WO2022027794A1 - 组合式电机控制器及其组合方法 - Google Patents

组合式电机控制器及其组合方法 Download PDF

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Publication number
WO2022027794A1
WO2022027794A1 PCT/CN2020/115751 CN2020115751W WO2022027794A1 WO 2022027794 A1 WO2022027794 A1 WO 2022027794A1 CN 2020115751 W CN2020115751 W CN 2020115751W WO 2022027794 A1 WO2022027794 A1 WO 2022027794A1
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WIPO (PCT)
Prior art keywords
module
motor
functional
functional modules
modules
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Application number
PCT/CN2020/115751
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English (en)
French (fr)
Inventor
胡戈·盖锐特·詹姆斯
边文清
孙海荣
Original Assignee
中山大洋电机股份有限公司
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
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Publication date
Priority claimed from CN202010790572.XA external-priority patent/CN114094877A/zh
Priority claimed from CN202021631386.3U external-priority patent/CN212627741U/zh
Application filed by 中山大洋电机股份有限公司 filed Critical 中山大洋电机股份有限公司
Priority to CA3164538A priority Critical patent/CA3164538A1/en
Priority to MX2022010598A priority patent/MX2022010598A/es
Priority to US17/517,658 priority patent/US11843337B2/en
Publication of WO2022027794A1 publication Critical patent/WO2022027794A1/zh

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    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02P—CONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
    • H02P6/00—Arrangements for controlling synchronous motors or other dynamo-electric motors using electronic commutation dependent on the rotor position; Electronic commutators therefor
    • H02P6/04—Arrangements for controlling or regulating the speed or torque of more than one motor
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K5/00—Casings, cabinets or drawers for electric apparatus
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K7/00—Constructional details common to different types of electric apparatus

Definitions

  • the present invention relates to a combined motor controller and a combined method thereof.
  • the indoor units or indoor units of different brands of HVAC generally include centrifugal blower motors, gas induced draft fans, compressor motors and axial fan motors.
  • signal communication, speed, torque and other parameters are different, and need to match the motors produced by different manufacturers, as shown in Figure 1, Figure 2, Figure 3 and Figure 4, if these motors are brushless DC motors or ECM motors , generally with a fuselage 1a and a motor controller 2a
  • the fuselage 1a includes a stator assembly 12a, a rotor assembly 13a, a casing assembly 11a and bearings
  • the motor controller 2a generally includes a control box 21a and a control circuit board 22a, a control circuit
  • the board 22a basically integrates all functional circuits.
  • the traditional method is that a manufacturer produces one or several motor products, and its controllers are produced by itself. Once a functional component of the controller is damaged, the entire motor controller or even the entire motor needs to be replaced, which is for after-sales maintenance. The market brings great inconvenience and leads to high maintenance costs.
  • the traditional production method of motor controllers has poor compatibility and versatility, that is, all functional components of motor control are concentrated on one or two circuit boards, which loses flexibility.
  • Different some need 5 gears plus PWM, some only need 0-10VDC, some need 0-10VDC+10 gears; some only need to control one outdoor unit motor, and some need to control multiple outdoor units at the same time Motor; some require a 5HP motor controller, and some require a 3HP motor controller.
  • the size of the circuit board and control box in the motor controller is fixed, and the functions of the circuit board are also fixed.
  • One object of the present invention is to provide a combined motor controller and a combined method thereof to solve the technical problems of inflexible and convenient production of motor controllers in the aftermarket, long research and development time and production time, inconvenient after-sales maintenance and high maintenance costs.
  • a combined motor controller comprising:
  • the first functional module that is, the power module, which is connected to the mains, and outputs the corresponding VDC power supply to supply power to other modules;
  • the second functional module the motor control module, a motor control module controls a motor body, including a microprocessor and IGBT inverter components, accepts VDC power supply and external input control signals, and outputs power to the motor body , to achieve speed or torque or air volume control;
  • the third functional module the I/O module, which is used for signal transmission between the system main control board or peripheral equipment and the motor control module; at least one third functional module is configured, and multiple types of third functional modules can be combined according to communication requirements.
  • the function module realizes signal transmission between the system main control board or peripheral equipment and the motor control module;
  • each functional module has an independent metal or plastic shell and a circuit board located in the shell, and the functional modules and the functional modules are connected by mutually matched connectors, which are used to transmit power or control signals between the functional modules. .
  • the above-mentioned I/O modules are divided into multiple types according to different functions. Specifically, they include at least any one of the following according to the needs: a multi-position 24VAC input module, which accepts the 24VAC position signal sent by the system main control board and converts the The signal is transmitted to the motor control module; the PWM input module accepts the PWM signal sent by the system main control board and transmits this signal to the motor control module; the 0-10VDC input module accepts the 0-10VDC signal sent by the system main control board and This signal is transmitted to the motor control module; the serial communication module based on RS485, the motor control module must have corresponding drivers to be compatible with different communication protocols; the Bluetooth wireless communication module allows users to wirelessly communicate with the motor control module through a mobile app or PC Unicom, for configuration and diagnosis; pulse output module, by outputting pulses, the main control board of the customer can monitor a certain parameter of the motor.
  • a multi-position 24VAC input module which accepts the 24VAC position signal sent by the system
  • the above-mentioned combined motor controller also includes a fourth functional module: the Ethernet local area network module, which supports the common TCP/IP protocol.
  • the motor control module can be connected to the building network control, or the parameter status of the motor can be remotely controlled and monitored through the Internet.
  • the fourth functional module also has an independent metal or plastic shell and a circuit board inside the shell. The fourth functional module is connected with other functional modules through mutually matched connectors to transmit power or control signals between the functional modules. .
  • the above-mentioned combined motor controller also includes a fifth functional module: the human-machine interface HMI function module, which provides a monochrome basic HMI and an advanced high-definition color screen according to market divisions, allowing users to directly control the motor, real-time Control the speed/torque/air volume of the motor, or perform configuration and diagnosis, and even be used for laboratory tests.
  • the fifth functional module also has an independent metal or plastic housing and a circuit board inside the housing.
  • the fifth functional module and other functions The modules are connected through mutually matched connectors, which are used to transmit power or control signals between the functional modules.
  • the above-mentioned combined motor controller also includes a sixth functional module: a code disc switch module, the code disc switch module and the motor control module are connected by a connector, and a row of several DipSwitches are provided for the user to change the parameters of the motor in real time.
  • connection between the functional modules and the functional modules through the inter-matching connectors means that each functional module can be flexibly placed in different positions by using a flexible cable connection.
  • connection between the functional modules and the functional modules through the inter-matching connectors means that the male plug-in and the female plug-in are used to plug each other into each other, so that the functional modules can be brought together and space is saved.
  • All the above functional modules are fixed on a base, and the base is designed as a purely mechanical installation base.
  • the above purely mechanical mounting base adds a bus interface to allow each functional module to supply power or transmit control signals to each other.
  • a combination method of a combined motor controller which subdivides the motor controller into multiple functional modules according to functions, and the functions include:
  • the first functional module that is, the power module, which is connected to the mains, outputs the corresponding DC power to supply power to other modules, and forms multiple power modules with different specifications according to different voltage and motor power requirements;
  • the second functional module the motor control module, a motor control module controls a body, including a microprocessor, an IGBT inverter component and a heat sink, accepts VDC power supply and external input control signals, and outputs power to the motor
  • the fuselage realizes speed or torque or air volume control; according to the motor power, multiple motor control modules of different specifications are formed;
  • the third functional module the I/O module, which is used for signal transmission between the system main control board or peripheral equipment and the motor control module; at least one third functional module is configured, and multiple types of third functional modules can be combined according to communication requirements.
  • the function module realizes signal transmission between the system main control board or peripheral equipment and the motor control module;
  • matching power supply module motor control module and one or more I/O modules are selected and connected together to form a matching motor controller according to the specific parameter requirements of the control motor.
  • the above-mentioned I/O modules are divided into multiple types according to different functions. Specifically, they include at least any one of the following according to the requirements.
  • the multi-position 24VAC input module accepts the 24VAC position signal sent by the system main control board and converts the The signal is transmitted to the motor control module;
  • the PWM input module accepts the PWM signal sent by the system main control board and transmits this signal to the motor control module;
  • the 0-10VDC input module accepts the 0-10VDC signal sent by the system main control board and This signal is transmitted to the motor control module;
  • the serial communication module based on RS485, the motor control module must have corresponding drivers to be compatible with different communication protocols;
  • the Bluetooth wireless communication module allows users to wirelessly communicate with the motor control module through a mobile app or PC Unicom, for configuration and diagnosis; pulse output module, by outputting pulses, the main control board of the customer can monitor a certain parameter of the motor.
