WO2022049098A1

WO2022049098A1 - Controller, in particular steering controller

Info

Publication number: WO2022049098A1
Application number: PCT/EP2021/074083
Authority: WO
Inventors: Tobias Lupfer
Original assignee: Robert Bosch Gmbh
Priority date: 2020-09-02
Filing date: 2021-09-01
Publication date: 2022-03-10
Also published as: CN115996873A; DE102020211081A1

Abstract

The starting point for the invention is a controller (10a-e), in particular a steering controller, comprising an electronics unit (12a-e) for driving at least one electric motor (14a-e) and/or for detecting at least one operational variable of the electric motor (14a-e) and comprising at least one printed circuit board (16a-e), on which the electronics unit (12a-e) is at least partly arranged. It is proposed that the printed circuit board (16a-e) be produced by means of a 3-D printing method.

Description

description

title

Control device, in particular steering control device

State of the art

The invention is based on a control device according to the preamble of claim 1. The invention also relates to an actuator assembly having such a control device, a steering system having such an actuator assembly and a method for producing such a control device.

Steering systems are known from the prior art, which include steering actuators with an electric motor and with a control device for controlling an operation of the electric motor. The control device is generally arranged in an electronics housing adjacent to the electric motor and includes an electronics unit and at least one printed circuit board on which the electronics unit is arranged.

One difficulty is accommodating all of the electronics in the electronics housing, while at the same time good cooling of the electronics unit must be ensured. In order to increase the area of the printed circuit board, a printed circuit board with a base plate and two side plates that can be bent relative to the base plate was therefore proposed in the subsequently published DE 10 2020 202 364 A1. An existing installation space in the electronics housing can be better utilized as a result. However, due to the partially rigid shape, there are still opportunities for improvement in this case, particularly in terms of handling, heat dissipation and the use of installation space. There are also different 3D printing processes that can now also be used to produce printed circuit boards very cheaply and in almost any shape. In this context, reference is made to US 2019/0098771 A1 by way of example.

Proceeding from this, the object of the invention consists in particular in providing a control device with improved properties with regard to a structure. The object is achieved by the features of claims 1, 11, 12 and 13, while advantageous configurations and developments of the invention can be found in the dependent claims.

Disclosure of Invention

The invention is based on a control device, in particular a steering control device, with an electronics unit for controlling at least one electric motor and/or for detecting at least one operating variable of the electric motor and with at least one printed circuit board on which the electronics unit is at least partially, preferably at least for the most part and especially preferably completely, is arranged.

It is proposed that the printed circuit board is made using a 3D printing process. This refinement makes it possible in particular to provide a control device with an advantageous structure. In particular, an advantageous flexibility can be achieved, as a result of which the printed circuit board can advantageously be adapted to a predetermined installation volume. Furthermore, efficiency, in particular manufacturing efficiency, assembly efficiency, installation space efficiency and/or cost efficiency, can advantageously be improved. In particular, a predetermined installation volume can be used particularly efficiently in this context. In addition, in particular cooling of the control device can be improved.

In this context, a “control device” is to be understood in particular as at least a part, in particular a subassembly, of an actuator assembly which/which, in particular, in at least one operating state for controlling an operation of at least one electric motor of the actuator gate assembly is provided. The electric motor is designed in particular as a brushless motor and advantageously as an asynchronous motor or as a permanently excited synchronous motor and preferably comprises at least one motor shaft, which in particular defines an axis of rotation of the electric motor. In addition, the electric motor can advantageously comprise a motor housing, in particular designed as a receiving housing, and/or at least one bearing plate. Furthermore, the control device preferably comprises an electronics housing which adjoins the electric motor, advantageously the end shield, and is preferably coupled directly to the electric motor, in which at least the electronics unit and the printed circuit board are arranged. Furthermore, the electronics unit includes in particular control electronics, in particular in the form of control logic and/or power electronics, for controlling the electric motor and/or detection electronics for detecting at least one operating variable, such as a rotor position and/or a temperature, of the electric motor. The electronic unit consequently comprises a plurality of electronic components, in which case in particular at least one of the electronic components can be in the form of a power electronic component and can be part of the power electronic system.

Furthermore, the printed circuit board comprises in particular a carrier substrate printed using the 3D printing process, in particular in the form of a base body, and preferably at least one conductor track printed using the 3D printing process and arranged on the carrier substrate. In particular, the printed circuit board can also include a plurality of conductor tracks which are printed using the 3D printing process and are arranged on the carrier substrate. In addition, the printed circuit board can in principle also include at least part of the electronic unit, in particular at least one active or passive electronic component printed using the 3D printing process, such as an electrical resistor, a capacitor, an inductance and/or a sensor element. The 3D printing method can be, for example, a stereolithography method, a laser sintering method, a laser beam melting method, an electron beam melting method, a fused deposition modeling method or fused filament fabrication method and /or an aerosol jet 3D printing process. However, the 3D printing process is preferably a type of inkjet printing process and/or material jetting process, for example in the form of a multi-jet modeling process and/or a poly-jet mode ling procedure. Furthermore, the printed circuit board could be designed in particular as a flexible printed circuit board. However, the printed circuit board is advantageously at least partially, preferably at least to a large extent and particularly preferably completely, rigid and/or dimensionally stable. Furthermore, the printed circuit board is preferably designed in one piece. “In one piece” is to be understood in particular as being at least cohesively connected and/or formed with one another. The material connection can be produced, for example, by an adhesive process, an injection molding process, a melting process, a soldering process and/or another process. Advantageously, however, one-piece is to be understood as meaning one-piece and in particular formed from one piece and/or in one piece. Furthermore, the expression “for the most part” is to be understood to mean in particular at least 55%, advantageously at least 75% and particularly advantageously at least 90%. “Provided” should be understood to mean, in particular, specially programmed, designed and/or equipped. The fact that an object is provided for a specific function is to be understood in particular to mean that the object fulfills and/or executes this specific function in at least one application and/or operating state.

It is also proposed that the printed circuit board has at least one first printed circuit board section, which is arranged perpendicularly to a motor shaft of the electric motor, in particular the motor shaft already mentioned, and has at least one second printed circuit board section connected, in particular connected in one piece, to the first printed circuit board section, which is angled to the first printed circuit board section and in particular encloses an angle of at least 80°, advantageously at least 90°, and/or at most 170°, advantageously at most 150°, with the first printed circuit board section, in particular in a direction perpendicular to the motor shaft of the electric motor considered. In particular, a surface and/or a main extension plane of the first printed circuit board section, in particular one that can be assembled, and a surface and/or a main extension plane of the second printed circuit board section, in particular one that can be assembled, enclose an angle of at least 80°, advantageously of at least 90°, and/or of at most 170°, advantageously at most 150°. In addition, the first printed circuit board section and the second printed circuit board section can be connected to one another in particular in such a way that a connection region of the first printed circuit board section and the second printed circuit board section has a sharp edge or a bend and/or rounding with a defined radius. The first printed circuit board section is designed in particular to be rigid and/or dimensionally stable and is provided in particular to accommodate at least one electronic component of the electronic unit. The second printed circuit board section is designed in particular to be rigid and/or dimensionally stable and is provided in particular to accommodate at least one further electronic component of the electronic unit. The fact that “the first printed circuit board section is arranged perpendicularly to the motor shaft of the electric motor” is to be understood in particular to mean that a surface, in particular one that can be assembled, and/or a main extension plane of the first printed circuit board section is arranged perpendicular to the axis of rotation and/or a longitudinal direction of extension of the motor shaft. A “main extension plane” of an object is to be understood in particular as a plane which is parallel to a largest side surface of a smallest, in particular imaginary, cuboid which just barely completely encloses the object. In this way, in particular, a predetermined installation volume can be advantageously utilized and a particularly large area expansion of the printed circuit board can be achieved.

