Rugged Modular Actuator Controllers with Stacked Liquid Cooling
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Solution Overview
Problem
Existing actuator control systems lack modularity, adaptability, and efficient cooling mechanisms, leading to inefficiencies and limitations in controlling multiple actuators with varying motion axes.
Innovation Solution
A modular actuator control system comprising stacked controller modules with integrated cooling and power management, allowing for flexible configuration and cooling paths to manage multiple actuators with varying motion axes, including linear and rotary actuators, and electrohydraulic systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple actuators are controlled using separate control systems, then each actuator can be precisely controlled, but the system complexity and space occupation increase significantly
Solution Approach 1:
The patent combines multiple actuator control functions into a single integrated controller module. The controller includes power electronics and control electronics that can manage multiple actuators with different motion axes (linear and rotary) through a unified architecture, reducing the number of separate control systems needed while maintaining precise control capability
Solution Approach 2:
The controller is designed with universal functionality to handle various actuator types and motion axes. The power electronics module can switch between controlling linear actuators, rotary actuators, or electrohydraulic systems, allowing one controller to perform multiple functions that would traditionally require separate dedicated controllers
2Loss of energy
If power electronics are cooled using traditional air cooling methods, then the system structure remains simple, but the cooling efficiency is insufficient for high-power applications
Solution Approach 1:
The patent implements liquid cooling for power electronics using a coolant circulation system. The coolant flows through channels in the power electronics housing or heat sinks, efficiently removing heat from high-power components. This hydraulic cooling approach provides superior cooling efficiency compared to air cooling, enabling the system to handle high-power applications
3Adaptability or versatility
If controller modules are designed as fixed non-modular units, then manufacturing is simpler, but adaptability to different application requirements is reduced
Solution Approach 1:
The control system is divided into modular controller units that can be independently manufactured and then assembled in different configurations. Each module contains standardized interfaces and can be stacked or arranged to meet specific application requirements, combining manufacturing simplicity with configuration flexibility
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system provides a compact, rugged, and adaptable solution for controlling multiple actuators with efficient cooling, enhancing performance and flexibility in various industrial applications.
Implementation Method 1
a first flow path (87a) in the first housing (30a) between the first coolant inlet port (80a, 82a) and the first coolant outlet port (81a, 83a) that is configured to provide a liquid coolant to the first power electronics (31a)
Data Source
AI summary
A modular actuator control system comprising first and second actuator control modules configured to control first and second actuators and each having a housing, control and power electronics, power and communication connections, an actuator power connection, a flow path in each housing between an inlet and outlet port that is configured to provide a liquid coolant to the power electronics in the housing, an attachment connecting the first and second housings of the first and second actuator control modules, and 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 a 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.