  • connection between the above-mentioned functional modules and the functional modules through the inter-matching connectors means that the flexible cable connection is adopted to facilitate the flexible placement of each functional module in different positions.
  • Each different functional module is a cuboid shell with uniform height and depth. , the shell width and size can be different, choose to line up all the functional modules, leave no gap between the two adjacent modules, and then install them on the electrical installation rails.
  • connection between the functional modules and the functional modules through the mutual matching connectors means that the flexible cable connection is used to facilitate the flexible placement of each functional module in different positions. All functional modules are fixed on a base, and the base is designed to be a Purely mechanical mounting base.
  • All the above functional modules are fixed on a base, which is designed as a purely mechanical mounting base.
  • the purely mechanical mounting base adds a bus interface to allow each functional module to supply power to each other or transmit control signals.
  • the above-mentioned combined motor controller also includes a fourth functional module: the Ethernet local area network module, which supports the common TCP/IP protocol.
  • the motor control module can be connected to the building network control, or the parameter status of the motor can be remotely controlled and monitored through the Internet.
  • the fourth functional module also has an independent metal or plastic shell and a circuit board inside the shell. The fourth functional module is connected with other functional modules through mutually matched connectors to transmit power or control signals between the functional modules. .
  • the above-mentioned combined motor controller also includes a fifth functional module: the human-machine interface HMI function module, which provides a monochrome basic HMI and an advanced high-definition color screen according to market divisions, allowing users to directly control the motor, real-time Control the speed/torque/air volume of the motor, or perform configuration and diagnosis, and even be used for laboratory tests.
  • the fifth functional module also has an independent metal or plastic housing and a circuit board inside the housing.
  • the fifth functional module and other functions The modules are connected through mutually matched connectors, which are used to transmit power or control signals between the functional modules.
  • the above-mentioned combined motor controller also includes a sixth functional module: a code disc switch module, the code disc switch module and the motor control module are connected by a connector, and a row of several DipSwitches are provided for the user to change the parameters of the motor in real time.
  • the present invention has the following advantages:
  • the motor controller is subdivided into multiple functional modules according to functions. These functions include: the first functional module: the power module, which is connected to the mains, and outputs the corresponding DC power to supply power to other modules. According to different voltages and motor powers It is required to form multiple power modules of different specifications; the second functional module: namely the motor control module, one motor control module controls one body, including microprocessors, IGBT inverter components and heat sinks, and accepts VDC power supply and external The input control signal, and output UVW three-phase power supply to the motor body to achieve speed or torque or air volume control; according to the motor power to form a number of motor control modules of different specifications; the third functional module: the I/O module, used for Signal transmission is performed between the system main control board or peripheral equipment and the motor control module; at least one third functional module is configured, and multiple types of third functional modules can be combined according to communication requirements to realize the system main control board or peripheral equipment and motor control The signal transmission is carried out between the modules; it is characterized in that: according to the specific
  • FIG. 1 is a block diagram of a prior art HVAC system
  • FIG. 2 is a perspective view of a BLDC motor in the prior art
  • FIG. 3 is a perspective view of the motor control of a BLDC motor in the prior art
  • FIG. 4 is a cross-sectional view of a BLDC motor in the prior art
  • FIG. 5 is a block diagram of an embodiment of the present invention.
  • FIG. 6 is a perspective view of a functional module according to Embodiment 1 of the present invention.
  • FIG. 7 is a perspective view of another angle of the functional module according to the first embodiment of the present invention.
  • Embodiment 8 is an exploded view of a functional module of Embodiment 1 of the present invention.
  • FIG. 9 is an angular perspective view of the assembled motor controller of the first embodiment of the present invention after assembly
  • Fig. 10 is another perspective view of the assembled motor controller after assembly according to an embodiment of the present invention.
  • FIG. 11 is a perspective view of an electrical appliance installation guide rail according to Embodiment 1 of the present invention.
  • FIG. 12 is a circuit block diagram of a power module according to Embodiment 1 of the present invention.
  • FIG. 13 is a circuit diagram of a serial communication module according to Embodiment 1 of the present invention.
  • FIG. 14 is a circuit diagram of a PWM input module according to Embodiment 1 of the present invention.
  • FIG. 15 is a circuit diagram of a 5-position 24VAC input module according to Embodiment 1 of the present invention.
  • FIG. 16 is a perspective view of a functional module of Embodiment 2 of the present invention.
  • FIG. 17 is an exploded view of a functional module of Embodiment 2 of the present invention.
  • Figure 19 is an exploded view of the base of the second embodiment of the present invention.
  • FIG. 20 is an assembled view of an angle of the combined motor controller according to the second embodiment of the present invention.
  • Embodiment 1 As shown in Figure 5, a combined motor controller of the present invention includes:
  • the first functional module that is, the power module, which is connected to the mains, and outputs the corresponding VDC power supply to supply power to other modules;
  • the second functional module the motor control module, a motor control module controls a motor body, including a microprocessor, an IGBT inverter component and a heat sink, accepts VDC power supply and external input control signals, and outputs UVW three Phase (or multi-phase) power supply to the motor body to achieve speed or torque or air volume control;
  • the third functional module the I/O module, which is used for signal transmission between the system main control board or peripheral equipment and the motor control module; at least one third functional module is configured, and multiple types of third functional modules can be combined according to communication requirements.
  • the function module realizes signal transmission between the system main control board or peripheral equipment and the motor control module;
  • each functional module has an independent metal or plastic shell and a circuit board located in the shell, and the functional modules and the functional modules are connected by mutually matched connectors, which are used to transmit power or control signals between the functional modules.
  • the heat sink is installed inside or outside the casing.
  • the production method of the combined module of the present invention is flexible and convenient, and has strong adaptability, can shorten the research and development cycle, and is fast and convenient in production. .
  • the function module itself is designed and modified, and at most the driver of the motor control module needs to be updated to support the new functions. Modules that do not involve modifications can continue to be produced and sold as-is. In this way, by dividing the function of the original motor into different functional modules, the cycle of new development or the workload involved in modifying the existing design is reduced, while ensuring that all or most of the existing designs can continue to be supplied. state.
  • the I/O modules are further divided into multiple types according to different functions, and specifically include at least any one of the following according to requirements:
  • the multi-gear 24VAC input module accepts the 24VAC gear signal sent by the system main control board and transmits the signal to the motor control module. Show;
  • the PWM input module accepts the PWM signal sent by the system main control board and transmits this signal to the motor control module, its part number is C102; one of the circuit structures is shown in Figure 14;
  • the 0-10VDC input module accepts the 0-10VDC signal from the system main control board and transmits this signal to the motor control module, its part number is C103; a general function module, so no specific circuit diagram is provided;
  • the motor control module must have corresponding drivers to be compatible with different communication protocols, and its part number is C104; one of the serial communication modules, its circuit structure is shown in Figure 13;
  • the Bluetooth wireless communication module allows users to wirelessly communicate with the motor control module through the mobile phone App or PC for configuration and diagnosis.
  • the part number is C105; the general function module, so no specific circuit diagram is provided;
  • the pulse output module can monitor a certain parameter of the motor by outputting pulses for the main control board of the customer, and its part number is C106.
  • the general general circuit is not shown in the figure.
  • I/O modules are subdivided into various types, which are easy to adapt to the needs of different customers and are flexible and convenient.
  • each functional module has an independent metal or plastic casing 1 and a circuit board 2 located in the casing.
  • the circuit board 2 extends out of the plug port 3, and the plug port 3 is exposed to the casing 1.
  • the functional modules are connected with flexible cables 4 to realize power supply and signal transmission.
  • Each functional module has an independent metal or plastic shell 1, which can effectively protect the parts and avoid the risk of contact between the functional modules. Anti-electromagnetic interference, to ensure the reliability of product operation.
  • a power module A10 + a motor control module B10 and two I/O modules are used to combine, and two card blocks 11 are arranged on the rear side of the housing 1 , a card slot is formed between the two card blocks 11, and the electrical installation guide rail 6 is used to pass through the card slot between the two card blocks 11 to combine multiple functional modules side by side.
  • the middle of the electrical installation guide rail 6 protrudes to form a boss 61, A number of mounting holes 62 are arranged on the boss 61 at intervals, and the electrical installation guide rail 6 can be locked on the load by using screws through the mounting holes 62. in groove 63.