The first printed circuit board section and the second printed circuit board section could in particular be arranged relative to one another in such a way that the first printed circuit board section and the second printed circuit board section at least partially overlap when viewed in the direction of the motor shaft. However, it is advantageously proposed that the first printed circuit board section and the second printed circuit board section are arranged relative to one another in such a way that the first printed circuit board section and the second printed circuit board section do not overlap when viewed in the direction of the motor shaft. In particular, the first printed circuit board section and the second printed circuit board section are arranged relative to one another in such a way that the first printed circuit board section and the second printed circuit board section have no intersection area and/or overlapping area when viewed in the direction of the motor shaft. In this way, in particular, an advantageously simple assembly of the printed circuit board can be achieved. In addition, thermal behavior in particular can be improved.

Furthermore, the second printed circuit board section can move away from the first printed circuit board section, at least when viewed perpendicularly to the motor shaft extend in a direction facing the electric motor. In this case, the printed circuit board and in particular the first printed circuit board section can advantageously be arranged, in particular fastened, on a housing cover of the electronics housing, as a result of which the printed circuit board can advantageously be assembled together with the housing cover and in particular in one work step.

Alternatively, the second printed circuit board section can also extend from the first printed circuit board section in a direction opposite to the electric motor, at least when viewed perpendicularly to the motor shaft. In this case, the printed circuit board and in particular the first printed circuit board section can advantageously be arranged, in particular fastened, on the bearing plate of the electric motor. In this way, in particular, changes to the existing structure can be minimized and advantageously a structure of the control device known from the prior art can be largely retained.

Furthermore, it is proposed that the electronics unit and in particular the control electronics include at least one power electronics component, preferably designed as a switching element, and advantageously a plurality of power electronics components, in particular designed as switching elements. The power electronics component and/or the power electronics components can be arranged in particular on the first printed circuit board section and preferably on a side of the first printed circuit board section that faces the electric motor. However, it is preferably proposed that at least one power electronics component is arranged on the second printed circuit board section. The power electronics component is preferably arranged on a side of the second printed circuit board section that faces the electric motor. In this way, in particular, a heat distribution of the control device can be further improved.

It is also proposed that the control device comprises at least one motor contact, for example in the form of a soldering contact and/or welding contact, and advantageously a plurality of motor contacts, preferably of identical design, for the electrical connection of the electric motor. In particular, the electronics unit and advantageously the control electronics are electrically connected to the electric motor via the motor contact and/or via the motor contacts. The motor contact and/or the motor contacts can, in particular, be on the first th printed circuit board section can be arranged, whereby in particular an advantageously compact connection of the electric motor can be realized. However, it is preferably proposed that at least one motor contact is arranged on the second printed circuit board section, as a result of which a particularly advantageous heat distribution can be achieved in particular.

According to a further embodiment, it is proposed that the printed circuit board comprises a carrier substrate printed using the 3D printing method and at least one conductor track printed using the 3D printing method, the conductor track extending at least partially over the first printed circuit board section and the second printed circuit board section. In particular, the conductor track is thus arranged on the first printed circuit board section and on the second printed circuit board section. In particular, the printed circuit board can also include a plurality of conductor tracks printed by means of the 3D printing process, which extend at least partially over the first printed circuit board section and the second printed circuit board section. In this way, in particular, advantageously flexible contacting can be achieved.

A particularly efficient use of a given installation volume and an advantageous heat distribution can be achieved in particular if the circuit board viewed in a direction perpendicular to a motor shaft of the electric motor, in particular to the motor shaft already mentioned, has an at least essentially U-shaped, an at least essentially C - Has shaped or a rectangular cross-section and the electronics unit is distributed over at least three sides of the printed circuit board. In particular, the printed circuit board in this case comprises at least three sides and/or at least three surfaces, which can in particular be equipped, which are advantageously arranged at an angle to one another, with at least one electronic component of the electronics unit being arranged on each of the sides and/or surfaces. In this context, an “at least essentially U-shaped” object is to be understood in particular as an object that deviates from a U-shaped reference object with a surface area of at most 30%, preferably at most 20% and particularly preferably at most 10% . The same should apply in particular to the turn, at least essentially in a C-shape. In this case, the printed circuit board can be, for example, a cuboid, a hollow cuboid, a cylinder be formed or as a hollow cylinder. A cylinder is to be understood in particular as a general or mathematical cylinder, so that the cylinder can basically have any base and/or top surface, such as a circle, an ellipse or any polygon.

It is also preferably proposed that the circuit board includes a carrier substrate that is printed using the 3D printing process and consists of at least two different materials. In this case, for example, the first printed circuit board section and the second printed circuit board section can consist of different materials. Furthermore, a printed circuit board section of the printed circuit board, on which the power electronics are arranged, and a further printed circuit board section of the printed circuit board, on which the control logic and/or the detection electronics are arranged, could consist of different materials. In this context, for example, an especially more expensive, heat-resistant material can be used for the printed circuit board section and an especially cheaper, less heat-resistant material can be used for the further printed circuit board section. Alternatively or additionally, an internal printed circuit board section of the printed circuit board could have a different material than an external printed circuit board section of the printed circuit board, as a result of which thermal conductivity, electrical conductivity and/or robustness of the printed circuit board can be improved, for example. In addition, costs can be advantageously reduced.

Alternatively or additionally, it is proposed that the printed circuit board comprises at least two conductor tracks, which are made of different materials and are printed using the 3D printing process. In this case, for example, a conductor track for the electrical connection of the power electronics and a further conductor track for the electrical connection of the control logic and/or the detection electronics can consist of different materials. In this context, for example, a first material with a high electrical conductivity can be used for the conductor track and a second material with a lower electrical conductivity can be used for the further conductor track. In addition, an internal conductor track, in particular a conductor track integrated and/or embedded in the carrier substrate, could alternatively or additionally have a material other than an external conductor track, in particular a conductor track arranged on an outer surface of the carrier substrate. As a result, the conductor tracks can be adapted to different requirements in a particularly flexible manner. In addition, costs can be advantageously reduced.

