Modularized servo control system

• US 20070273359A1
• Filed: 02/05/2007
• Published: 11/29/2007
• Est. Priority Date: 02/03/2006
• Status: Active Grant

• Current Assignee: BAE Systems Land and Armaments LP (BAE Systems Plc)
• Original Assignee: BAE Systems Land and Armaments LP (BAE Systems Plc)
• Inventors: Grupa, Timothy, Walters, Keith, Stocker, Stephen, Badzinski, David, Shoemaker, Jeffrey, Bartness, Bret, Woodland, Lane, Sukup, Martin
• Granted Patent: US 7,459,900 B2
• Time in Patent Office: Days
• US Class Current: 324/117.H
• CPC Class Codes: G01R 15/202 using Hall-effect devices Hall elements in arrangements for measuring electrical power G01R21/08

Abstract

A modular current sensing system for a servo control system that includes a magnetic core with an open center portion and a connection plate that includes at least three wire connectors, wherein the wire connectors are capable of connecting at least two wires electrically in series. The system also includes a plurality of wires, including a first wire with a first end and a second end, wherein the first end of the first wire is electrically connected to a first power source, and the second end of the first wire is connected to the connection plate at the first wire connector and wherein the first wire passes through the open portion defined by the magnetic core at least once. A first motor current flowing through the first wire induces a core current to flow in the magnetic core, causing the magnetic core to emit a magnetic field. A Hall effect sensor detects the magnetic field, produces an output current, and delivers the output current to a control device within a servo control system.

Claims

1. A modular current sensing system for a servo control system comprising:

a magnetic core defining an open center portion;

a connection plate including at least three wire connectors, including a first, a second, and a third wire connector, wherein each wire connector is capable of connecting at least two wires electrically in series;

a plurality of wires, including a first wire with a first end and a second end, wherein the first end of the first wire is electrically connected to a first power source, and the second end of the first wire is connected to the connection plate at the first wire connector and wherein the first wire passes through the open portion defined by the magnetic core at least once, the first wire thereby inducing a core current to flow in the magnetic core and causing the magnetic core to emit a magnetic field upon initiation of a first motor current; and

a Hall effect sensor that detects the magnetic field, produces an output current, and delivers the output current to a control device within a servo control system.

2. The current sensing system of claim 1 wherein the first wire connector is also electrically connected to the primary winding of a motor.

3. The current sensing system of claim 1 wherein the plurality of wires further includes a second wire with a first end connected to the second wire connector and a second end connected to the third wire connector.

4. The current sensing system of claim 3 wherein the second wire is electrically connected to the secondary winding of a motor.

5. The current sensing system of claim 1 wherein at least one of the wire connectors is connected only to one of the plurality of wires.

6. The current sensing system of claim 1 further including a splicing device for electrically connecting at least two of the wire connectors.

7. The current sensing system of claim 1, wherein at least two motors are electrically connected to the connection plate.

8. The current sensing system of claim 6, wherein the at least two motors have different rms current ratings.

9. The current sensing system of claim 1 further including a second power source connected to one of the plurality of wires.

10. The current sensing system of claim 8, wherein the second power source is capable of supplying substantially more power than the first power source.

11. A method for sensing current flowing from a power source to a motor in a servo control system comprising:

generating a primary current in the power source;

conducting the primary current through a first primary wire;

winding the first primary wire about a magnetic core, inducing a first core current and a first magnetic field in the magnetic core;

connecting the first primary wire to a connection plate;

conducting the primary current through the connection plate, through a splice device, back through the connection plate, and into a second primary wire;

winding the second primary wire around the core, inducing a second core current in the magnetic core and a second magnetic field;

sensing the first and second magnetic fields with a Hall effect sensor and generating an output current proportional to the sum of all core currents; and

sending the output current to a control device in a servo control system.

12. The current sensing method of claim 11, further comprising

generating a secondary current in the power source;

conducting the secondary current through a first secondary wire;

connecting a first end of the first secondary wire to the connection plate;

winding the first secondary wire about a magnetic core, inducing a third core current and a third magnetic field in the magnetic core;

connecting a second end of the first secondary wire to the connection plate; and

further sensing the third magnetic field with the Hall effect sensor.

13. A thermal management system integrated into a servo control unit and servo power electronics system, comprising:

a power-side distribution manifold including at least one connection port and at least one fluid connector, wherein the manifold also forms a cooling plate for the servo power electronics system;

a plurality of control-side distribution manifolds, wherein each control-side distribution manifold includes an inlet connected to the power-side distribution manifold and an outlet connected to the power-side distribution manifold;

a plurality of control-side cold plates that provide cooling for electronics located in the servo control unit, wherein the cold plates are connected to the control-side distribution manifolds;

a frame supporting the cold plates and control-side manifolds; and

a coolant flowing through the power-side distribution manifold, inlets, outlets, control-side manifolds and cold plates.

14. The thermal management system of claim 13 further comprising a blind fluid connector removably attached to each inlet and to each outlet.

15. The thermal management system of claim 13 wherein an inner volume of the power-side distribution manifold is substantially larger than the inner volume of any one of the plurality of control-side manifolds.

16. The thermal management system of claim 13 wherein a top surface of the power-side distribution manifold has a substantially rectangular shape and a height that is substantially less than a power-side distribution width or a power-side distribution length.

17. The thermal management system of claim 13 wherein each control-side distribution manifold is substantially the same.

18. The thermal management system of claim 13 wherein the plurality of servo control units numbers three.

19. The thermal management system of claim 13 wherein the plurality of servo control units numbers four.

20. A method of simultaneously managing the thermal properties of a servo control unit and servo power electronics system, comprising:

locating a servo power electronics system distribution manifold beneath a set of power electronics;

locating a plurality of servo control unit distribution manifolds in a servo control unit;

connecting a servo control unit distribution manifold to a servo power electronics system manifold via a plurality of inlets and outlets;

connecting a plurality of cold plates to each servo control distribution manifold;

supporting the cold plates and the servo control unit distribution manifolds with a support frame;

flowing a coolant from the servo power electronics system through the outlets and into the servo control unit manifolds;

flowing the coolant from the servo control unit manifolds into the plurality of cold plates; and

flowing the coolant from the servo control unit manifolds through the outlets and back into the power-side distribution manifold.