  • Each different functional module is a cuboid shell with the same height and depth.
  • the width of the shell can be different. Choose to line up all the functional modules, leaving no gap between the two adjacent modules, and then install them on the electrical installation rail 6 It is convenient and flexible to install, and can be quickly produced and assembled.
  • FIG 7 only 2 plug-in ports 3 are shown in the circuit board 2, but for the motor control module, there are usually more than 3 plug-in ports 3, because it has many external connections, and will not be described here. The number of 3 is determined according to the requirements of the functional modules.
  • the modules from left to right are the power module 7, the motor control module 8, the 5th gear 24VAC input module 9 (which is an I/O module) and
  • the pulse output module 10 (which is another I/O module) constitutes a combined motor controller.
  • the combined motor controller of the present invention also includes a fourth functional module: an Ethernet local area network module, which supports the common TCP/IP protocol, and can connect the motor control module to the building network control, or remotely control and monitor the parameter state of the motor through the Internet , the fourth functional module also has an independent metal or plastic shell and a circuit board located in the shell, the fourth functional module and other functional modules are connected by mutually matched connectors, which are used to transmit power or control between the functional modules.
  • the Ethernet LAN module establishes connection and communication with the microprocessor in the motor control module, its part number is D101, which can expand the network function of the motor and facilitate remote diagnosis and maintenance, control, management, etc.
  • the combined motor controller of the present invention also includes a fifth functional module: a human-machine interface HMI functional module, which provides a basic monochrome HMI and an advanced high-definition color screen according to market divisions, allowing users to directly control the motor, Control the speed/torque/air volume of the motor in real time, or perform configuration and diagnosis, and even be used for laboratory tests.
  • the fifth functional module also has an independent metal or plastic housing and a circuit board inside the housing.
  • the fifth functional module and other The function modules are connected through the matching connectors, which are used to transmit power or control signals between the function modules.
  • the HMI function module of the human-machine interface establishes connection and communication with the motor control module. Its part number is E101, which is convenient for customers to debug the motor. Bring great convenience to customers.
  • the combined motor controller of the present invention also includes a sixth functional module: a code disc switch module, the code disc switch module and the motor control module are connected by a connector, and a row of several DipSwitches is provided for the user to change the parameters of the motor in real time,
  • the code disc switch module establishes connection and communication with the motor control module, and its part number is F101, which is convenient to change the parameters of the motor and make the motor debugging more quickly.
  • the functional modules can be connected with each other through the connecting pieces that cooperate with each other, which means that each functional module can be flexibly placed in different positions by adopting a flexible cable connection.
  • the functional modules can also be connected by matching connectors, which means that the male plug-in and the female plug-in are plugged together to facilitate the closeness of the functional modules and save space.
  • the combined motor controller of the present invention does not distinguish the motor of the indoor unit or the motor of the outdoor unit. As long as the voltage and power are suitable, the body of the indoor unit and the outdoor unit can use the same function module part number.
  • the following description of each functional module not only takes into account the needs of OEM mass production, but also applies to the aftermarket.
  • the first functional module namely the power module, as shown in Figure 12, is composed of a surge protection circuit + a rectifier filter circuit + a DC-DC step-down circuit, which accepts the mains power and outputs the corresponding DC power.
  • the design idea of this patent application is to provide power modules with different part numbers according to different voltages and motor powers, such as:
  • Part number A101 120/230/277VAC tri-voltage/60Hz/1Ph, covering motors suitable for 1/4HP and below;
  • Part number A102 120/230/277VAC tri-voltage/60Hz/1Ph, covering 1/3HP and 1/2HP motors;
  • Part number A101 120/230/277VAC tri-voltage/60Hz/1Ph, covering 3/4HP and 1HP motors;
  • Part number A104 460VAC/60Hz/3Ph, covering motors from 1.2HP to 2HP;
  • Part number A105 460VAC/60Hz/3Ph, covering motors from 2.3HP to 3.5HP;
  • Part number A105 460VAC/60Hz/3Ph, covering 5HP motors;
  • Part number A10N 575VAC/60Hz3Ph, covering 5HP motors;
  • the power modules of other voltage segments and power segments are not written out one by one.
  • the power supply modules have multiple part numbers. Once these part numbers are all determined, the customer can flexibly choose and match, and a 1HP power module can supply power to two 1/2HP bodies at the same time.
  • the second functional module the motor control module, a motor control module controls the body of a motor, including a microprocessor MCU + IGBT inverter components (inverter circuit components) + cooling device, accepts VDC power supply and control signals, And output UVW three-phase (or multi-phase) power supply to the motor body to achieve speed, torque or air volume control. If the Hall element is required to detect the rotor position signal, the motor control module also needs to have a Hall signal input port.
  • the motor control module also has a driver update port to ensure compatibility with different input and output modules, fix driver defects, and add functions in the future. As well as a port to connect to a PC, which is used to configure various parameters of the motor through programming.
  • the part number of this function module can be as follows:
  • Part No. B101 Body for DM2 motors of 1/4HP and below
  • Part No. B102 Body for DM3 motors 1/4HP and below
  • Part No. B103 Body for 1/3HP and 1/2HP DM2 Motors
  • Part No. B104 Body for 1/3HP and 1/2HP DM3 Motors
  • Part No. B120 Body for 5HP DM2 Motor
  • Part No. B131 Body for 5HP DM3 Motor
  • the multi-gear 24VAC input module in the third functional module can be divided into multiple parts, and multiple module parts are formed according to the number of gears and the magnitude of the voltage of the gears.
  • the motor control module must be supported by the corresponding driver.
  • the motor control module must have corresponding drivers to be compatible with different communication protocols such as Modbus and climateTalk.
  • a dedicated communication module can be set up in the I/O module and the communication module of the client's system control unit.
  • Example 1 User A, a commercial air conditioner, needs to control a 3HP indoor unit motor and two 1/3HP outdoor unit motors at the same time, and each motor is a 5-speed control signal.
  • the solution is as follows:
  • One power module is enough to power three motors, (two or three smaller power modules can also be selected), select the power module with a specific part number;
  • a 3HP motor control module select the motor control module corresponding to a specific part number
  • Three 5-speed input modules select the multi-speed input module corresponding to a specific part number
  • Example 2 User B, a household air conditioner, needs to control a 1/2HP indoor unit motor and a 1/4HP outdoor unit motor at the same time, the indoor unit motor needs to provide 0-10VDC+10 gears, and the outdoor unit needs to provide 3 gears .
  • the indoor unit motor needs to output a pulse signal to the system main control board to realize the function of adjusting the motor speed in real time. solution:
  • One power module is enough to power two motors
  • the previous centralized controller is divided into various functional modules, allowing users to follow their needs and flexibly choose different parts. Compared with the previous "big and comprehensive" design, it reduces the number of OEM users. cost, and replace which module is damaged, which also saves costs for the aftermarket. Moreover, these functional modules can be installed on a base, or can be installed in different positions, which also provides convenience for customers in installation.
  • Embodiment 2 is a diagrammatic representation of Embodiment 1:
  • the present embodiment improves the installation and connection methods of each functional module on the basis of Embodiment 1: Specifically, all functional modules of the present invention are fixed on a base 100, and the base is designed as A purely mechanical mounting base can also add a bus interface to the purely mechanical mounting base, allowing each functional module to supply power to each other or transmit control signals.
  • each functional module such as the power supply module, the motor control module and the I/O module has an independent metal or plastic casing 1b and a first circuit board 2b located inside the casing.
  • the first circuit board 2b protrudes several
  • the male plug port 3b extends out of the housing 1b for a distance, so that the male plug port 3b and the female plug port 103 on the base 100 are electrically connected together.
  • the base 100 includes an upper shell 101, a lower shell 102 and a second circuit board 104.
  • the second circuit board 104 is installed in the cavity enclosed by the upper shell 101 and the lower shell 102.
  • the second circuit board 104 is provided with a number of bus communication unit circuits and power supply lines, the second circuit board 104 extends out a number of female sockets 103, the base 100 is provided with multiple rows of female sockets 103, each row has two spaced female sockets 103 .
  • the first circuit board 2b extends out of two male sockets 3b for plug-in connection with the two female sockets 103 in the same row on the base 100 for power supply connection and signal transmission respectively connect.
  • the first circuit board 2b also has other plug-in ports, which are not shown in the figure, so as to facilitate the input and output of external AC AC or peripheral control signals.
  • the modules from left to right are the power supply module 7, the motor control module 8, the Bluetooth wireless communication module 9 (which is a kind of I/O module) and the PWM input module 10 (which is another kind of I/O module). ) to form a combined motor controller.