Alternatively or additionally, it is proposed that the printed circuit board comprises at least one conductor track printed by means of the 3D printing process, with at least two conductor track sections, which consist of different materials. For example, the conductor track, which extends at least partially over the first printed circuit board section and the second printed circuit board section, can consist of at least two different materials. In this case, a first conductor track section arranged on the first circuit board section and a second conductor track section arranged on the second circuit board section can consist of different materials. Alternatively, in this case, a different material can be used for the conductor track in a connection area of the first printed circuit board section and the second printed circuit board section. Furthermore, the conductor track could consist of different materials in an area of the power electronics and in an area of the control logic and/or the detection electronics. In addition, in this case, in particular, various components can also be integrated directly into the conductor track, such as an electrical resistor advantageously printed using the 3D printing method, a sensor element advantageously printed using the 3D printing method and/or a sensor element advantageously using circuit board fuse printed by the 3D printing process. As a result, individual conductor tracks in particular can be adapted particularly flexibly to different requirements. In addition, costs can be advantageously reduced.

In a further embodiment it is proposed that the electronic unit comprises at least one electronic component which is integrated and/or embedded in the printed circuit board. The electronic component is preferably at least largely or completely surrounded by the carrier substrate of the printed circuit board and is advantageously integrated and/or embedded in the printed circuit board in the 3D printing process. The electronic component can, for example, be an electrical resistor, a capacitor, an inductance and/or a sensor element, for example the detection electronics, and in particular also be printed using the 3D printing process. In this way, in particular, a particularly flexible and/or compact printed circuit board can be provided.

It is also proposed that the control device comprises at least one cooling element, for example in the form of a cooling block, which is integrated and/or embedded in the printed circuit board. The cooling element is preferably at least largely or completely surrounded by the carrier substrate of the printed circuit board and is advantageously integrated and/or embedded in the printed circuit board in the 3D printing process. In particular, the cooling element can also be printed using the 3D printing process. The cooling element consists in particular of a thermally conductive material with a thermal conductivity of at least 15 W/mK, preferably at least 100 W/mK and particularly preferably at least 200 W/mK, and is provided in particular for cooling the electronics unit and in particular the power electronics. Furthermore, the cooling element is particularly preferably designed in one piece and is advantageously connected in one piece to the printed circuit board. Cooling of the electronics unit and in particular of the power electronics can in particular be further improved by the cooling element.

A particularly efficient heat dissipation and/or advantageous control of the heat dissipation can be achieved in particular if the cooling element comprises a base body which is on the inside with respect to the printed circuit board and is in particular assigned to the electronics unit, advantageously the power electronics, and a plurality of dissipation elements which thermally connect the base body to an outside of the printed circuit board connect and are provided for the purpose of dissipating thermal energy generated by the electronic unit during operation and, in particular, absorbed by the base body, to the outside, in particular to an area surrounding the printed circuit board. The dissipation elements are preferably distributed over the circuit board in such a way that the thermal energy generated by the electronic unit during operation is dissipated via at least two, advantageously at least three and particularly preferably at least four sides and/or surfaces of the circuit board. In addition, it is proposed that the control device comprises an electronics housing, in particular the electronics housing already mentioned above, which comprises a base housing adjoining an end plate of the electric motor, in particular the end plate already mentioned, and a housing cover, in particular the housing cover already mentioned. In particular, the basic housing defines at least one receiving area for the electronics unit and the printed circuit board, while the housing cover is provided to cover the receiving area at least in the assembled state. The basic housing is also advantageously coupled directly to the electric motor and is particularly advantageously connected to the electric motor, in particular the motor housing and/or the end shield, in a material, positive and/or non-positive manner, in particular by means of a rivet and/or adhesive connection. In this way, in particular, an advantageously compact control device and/or actuator assembly can be provided.

The printed circuit board is advantageously adapted to the receiving area of the basic housing, in particular by means of the 3D printing process, in such a way that the printed circuit board is in direct thermal contact with the electronics housing and thermal energy generated by the electronics unit, in particular the power electronics, during operation is directly and in particular at least is discharged to a large extent or completely via the end shield of the electric motor, a side wall of the basic housing, which is in particular arranged parallel to the motor shaft, and/or the housing cover. In this way, in particular, heat dissipation can be further improved.

In addition, the invention relates to an actuator assembly with at least one electric motor, which has at least one motor shaft, and with the aforementioned control device. The control device and the electric motor are advantageously part of a steering actuator. The control device and the electric motor are therefore particularly preferably part of a steering system which is intended in particular for use in a vehicle and preferably a motor vehicle.

In addition, a method for producing a control device, in particular a steering control device, is proposed in which we at least one printed circuit board is produced using a 3D printing process and an electronics unit for controlling at least one electric motor and/or for detecting at least one operating variable of the electric motor is arranged at least partially, preferably at least to a large extent and particularly preferably completely, on the printed circuit board. At least one carrier substrate and at least one conductor track are advantageously printed using the 3D printing process to produce the printed circuit board. Furthermore, in the 3D printing method, at least one electronic component of the electronic unit and/or at least one cooling element is preferably integrated and/or embedded in the printed circuit board. In particular, the electronic component and/or the cooling element can also be printed using the 3D printing process. In addition, at least one motor contact for the electrical connection of the electric motor can be printed using the 3D printing process, in particular on the carrier substrate and preferably on a surface of the printed circuit board that can be populated. In this way, in particular, the advantages already mentioned can be achieved, it being possible in particular to provide a control device with an advantageous structure.

The control device, the actuator assembly, the steering system and the method are not intended to be limited to the application and embodiment described above. In particular, the control device, the actuator assembly, the steering system and the method for fulfilling a functionality described herein can have a number of individual elements, components and units that differs from the number specified herein.

drawings

Further advantages result from the following description of the drawing. Several exemplary embodiments of the invention are shown in the drawings.

Show it:

1 shows part of an exemplary steering system with an actuator assembly configured as a steering actuator, comprising a Electric motor and a control device in a perspective view,

2 shows the control device and part of the electric motor in a schematic sectional view,

3 shows a printed circuit board of the control device in a plan view,

4 shows an exemplary flowchart with main method steps of a method for producing the control device,

5 shows a further exemplary embodiment of a further control device in a schematic sectional view,

6 shows a further exemplary embodiment of a further control device in a schematic sectional view,

7 shows a further exemplary embodiment of a further control device in a schematic sectional view and

8 shows a further exemplary embodiment of a further control device in a schematic sectional view.

Description of the exemplary embodiments

The following exemplary embodiment relates to a steering system purely by way of example. In principle, however, the invention is not limited to use in a steering system and could, for example, also be used in other areas of a vehicle, such as a wiper system, a window regulator system and/or a drive system, and/or in other electronic systems, for example in the area of household appliances and/or or machine tools.

Figure 1 shows at least part of an exemplary steering system 70a in a perspective view. In the present case, the steering system 70a is designed as an electrically assisted steering system. The steering system 70a is designed as a conventional steering system, for example, and includes an electric power steering system in the form of a power steering system. Furthermore, the steering system 70a is provided for use in a vehicle (not shown), in particular a motor vehicle. In an installed state, the steering system 70a has an operative connection with vehicle wheels (not shown) of the vehicle and is provided for influencing a direction of travel of the vehicle. hen. Alternatively, however, it is also conceivable to design a steering system with an electrical superimposed steering system and/or active steering. In addition, a steering system could in principle also be designed as a steer-by-wire steering system.

