REGIONAL TEMPERATURE-BASED SEGMENT-SELECTED BRAKE RESISTANCE INTERMEDIATE PLATE

Abstract

The invention relates to servo motors, integrated servo drives, regenerative braking circuits, and thermal management, and specifically concerns a mounting spacer placed between the motor's front mounting flange and the machine body, designed to dissipate the energy transferred back to the DC bus during deceleration and to remove the resulting heat from the motor electronics in integrated servo motors where the drive electronics are located on the motor housing.

Description

1 TARIFF SEGMENT-SELECTED BRAKING RESISTANCE ANALYSIS BASED ON REGIONAL TEMPERATURE. LICENSE PLATE Technical Area The invention comprises servo motors, integrated servo drives, regenerative braking circuits, and thermal 5. It relates to control, and specifically the driver electronics are located on the engine housing. In integrated servo motors, the energy transferred back to the DC bus during deceleration. for the dissipation of heat and the removal of the generated heat from the engine electronics, a mounting plate placed between the motor's front mounting flange and the machine body It is related to. 10 State of the Art Today, in integrated servo motors, the inverter, control board, encoder, and motor are all the same. They are located inside the housing or very close to each other. This structure, cabling It reduces the need for and panel volume; however, the regenerative braking that occurs during braking... This makes it difficult to manage energy within a small volume. 15 In known systems, when the DC bus voltage exceeds a certain threshold value, a single brake switch is activated. A fixed-value internal or external braking resistor is activated via this. Internal When resistors are used, braking heat is transferred to the motor windings, power semiconductors, and encoder. and can be transferred to DC bus capacitors, extending the lifespan of these heat-sensitive components. It has a negative impact. When an external resistor is used, an additional box, cable, connector and 20 Mounting space is required; this is addressed by the space savings provided by the integrated servo motor. It reduces its advantage. In known multi-stage braking systems, different resistors are connected to the circuit in series or parallel. The total braking power can be altered by adjusting these systems. However, these systems... Generally controlled only according to DC bus voltage or total resistance temperature 25 is being monitored; the physical location of the resistance elements, the temperature of each region, the machine the quality of thermal contact with the body and the thermal usage history of the segments together It is not being evaluated. Some of the documents included in the prior art are listed below. Document number GB2415510A describes the voltage and current measurement of a brake resistor for 30 seconds. 2 It describes a system for determining temperature or resistance status. Document number WO2005077702A1 describes the phased assembly of multiple resistor elements. It describes a braking resistor network that can be activated. CN214545298U numbered... The document describes the placement of a servo drive brake resistor inside a cooling structure. This is explained in documents numbered US20240305171A1 and US12587072B2, a 5 The converter motor contains a brake resistor with a metallic carrier or thermal structure. It describes the integration. Document number US11239770B2 describes regenerative. the braking energy is dissipated through a resistive element in the motor structure It explains. The documents in question describe temperature monitoring of the brake resistor, and the operation of multiple resistors. the phased use or the integration of resistance into a thermal structure separately However, none of these documents show the load between the engine and the machine. regional equivalent resistance segments distributed on a thin mounting spacer carrying Selected alternately according to temperature and thermal contact conditions. It is not taught. 15 In current systems, local hot spot formation occurs, along with thermal degradation in the resistance and insulation layers. fatigue, premature limitation of braking capacity, failure of a single resistor in this situation, the braking function is completely lost and the engine block is overheated. Problems such as overheating occur. Also, the machine body is already... The available thermal mass of a cooling element is usually controlled and measurable. It is not used as such. In conclusion, due to the negative aspects described above and the current solutions being the subject of discussion... Due to its shortcomings, an improvement is needed in the relevant technical field. It has been made. Purpose of the Invention 25 The invention was created by drawing inspiration from existing situations and overcoming the aforementioned drawbacks. It aims to solve the problem. The primary aim of this invention is to improve regenerative braking in integrated servo motors. The generated energy is transferred to the motor's front flange without the need for a separate external brake box. a mounting plate placed between the machine body and the dispenser, and 30 3 The heat generated is dissipated from the control board, power board, encoder, and windings inside the motor. The goal is to provide a structure that removes and transfers the fluid to the machine body. Another aim of the invention is to use a resistor that is distributed regionally within the intermediate plate, instead of a single fixed resistor. multiple brake resistance segments distributed and independently selectable By using it, it provides the required equivalent resistance and braking power while reducing the thermal load to 5. The goal