  • other functional modules can still be added according to customer requirements, such as: Ethernet LAN module, encoder switch module, etc., which will not be described in detail here.
  • a combined method of a combined motor controller subdivides the motor controller into multiple functional modules according to functions, and these functions include:
  • the first functional module that is, the power module, which is connected to the mains, outputs the corresponding DC power to supply power to other modules, and forms multiple power modules with different specifications according to different voltage and motor power requirements;
  • the second functional module the motor control module, a motor control module controls a body, including a microprocessor, an IGBT inverter component and a heat sink, accepts VDC power supply and external input control signals, and outputs power to the motor
  • the fuselage can realize speed or torque or air volume control; according to motor power and voltage requirements, multiple motor control modules of different specifications are formed;
  • the third functional module the I/O module, which is used for signal transmission between the system main control board or peripheral equipment and the motor control module; at least one third functional module is configured, and multiple types of third functional modules can be combined according to communication requirements.
  • the function module realizes signal transmission between the system main control board or peripheral equipment and the motor control module;
  • matching power supply module motor control module and one or more I/O modules are selected and connected together to form a matching motor controller according to the specific parameter requirements of the control motor.
  • I/O modules are further divided into multiple types according to different functions, and specifically include at least any one of the following according to requirements:
  • the multi-gear 24VAC input module accepts the 24VAC gear signal sent by the system main control board and transmits the signal to the motor control module;
  • the PWM input module accepts the PWM signal sent by the system main control board and transmits this signal to the motor control module;
  • the 0-10VDC input module accepts the 0-10VDC signal sent by the system main control board and transmits this signal to the motor control module;
  • the motor control module must have corresponding drivers to be compatible with different communication protocols
  • the Bluetooth wireless communication module allows users to wirelessly communicate with the motor control module through a mobile app or PC for configuration and diagnosis;
  • the functional modules have independent metal or plastic shells and circuit boards or electrical components located inside the shells.
  • the functional modules are connected with the functional modules through mutually matched connectors, which are used to transmit power or control between the functional modules. Signal.
  • each functional module can be flexibly placed in different positions by means of flexible cable connection.
  • Each different functional module is a rectangular parallelepiped with uniform height and depth. Shell, shell width and size can be different, choose to line up all functional modules, leave no gap between two adjacent modules, and then install it on the electrical installation rail.
  • connection between the functional modules and the functional modules through the mutual matching connectors means that the flexible cable connection is used to facilitate the flexible placement of each functional module in different positions. All functional modules are fixed on a base, and the base is designed to be a Purely mechanical mounting base.
  • All the above functional modules can also be fixed on a base, the base is designed as a purely mechanical mounting base, and the purely mechanical mounting base adds a bus interface, so that each functional module can supply power to each other or transmit control signals.
  • the above-mentioned combined motor controller also includes a fourth functional module: the Ethernet local area network module, which supports the common TCP/IP protocol.
