CONTROL DEVICE WITH INTEGRATED ENERGY CONDITIONING AND INTEGRATED ENERGY MANAGEMENT

Abstract

A control device with integrated energy conditioning and energy management for actuating an electrically operated and/or controlled actuator, including: a controller for generating an actuation signal for the actuator; a connection for connecting the control device to an external electrical energy supply that provides a grid voltage; a circuit arrangement for the conditioning, rectification and conversion of the grid voltage into a first intermediate circuit DC voltage, a level of which is independent of a level of the grid voltage; at least one electrical buffer store for the first intermediate circuit DC voltage for buffering a power necessary for maintaining a further voltage, derived from the first intermediate circuit DC voltage, for supplying power to the controller unit in the event of failure of the external electrical energy supply and for transferring the actuator to a safe state, for example upon failure of the external electrical energy supply.

Claims

1. A control device (1) with integrated energy conditioning and integrated energy management for actuating an electrically operated and/or controlled actuator (2), the control device (1) comprising: a controller (4) for generating an actuation signal for the actuator (2); a connection (A-C) for connecting the control device (1) to an external electrical energy supply that provides a grid voltage (VAC.sub.0); a circuit arrangement (8) for the conditioning, rectification and conversion of the grid voltage (VAC.sub.0) into a first intermediate circuit DC voltage (VCC.sub.1), wherein a level of the first intermediate circuit DC voltage (VCC.sub.1) is independent of a level of the grid voltage (VAC.sub.0); and at least one electrical buffer store (7) for the first intermediate circuit DC voltage (VCC.sub.1) for buffering a power necessary for maintaining at least one further voltage (VCC.sub.2, VCC.sub.3), derived from the first intermediate circuit DC voltage, for supplying power to the controller (4) in the event of failure of the external electrical energy supply and for transferring the actuator (2) to a safe state, in an event of failure of the external electrical energy supply.

2. The control device (1) as claimed in claim 1, wherein the circuit arrangement (8) for the conditioning, rectification and conversion of the grid voltage comprises a power factor correction filter comprising a step-up converter or a PFC input stage (5).

3. The control device (1) as claimed in claim 1, wherein the first intermediate circuit DC voltage (VCC.sub.1) is adapted to be adjusted in principle as desired and independently of a value of the grid voltage (VAC.sub.0).

4. The control device (1) as claimed in claim 3, wherein the first intermediate circuit DC voltage (VCC.sub.1) is adapted to be adjusted to a value greater than a peak value of the grid voltage (VAC.sub.0).

5. The control device (1) as claimed in claim 1, wherein a size of the buffer store (7) for the first intermediate circuit DC voltage (VCC.sub.1), with respect to a power that is buffer-stored or is adapted to be buffer-stored therein, corresponds at least to a maximum power required by the actuator (2) that is permissibly adapted to be connected to the control device (1) for transfer to a safe final position.

6. The control device (1) as claimed in claim 1, wherein the at least one further derived voltage (VCC.sub.2, VCC.sub.3) is derived from the first intermediate circuit DC voltage (VCC.sub.1), and the at least one further derived voltage (VCC.sub.2) provides a sequential energy supply in order to supply electrical power to one or more further components of the control device (1), including at least one of the controller (4), or internal and external communication interfaces.

7. The control device (1) as claimed in claim 6, wherein the at least one further derived voltage (VCC.sub.2, VCC.sub.3) is derived from the first intermediate circuit DC voltage (VCC.sub.1) and the at least one further voltage (VCC.sub.3).

8. The control device (1) as claimed in claim 1, wherein the at least one further derived voltage (VCC.sub.2) is lower than the first intermediate circuit DC voltage (VCC.sub.1) in terms of absolute value.

9. The control device (1) as claimed in claim 6, wherein the grid voltage is 110-230 V AC, the intermediate circuit DC voltage (VCC.sub.1) is 380 V DC, the at least one further derived voltage (VCC.sub.2) is 24 V DC.