is to establish a system that distributes information onto license plates. Another objective of the invention is to measure segment temperatures, machine side temperatures, and DC bus temperatures. voltage, braking time and thermal usage history of each segment through a control unit that evaluates the need for the same electrical braking. By selecting the thermally most suitable option from among the matching segment combinations, 10 The aim is to reduce local hot spots and balance the thermal load. Another objective of the invention is to reduce thermal load between independent segments. By applying rotation, thermal degradation occurs in the resistance elements and the insulation layer. The goal is to balance fatigue and increase repetitive braking capacity. Another purpose of the invention is to repair a faulty, overheated or poorly thermally connected 15 by removing the segment from the selection pool, limiting braking to the remaining segments. to create a fault-tolerant braking system that enables continued operation and Thus, the braking function is completely lost in the event of a single resistor failure. The goal is to prevent. Another objective of the invention is to increase the existing thermal mass of the machine body by 20. by using a controlled and measurable cooling element, the integrated servo motor The goal is to maintain the volume advantage it provides. The structural and characteristic features and all the advantages of the invention are given in the figures below. And thanks to the detailed explanation written with references to these figures, it becomes clearer. This will be understood as such, and therefore the evaluation will also be based on these forms and detailed explanations. 25 This should be done taking that into consideration. Figures that will help understand the invention. Figure 1 is a side view of the motor including the intermediate plate that is the subject of the invention. Explanation of Part References 4 A. Intermediate plate 1. Body 2. Control card 3. Power board 4. Stator 5 5. Rotor 6. Motor shaft 7. Engine front flange 8. Thermal barrier 9. Brake resistor spacer plate 10 10. Braking arms 11. Electrical insulation layer 12. Heat distribution plate 13. Machine body 14. Brake linkage 15 15. Power and communication link R. Brake resistance segment Q. Segment switch T-segment temperature sensing element TM. Machine temperature sensing element 20 Detailed Description of the Invention In this detailed description, the preferred configurations of the intermediate plate (A) which is the subject of the invention are: This explanation is provided solely to facilitate a better understanding of the subject. The intermediate plate (A) subject to the invention is between an integrated servo motor and the machine body (13). It is in operation; in the said system, the motor, drive electronics and support structure are 25 a body (1) where they come together, the body (1) on which the DC bus is located At least one controller that performs braking control based on voltage and temperature data. card (2), which drives the motor phases and monitors the generation of regenerative energy from the DC bus at least one power card (3), at least one stator with a stationary motor section that produces electromagnetic torque. (4), rotating section 30 which converts mechanical energy into electrical energy during braking at least one rotor (5) which provides torque transmission between the mechanical load and the motor. a small motor shaft (6) and the mechanical and centering of the intermediate plate (A) on the motor side There is at least one engine front flange (7) that forms the connection. The intermediate plate in question (A); between the brake resistor segments (R) and the motor front flange (7) at least one thermal barrier (8), 5 which reduces the transfer of braking heat to the engine side. placed between the front flange (7) of the engine and the machine body (13) of the engine centering enables the reaction torque to be transferred to the machine body (13). at least one brake resistor spacer (9), each with a brake resistor segment (R) and its corresponding one at least one braking branch consisting of a segment switch (Q) and carrying the braking current (10) is located between the brake resistor segments (R) and the heat distribution plate (12) and 10 at least one that electrically insulates the segments (R) from the heat distribution plate (12) The electrical insulation layer (11) dissipates the heat generated in the brake resistor segments (R) over a wide area. At least one heat distribution plate (12) that transmits heat to the machine body (13) by spreading it over the surface, motor The machine body (13), which mechanically supports and acts as a heat sink for braking heat, At least one brake that transfers energy to the braking branches (10) via DC+ and DC− lines 15 connection (14) provides the power and data connections of the integrated drive with the external system. a small power and communication link (15), regional on brake resistor intermediate plate (9) distributed independently of each other and regenerative braking energy at least one brake resistance segment (R) that converts to heat, each brake resistance segment (R) activated independently of others, the segments in question (R) singular or 20 enabling them to be operated together, with each segment (R) and the machine opposite it. thermal contact condition determined by the temperature difference between the surface of the body (13) Depending on the segment (R) temperatures, different braking resistances provide the required equivalent braking resistance. according to a combination selected from among the brake resistance segment (R) combinations At least one segment switch (Q) is driven, the temperature of each brake resistance segment (R) is 25 measuring at least one segment temperature sensing element (T) and each brake resistor at least one measuring the surface temperature of the machine body (13) opposite the segment (R). The machine contains a temperature sensing element (TM). The control board (2) consists of segment temperature sensing elements (T) and machine temperature Temperature information received from sensing elements (TM), DC bus voltage and demand 30 by evaluating the braking power obtained, it meets the same electrical braking requirement. select the thermally suitable one among the segment (R) combinations and the relevant It drives segment switches (Q). 