  • the motor control module can be connected to the building network control, or the parameter status of the motor can be remotely controlled and monitored through the Internet.
  • the fourth functional module also has an independent metal or plastic shell and a circuit board inside the shell. The fourth functional module is connected with other functional modules through mutually matched connectors to transmit power or control signals between the functional modules. .
  • the above-mentioned combined motor controller also includes a fifth functional module: the human-machine interface HMI functional module, which provides a monochrome basic HMI and an advanced high-definition color screen according to market divisions, allowing users to directly control the motor, in real time. Control the speed/torque/air volume of the motor, or perform configuration and diagnosis, and even be used for laboratory tests.
  • the fifth functional module also has an independent metal or plastic housing and a circuit board inside the housing.
  • the fifth functional module and other functions The modules are connected through mutually matched connectors, which are used to transmit power or control signals between the functional modules.
  • the above-mentioned combined motor controller also includes a sixth functional module: a code disc switch module, the code disc switch module and the motor control module are connected by a connector, and a row of several DipSwitches are provided for the user to change the parameters of the motor in real time.

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Abstract

本发明公开了组合式电机控制器及其组合方法，包括电源模块、电机控制模块和I/O模块，一个电机控制模块控制一台电机机身，包括微处理器、IGBT逆变组件和散热装置，接受VDC直流电源供电和外部输入的控制信号，并输出电源给电机机身，实现转速或力矩或者风量控制；I/O模块用于在系统主控板或者外围设备与电机控制模块之间进行信号传送；各功能模块均具有独立金属或者塑料的外壳和位于外壳里面的线路板，功能模块与功能模块之间通过互相配合的连接件连接，用来在功能模块之间传输电源或者控制信号,散热装置安装在外壳里面或者外面，它的生产方式灵活方便，适应性强，缩短研发周期，生产快捷方便，方便维修替换，降低维修成本。

Description

组合式电机控制器及其组合方法 技术领域：
本发明涉及组合式电机控制器及其组合方法。
背景技术：
近年来，在暖通空调领域中，不同品牌的暖通空调的室内机或者室内机，一般都包括离心式鼓风机电机、燃气引风机、压缩机电机和轴流风扇电机，这些电机的电压、功率、信号通信、转速、力矩等参数需求各不通，需要不同厂家生产的电机进行匹配，如图1、图2、图3和图4所示，这些电机如果是无刷直流电机或者称为ECM电机，一般带有机身1a和电机控制器2a，机身1a包括定子组件12a、转子组件13a、机壳组件11a和轴承，电机控制器2a一般包括控制盒21a和控制线路板22a，一块控制线路板22a基本集成所有的功能电路。传统的方式是一个厂家生产一种或者几种电机产品，其控制器都是自家生产的，一旦控制器的某个功能部件损坏，需要更换整个电机控制器，甚至整台电机，这给售后维修市场带来很大的不便，且导致维修成本偏高。
另外，传统的电机控制器的生产方式，兼容性、通用性差，即将电机控制的所有功能部件都集中在一块或者两块线路板上，这反而失去了灵活性，因每家客户需要的电机特点不同，有的需要5档位加PWM，有的只需要0-10VDC，有的需要0-10VDC+10档位；有的只需要控制一个室外机电机，而有的需要同时控制多个室外机电机；有的需要5HP的电机控制器，有的需要3HP的电机控制器，电机控制器中的线路板、控制盒尺寸被固定，线路板的各项功能也被固定。导致兼容性的较差，且生产周期长，研发时间长，因为，电机生产厂家会根据客户的每项需要独立设计一款电机控制器，在收到客户的每项需要重新研发和生产，这给电机生产和销售带来很大的不便。
有鉴于此，需要思考一种生产组装方便、设计和生产周期短、便于维修更换的电机控制器，且这款电机控制器在售后市场维修成本非常低。
发明内容：
本发明的一个目的是提供组合式电机控制器及其组合方法，解决售后市场上电机控制器生产不够灵活方便，研发时间和生产时间长，售后维修不便和维修成本高的技术问题。
本发明是通过下述技术方案予以实现的：
一种组合式电机控制器，包括：
第一功能模块：即电源模块，接入市电，输出对应的VDC直流电源供电为其它模块供电；
第二功能模块：即电机控制模块，一个电机控制模块控制一台电机机身，包括微处理器和IGBT逆变组件，接受VDC直流电源供电和外部输入的控制信号，并输出电源给电机机身，实现转速或力矩或者风量控制；
第三功能模块：即I/O模块，用于在系统主控板或者外围设备与电机控制模块之间进行信号传送；第三功能模块至少配置一个，根据通信需求可以组合多个类型的第三功能模块实现系统主控板或者外围设备与电机控制模块之间进行信号传送；
其特征在于：各功能模块均具有独立金属或者塑料的外壳和位于外壳里面的线路板，功能模块与功能模块之间通过互相配合的连接件连接，用来在功能模块之间传输电源或者控制信号。
上述所述的I/O模块根据功能不同再划分成多个类型,具体根据需求至少包括以下中的任一个：多档位24VAC输入模块，接受系统主控板发来的24VAC档位信号并把信号传输给电机控制模块；PWM输入模块，接受系统主控板发来的PWM信号并把这个信号传输给电机控制模块；0-10VDC输入模块，接受系统主控板发来的0-10VDC信号并把这个信号传输给电机控制模块；基于RS485的串口通讯模块，电机控制模块要有对应的驱动来兼容不同的通讯协议；蓝牙无线通讯模块，让用户可通过手机App或者PC来无线与电机控制模块联通，进行配置和诊断；脉冲输出模块，通过输出脉冲，供客户的主控板监视电机的某个 参数。
上述的组合式电机控制器还包括第四功能模块：即Ethernet局域网模块，支持常见的TCP/IP协议，可把电机控制模块接入楼宇网络控制中，或通过互联网远程控制监视电机的参数状态，第四功能模块也具有独立金属或者塑料的外壳和位于外壳里面的线路板，第四功能模块与其它功能模块之间通过互相配合的连接件连接，用来在功能模块之间传输电源或者控制信号。
上述的组合式电机控制器还包括第五功能模块：即人机界面HMI功能模块，根据市场的划分提供单色基本型的HMI和高级的高清晰度彩色屏，让用户可直接控制电机，实时控制电机的转速/力矩/风量，或者进行配置和诊断，甚至可以用于实验室测试，第五功能模块也具有独立金属或者塑料的外壳和位于外壳里面的线路板，第五功能模块与其它功能模块之间通过互相配合的连接件连接，用来在功能模块之间传输电源或者控制信号。
上述的组合式电机控制器还包括第六功能模块：即码盘开关模块，码盘开关模块与电机控制模块之间通过连接件连接，提供一排数个DipSwitch供用户实时改变电机的参数。
上述所述的功能模块与功能模块之间通过互相配合的连接件连接是指采用柔性排线连接的方式便于各功能模块灵活的放置在不同位置。
上述的功能模块与功能模块之间通过互相配合的连接件连接是指采用公插件和母插件对插的方式便于各功能模块靠拢在一起，节省空间。
上述所有功能模块一字排开，然后安装在电器安装导轨上。
上述的所有功能模块均固定在一底座上，底座设计成一个纯机械性的安装底座。
上述的纯机械性的安装底座增加总线接口，让各功能模块之间互相供电或者传输控制信号。
一种组合式电机控制器的组合方法，将电机控制器按照功能细分成多个功能模块，这些功能包括：
第一功能模块：即电源模块，接入市电，输出对应的直流电为其它模块供电，根据不同的电压和电机功率要求形成多个不同规格的电源模块；
第二功能模块：即电机控制模块，一个电机控制模块控制一台机身，包括微处理器、IGBT逆变组件和散热装置，接受VDC直流电源供电和外部输入的控制信号，并输出电源给电机机身，实现转速或力矩或者风量控制；根据电机功率形成多个不同规格的电机控制模块；