The steering system 70a includes a steering gear 72a, designed as a rack and pinion steering gear, for example, which is provided to convert a steering specification into a steering movement of the vehicle wheels. For this purpose, the steering gear 72a comprises at least one steering control element 74a, in the present case designed in particular as a toothed rack.

Furthermore, the steering system 70a includes at least one actuator assembly 68a. The actuator assembly 68a is designed as a steering actuator and has an operative connection with the steering control element 74a. The actuator assembly 68a is provided to provide a steering torque. In the present case, the actuator assembly 68a is provided to provide a steering torque in the form of a support torque and/or servo torque and to introduce it into the steering gear 72a, in particular for steering support. Alternatively, however, an actuator assembly could also be part of an electric superimposed steering system and/or active steering system and, in particular, be provided to provide an additional steering angle and/or a variable transmission ratio. Furthermore, an actuator assembly could be part of a steer-by-wire steering system. In this case, the actuator assembly could be provided in particular for use in a wheel steering angle adjuster and in particular for providing a steering torque for directly controlling a direction of travel of a vehicle. In addition, in this case the actuator assembly could also be provided for use in an operating unit of the steer-by-wire steering system and for providing a feedback torque and/or restoring torque on a steering handle. Furthermore, as mentioned at the outset, an actuator assembly could also be used independently of a steering system.

The actuator assembly 68a includes an electric motor 14a known per se. The electric motor 14a is designed as a synchronous motor, in particular a permanently excited one. The electric motor 14a is also designed as a multi-phase electric motor. The electric motor 14a is provided to generate the steering torque. The electric motor 14a comprises an outer housing designed in particular tes, motor housing 76a, a stator (not shown) arranged in motor housing 76a, a rotor (not shown) arranged in motor housing 76a, a motor shaft 20a arranged in motor housing 76a and at least one end shield 58a, in the present case in particular in the form of a B end shield (see FIG. 2). The motor shaft 20a defines an axis of rotation 78a of the electric motor 14a.

Furthermore, the actuator assembly 68a has a control device 10a (cf. in particular also FIG. 2). In the present case, the control device 10a is designed as a steering control device. The control device 10a includes an electronics housing 56a. The electronics housing 56a is designed as an outer housing. The electronics housing 56a is designed as a receiving housing. The electronics housing 56a is coupled to the electric motor 14a, in particular the motor housing 76a, and is directly adjacent to the end shield 58a. The electronics housing 56a is consequently arranged axially with respect to the motor shaft 20a. Furthermore, the electronics housing 56a has a multi-part design. The electronics housing 56a comprises a basic housing 60a, which in particular provides a receiving area 64a, and a housing cover 62a for covering the receiving area 64a, in particular in the direction of the motor shaft 20a and/or the axis of rotation 78a. In the present case, the basic housing 60a is also formed at least partially in one piece with the motor housing 76a and the end shield 58a. The basic housing 60a and/or the housing cover 62a preferably consist of a metal, such as aluminum, and/or a material with high thermal conductivity. In addition, the housing cover 62a can include at least one plug connector 80a for external, electrical contacting of the control device 10a. In principle, an electronics housing and in particular a basic housing could of course also be designed separately from a motor housing and/or an end shield. Furthermore, a basic housing and/or a housing cover could in principle also consist of a plastic.

In addition, the control device 10a includes an electronic unit 12a. The electronics unit 12a is arranged in the electronics housing 56a, in particular the receiving area 64a. The electronics unit 12a includes control electronics 82a for controlling the electric motor 14a. The control electronics 82a includes control logic with at least one computing unit 84a and power electronics with at least one power electronics component 24a, 26a. The at least one electronic power component 24a, 26a is designed as a discrete switching element, advantageously as a MOSFET, or as a B6 power module. In addition, the control electronics 82a can include at least one intermediate circuit capacitance and/or at least one current measuring resistor. In the present case, the control electronics 82a are provided to provide a phase current for the electric motor 14a, in particular all phases of the electric motor 14a. In principle, however, an electronics unit could also be free of control electronics. Furthermore, an electronics unit could have control electronics in the form of control logic or control electronics in the form of power electronics.

In addition, the electronics unit 12a in the present case includes detection electronics 86a for detecting at least one operating variable of the electric motor 14a. In the present case, the detection electronics 86a includes at least one position sensor 88a for detecting a rotor position of the electric motor 14a and in particular of the motor shaft 20a. Alternatively or additionally, an electronic detection system could also include at least one temperature sensor for detecting a temperature of the electric motor 14a. In addition, it is conceivable to completely dispense with detection electronics.

To accommodate the electronics unit 12a, the control device 10a also includes at least one printed circuit board 16a. In the present exemplary embodiment, the control device 10a includes precisely one printed circuit board 16a. Consequently, all of the control electronics 82a and all of the detection electronics 86a are arranged on the printed circuit board 16a. The circuit board 16a is formed in one piece. The printed circuit board 16a is also rigid and/or dimensionally stable. Alternatively, a control device could also include several, in particular at least two or at least three, printed circuit boards, in which case control electronics and/or detection electronics could be distributed over the printed circuit boards and/or the detection electronics could be arranged on a separate printed circuit board. Furthermore, a printed circuit board could in principle also be designed as a flexible or rigid-flexible printed circuit board. In the present case, the printed circuit board 16a is produced using a 3D printing process. The printed circuit board 16a comprises a carrier substrate 28a printed by means of the 3D printing process and, in particular, which is dimensionally stable, and a plurality of conductor tracks 30a, 32a, 34a that are printed by means of the 3D printing process and arranged on the carrier substrate 28a (cf. in particular also FIG. 3). The 3D printing method used is, for example, an inkjet printing method or material jetting method, in particular in the form of a multi-jet modeling method and/or a poly-jet modeling method. In principle, of course, a 3D printing method that differs from an inkjet printing method or material jetting method could also be used to produce the printed circuit board 16a. It is also conceivable to print at least one active or passive electronic component, such as an electrical resistor, advantageously in the form of a current measuring resistor, a capacitor, an inductance and/or a sensor element, using the 3D printing process and advantageously simultaneously with a carrier substrate, and on and / or to be arranged within the carrier substrate.

The printed circuit board 16a also has a first printed circuit board section 18a. The first printed circuit board section 18a is designed as a base plate. The first printed circuit board section 18a is arranged perpendicular to the motor shaft 20a and/or to the axis of rotation 78a of the electric motor 14a. The first printed circuit board section 18a is arranged in such a way that the axis of rotation 78a intersects a geometric center 90a of the first printed circuit board section 18a. The first printed circuit board section 18a is consequently arranged parallel to the bearing plate 58a of the electric motor 14a and in particular is directly adjacent to the bearing plate 58a. A shape of the first printed circuit board section 18a is also adapted to a shape of the electronics housing 56a. Furthermore, the first printed circuit board section 18a is provided for accommodating at least one electronic component of the electronic unit 12a. In the present case, the first printed circuit board section 18a is provided at least to accommodate the computing unit 84a of the control electronics 82a and to accommodate the position sensor 88a of the detection electronics 86a. Alternatively, it is conceivable not to arrange a computing unit and/or a position sensor on a first printed circuit board section and instead, for example, to have power electronics or at least one power electronics component to arrange the first circuit board section. Furthermore, it is conceivable to arrange a first printed circuit board section in such a way that a geometric center point of the first printed circuit board section is offset from an axis of rotation of an electric motor.