10. The control device (1) as claimed in claim 9, wherein the at least one further derived voltage includes additionally derived voltages (VCC.sub.3) that are 5 V DC and 3.3 V DC.

11. The control device (1) as claimed in claim 1, wherein the at least one further derived voltage (VCC.sub.2) is a DC voltage, and the grid voltage (VAC.sub.0) is an AC voltage.

12. The control device (1) as claimed in claim 1, further comprising at least one external connection (N, O); and the at least one further derived voltage (VCC.sub.2) is applied to the external connection (N, O) in order for the at least one further derived voltage to be captured by an external superordinate controller (3) or to supply electrical energy to external components; or the external connection (N, O) is used as an external voltage input for externally supplying this voltage (VCC.sub.2) to the control device (1).

13. The control device (1) as claimed in claim 1, wherein the at least one further derived voltage (VCC.sub.2) or at least one additionally derived voltage (VCC.sub.2) is applied to the external connection (N, O) in order for the at least one further derived voltage to be captured by an external superordinate controller (3) or to supply electrical energy to external components or at least one optionally additionally derived voltage (VCC.sub.2).

14. The control device (1) as claimed in claim 1, wherein power is supplied or is adapted to be supplied to the controller (4) by the at least one further derived voltage.

15. The control device (1) as claimed in claim 1, wherein power is supplied or is adapted to be supplied to the controller (4) by an optionally additionally derived voltage (VCC.sub.3) or by an external supply at an external connection (N, O) of the control device.

16. The control device (1) as claimed in claim 1, further comprising: at least one sensor (6) configured to capture the grid voltage (VAC.sub.0) and for detecting failure of the external electrical energy supply and for transmitting corresponding signals (S1) to the controller (4).

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0047] Further properties and advantages of the invention emerge from the following description of exemplary embodiments with reference to the drawing.

[0048] The single FIGURE, FIG. 1 shows a possible configuration of the control device according to the invention.

DETAILED DESCRIPTION

[0049] In FIG. 1, reference sign 1 denotes the control device according to the invention. Reference sign 2 denotes an actuator (in this case an electric motor) connected to the control device. Reference sign 3 stands for a superordinate control unit in the form of a PLC. The reference signs A to O stand for inputs/outputs (or corresponding connections) of the control device 1; the associated arrows symbolize input or output signals (depending on the direction of the arrow). Reference sign 4 denotes a microcontroller (C), and reference sign 5 denotes a PFC, i.e. a power factor correction filter in the form of a step-up converter or a PFC input stage.

[0050] A grid voltage is applied to the PFC 5 (between N and L1 or at the connections B and C), which is 230 V AC without limitation, in this case referred to as VAC.sub.0. The connections at least at B and C therefore represent a connection for connecting the control device 1 to an external electrical energy supply, which provides a grid voltage. A sensor means 6 in the form of a voltmeter, which measures or monitors the grid voltage, is connected in parallel with the PFC 5 between the connections B and C. A corresponding measuring/monitoring signal S1 is provided for further use, e.g. state monitoring or fault analysis, at the microcontroller 4 (dashed arrow in FIG. 1). The microcontroller 4, for its part, is able to generate a corresponding signal S2 and provide it at the connection M for use by the PLC 3.

[0051] The PFC 5 generates a higher (in terms of absolute value, in particular in relation to a peak value of the grid voltage VAC.sub.0) (DC) voltage VCC.sub.1 of e.g. 380 V from the grid voltage VAC.sub.0, which in this case is referred to as the first intermediate circuit DC voltage VCC.sub.1. For this purpose, the grid voltage VAC.sub.0 is conditioned, rectified, converted and transformed into the first intermediate circuit DC voltage, i.e. the voltage VCC.sub.1, VCC.sub.1>>, which has already been mentioned, wherein a level of the first intermediate circuit DC voltage VCC.sub.1 is preferably independent of a level of the (external) grid voltage. The following is known to apply in this case:

[00001]$V{\mathrm{AC}}_0=\frac{\sqrt{2}}{}.$

[0052] An electrical buffer store in the form of a capacitor 7 is connected downstream of the PFC 5 and parallel therewith, and will be discussed in more detail below.