第三功能模块：即I/O模块，用于在系统主控板或者外围设备与电机控制模块之间进行信号传送；第三功能模块至少配置一个，根据通信需求可以组合多个类型的第三功能模块实现系统主控板或者外围设备与电机控制模块之间进行信号传送；
其特征在于：根据控制电机的具体参数要求选择与之相匹配的电源模块、电机控制模块和一个或者多个I/O模块组合连接在一起形成匹配的电机控制器。
上述所述的I/O模块根据功能不同再划分成多个类型，具体根据需求至少包括以下中的任一个，多档位24VAC输入模块，接受系统主控板发来的24VAC档位信号并把信号传输给电机控制模块；PWM输入模块，接受系统主控板发来的PWM信号并把这个信号传输给电机控制模块；0-10VDC输入模块，接受系统主控板发来的0-10VDC信号并把这个信号传输给电机控制模块；基于RS485的串口通讯模块，电机控制模块要有对应的驱动来兼容不同的通讯协议；蓝牙无线通讯模块，让用户可通过手机App或者PC来无线与电机控制模块联通，进行配置和诊断；脉冲输出模块，通过输出脉冲，供客户的主控板监视电机的某个参数。
上述的大部分功能模块均具有独立金属或者塑料的外壳和位于外壳里面的线路板或者电器元件，功能模块与功能模块之间通过互相配合的连接件连接，用来在功能模块之间传输电源或者控制信号。
上述功能模块与功能模块之间通过互相配合的连接件连接是指采用柔性排线连接的方式便于各功能模块灵活的放置在不同位置，每个不同的功能模块都是高度和深度统一的长方体外壳，外壳宽度尺寸可不同的，选择把所有功能模 块一字排开，相邻两模块之间不留缝隙，然后安装在电器安装导轨上。
上述的功能模块与功能模块之间通过互相配合的连接件连接是指采用柔性排线连接的方式便于各功能模块灵活的放置在不同位置，所有功能模块均固定在一底座上，底座设计成一个纯机械性的安装底座。
上述所有功能模块均固定在一底座上，底座设计成一个纯机械性的安装底座，纯机械性的安装底座增加总线接口，让各功能模块之间互相供电或者传输控制信号。
上述的组合式电机控制器还包括第四功能模块：即Ethernet局域网模块，支持常见的TCP/IP协议，可把电机控制模块接入楼宇网络控制中，或通过互联网远程控制监视电机的参数状态，第四功能模块也具有独立金属或者塑料的外壳和位于外壳里面的线路板，第四功能模块与其它功能模块之间通过互相配合的连接件连接，用来在功能模块之间传输电源或者控制信号。
上述的组合式电机控制器还包括第五功能模块：即人机界面HMI功能模块，根据市场的划分提供单色基本型的HMI和高级的高清晰度彩色屏，让用户可直接控制电机，实时控制电机的转速/力矩/风量，或者进行配置和诊断，甚至可以用于实验室测试，第五功能模块也具有独立金属或者塑料的外壳和位于外壳里面的线路板，第五功能模块与其它功能模块之间通过互相配合的连接件连接，用来在功能模块之间传输电源或者控制信号。
上述的组合式电机控制器还包括第六功能模块：即码盘开关模块，码盘开关模块与电机控制模块之间通过连接件连接，提供一排数个DipSwitch供用户实时改变电机的参数。
本发明与现有技术相比具有如下优点：
1)将电机控制器按照功能细分成多个功能模块，这些功能包括：第一功能模块：即电源模块，接入市电，输出对应的直流电为其它模块供电，根据不同的电压和电机功率要求形成多个不同规格的电源模块；第二功能模块：即电机控制模块，一个电机控制模块控制一台机身，包括微处理器、IGBT逆变组件和 散热装置，接受VDC直流电源供电和外部输入的控制信号，并输出UVW三相电源给电机机身，实现转速或力矩或者风量控制；根据电机功率形成多个不同规格的电机控制模块；第三功能模块：即I/O模块，用于在系统主控板或者外围设备与电机控制模块之间进行信号传送；第三功能模块至少配置一个，根据通信需求可以组合多个类型的第三功能模块实现系统主控板或者外围设备与电机控制模块之间进行信号传送；其特征在于：根据控制电机的具体参数要求选择与之相匹配的电源模块、电机控制模块和一个或者多个I/O模块组合连接在一起形成匹配的电机控制器，这种组合模块的生产方式，灵活方便，适应性强，可以缩短研发周期，生产快捷方便，当售后维修时，发现某个功能模块出现故障，可以方便替换，降低维修成本，维修方便快捷。
2)本发明的其它优点在实施例部分详细叙述。
附图说明：
图1是现有技术中HVAC暖通空调系统的方框图；
图2是现有技术中BLDC电机的立体图；
图3是现有技术中BLDC电机的电机控制的立体图；
图4是现有技术中BLDC电机的剖视图；
图5是本发明实施例一方框结构图；
图6是本发明实施例一的功能模块的一个角度的立体图；
图7是本发明实施例一的功能模块的另一个角度的立体图；
图8是本发明实施例一的功能模块的分解图；
图9是本发明实施例一的组合式电机控制器的组装后的一个角度立体图；
图10是本发明实施例一组合式电机控制器的组装后的另一个角度立体图；
图11是本发明实施例一的电器安装导轨的立体图；
图12是本发明实施例一的电源模块的电路方框图；
图13是本发明实施例一的串行通信模块的电路图；
图14是本发明实施例一的PWM输入模块的电路图；
图15是本发明实施例一的5档位24VAC输入模块的电路图；
图16是本发明实施例二的功能模块的一个角度的立体图；
图17是本发明实施例二的功能模块的分解图；
图18是本发明实施例二的底座的立体图；
图19是本发明实施例二的底座的分解图；
图20是本发明实施例二的组合式电机控制器的一个角度组装图。
具体实施方式：
下面通过具体实施例并结合附图对本发明作进一步详细的描述。
实施例一：如图5所示，本发明的一种组合式电机控制器，包括：
第一功能模块：即电源模块，接入市电，输出对应的VDC直流电源供电为其它模块供电；
第二功能模块：即电机控制模块，一个电机控制模块控制一台电机机身，包括微处理器、IGBT逆变组件和散热装置，接受VDC直流电源供电和外部输入的控制信号，并输出UVW三相(或者多相)电源给电机机身，实现转速或力矩或者风量控制；
第三功能模块：即I/O模块，用于在系统主控板或者外围设备与电机控制模块之间进行信号传送；第三功能模块至少配置一个，根据通信需求可以组合多个类型的第三功能模块实现系统主控板或者外围设备与电机控制模块之间进行信号传送；
其特征在于：各功能模块均具有独立金属或者塑料的外壳和位于外壳里面的线路板，功能模块与功能模块之间通过互相配合的连接件连接，用来在功能模块之间传输电源或者控制信号,散热装置安装在外壳里面或者外面。
本发明这种组合模块的生产方式，灵活方便，适应性强，可以缩短研发周期，生产快捷方便，当售后维修时，发现某个功能模块出现故障，可以方便替换，降低维修成本，维修方便快捷。组合式设计相对当前的一体化设计的优势：未来如果需要增加新的功能模块，或者针对现有的某个功能模块进行硬件或者 软件级别的升级来修复缺陷和增强功能，原则上只需要针对那个功能模块本身进行设计和修改，最多需要对电机控制模块的驱动也更新一下以支持新增的功能。不涉及改动的模块可以保持原样继续生产和销售。这样，通过把原有电机的功能拆分为不同功能模块的方法，减少了新开发的周期或者修改现有设计牵涉到的工作量，同时保证现有的全部或者大部分设计可以继续保持供货状态。
所述的I/O模块根据功能不同再划分成多个类型，具体根据需求至少包括以下中的任一个：
多档位24VAC输入模块，接受系统主控板发来的24VAC档位信号并把信号传输给电机控制模块，其连接编号为C101；其中一种5档位24VAC输入模块，其电路如图15所示；
PWM输入模块，接受系统主控板发来的PWM信号并把这个信号传输给电机控制模块，其零件编号为C102；其中一种电路结构如图14所示；
0-10VDC输入模块，接受系统主控板发来的0-10VDC信号并把这个信号传输给电机控制模块，其零件编号为C103；通用功能模块，因此不提供具体电路图；
基于RS485的串口通讯模块，电机控制模块要有对应的驱动来兼容不同的通讯协议，其零件编号为C104；其中一种串口通讯模块，其电路结构如图13所示；
蓝牙无线通讯模块，让用户可通过手机App或者PC来无线与电机控制模块联通，进行配置和诊断，其零件编号为C105；通用功能模块，因此不提供具体电路图；
脉冲输出模块，通过输出脉冲，供客户的主控板监视电机的某个参数，其零件编号为C106。一般的通用电路，没有在图中给出。
以上I/O模块细分成多种，便于适应不同的客户的需求，灵活方便。
如图6至图11所示，各功能模块均具有独立金属或者塑料的外壳1和位于外壳里面的线路板2,线路板2伸出接插端口3，接插端口3裸露露出外壳1，各功能模用柔性排线4来连接，实现电源供应和信号传输，各功能模块具有独立 金属或者塑料的外壳1，可以有效保护零件，通便可以避免各功能模块之间的碰触产生风险，有效抗电磁干扰，保证产品的运行可靠性。图10中，采用1个电源模块A10+1个电机控制模块B10和2个I/O模块(多档位24VAC输入模块C10+脉冲输出模块C16)组合而成，外壳1后侧设置两卡块11，两卡块11之间形成卡槽，利用电器安装导轨6穿过两卡块11之间的卡槽，将多个功能模块并排组合在一起，电器安装导轨6中部凸起形成凸台61，凸台61上间隔设置若干安装孔62，利用螺钉穿过安装孔62可以将电器安装导轨6锁紧在负载上，螺钉(图中没有画出)上的螺钉头沉入凸台61一侧的凹槽63中。每个不同的功能模块都是高度和深度统一的长方体外壳，外壳宽度尺寸可不同的，选择把所有功能模块一字排开，相邻两模块之间不留缝隙，然后安装在电器安装导轨6上，安装方便灵活，可以快速生产组装。图7中，线路板2中只画出2个接插端口3，但对于电机控制模块，通常超过3个接插端口3，因为它与外接连接较多，在此不再叙述，接插端口3的数量根据功能模块的需求而定，在图9中，从左至右的模块分别是电源模块7、电机控制模块8、5档位24VAC输入模块9(是一种I/O模块)和脉冲输出模块10(是另一种I/O模块)组成组合式电机控制器。