In addition, the printed circuit board 16a comprises at least one second printed circuit board section 22a, 23a connected to the first printed circuit board section 18a. In the present case, the printed circuit board 16a has two second printed circuit board sections 22a, 23a. In principle, however, a printed circuit board could also have precisely one second printed circuit board section. The second printed circuit board sections 22a, 23a are rigidly connected to the first printed circuit board section 18a. The second printed circuit board sections 22a, 23a have the same material thickness as the first printed circuit board section 18a. The second printed circuit board sections 22a, 23a are designed as side plates. The second printed circuit board sections 22a, 23a are also arranged on different, in particular opposite, sides of the first printed circuit board section 18a. The second printed circuit board sections 22a, 23a are arranged at an angle relative to the first printed circuit board section 18a. An angle Oi, in particular an obtuse one, between the first printed circuit board section 18a and the second printed circuit board section 22a and an angle CI2, in particular obtuse, between the first printed circuit board section 18a and the other second printed circuit board section 23a are identical in the present case and are in particular between 120° and 150° . Furthermore, the second printed circuit board sections 22a, 23a extend, at least when viewed perpendicularly to the motor shaft 20a and/or to the axis of rotation 78a, each starting from the first printed circuit board section 18a in a direction opposite to the electric motor 14a, in particular in the direction of the housing cover 62a. The printed circuit board 16a accordingly has an at least essentially U-shaped or an at least essentially C-shaped cross section when viewed in a direction perpendicular to the motor shaft 20a and/or to the axis of rotation 78a of the electric motor 14a.

Alternatively, however, at least one second printed circuit board section could also extend, starting from a first printed circuit board section, in a direction facing an electric motor. In addition, at least one second printed circuit board section could also be movably connected to a first printed circuit board section. be, in particular such that the first printed circuit board section and the second printed circuit board section can be moved and, in particular, pivoted relative to one another. A material recess and/or a narrowing of the cross section in the printed circuit board, for example, could be used for the movable connection of the second printed circuit board section and the first printed circuit board section. In addition, it is conceivable to design second printed circuit board sections differently from one another, for example in the case of an asymmetrically designed electronics housing, in order to make the best possible use of an existing installation volume. In addition, a printed circuit board could also comprise at least three or at least four second printed circuit board sections, advantageously of identical design and particularly preferably arranged on different sides of a first printed circuit board section.

In the present case, the second printed circuit board sections 22a, 23a are also at least essentially mirror-symmetrical with respect to a central plane 92a which is aligned perpendicularly to the first printed circuit board section 18a and intersects the geometric center 90a of the first printed circuit board section 18a. The second printed circuit board sections 22a, 23a are arranged in such a way that an edge and/or bend 94a between the first printed circuit board section 18a and the second printed circuit board section 22a and a further edge and/or bend 96a between the first printed circuit board section 18a and the further second printed circuit board section 23a are parallel are arranged to one another and perpendicularly to the motor shaft 20a and/or to the axis of rotation 78a (cf. in particular FIG. 3).

In addition, the first printed circuit board section 18a and the second printed circuit board sections 22a, 23a are arranged relative to one another in such a way that the first printed circuit board section 18a and the second printed circuit board sections 22a, 23a do not overlap when viewed in the direction of the motor shaft 20a and/or the axis of rotation 78a and are therefore particularly have no cutting area and/or overlapping area. Alternatively, at least one second printed circuit board section could at least partially cover a first printed circuit board section when viewed in the direction of a motor shaft and/or axis of rotation. Furthermore, at least one power electronics component 24a, 26a of the power electronics is arranged on each of the second printed circuit board sections 22a, 23a. All power electronic components 24a, 26a can advantageously also be arranged on the second printed circuit board sections 22a, 23a. The power electronics components 24a, 26a are each arranged on a side of the corresponding second printed circuit board section 22a, 23a that faces the electric motor 14a, in particular the bearing plate 58a. In the present case, the electronic unit 12a is arranged on the printed circuit board 16a in such a way that the electronic unit 12a is distributed over at least three sides 38a, 40a, 42a of the printed circuit board 16a.

Furthermore, at least one of the printed conductors 30a, 32a, 34a, in particular printed by means of the 3D printing process, extends at least partially over the first printed circuit board section 18a and the second printed circuit board section 22a and is consequently arranged both on the first printed circuit board section 18a and on the second printed circuit board section 22a . In the present case, for example, at least a first conductor track 30a and a second conductor track 32a of the conductor tracks 30a, 32a, 34a are routed directly over the edge and/or bend 94a between the first circuit board section 18a and the second circuit board section 22a.

In addition, the carrier substrate 28a, which is printed in particular by means of the 3D printing process, can consist of at least two different materials. In the present case, for example, the first printed circuit board section 18a and the second printed circuit board sections 22a, 23a are made of different materials. The first circuit board section 18a, on which in particular the control logic and the detection electronics are arranged, consists in particular of a less heat-resistant material, while the second circuit board sections 22a, 23a, on which in particular the power electronics are arranged, consist of a heat-resistant material. Alternatively or additionally, however, an internal printed circuit board section of the printed circuit board could also have a different material than an external printed circuit board section of the printed circuit board. Furthermore, a carrier substrate produced by means of a 3D printing process can in principle also be formed from a single material. Furthermore, at least two conductor tracks 30a, 32a, 34a, in particular printed by means of the 3D printing process, can consist of different materials. In the present case, for example, the first conductor track 30a and a third conductor track 34a consist of different materials. The first conductor track 30a is provided for the electrical connection of the power electronics and consists of a material with high electrical conductivity, while the third conductor track 34a is provided for the electrical connection of the control logic and/or the detection electronics 86a and is made of a material with a lower electrical conductivity consists. Alternatively or additionally, however, an internal conductor track could also have a different material than an external conductor track. Furthermore, conductor tracks produced by means of a 3D printing process can in principle also be formed from a single material.

In addition, at least one conductor track 30a, 32a, 34a, in particular printed by means of the 3D printing process, can consist of several different materials. In the present case, by way of example, the second conductor track 32a has at least two conductor track sections 44a, 46a, which consist of different materials. A first conductor track section 44a of the conductor track sections 44a, 46a is arranged in an area of the power electronics, in particular of the power electronics component 24a. A second conductor track section 46a of the conductor track sections 44a, 46a is in a further area that deviates from the area of the power electronics and is spaced apart, for example in an area of the control logic and/or the detection electronics 86a and/or in a connection area of the first printed circuit board section 18a and the second printed circuit board section 22a arranged. In this case, the first conductor track section 44a can consist, for example, of a material with a high electrical conductivity and the second conductor track section 46a can consist of a material with a lower electrical conductivity. Alternatively or additionally, by using different materials for a single conductor track, different components could also be integrated directly into the conductor track, such as an electrical resistor advantageously printed using the 3D printing process printed sensor element and/or a circuit board fuse advantageously printed by means of the 3D printing process.

