Electric Controller

Abstract

An electrical controller includes a housing, wherein the housing has cooling air openings on two different housing sides. A heat sink is arranged inside the housing, in particular so as to be protected against contact, and forms a cooling air channel, wherein the cooling air channel runs between the cooling air openings of the different housing sides. An electrically insulating holding element is designed to mechanically fix the heat sink inside the housing in a manner electrically insulated from the housing. A number of components to be cooled are provided, wherein the components are thermally conductively coupled to the heat sink and are held by the heat sink.

Claims

1.-14. (canceled)

15. An electrical controller, comprising: a housing, wherein the housing has cooling air openings on two different housing sides; a heat sink that is arranged inside the housing, so as to be protected against contact, and that forms a cooling air channel, wherein the cooling air channel runs between the cooling air openings of the different housing sides; an electrically insulating holding element that mechanically fixes the heat sink inside the housing in a manner electrically insulated from the housing; and a number of components to be cooled, wherein the components to be cooled are thermally conductively coupled to the heat sink and are held by the heat sink.

16. The electrical controller as claimed in claim 15, wherein the two different housing sides lie opposite one another.

17. The electrical controller as claimed in claim 15, wherein the number of components to be cooled are thermally conductively coupled to the heat sink on at least two different sides of the heat sink.

18. The electrical controller as claimed in claim 17, wherein the number of components to be cooled are thermally conductively coupled to the heat sink on three different sides of the heat sink.

19. The electrical controller as claimed in claim 15, further comprising: a blower that brings about a flow of air in the cooling air channel.

20. The electrical controller as claimed in claim 15, wherein the number of components to be cooled comprises power semiconductors, coils and/or capacitors.

21. The electrical controller as claimed in claim 15, wherein the electrical controller is a frequency converter, a servo converter or a feedback unit.

22. The electrical controller as claimed in claim 15, wherein the electrical controller has a power rating that is greater than 25 kW.

23. The electrical controller as claimed in claim 15, wherein the electrical controller has a power rating that is greater than 48 kW.

24. The electrical controller as claimed in claim 15, further comprising: an EMC filter electrically and thermally decoupled from the heat sink.

25. The electrical controller as claimed in claim 20, wherein a first number of coils are thermally conductively coupled to the heat sink on a first side of the heat sink, a second number of coils are thermally conductively coupled to the heat sink on a second side of the heat sink, and the first side of the heat sink lies opposite the second side of the heat sink.

26. The electrical controller as claimed in claim 25, wherein a number of power semiconductors are thermally conductively coupled to the heat sink on a third side of the heat sink, and the third side of the heat sink is perpendicular to the first side and the second side of the heat sink.

27. The electrical controller as claimed in claim 26, further comprising: a first circuit board that is arranged parallel and offset to the third side of the heat sink and that is electrically connected to the power semiconductors.

28. The electrical controller as claimed in claim 27, further comprising: a second circuit board that is arranged parallel and offset to the second side of the heat sink and that is electrically connected to the second number of coils.

29. The electrical controller as claimed in claim 28, further comprising: a third circuit board that is arranged parallel and offset to the second side of the heat sink and that bears a number of electrical contacts, wherein the electrical contacts are designed to connect an electrical supply line to the electrical controller.

30. The electrical controller as claimed in claim 29, wherein the second circuit board is mechanically attached to the third circuit board.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0039] The invention is described in detail below with reference to the drawings. In the figures:

[0040] FIG. 1 shows a perspective illustration of a partially open controller according to the invention in a first view and

[0041] FIG. 2 shows a perspective illustration of the partially open controller according to the invention in a further view.

DETAILED DESCRIPTION OF THE DRAWINGS

[0042] FIG. 1 shows a perspective illustration of a partially open electrical controller 10 in a first view. FIG. 2 shows a perspective illustration of the partially open controller 10 in a further view.

[0043] The controller 10 is in this case a (grid) feedback unit that is designed to feed excess electrical energy possibly present in an intermediate circuit back into a supply grid. In this respect, reference is also made to the relevant literature in the art.

[0044] The controller has a power rating greater than 48 kW.

[0045] The controller 10 has a metal housing 100, wherein the housing 100 has respective cooling air openings 105 on a first housing side 101 and on a second housing side 102 that lies opposite the first housing side.

[0046] A heat sink 110 of the controller 10 is arranged so as to be protected against contact in the housing 100. The heat sink forms a closed cooling air channel 111 that runs between the cooling air openings 105 of the first housing side 101 and the second housing side 102. A number of cooling fins 112 is provided inside the cooling air channel 111.

[0047] The electrical controller 10 furthermore has an electrically insulating holding element having a first plastic molded body 115 and a second plastic molded body 115′, wherein the heat sink 110, on a first end side, is form-fittingly connected to the first plastic molded body 115 and, on a second end side, is form-fittingly connected to the second plastic molded body 115′, wherein the plastic molded bodies 115 and 115′ are in turn each mechanically fixed to associated housing regions.

[0048] The electrical controller 10 furthermore has a number of components 120, 121, 122 to be cooled, wherein the components 120, 121, 122 are thermally conductively coupled to the heat sink 110 and are held by the heat sink 110. The components 120 and 121 are each coils, and the components 122 are power semiconductors.

[0049] It is understood that the housing 100 in FIGS. 1 and 2 is illustrated as being partially open for the purposes of describing the invention. In an operating state of the controller 10, the housing 100 is closed, for example by adding further housing parts that are not illustrated, such that it is not possible to touch components potentially channeling a voltage, such as for example the heat sink 110.

[0050] The controller 10 furthermore has a blower 135 that is designed to bring about a flow of air in the cooling air channel 111.

[0051] The electrical controller 10 furthermore has an EMC filter 140 that is designed to be electrically and thermally decoupled from the heat sink 110.

[0052] The components 120, 121, 122 are thermally conductively coupled to various outer sides 130, 131, 132, 133 of the heat sink 110, the sides being outer with respect to the cooling air channel 111. The coils 120 are thermally conductively coupled to the heat sink 110 on a first side 133 of the heat sink 110. The coils 121 are thermally conductively coupled to the heat sink 110 on the second side 132 of the heat sink 110. The first side 133 of the heat sink 110 lies opposite the second side 132 of the heat sink 110. The power semiconductors 122 are thermally conductively coupled to the heat sink 110 on the third side 131 of the heat sink 110, wherein the third side 131 is perpendicular to the first side 133 and the second side 132.

[0053] The electrical controller 10 furthermore has a first circuit board 145 that is arranged parallel and offset to the third side 131 of the heat sink 110 and that is electrically connected to the power semiconductors 122.

[0054] The electrical controller 10 furthermore has a second circuit board 146 that is arranged parallel and offset to the second side 132 of the heat sink 110 and that is electrically connected to the coils 121.

[0055] The electrical controller 10 furthermore has a third circuit board 147 that is arranged parallel and offset to the second side 132 of the heat sink 110 and that bears a number of electrical contacts 150, wherein the electrical contacts 150 are designed to connect an electrical supply line to the electrical controller 10. The second circuit board 146 is mechanically attached to the third circuit board 147.

[0056] The electrical controller 10 furthermore has a number (for example two) of Cy interference suppression capacitors 123 that are each electrically connected to the heat sink 110 at one of their electrical terminals and are electrically connected to an electrical intermediate circuit of the electrical controller 10 at another of their terminals.