本发明的组合式电机控制器还包括第四功能模块：即Ethernet局域网模块，支持常见的TCP/IP协议，可把电机控制模块接入楼宇网络控制中，或通过互联网远程控制监视电机的参数状态，第四功能模块也具有独立金属或者塑料的外壳和位于外壳里面的线路板，第四功能模块与其它功能模块之间通过互相配合的连接件连接，用来在功能模块之间传输电源或者控制信号，Ethernet局域网模块与电机控制模块中的微处理器建立连接通信,其零件编号为D101，这样可以拓展电机的网络功能，便于远程诊断和维护、控制、管理等。
本发明的组合式电机控制器还包括第五功能模块：即人机界面HMI功能模块，根据市场的划分提供单色基本型的HMI和高级的高清晰度彩色屏，让用户可直接控制电机，实时控制电机的转速/力矩/风量，或者进行配置和诊断，甚至可以用于实验室测试，第五功能模块也具有独立金属或者塑料的外壳和位于 外壳里面的线路板，第五功能模块与其它功能模块之间通过互相配合的连接件连接，用来在功能模块之间传输电源或者控制信号，人机界面HMI功能模块与电机控制模块建立连接通信,其零件编号为E101，方便客户调试电机，为客户带来极大方便。
本发明的组合式电机控制器还包括第六功能模块：即码盘开关模块，码盘开关模块与电机控制模块之间通过连接件连接，提供一排数个DipSwitch供用户实时改变电机的参数，码盘开关模块与电机控制模块建立连接通信,其零件编号为F101，便于改变电机的参数，使电机调试更加快捷。
本发明功能模块与功能模块之间可以通过互相配合的连接件连接是指采用柔性排线连接的方式便于各功能模块灵活的放置在不同位置。本发明的功能模块与功能模块之间也可以通过互相配合的连接件连接是指采用公插件和母插件对插的方式便于各功能模块靠拢在一起，节省空间。
本发明的组合式电机控制器不区分室内机电机还是室外机电机，只要电压和功率适合，室内机和室外机的机身可以使用同一个功能模块的零件号。以下的各功能模块的描述既考虑到OEM量产的需要，也可以适用于售后市场。
第一功能模块，即电源模块，见图12所示，浪涌保护电路+整流滤波电路+DC-DC降压电路组成，接受市电，输出对应的直流电。本专利申请的设计思路是根据不同的电压和电机功率，提供不同零件号的电源模块，如：
零件号A101：120/230/277VAC三电压/60Hz/1Ph，涵盖适合1/4HP及以下的电机；
零件号A102：120/230/277VAC三电压/60Hz/1Ph，涵盖1/3HP和1/2HP的电机；
零件号A101：120/230/277VAC三电压/60Hz/1Ph，涵盖3/4HP和1HP的电机；
零件号A104：460VAC/60Hz/3Ph,涵盖1.2HP到2HP的电机；
零件号A105：460VAC/60Hz/3Ph,涵盖2.3HP到3.5HP的电机；
零件号A105：460VAC/60Hz/3Ph,涵盖5HP的电机；
……
零件号A10N：575VAC/60Hz3Ph，涵盖5HP的电机；
其他电压段和功率段的电源模块，就不一一写出来了，总之，为了应对不同电压和功率的需要，电源供电模块有多个零件号。一旦把这些零件号全部确定后，客户可以灵活的选择搭配，而且一个1HP的电源模块，可以同时给两个1/2HP的机身供电。
第二功能模块：即电机控制模块，一个电机控制模块控制一台电机的机身，含微处理器MCU+IGBT逆变组件(逆变电路组件)+散热装置，接受VDC直流电源和控制信号，并输出UVW三相(也可以是多相)电源给电机机身，实现转速，力矩或者风量控制。如果是需要霍尔元件检测转子位置信号，则电机控制模块还需要有霍尔信号输入端口。
电机控制模块，还有一个驱动程序更新用的端口，用来确保跟不同的输入输出模块兼容，修正驱动程序的缺陷，未来增加功能等。以及一个连接PC的端口，用来通过编程来配置电机的各项参数。类似的，这个功能模块的零件号可以这样：
零件号B101：适合1/4HP及以下的DM2电机的机身
零件号B102：适合1/4HP及以下的DM3电机的机身
零件号B103：适合1/3HP和1/2HP的DM2电机的机身
零件号B104：适合1/3HP和1/2HP的DM3电机的机身
……
零件号B120：适合5HP的DM2电机的机身
零件号B131：适合5HP的DM3电机的机身
第三功能模块中的多档位24VAC输入模块，可以拆分成多个，按档位数和档位电压的大小形成多个模块零件。当然无论是哪种方式，电机控制模块要有对应的驱动来支持。
基于RS485的串口通讯模块，电机控制模块要有对应的驱动来兼容不同的通讯协议如Modbus，ClimateTalk。
I/O模块中可以设立专用的通讯模块与客户端的系统控制单元的通讯模块。
通过以上的功能模块，用户可以根据自己的需要灵活的选择，这里给出几个例子：
例子一：用户A，商用空调，需要同时控制一台3HP室内机电机和两台1/3HP的室外机电机，每台电机均是5档位控制信号。解决方案如下：
一个电源模块足够为三台电机供电，(也可以选择两个或者三个小一点的电源模块)，选择特定零件号的电源模块；
一个3HP电机控制模块，选择对应的特定的零件号的电机控制模块；
两个1/3HP电机控制模块，选择两个对应的特定的零件号的电机控制模块；
三个5档位输入模块，选择对应的特定的零件号的多档位输入模块；
通过选择不同模块进行组装生产就可以，前期无需进行研发和设计，生产周期短，节省研发费用，便于售后维修。
例子二：用户B，家用空调，需要同时控制一台1/2HP室内机电机和一台1/4HP室外机电机，室内机电机需要提供0-10VDC+10档位，室外机需要提供3档位。需要室内机电机输出一个脉冲信号给系统主控板来实现实时调整电机转速的功能。解决方案：
一个电源模块足够为两台电机供电
一个1/2HP电机控制模块
一个1/4HP电机控制模块
两个5档位输入模块
一个0-10VDC输入模块
一个脉冲输出模块
通过以上的案例可以看出，把之前的集中控制器拆分为各个功能模块，让用户跟进自己的需要灵活的选择不同零部件，相对之前“大而全”的设计，为OEM用户减少了成本，而且哪个模块损坏了就更换哪个模块，为售后市场也节省了成本。而且这些功能模块可以安装在一个底座上，也可以安装在不同位置，同样给客户提供了安装方面的便利性。
实施例二：
如图16至图20所示，本实施例是在实施例一基础上对各功能模块的安装和连接方式进行改良：具体是本发明的所有功能模块均固定在一底座100上，底座设计成一个纯机械性的安装底座，也可以在纯机械性的安装底座增加总线接口，让各功能模块之间互相供电或者传输控制信号。
图16、图17中，电源模块、电机控制模块和I/O模块等各功能模块均具有独立金属或者塑料的外壳1b和位于外壳里面的第一线路板2b,第一线路板2b伸出若干公接插端口3b，公接插端口3b伸出外壳1b一段距离，以便公接插端口3b与底座100上的母接插端口103对插电连接在一起。
图18和图19所示，底座100包括上壳101、下壳102和第二线路板104，第二线路板104安装在上壳101和下壳102围成的空腔里，第二线路板104设置若干总线通讯单元电路和电源供电线路，第二线路板104伸出若干母接插端口103，底座100设置多排的母接插端口103，每排具有两个间隔的母接插端口103。
如图19和图20所示，第一线路板2b伸出2个公接插端口3b与底座100上同一排的2个母接插端口103对插电连接，以便分别进行供电连接和信号传送连接。当然第一线路板2b还有其它接插端口，图中没有画出，以便外接市电交流或者外围控制信号的输入和输出。在图20中，从左至右的模块分别是电源 模块7、电机控制模块8、蓝牙无线通讯模块9(是一种I/O模块)和PWM输入模块10(是另一种I/O模块)组成组合式电机控制器。当然，还是可以根据客户需求，添加上其它功能模块，例如：Ethernet局域网模块、码盘开关模块等，在此不再详细叙述。
实施例三:
如图9和图10所示，一种组合式电机控制器的组合方法，将电机控制器按照功能细分成多个功能模块，这些功能包括：
第一功能模块：即电源模块，接入市电，输出对应的直流电为其它模块供电，根据不同的电压和电机功率要求形成多个不同规格的电源模块；
第二功能模块：即电机控制模块，一个电机控制模块控制一台机身，包括微处理器、IGBT逆变组件和散热装置，接受VDC直流电源供电和外部输入的控制信号，并输出电源给电机机身，实现转速或力矩或者风量控制；根据电机功率和电压要求形成多个不同规格的电机控制模块；
第三功能模块：即I/O模块，用于在系统主控板或者外围设备与电机控制模块之间进行信号传送；第三功能模块至少配置一个，根据通信需求可以组合多个类型的第三功能模块实现系统主控板或者外围设备与电机控制模块之间进行信号传送；
其特征在于：根据控制电机的具体参数要求选择与之相匹配的电源模块、电机控制模块和一个或者多个I/O模块组合连接在一起形成匹配的电机控制器。
上述所述的I/O模块根据功能不同再划分成多个类型，具体根据需求至少包括以下中的任一个：
多档位24VAC输入模块，接受系统主控板发来的24VAC档位信号并把信号传输给电机控制模块；
PWM输入模块，接受系统主控板发来的PWM信号并把这个信号传输给电机控 制模块；
0-10VDC输入模块，接受系统主控板发来的0-10VDC信号并把这个信号传输给电机控制模块；
基于RS485的串口通讯模块，电机控制模块要有对应的驱动来兼容不同的通讯协议；
蓝牙无线通讯模块，让用户可通过手机App或者PC来无线与电机控制模块联通，进行配置和诊断；
上述大部分功能模块均具有独立金属或者塑料的外壳和位于外壳里面的线路板或者电器元件，功能模块与功能模块之间通过互相配合的连接件连接，用来在功能模块之间传输电源或者控制信号。
上述功能模块与功能模块之间可以通过互相配合的连接件连接是指采用柔性排线连接的方式便于各功能模块灵活的放置在不同位置，每个不同的功能模块都是高度和深度统一的长方体外壳，外壳宽度尺寸可不同的，选择把所有功能模块一字排开，相邻两模块之间不留缝隙，然后安装在电器安装导轨上。
上述的功能模块与功能模块之间通过互相配合的连接件连接是指采用柔性排线连接的方式便于各功能模块灵活的放置在不同位置，所有功能模块均固定在一底座上，底座设计成一个纯机械性的安装底座。