In addition, in the present case at least one electronic component 48a of the electronic unit 12a is integrated and/or embedded in the printed circuit board 16a. In the present case, the electronic component 48a is, for example, a capacitor which is completely surrounded by the carrier substrate 28a and is integrated and/or embedded in the carrier substrate 28a in the 3D printing process. In principle, however, it is also conceivable to integrate and/or embed an electronic component other than a capacitor in circuit board 16a, such as position sensor 88a of detection electronics 86a, a temperature sensor of detection electronics and/or another active or passive electronic component.

Furthermore, the printed circuit board 16a has a plurality of motor contacts 98a, 100a, in particular of identical design, for the electrical connection of the electric motor 14a. In the present case, the control device 10a has, for example, six motor contacts 98a, 100a, each of the motor contacts 98a, 100a being provided for connecting a motor wire 102a (only indicated schematically) of the, in particular multi-phase, electric motor 14a. The motor wires 102a are guided through recesses in the bearing plate 58a. The motor contacts 98a, 100a are provided for the electrical connection of the control electronics 82a to the electric motor 14a. The motor contacts 98a, 100a are arranged on the first printed circuit board section 18a. The motor contacts 98a, 100a are, for example, in the form of welded contacts soldered onto the first printed circuit board section 18a. In addition, the motor contacts 98a, 100a are divided into two groups of motor contacts 98a, 100a, in particular of equal size, with a first group of motor contacts 98a and a second group of motor contacts 100a being arranged at least essentially mirror-symmetrically with respect to the center plane 92a. Alternatively, however, at least one motor contact could also be arranged on a second printed circuit board section. Furthermore, a printed circuit board could have a different number of motor contacts than six. In addition, at least one motor contact could be printed using the 3D printing process. To heat and/or cool power electronic components 24a, 26a, control device 10a also includes a plurality of heat sinks 104a, 106a, in the present case in particular two heat sinks 104a, 106a, one of heat sinks 104a, 106a being assigned to each of second printed circuit board sections 22a, 23a. The heat sinks 104a, 106a are formed at least essentially mirror-symmetrically with respect to the center plane 92a. The heat sinks 104a, 106a are each in direct contact and/or in direct thermal connection with the electronics housing 56a, in particular the basic housing 60a. In addition, the heat sinks 104a, 106a each have a cooling surface which is assigned to the corresponding power electronics component 24a, 26a and which runs parallel to the corresponding second printed circuit board section 22a, 23a. The heat sinks 104a, 106a are each provided to dissipate thermal energy generated by the respective power electronics component 24a, 26a during operation via a side wall 66a, 67a of the basic housing 60a and/or the end shield 58a, in particular adjacent to the corresponding heat sink 104a, 106a. In principle, however, it is also conceivable to do without additional heat sinks and to dissipate thermal energy generated during operation directly and in particular at least to a large extent or completely via an end shield of an electric motor, a side wall of a basic housing, in particular arranged parallel to the motor shaft, and/or a housing cover .

FIG. 4 shows an exemplary flow chart with main method steps of a method for producing the control device 10a.

In a method step 110a, the printed circuit board 16a is produced using a 3D printing method. In this case, a carrier substrate 28a, in particular a dimensionally stable one, and a plurality of conductor tracks 30a, 32a, 34a are printed using the 3D printing process. The conductor tracks 30a, 32a, 34a are printed onto the carrier substrate 28a and preferably onto a surface of the printed circuit board 16a that can be populated. Furthermore, the electronic component 48a of the electronic unit 12a can be integrated and/or embedded in the printed circuit board 16a. The 3D printing method used is, for example, an inkjet printing method or material jetting method, in particular in the form of a multi-jet modeling method and/or a poly-jet modeling method. Here- the printed circuit board 16a can be produced very inexpensively and with almost any shape.

In a method step 112a, the printed circuit board 16a is populated by the electronic unit 12a being arranged and fastened on the printed circuit board 16a. In particular, an adhesive process, a melting process, a welding process and/or preferably a soldering process can be used for fastening. In addition, the electronics unit 12a is electrically connected to the conductor tracks 30a, 32a, 34a.

In a method step 114a, the circuit board 16a together with the electronics unit 12a is mounted in the electronics housing 56a. The printed circuit board 16a with the electronics unit 12a arranged thereon is introduced into the receiving area 64a of the basic housing 60a and fastened therein. Then the printed circuit board 16a and consequently the electronics unit 12a are electrically coupled to the electric motor 14a. Finally, the receiving area 64a is closed by means of the housing cover 62a.

The exemplary flow chart in FIG. 4 is intended to describe a method for producing the control device 10a, in particular only as an example. In particular, individual process steps can also vary or additional process steps can be added. For example, with the 3D printing method, at least one additional cooling element can also be integrated and/or embedded in the printed circuit board 16a. Furthermore, at least one electronic component, at least one cooling element and/or at least one motor contact for the electrical connection of an electric motor could be printed using the 3D printing process and in particular together with the carrier substrate 28a and the conductor tracks 30a, 32a, 34a.

Further exemplary embodiments of the invention are shown in FIGS. The following descriptions and the drawings are essentially limited to the differences between the exemplary embodiments, whereby with regard to components with the same designation, in particular with regard to components with the same reference numbers, the drawings and/or the description of the other exemplary embodiments, in particular Figures 1 until 4, can be referenced. To distinguish between the exemplary embodiments, the letter a follows the reference number of the exemplary embodiment in FIGS. In the exemplary embodiments of FIGS. 5 to 8, the letter a has been replaced by the letters b to e.

FIG. 5 shows a further exemplary embodiment of the invention. The embodiment of FIG. 5 is followed by the letter b. The further exemplary embodiment in FIG. 5 differs from the previous exemplary embodiment at least essentially in terms of the design and arrangement of a printed circuit board 16b of a control device 10b.

In this case, the printed circuit board 16b produced by means of a 3D printing process is in turn designed in one piece and is rigid and/or dimensionally stable. In addition, an entire electronic unit 12b is arranged on the printed circuit board 16b in such a way that the electronic unit 12b is distributed over at least three sides 38b, 40b, 42b of the printed circuit board 16b.

The printed circuit board 16b comprises a first printed circuit board section 18b and two second printed circuit board sections 22b, 23b which are connected to the first printed circuit board section 18b and are arranged at an angle relative to the first printed circuit board section 18b. In the present case, the first printed circuit board section 18b and the second printed circuit board sections 22b, 23b are arranged at an angle relative to one another such that an angle Oi between the first printed circuit board section 18b and the second printed circuit board section 22b and an angle CI2 between the first printed circuit board section 18b and the further second printed circuit board section 23b be 90° each. The printed circuit board 16b accordingly has a U-shaped cross section when viewed in a direction perpendicular to a motor shaft 20b of an electric motor 14b.