6 The brake resistor spacer plate (9) is placed between the front flange (7) of the engine and the machine body (13). It is a thin mechanical carrier structure placed in place. The intermediate plate (9) in question is the engine's centering and transfer of reaction torque to the machine body (13) while providing bolt preload and mechanical load, insulation with brake resistance segments (R). It passes through metal carrier regions independent of the layers. Thus, 5 The layers responsible for the braking function are not subjected to mechanical load. Brake resistor segments (R) are circumferential or on the brake resistor spacer plate (9). They are distributed regionally and independently of each other. These segments (R), They can be produced with the same resistance value, or with different resistance values. can be produced. Each brake resistance segment (R) has its own segment switch 10 It is activated independently of others via (Q). In this way, the same Equivalent resistance can be obtained with different combinations of physical segments (R), or Different equivalent resistance levels can be created. Segment temperature sensing elements (T) are the temperature sensing elements of each brake resistance segment (R). its temperature; machine temperature sensing elements (TM) measure the temperature of each segment (R) at 15°C. It measures the temperature of the surface of the machine body (13) opposite it. With a segment (R) By using the temperature difference between the surface of the machine body (13) opposite it, it The thermal contact quality and cooling performance in the region are determined. A large temperature difference indicates poor thermal contact, while a small difference indicates good thermal contact. It indicates contact. 20 The heat distribution plate (12) consists of a material with high thermal conductivity, By spreading the heat generated in the brake resistance segments (R) over a wide surface, the machine It transfers heat to the body (13). The heat distribution plate (12) is in the direction of the segment (R) of the machine. Thermal resistance towards the body (13) direction, from the segment (R) direction, engine front flange It is arranged in such a way that the thermal resistance in the direction of (7) will be lower. 25 Electrical insulation between brake resistor segments (R) and heat distribution plate (12) layer (11) electrically insulates segments (R) from heat distribution plate (12). It allows heat transfer. Brake resistance segments (R) and engine front flange (7) The thermal barrier (8) between them reduces the transfer of braking heat to the engine side. Thus, braking heat is removed from heat-sensitive engine components, resulting in a dominant 30 It is directed towards the machine body (13) in this way. 7 The control board (2) consists of segment temperature sensing elements (T) and machine temperature Temperature information received from sensing elements (TM), DC bus voltage, braking the duration and the energy each segment (R) expended in previous cycles and cooling It evaluates the situation. The control card (2) requests electrical braking. Among the different segment (R) combinations that meet the requirement, the one that is thermally the best is 5 It selects the appropriate one and drives the relevant segment keys (Q). The key feature of the invention is that it can satisfy the same electrical braking requirement using different physical components. Among the segment (R) combinations, regional temperature and thermal contact status The choice is made according to the known state of the art, whether it is the only resistor or only one. Unlike multi-stage braking systems controlled by total temperature, the invention has 10 The subject is segment (A) selection on the intermediate plate, regional temperature (R) of each segment and This is done taking into account the quality of thermal contact with the machine body (13). For example, two of four brake resistor segments (R1, R2, R3, R4) with the same value can be placed in parallel. In a situation where it needs to be operated; different options such as R1‖R2, R3‖R4 or R1‖R3 Combinations can provide the same equivalent resistance. The control board (2) will be the next 15 cooler in the braking cycle or better thermal contact with the machine body (13) By selecting the segments (R) that have the thermal load, the thermal load is alternated between the segments (R). It distributes them. This reduces the formation of local hot spots, and reduces the distribution of resistance elements. Thermal fatigue on the electrical insulation layer (11) is balanced and repeated Braking capacity is being increased. 