上述所有功能模块也可以均固定在一底座上，底座设计成一个纯机械性的安装底座，纯机械性的安装底座增加总线接口，让各功能模块之间互相供电或者传输控制信号。
上述的组合式电机控制器还包括第四功能模块：即Ethernet局域网模块，支持常见的TCP/IP协议，可把电机控制模块接入楼宇网络控制中，或通过互联网远程控制监视电机的参数状态，第四功能模块也具有独立金属或者塑料的外壳和位于外壳里面的线路板，第四功能模块与其它功能模块之间通过互相配合的连接件连接，用来在功能模块之间传输电源或者控制信号。
上述的组合式电机控制器还包括第五功能模块：即人机界面HMI功能模块， 根据市场的划分提供单色基本型的HMI和高级的高清晰度彩色屏，让用户可直接控制电机，实时控制电机的转速/力矩/风量，或者进行配置和诊断，甚至可以用于实验室测试，第五功能模块也具有独立金属或者塑料的外壳和位于外壳里面的线路板，第五功能模块与其它功能模块之间通过互相配合的连接件连接，用来在功能模块之间传输电源或者控制信号。
上述的组合式电机控制器还包括第六功能模块：即码盘开关模块，码盘开关模块与电机控制模块之间通过连接件连接，提供一排数个DipSwitch供用户实时改变电机的参数。
以上实施例为本发明的较佳实施方式，但本发明的实施方式不限于此，其他任何未背离本发明的精神实质与原理下所作的改变、修饰、替代、组合、简化，均为等效的置换方式，都包含在本发明的保护范围之内。

Claims (19)

  1. 一种组合式电机控制器，包括：
    第一功能模块：即电源模块，接入市电，输出对应的VDC直流电源供电,为其它模块供电；
    第二功能模块：即电机控制模块，一个电机控制模块控制一台电机机身，包括微处理器和IGBT逆变组件，接受VDC直流电源供电和外部输入的控制信号，并输出电源给电机机身，实现转速或力矩或者风量控制；
    第三功能模块：即I/O模块，用于在系统主控板或者外围设备与电机控制模块之间进行信号传送；第三功能模块至少配置一个，根据通信需求可以组合多个类型的第三功能模块实现系统主控板或者外围设备与电机控制模块之间进行信号传送；
    其特征在于：上述各功能模块均具有独立金属或者塑料的外壳和位于外壳里面的线路板，功能模块与功能模块之间通过互相配合的连接件连接，用来在功能模块之间传输电源或者控制信号。
  2. 根据权利要求1所述的一种组合式电机控制器，其特征在于：所述的I/O模块根据功能不同再划分成多个类型，具体根据需求至少包括以下中的任一个：
    多档位24VAC输入模块，接受系统主控板发来的24VAC档位信号并把信号传输给电机控制模块；
    PWM输入模块，接受系统主控板发来的PWM信号并把这个信号传输给电机控制模块；
    0-10VDC输入模块，接受系统主控板发来的0-10VDC信号并把这个信号传输给电机控制模块；
    基于RS485的串口通讯模块，电机控制模块要有对应的驱动来兼容不同的通讯协议；
    蓝牙无线通讯模块，让用户可通过手机App或者PC来无线与电机控制模块联通，进行配置和诊断；
    脉冲输出模块，通过输出脉冲，供系统主控板监视电机的某个参数。
  3. 根据权利要求2所述的一种组合式电机控制器，其特征在于：它还包括第四功能模块：即Ethernet局域网模块，支持常见的TCP/IP协议，可把电机控制模块接入楼宇网络控制中，或通过互联网远程控制监视电机的参数状态，第四功能模块也具有独立金属或者塑料的外壳和位于外壳里面的线路板，第四功能模块与其它功能模块之间通过互相配合的连接件连接，用来在功能模块之间传输电源或者控制信号。
  4. 根据权利要求2所述的一种组合式电机控制器，其特征在于：它还包括第五功能模块：即人机界面HMI功能模块，根据市场的划分提供单色基本型的HMI和高级的高清晰度彩色屏，让用户可直接控制电机，实时控制电机的转速/力矩/风量，或者进行配置和诊断，甚至可以用于实验室测试，第五功能模块也具有独立金属或者塑料的外壳和位于外壳里面的线路板，第五功能模块与其它功能模块之间通过互相配合的连接件连接，用来在功能模块之间传输电源或者控制信号。
  5. 根据权利要求2所述的一种组合式电机控制器，其特征在于：它还包括第六功能模块：即码盘开关模块，码盘开关模块与电机控制模块之间通过连接连接，提供一排数个DipSwitch供用户实时改变电机的参数。
  6. 根据权利要求1至5任意一项所述的组合式电机控制器，其特征在于：功能模块与功能模块之间通过互相配合的连接件连接是指采用柔性排线连接的方式便于各功能模块灵活的放置在不同位置。
  7. 根据权利要求1至5任意一项所述的组合式电机控制器，其特征在于：功能模块与功能模块之间通过互相配合的连接件连接是指采用公插件和母插件对插的方式便于各功能模块靠拢在一起，节省空间。
  8. 根据权利要求1至5任意一项所述的组合式电机控制器，其特征在于：所有功能模块一字排开，然后安装在电器安装导轨上，通过柔性排线连接的方使各功能模块连接起来，柔性排线连接允许用户的各功能模块竖向排列或者横 向排列或者分散不同位置安装。
  9. 根据权利要求1至5任意一项所述的组合式电机控制器，其特征在于：所有功能模块均固定在一底座上，底座设计成一个纯机械性的安装底座，通过柔性排线连接的方使各功能模块连接起来，柔性排线连接允许用户的各功能模块竖向排列或者横向排列或者分散不同位置安装。
  10. 根据权利要求9所述的组合式电机控制器，其特征在于：纯机械性的安装底座增加总线接口，让各功能模块之间互相供电或者传输控制信号。
  11. 一种组合式电机控制器的组合方法，将电机控制器按照功能细分成多个功能模块，这些功能模块包括：
    第一功能模块：即电源模块，接入市电，输出对应的直流电为其它模块供电，根据不同的电压和电机功率要求形成多个不同规格的电源模块；
    第二功能模块：即电机控制模块，一个电机控制模块控制一台机身，包括微处理器、IGBT逆变组件和散热装置，接受VDC直流电源供电和外部输入的控制信号，并输出电源给电机机身，实现转速或力矩或者风量控制；根据电机功率形成多个不同规格的电机控制模块；
    第三功能模块：即I/O模块，用于在系统主控板或者外围设备与电机控制模块之间进行信号传送；第三功能模块至少配置一个，根据通信需求可以组合多个类型的第三功能模块实现系统主控板或者外围设备与电机控制模块之间进行信号传送；
    其特征在于：根据控制电机的具体参数要求选择与之相匹配的电源模块、电机控制模块和一个或者多个I/O模块组合连接在一起形成匹配的电机控制器。
  12. 根据权利要求11所述的组合式电机控制器的组合方法，其特征在于：所述的I/O模块根据功能不同再划分成多个类型，具体根据需求选择其中至少一个组合使用：
    多档位24VAC输入模块，接受系统主控板发来的24VAC档位信号并把信号传输给电机控制模块；
    PWM输入模块，接受系统主控板发来的PWM信号并把这个信号传输给电机控制模块；
    0-10VDC输入模块，接受系统主控板发来的0-10VDC信号并把这个信号传输给电机控制模块；
    基于RS485的串口通讯模块，电机控制模块要有对应的驱动来兼容不同的通讯协议；
    蓝牙无线通讯模块，让用户可通过手机App或者PC来无线与电机控制模块联通，进行配置和诊断；
    脉冲输出模块，通过输出脉冲，供系统主控板监视电机的某个参数。
  13. 根据权利要求11或者12所述的组合式电机控制器的组合方法，其特征在于：上述大部分功能模块均具有独立金属或者塑料的外壳和位于外壳里面的线路板或者电器元件，功能模块与功能模块之间通过互相配合的连接件连接，用来在功能模块之间传输电源或者控制信号。
  14. 根据权利要求13所述的组合式电机控制器的组合方法，其特征在于：功能模块与功能模块之间通过互相配合的连接件连接是指采用柔性排线连接的方式便于各功能模块灵活的放置在不同位置，每个不同的功能模块都是高度和深度统一的长方体外壳，外壳宽度尺寸可不同的，选择把所有功能模块一字排开，相邻两模块之间不留缝隙，然后安装在电器安装导轨上。
  15. 根据权利要求13所述的组合式电机控制器的组合方法，其特征在于：功能模块与功能模块之间通过互相配合的连接件连接是指采用柔性排线连接的方式便于各功能模块灵活的放置在不同位置，所有功能模块均固定在一底座上，底座设计成一个纯机械性的安装底座。
  16. 根据权利要求13所述的组合式电机控制器的组合方法，其特征在于：所有功能模块均固定在一底座上，底座设计成一个纯机械性的安装底座，纯机械性的安装底座增加总线接口，让各功能模块之间互相供电或者传输控制信号。
  17. 根据权利要求11或者12所述的组合式电机控制器的组合方法，其特 征在于：它还包括第四功能模块：即Ethernet局域网模块，支持常见的TCP/IP协议，可把电机控制模块接入楼宇网络控制中，或通过互联网远程控制监视电机的参数状态，第四功能模块也具有独立金属或者塑料的外壳和位于外壳里面的线路板，第四功能模块与其它功能模块之间通过互相配合的连接件连接，用来在功能模块之间传输电源或者控制信号。
  18. 根据权利要求11或者12所述的组合式电机控制器的组合方法，其特征在于：它还包括第五功能模块：即人机界面HMI功能模块，根据市场的划分提供单色基本型的HMI和高级的高清晰度彩色屏，让用户可直接控制电机，实时控制电机的转速/力矩/风量，或者进行配置和诊断，甚至可以用于实验室测试，第五功能模块也具有独立金属或者塑料的外壳和位于外壳里面的线路板，第五功能模块与其它功能模块之间通过互相配合的连接件连接，用来在功能模块之间传输电源或者控制信号。
  19. 根据权利要求11或者12所述的组合式电机控制器的组合方法，其特征在于：其特征在于：它还包括第六功能模块：即码盘开关模块，码盘开关模块与电机控制模块之间通过连接连接，提供一排数个DipSwitch供用户实时改变电机的参数。
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