Furthermore, the first printed circuit board section 18b is directly adjacent to a housing cover 62b of an electronics housing 56b. The second printed circuit board sections 22b, 23b each extend from the first printed circuit board section 18b in a direction facing the electric motor 14b, at least when viewed perpendicularly to the motor shaft 20b. In this case, the printed circuit board 16b and in particular the first printed circuit board section 18b can advantageously arranged, in particular fastened, on the housing cover 62b, as a result of which the printed circuit board 16b can advantageously be assembled together with the housing cover 62b and in particular in one work step.

In addition, the control device 10b is free of any heat sinks and/or cooling elements. In this case, circuit board 16b is adapted to a receiving area 64b of a basic housing 60b of electronics housing 56b in such a way that circuit board 16b is in direct thermal contact with electronics housing 56b and thermal energy generated by electronics unit 12b, in particular power electronics, during operation is directly above a side wall 66b, arranged parallel to the motor shaft 20b, of the basic housing 60b and the housing cover 62b. In this case, the basic housing 60b and the housing cover 62b consist of a metal, in particular aluminum.

In addition, motor contacts 98b, 100b for the electrical connection of the electric motor 14b are arranged on the second printed circuit board sections 22b, 23b. Each of the motor contacts 98b, 100b is provided for connecting a motor wire 102b (only indicated schematically) of the, in particular multi-phase, electric motor 14b. In addition, the motor contacts 98b, 100b are divided into two groups of motor contacts 98b, 100b, in particular of equal size, with a first group of motor contacts 98b being arranged on the second printed circuit board section 22b and a second group of motor contacts 100b being arranged on the further second printed circuit board section 23b.

Another exemplary embodiment of the invention is shown in FIG. The embodiment of FIG. 6 is followed by the letter c. The further exemplary embodiment in FIG. 6 differs from the previous exemplary embodiments at least essentially in terms of the design and arrangement of a printed circuit board 16c of a control device 10c.

In this case, the printed circuit board 16c produced by means of a 3D printing process is in turn designed in one piece and is rigid and/or dimensionally stable. The printed circuit board 16c has a cuboid cross-section, viewed in a direction perpendicular to a motor shaft 20c of an electric motor 14c, and extends on the one hand from an end shield 58c of the electric motor 14c to a housing cover 62c of an electronics housing 56c and on the other hand from a side wall 66c of a basic housing 60c of the electronics housing 56c to a further side wall 67c of the basic housing 60c of the electronics housing 56c opposite the side wall 66c. In addition, an entire electronics unit 12c is arranged on circuit board 16c in such a way that electronics unit 12c is distributed over at least four sides 36c, 38c, 40c, 42c and preferably over at least six sides 36c, 38c, 40c, 42c of circuit board 16c.

In addition, the control device 10c is free of any heat sinks and/or cooling elements. In this case, printed circuit board 16c is adapted to a receiving area 64c of basic housing 60c in such a way that printed circuit board 16c is in direct thermal contact with electronics housing 56c and thermal energy generated by electronics unit 12c, in particular power electronics, during operation is transmitted directly via end shield 58c , the side wall 66c and/or the further side wall 67c of the basic housing 60c and the housing cover 62c.

FIG. 7 shows a further exemplary embodiment of the invention. The embodiment of FIG. 7 is followed by the letter d. The further exemplary embodiment in FIG. 7 differs from the previous exemplary embodiments at least essentially by an additional cooling element 50d integrated into a printed circuit board 16d of a control device 10d.

The printed circuit board 16d of the control device 10d corresponds at least essentially to the printed circuit board 16b of the previous exemplary embodiment and consequently comprises a first printed circuit board section 18d and two second printed circuit board sections 22d, 23d connected to the first printed circuit board section 18d. Accordingly, the printed circuit board 16d has a U-shaped cross section, viewed in a direction perpendicular to a motor shaft 20d of an electric motor 14d. In this case, however, the second printed circuit board sections 22d, 23d extend, at least when viewed perpendicularly to the motor shaft 20d, each starting from the first printed circuit board section 18d in a direction opposite to the electric motor 14d, in particular in the direction of a housing cover 62d electronics housing 56d. Alternatively, however, a circuit board could also have a different shape and/or cross-sectional shape in this case.

Furthermore, the control device 10d includes the cooling element 50d, which is integrated and/or embedded in the printed circuit board 16d. The cooling element 50d is integrated and/or embedded in the circuit board 16d during the 3D printing process and consequently directly during the production of the circuit board 16d. In principle, the cooling element 50d could also be printed directly using the 3D printing process and in particular together with the printed circuit board 16d. The cooling element 50d consists of a thermally conductive material with a thermal conductivity of at least 200 W/mK. The cooling element 50d is formed in one piece. In addition, the cooling element 50d is connected in one piece to the printed circuit board 16d. The cooling element 50d is at least largely surrounded by a carrier substrate 28d of the printed circuit board 16d. In the present case, the cooling element 50d is surrounded by the carrier substrate 28d of the circuit board 16d in such a way that a side of the cooling element 50d that faces an end shield 58d and a side of the cooling element 50d that faces a side wall 66d of a basic housing 60d are surrounded by the circuit board 16d and/or the carrier substrate 28d are completely covered. In addition, the cooling element 50d is surrounded by the carrier substrate 28d of the printed circuit board 16d in such a way that a side of the cooling element 50d facing the housing cover 62d is uncovered. In the present case, cooling element 50d is provided for cooling an electronics unit 12d, in particular power electronics, arranged on printed circuit board 16d. In the present case, the cooling element 50d is provided to absorb thermal energy generated by the electronic unit 12d during operation and to dissipate it via the housing cover 62d. For this purpose, the housing cover 62d preferably consists of a metal, in particular aluminum.

Alternatively, a cooling element could also consist of a thermally conductive material with a thermal conductivity of less than 200 W/mK and, for example, of at least 15 W/mK or of at least 100 W/mK. Furthermore, a side of a cooling element that faces an end shield and/or a side of a cooling element that faces a side wall of a base housing could be uncovered. In this case, the cooling element could be provided to one of absorb heat energy generated during operation of an electronic unit and dissipate it via the end shield and/or the side wall.

Another exemplary embodiment of the invention is shown in FIG. The embodiment of FIG. 8 is followed by the letter e. The further exemplary embodiment in FIG. 8 differs from the previous exemplary embodiments at least essentially by a design and an arrangement of an additional cooling element 50e integrated into a printed circuit board 16e of a control device 10e.

The printed circuit board 16e of the control device 10e corresponds at least essentially to the printed circuit board 16c of the previous exemplary embodiment. Accordingly, the printed circuit board 16e has a cuboid cross-section, viewed in a direction perpendicular to a motor shaft 20e of an electric motor 14e. Alternatively, however, a circuit board could also have a different shape and/or cross-sectional shape in this case.

Furthermore, the control device 10e includes the cooling element 50e, which is integrated and/or embedded in the printed circuit board 16e. The cooling element 50e is integrated and/or embedded in the circuit board 16e during the 3D printing process and consequently directly during the production of the circuit board 16e. In the present case, the cooling element 50e is printed directly using the 3D printing process and in particular together with the printed circuit board 16e. At least a large part of the cooling element 50e is surrounded by a carrier substrate 28e of the printed circuit board 16e. The cooling element 50e forms an inner core of the printed circuit board 16e.