20 In an example application of the invention, mechanical energy is generated when the engine enters the braking zone. It is converted into electrical energy and transferred to the DC bus. The DC bus voltage exceeds the braking threshold. When it exceeds the limit, the control board (2) calculates the required braking force, the appropriate equivalent resistor It determines the value and the combination of physical segments (R) that provide this value. Control card (2), segment temperature sensing elements (T) and machine temperature sensing 25 Based on the information received from its elements (TM), it selects the most suitable segments (R) and the relevant Segment switches (Q) can be switched on / off using PWM (pulse width modulation). The braking current continues through the brake linkage (14) to the selected brake resistor segment (R) and passes through its segment switch (Q) to reach the DC bus return line. The heat generated in the segments (R) is distributed through the electrical insulation layer (11) 30 It is transferred to the plate (12) and from there to the machine body (13). Segment (R) and machine By continuously monitoring the body (13) temperatures, segment selection is made between braking cycles. It is updated. 8 In an integrated servo motor, the regenerative braking energy is transferred to the front flange (7) of the motor. a brake resistor spacer plate (9) placed between the machine body (13) multiple brake resistors distributed independently in a regional manner Expenditure via segment (R) is carried out by a control card (2) The method for selecting the brake resistance segment (R) according to temperature is 5. i. equivalent braking resistance corresponding to the required braking force determination, ii. The temperature of each brake resistor segment (R) is measured using a segment temperature sensing system. with element (T) and the machine opposite each brake resistance segment (R). The surface temperature of the body (13) is measured by a machine temperature sensing element (TM) 10 measuring, iii. segment temperature for each brake resistance segment (R) and the corresponding machine the difference between the surface temperature of the body (13) and the brake resistance segment (R) Determining the thermal contact status, iv. Different brake resistance segment (R) providing the specified equivalent braking resistance 15 Identifying combinations, v. Among the combinations in question, the brake resistance segment (R) temperatures and Selecting the appropriate combination according to the thermal contact conditions, vi. Activation of the segment switches (Q) belonging to the selected combination It includes the following steps. 20 In a preferred application of the invention, an open circuit is formed in a braking resistor segment (R). If excessive temperature or poor thermal contact is detected, the segment in question (R) control card (2) is removed from the selection pool and braking, remaining The segments (R) are maintained at reduced power. In this case, the control card (2), It applies a negative torque and deceleration limit appropriate to the remaining thermal capacity. 25 Thus, the braking function continues even if only one segment (R) fails. It is not completely lost. In another preferred application of the invention, the brake resistor is applied during initial assembly. By applying controlled and low-energy test pulses to its segments (R), the machine The regional heat absorption capacity of the housing (13) and the assembly contact quality are determined. 30 The results obtained indicate that the braking energy budget allowed during the study... It is used in calculations. 9 In a preferred application of the invention, the brake resistance segments (R) are brake resistance intermediates. The plates are distributed at equal intervals around the circumference on plate (9). In another preferred application of the invention, the heat distribution plate (12) is aluminum, It consists of copper or a composite material with high thermal conductivity. In another preferred application of the invention, segment switches (Q) semiconductor power 5 It consists of keys. In another preferred application of the invention, the control card (2) segment switches (Q) Braking power by driving with PWM (pulse width modulation) method. It is adjusting. In another preferred application of the invention, the brake resistance segments (R) are separated by 10 They are produced with different resistance values ​​and are connected in series via segment switches (Q). Different equivalent resistance levels can be achieved by switching them in parallel or independently. is being created. Thanks to this configuration, regenerative braking energy is separated in integrated servo motors. 15 between the engine and the machine body (13) without the need for an external brake box The heat from braking, the power electronics inside the engine, can be consumed within the intermediate plate (A). It is transferred away from the encoder and windings to the machine body (13); same local temperature by alternating selection of different segments (R) that provide equivalent resistance Points are reduced and thermal fatigue is balanced; a faulty or overheated one By disengaging segment (R), braking continues in a controlled manner. 20 can be used and the existing thermal mass of the machine body (13) as an additional coolant By using an integrated servo motor, the volumetric advantage is preserved. The invention is a segment selectable brake resistor intermediate plate (A) based on regional temperature, servo It can be produced in the motor, servo drive and industrial motion control systems industry and It is applicable. Intermediate plate (A); robotics, CNC machines, packaging machines, 25 conveyors, automation axes, AGV (automated guided vehicle) / AMR (autonomous guided vehicle) mobile robot) systems and high-throughput motion control applications It can be used. The intermediate plate (A) consists of commonly available resistive elements, semiconductors. conductive power switches, temperature sensing elements, heat dissipation plate (12) and Economical 30 through mass production methods using standard electronic control components. It can be manufactured in this way.