[0053] Further components of a circuit arrangement 8 are located downstream of the capacitor 7. In this case, and without limitation, this circuit arrangement 8 comprises, in addition to the PFC 5 and downstream of the capacitor 7, two DC/DC voltage converters 8a, 8b, which successively derive and provide (DC) voltages VCC.sub.2 and VCC.sub.3 from the first intermediate circuit DC voltage VCC.sub.1, as shown. Without limitation, VCC.sub.1=380 V DC, VCC.sub.2 is 24 V DC, and VCC.sub.3 is 5 V DC. Further voltages may also be provided (derived) by means of an appropriate development, e.g. 3.3 V DC. GND stands for the ground potential. In this case, the voltage VCC.sub.1 is also referred to as first intermediate circuit DC voltage, as has already been mentioned.

[0054] According to FIG. 1, the voltage or intermediate circuit DC voltage VCC.sub.1 is applied to a safety circuit 9, which is described in a parallel patent application of the applicant, and is provided via this at the connections J and K to operate the actuator 2. The safety circuit 9 is preferably designed in terms of circuitry to change the polarity of the voltage at the output J/K to the actuator 2, which enables advantageous high-speed actuation.

[0055] The voltage VCC.sub.2 is output, inter alia, at the connection O. However, this connection may advantageously also be used to externally provide a corresponding voltage for the control device 1, for example by way of the PLC 3. Connection N is at ground potential GND. A voltage VCC.sub.2 provided externally at N, O is able to be converted to the voltage VCC.sub.3 by the converter 8b before it is used, for example, to supply power to the microcontroller 4.

[0056] The voltage VCC.sub.2 is also used to supply power to two position sensors 10, 11 (sensor 1, sensor 2), which are designed to capture a location or position of the actuator 2, via the connections H1 and H2 (ground potential GND at I1 and I2). Signals supplied by the position sensors 10, 11 are applied to D and F for use by the microcontroller 4 and are provided (after appropriate duplication) at E and G for the PLC 3.

[0057] The voltage VCC.sub.3 is used in the present exemplary embodiment specifically for supplying power to the microcontroller 4, as already mentioned.

[0058] The electrical buffer store (capacitor) 7 for the first intermediate circuit DC voltage VCC.sub.1 is used for buffering a power necessary for maintaining at least the voltage, derived from the first intermediate circuit DC voltage VCC.sub.1, in this case specifically the voltage VCC.sub.3 for supplying power to the microcontroller 4 in the event of failure of the external electrical energy supply and for transferring the actuator 2 to a safe state, for example in the event of failure of the external electrical energy supply.

[0059] The connections A and L are used to connect protective conductors for safely capturing and dissipating any fault currents. Electrical power may be supplied to at least the microcontroller 4 and/or corresponding communication interfaces via the external connection Q.

[0060] The feed voltage (grid voltage) at the connections B and C is therefore initially conditioned to VCC.sub.1 by way of the arrangement shown in FIG. 1. In other words, the AC-side feed voltage at the connections A-C or B and C is transformed by the PFC 5 into a DC voltage with VCC.sub.1. Where VCC.sub.1>>, higher, grid-voltage-independent voltages VCC.sub.1 are available for safety-relevant actuators (e.g. actuator 2). The PFC 5 preferably processes all grid voltages that are commonly used worldwide between 100 V and 230 V or 240 V. VAC.sub.0 denotes the grid voltage, i.e. 230 V. From an electrical point of view, this is an RMS value. The peak value is greater, and in the example mentioned is 230 V.Math.{square root over (2)}=230 V.Math.1.414325 V. A comparison is intended to be carried out against this peak value here. Peak values are usually indicated in the literature with a roof above the relevant symbol:

[00002]$={V\mathrm{AC}}_0.Math.\sqrt{2}=230V.Math.1.414325V,{V\mathrm{CC}}_1$

[0061] The connections N and O function selectively as input or output for the derived voltage VCC.sub.2. The derived or conditioned voltage VCC.sub.2 is output, for example, to a superordinate controller (PLC 3) for control thereby. The connections mentioned are also used as inputs or as information source for the PLC 3 in order to ascertain whether the energy conditioning in the control device 1 is functioning correctly.

