stacked in a parallel flow coolant configuration.

3. The first controller module includes a first actuator communication connection configured to connect the first control electronic equipment to the first actuator. The modular actuator control system according to claim 1, wherein the second controller module comprises a second actuator communication connection configured to connect the second control electronic equipment to the second actuator.

4. The first actuator comprises a first sensor for sensing the operating parameters of the first actuator, and the first actuator communication connection is configured to connect the first control electronic equipment to the first sensor of the first actuator. The modular actuator control system according to claim 3, wherein the second actuator comprises a second sensor for sensing the operating parameters of the second actuator, and the second actuator communication connection is configured to connect the second control electronic equipment to the second sensor of the second actuator.

5. The modular actuator control system according to claim 1, further comprising a common power bus that supplies power to the first power connection and the second power connection.

6. The modular actuator control system according to claim 1, further comprising a common serial bus that communicates with the first communication connection and the second communication connection.

7. The first housing comprises a first sealed electronic housing compartment defining a first electronic equipment chamber substantially isolated from the external environment, the first control electronic equipment and the first power electronic equipment being disposed within the first electronic equipment chamber. The modular actuator control system according to claim 1, wherein the second housing comprises a second sealed electronic housing compartment defining a second electronic equipment chamber substantially isolated from the external environment, and the second control electronic equipment and the second power electronic equipment are disposed within the second electronic equipment chamber.

8. The first housing comprises a first connection section defining a first connection chamber substantially isolated from the external environment, and the first power connection and the first communication connection are arranged within the first connection chamber. The modular actuator control system according to claim 7, wherein the second housing comprises a second connection section defining a second connection chamber substantially isolated from the external environment, and the second power connection and the second communication connection are disposed within the second connection chamber.

9. A common power bus that supplies power to the first power connection and the second power connection, The system comprises the first communication connection and a common serial bus that communicates with the second communication connection, The common power bus extends within the first connection chamber and the second connection chamber, The modular actuator control system according to claim 8, wherein the common serial bus extends within the first connection chamber and the second connection chamber.

10. Master controller housing and The master controller electronic equipment disposed within the master controller housing, The system includes a master communication connection configured to connect the first communication connection of the first controller module and the second communication connection of the second controller module. Master controller module and The modular actuator control system according to claim 1, comprising the first housing of the first controller module, the second housing of the second controller module, and the attachment connecting the master controller housing of the master controller module.

11. The modular actuator control system according to claim 10, further comprising a serial bus for communication between the master communication connection, the first communication connection, and the second communication connection.

12. Power management housing and The power management electronic equipment located within the power management housing, An input power connection configured to be connected to the master power supply, An output control power connection configured to connect to the first control electronic device and the second control electronic device, Power coolant inlet port, Power coolant outlet port, The power management housing comprises a power flow path between the power coolant inlet port and the power coolant outlet port, configured to supply a liquid coolant to the power management electronic equipment. Power management module and The modular actuator control system according to claim 10, comprising the attachment connecting the first housing of the first controller module, the second housing of the second controller module, the master controller housing of the master controller module, and the power management housing of the power management module.

13. The modular actuator control system according to claim 12, wherein the master controller module includes an input control power connection configured to connect to the output control power connection of the power management module.

14. The modular actuator control system according to claim 1, comprising a pump connected to the first coolant inlet port of the first controller module and configured to operate to pump the liquid coolant through the first coolant passage of the first housing and the second coolant passage of the second housing.

15. The modular actuator control system according to claim 14, further comprising a heat exchanger connected between the second coolant outlet port of the second controller module and the first coolant inlet port of the first controller module.

16. The modular actuator control system according to claim 15, wherein the heat exchanger is connected between the second coolant outlet port of the second controller module and the pump.

17. The modular actuator control system according to claim 1, further comprising a seal between the first housing of the first controller module and the second housing of the second controller module.

18. The modular actuator control system according to claim 12, wherein the power management module is stacked between the second controller module and the master controller module, and the second coolant outlet port of the second controller module is connected to the power coolant inlet port of the power management module.

19. A third controller module configured to control a third actuator having at least one operating axis and being electrically powered, The third housing and The third control electronic device in the housing described above, The third power electronic equipment within the third housing, A third power connection configured to be connected to the master power supply, A third communication connection configured to connect to the master controller electronic device, A third actuator power connection configured to connect the preceding third power electronic equipment to the preceding third actuator, A third coolant inlet port, A third coolant outlet port, A third coolant flow path within the third housing between the third coolant inlet port and the third coolant outlet port is configured to supply the liquid coolant to the third power electronic device, The third controller module, The device comprises the attachment connecting the first housing of the first controller module, the second housing of the second controller module, and the third housing of the third controller module, The second coolant outlet port of the second controller module is connected to the third coolant inlet port of the third controller module. The modular actuator control system according to claim 1, wherein the first controller module, the second controller module, and the third controller module are stacked so as to be in communication with each other via a coolant fluid.

20. The second controller module comprises a second secondary coolant outlet port and a second secondary flow path within the second housing between the second coolant inlet port and the second secondary coolant outlet port. The second coolant flow path is separated from the second secondary flow path. The third controller module is equipped with a third secondary coolant inlet port, The second secondary coolant outlet port of the second controller module is connected to the third secondary coolant inlet port of the third controller module. The modular actuator control system according to claim 19, wherein the first controller module and the second controller module are stacked in a series flow path coolant configuration, and the second controller module and the third controller module are stacked in a parallel flow path coolant configuration.

21. The modular actuator control system according to claim 1, wherein the first coolant flow path within the first housing between the first coolant inlet port and the first coolant outlet port comprises a plurality of separate coolant passages thermally close to the first power electronic equipment.

22. The modular actuator control system according to claim 1, wherein the first coolant flow path within the first housing between the first coolant inlet port and the first coolant outlet port comprises a meandering coolant passage thermally close to the first power electronic equipment.

23. The modular actuator control system according to claim 12, wherein the master controller housing of the master controller module includes a braking resistor and a capacitor.

24. The modular actuator control system according to claim 12, wherein the master power supply comprises an electric vehicle battery.

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