Claims

REQUESTS 1. Dissipation of regenerative braking energy in an integrated servo motor. It is an intermediate plate (A) which has the following feature; • placed between the front flange (7) of the engine and the machine body (13) with centering of the motor, the reaction torque to the machine body (13) 5 at least one brake resistor spacer (9) that enables the transfer of the brake resistor. • The brake resistor spacer plate (9) is regionally independent of each other. distributed in a way that converts regenerative braking energy into heat at least one brake resistance segment (R), • each brake resistance segment (R) can be engaged independently of the others. the area, the singular or combined operation of the segments (R) in question providing and each segment (R) and the machine body opposite it. (13) Thermal contact condition determined by the temperature difference between the surfaces. with segment (R) temperatures, the required equivalent braking Combinations of different brake resistance segments (R) that provide resistance 15 at least one segment driven according to a combination selected from among them key (Q), • located between the brake resistor segments (R) and the motor front flange (7) and at least one thermal barrier that reduces the transfer of braking heat to the engine side (8), 20 • each with a brake resistance segment (R) and its corresponding segment switch (Q) formed and carrying braking current (10), • by spreading the heat generated in the brake resistance segments (R) over a wide surface at least one heat distribution plate (12) transmitting heat to the machine body (13), • located between the brake resistor segments (R) and the heat distribution plate (12) 25 and segments (R) electrically insulate from the heat distribution plate (12) at least one electrical insulation layer (11), • The most powerful lines that transfer energy to the braking branches (10) via DC+ and DC− lines a small brake linkage (14), • at least one segment measuring the temperature (R) of each brake resistance segment 30 temperature sensing element (T), • the machine body opposite each brake resistance segment (R) (13) at least one machine temperature sensing element (TM) that measures surface temperature 11 It includes.

2. According to claim 1, the intermediate plate is (A) and its feature is; segment switches (Q), segment temperature sensing elements (T) and machine temperature sensing According to information received from the members (TM), at least one ongoing control card (2) It includes. 5 3. According to claim 1, the intermediate plate is (A), and its characteristic is that the segment switches (Q) are semi-automatic. They are conductive power switches.

4. Regenerative braking energy in an integrated servo motor, the front flange (7) 10 of the motor a brake resistor spacer plate (9) placed between the machine body (13) multiple regionally distributed independently of each other a control card (2) for dissipating through the brake resistance segment (R) Temperature-based brake resistance segment (R) selection method performed by and its characteristic is; 15 i. equivalent braking resistance corresponding to the required braking force determination, ii. the temperature of each brake resistance segment (R) is a segment temperature sensing element (T) and each brake resistance segment (R) 20 the surface temperature of the machine body (13) opposite a machine temperature Measurement by sensing element (TM), iii. the corresponding segment temperature for each brake resistance segment (R) the difference between the surface temperature of the machine body (13) and the brake resistance Determining the thermal contact condition of segment (R), 25 iv. different braking resistances that provide the specified equivalent braking resistance Detection of segment (R) combinations, v. among the combinations in question, brake resistance segment (R) suitable according to temperatures and thermal contact conditions Selecting the combination, 30 vi. Activation of the segment switches (Q) belonging to the selected combination It includes the steps. 12 5. The method according to claim 4, its characteristic is that in each braking cycle, a specified lower than the combinations that meet equivalent braking resistance better thermal contact with the temperature or machine body (13) Selecting segments (R) and alternating the thermal load between segments (R) 5 It is distributed as follows.

6. The method according to claim 4, its characteristic is; an open circuit in a braking resistor segment (R), When excessive temperature or poor thermal contact is detected, the segment in question (R) removal from the selection pool, reduced braking with the remaining segments (R) 10 with power supplied and a negative torque suitable for the remaining thermal capacity It is the application of the deceleration limit. 20

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