[0062] In particular, the superordinate PLC 3 is able to itself provide the voltage VCC.sub.2 of e.g. 24 V and therefore overwrite the 24 V generated in the control device 1 itself in order to independently supply the relevant voltage of 24 V to the control device 1. This enables the voltage VCC.sub.2 to be decoupled from the availability of a grid voltage. The microcontroller 4 also continues to operate at the connections A-C in terms of logic in the event of a power failure, as long as the PLC 3 provides the required voltage. The sensor system, that is to say in particular the position sensors 10 and 11 or the grid voltage sensor system 6, also continues to work fully and continues to provide status information regarding the state of the actuator 2 or, in particular, a clamping system (or any other connected system that comprises the actuator 2) and the grid voltage.

[0063] The described derivation of a 24 V voltage VCC.sub.2 from the intermediate circuit DC voltage VCC.sub.1 shows the advantages of a sequential energy supply downstream of the PFC 5 and the energy storage unit (buffer store or capacitor) 7: An energy failure is able to be detected via a sensor system (sensor means 6) and reported to the microcontroller 4. If the energy supply fails, at least the voltages VCC.sub.2 and VCC.sub.3 continue to be generated via the power in the energy storage unit 7, and so voltage continues to be supplied to the C 4 and the complete logic/sensor system (e.g. position sensors 10 and 11). The C 4 therefore continues to operate unaffected for a certain time t (t>0) despite a power failure. During this time t, the actuator 2 and accordingly a clamping system or the like operated thereby is therefore able to be shut down in a controlled and power-equivalent manner (i.e. with the nominally required power, that is to say without compromising the function), which corresponds to a transfer to a safe state, e.g. clamped. During this time t, status reports to or for the superordinate controller (PLC 3) are also preferably generated and output in a controlled manner (at output M). During this time t, system-relevant information is also preferably stored in a non-volatile memory area (EEPROM) of C 4, so that it is available after the power supply has been restored. This memory area is indicated with the reference sign 4a in FIG. 1. It can, without limitation, also be designed separately from the C 4 or even from the control device 1.

[0064] The described integration of controlled, fast (high-speed) switching behavior enables short switching cycles using the high voltage supply of VCC.sub.1380 V, which is provided by the PFC 5 and is (far) above the peak voltages of the (worldwide) feed voltages VAC.sub.0 of 110 V or 230 V. High voltages ensure fast loading and unloading of the actuator system and therefore short reaction times (safety for humans and machines).

[0065] When the actuator 2 is switched off, the polarity of the voltage may be reversed. As a result, a magnetic field that is regularly present in the actuator system is able to be removed as quickly as possible in order to transfer the actuator 2 or a clamping element or the like that is moved thereby, to a safe (clamped) state. In general, this enables the actuator system (the actuator 2 or a safety component) to be overexcited on both sides by means of a semiconductor relay 9a preferably present in the safety circuit 9, both when releasing and when disengaging the actuator system.

[0066] The described high-speed switch-off behavior is possible in this case due to the energy buffer storage in the capacitor 7 even in the event of a grid failure. In this case, the grid failure is identified via the sensor system (in this case the sensor means 6). If a grid failure is identified, so much power is available in the capacitor 7 at PFC level (i.e. at 380 V, for example) that it is possible to transfer the actuator 2 or a connected safety component to its safe state in a controlled manner and at full power and full speed. In this way, the connected safety component never sees a power failure.