In the present case, the cooling element 50e also includes a base body 52e which is internal to the printed circuit board 16e and is in particular assigned to an electronic unit 12e, and a plurality of discharge elements 54e which thermally connect the base body 52e to an outside of the printed circuit board 16e. The cooling element 50e comprises a large number of discharge elements 54e, in particular at least twelve discharge elements 54e, which are arranged distributed over the circuit board 16e and the main body 52e in particular with at least four sides 36e, 38e, 40e, 42e and preferably at least six sides 36e, 38e, 40e, 42e of the printed circuit board 16e. In the present case, the discharge elements 54e are configured identically to one another. The dissipation elements 54e are provided for controlling cooling. The dissipation elements 54e are provided to dissipate thermal energy generated by the electronics unit 12e during operation and absorbed by the base body 52e to the outside, in particular to an area surrounding the printed circuit board 16e. In the present case, the dissipation elements 54e are distributed over the circuit board 16e in such a way that the thermal energy generated by the electronic unit 12e during operation is dissipated via at least three sides 36e, 38e, 40e, 42e and/or surfaces of the circuit board 16e.

In principle, however, it is also conceivable to design at least two discharge elements with different shapes and/or different materials. For example, discharge elements in an area of power electronics could have a larger diameter and/or consist of a material with higher thermal conductivity than discharge elements in the area of control logic and/or detection electronics. It is also conceivable to provide different dissipation elements for controlling cooling. For example, it is conceivable in this context to arrange and/or design the dissipation elements in such a way that cooling and/or heat dissipation takes place at least to a large extent via an end shield of an electric motor, a side wall of a basic housing or a housing cover.

Claims

Expectations

1. Control device (10a-e), in particular steering control device, with an electronics unit (12a-e) for controlling at least one electric motor (14a-e) and/or for detecting at least one operating variable of the electric motor (14a-e) and with at least one circuit board (16a-e) on which the electronics unit (12a-e) is at least partially arranged, characterized in that the printed circuit board (16a-e) is produced using a 3D printing process.

2. Control device (10a-e) according to claim 1, characterized in that the printed circuit board (16a-e) has at least one first printed circuit board section (18a; 18b; 18d) which is perpendicular to a motor shaft (20a-e) of the electric motor (14a -e) and has at least one second printed circuit board section (22a, 23a; 22b, 23b; 22d, 23d) connected to the first printed circuit board section (18a; 18b; 18d), which is at an angle to the first printed circuit board section (18a; 18b; 18d ) is arranged.

3. Control device (10a-e) according to Claim 2, characterized in that the electronics unit (12a-e) comprises at least one power electronics component (24a, 26a) which is mounted on the second printed circuit board section (22a, 23a; 22b, 23b; 22d, 23d ) is arranged.

4. Control device (10a-e) according to claim 2 or 3, characterized in that the printed circuit board (16a-e) has a carrier substrate (28a; 28d; 28e) printed by means of the 3D printing process and at least one conductor track printed by means of the 3D printing process (30a, 32a), wherein the conductor track (30a, 32a) extends at least partially over the first printed circuit board section (18a; 18b; 18d) and the second printed circuit board section (22a, 23a; 22b, 23b; 22d, 23d).

5. Control device (10a-e) according to one of the preceding claims, characterized in that the printed circuit board (16a-e) viewed in a direction perpendicular to a motor shaft (20a-e) of the electric motor (14a-e) has an at least substantially U -shaped, has an at least essentially C-shaped or a rectangular cross section and the electronics unit (12a-e) extends over at least three sides (38a, 40a, 42a; 38b, 40b, 42b; 36c, 38c, 40c, 42c; 36e , 38e, 40e, 42e) of the printed circuit board (16a-e).

6. Control device (10a-e) according to one of the preceding claims, characterized in that the printed circuit board (16a-e) comprises a carrier substrate (28a; 28d; 28e) printed by means of the 3D printing process, which consists of at least two different materials, and/or comprises at least two conductor tracks (30a, 34a) printed using the 3D printing method, which consist of different materials, and/or comprises at least one conductor track (32a) printed using the 3D printing method and having at least two conductor track sections (44a, 46a). which are made of different materials.

7. Control device (10a-e) according to one of the preceding claims, characterized in that the electronic unit (12a-e) comprises at least one electronic component (48a) which is integrated and/or embedded in the printed circuit board (16a-e).

8. Control device (10d-e) according to one of the preceding claims, characterized by at least one cooling element (50d-e) which is integrated and/or embedded in the printed circuit board (16d-e).

9. Control device (10e) according to claim 8, characterized in that the cooling element (50e) comprises a base body (52e) lying on the inside with respect to the printed circuit board (16e) and a plurality of discharge elements (54e) which thermally connect the base body (52e) to an outside of the Connect printed circuit board (16e) and are intended to dissipate thermal energy generated by the electronic unit (12e) during operation. Control device (10a-e) according to one of the preceding claims, characterized by an electronics housing (56a; 56b; 56c; 56d) which has a base housing (60a; 60b; 60c; 60d) and a housing cover (62a; 62b; 62c; 62d), wherein the main housing (60a; 60b; 60c; 60d) has a receiving area (64a; 64b; 64c) for the at least one printed circuit board (16a - e ) and the housing cover (62a; 62b; 62c; 62d) is provided to cover the receiving area (64a; 64b; 64c), and the printed circuit board (16a-e) being attached to the receiving area (64a; 64b; 64c) of the basic housing in this way (60a; 60b; 60c; 60d) is adapted so that the printed circuit board (16a-e) is in direct thermal contact with the electronics housing (56a; 56b; 56c; 56d) and generates one of the electronics unit (12a-e) during operation Thermal energy directly via the bearing plate (58a; 58c; 58d) of the electric motor (14a-e), a side wall (66a, 67a; 66b; 66c, 67c; 66d) of the basic housing (60a; 60b; 60c; 60d) and/or the housing cover (62a; 62b; 62c; 62d). Actuator assembly (68a), in particular steering actuator, with at least one electric motor (14a-e) which has at least one motor shaft (20a-e), and with at least one control device (10a-e) according to one of the preceding claims. Steering system (70a) with at least one actuator assembly (68a) according to claim 11. Method for producing a control device (10a-e), in particular according to one of claims 1 to 10, in which at least one circuit board (16a-e) by means of a 3D printing process is produced and an electronics unit (12a-e) for controlling at least one electric motor (14a-e) and/or for detecting at least one operating variable of the electric motor (14a-e) is at least partially arranged on the printed circuit board (16a-e). Method according to Claim 13, characterized in that to produce the printed circuit board (16a-e), a carrier substrate (28a; 28d; 28e) and at least one conductor track (30a, 32a, 34a) are printed using the 3D printing method. Method according to Claim 13 or 14, characterized in that in the 3D printing method at least one electronic component (48a) of the electronic unit (12a-e) and/or at least one cooling element (50d; 50e) is integrated into the printed circuit board (16a-e) and /or is embedded.