Electronic control module for an electric motor

• US 6,099,325 A
• Filed: 11/05/1998
• Issued: 08/08/2000
• Est. Priority Date: 11/05/1998
• Status: Expired due to Fees

• Current Assignee: Visteon Global Technologies Incorporated (Visteon Corporation)
• Original Assignee: Ford Motor Company
• Inventors: Parkhill, Scott Thomas
• Primary Examiner(s): Abrams, Neil
• Application Number:
  US09/187,132
• Time in Patent Office: 642 Days
• Field of Search: 439/34, 439/76.1, 439/76.2, 361/736, 361/707, 361/704, 310/71
• US Class Current: 439/76.1
• CPC Class Codes: H01R 13/52 Dustproof, splashproof, drip-proof, waterproof, or flameproof cases
• CPC Class Codes: H01R 9/2466 using a planar conductive structure, e.g. printed circuit board
• CPC Class Codes: H02K 11/33 Drive circuits, e.g. power electronics H02K11/38 takes precedence
• CPC Class Codes: H02K 2211/03 Machines characterised by circuit boards, e.g. pcb
• CPC Class Codes: H02K 23/66 Structural association with auxiliary electric devices influencing the characteristic of, or controlling, the machine, e.g. with impedances or switches
• CPC Class Codes: H02K 5/225 Terminal boxes or connection arrangements specially adapted for submersible motors H02K5/132
• CPC Class Codes: H02K 7/14 Structural association with mechanical loads, e.g. with hand-held machine tools or fans with fan or impeller for cooling the machine H02K9/06

Abstract

An electronic control module (16) for an electric motor (12) includes a first module member (20) attached to the electric motor and a second module member (24) defining an interior for housing a circuit board (28). The second module member (24) includes a control signal connector on with control signal terminals for quick attachment and release to a control signal wire set. The second module member also includes molded in positive and negative supply blades (50, 60) spaced apart from the control signal connector (40). The second module member also includes molded in positive and negative motor blades (70, 82), also spaced apart from the control signal connector. Each of the blades (50,60,70,82) is connected to the circuit board on the inside and has an aperture external of the control module for attachment to the power supply or to the electric motor (12). A series of fasteners interconnect the blades (50, 60, 70, 82) to a positive and negative supply leads (19, 21) and to positive and negative motor leads (76, 88), respectively. The first module member (20) may be formed of cast aluminum and integrally formed with a housing (22) for a pump (164) to be driven by the motor. The circuit board (28) may be supported on a thermally conductive pad (175).

Claims

1. An electrical control module for an electric motor comprising:

a first module member adapted to be attached to said electric motor;

a second module member, together with said first module member defining an interior for housing a circuit board therein;

control signal connector means on said second module member and having therein control signal terminals, said control signal connector means allowing quick attachment and release of a control signal wire set to said control signal terminals;

a positive supply blade molded in said second module member spaced apart from said control signal connector means and having a first end disposed within said interior and connected to said circuit board and a second end protruding externally from said interior;

a negative supply blade molded in said second module member spaced apart from said control signal connector means and having a third end disposed within said interior and connected to said circuit board and a fourth end protruding externally from said interior;

a positive motor blade molded in said second module member spaced apart from said control signal connector means and having a fifth end disposed within said interior and connected to said circuit board and a sixth end protruding externally from said interior;

a negative motor blade molded in said second module member spaced apart from said control signal connector means and having a seventh end disposed within said interior and connected to said circuit board and a eighth end protruding externally from said interior;

first fastener means for conductively connecting a positive supply lead to said second end of said positive supply blade;

second fastener means for conductively connecting a negative supply lead to said fourth end of said negative supply blade;

third fastener means for conductively connecting said sixth end of said positive motor blade to a positive motor lead;

fourth fastener means for conductively connecting said eighth end of said negative motor blade to a negative motor lead and;

a thermally conductive pad formed with said first module member supporting the circuit board.

2. The electronic control module according to claim 1, wherein said second module member is maintained in a sealed relationship with said first module member by at least one of said fastener means.

3. The electronic control module according to claim 1, wherein said first fastener means comprises a first threaded fastener extending through a first aperture disposed on said second end of said positive supply blade to engage a first threaded bore, said first threaded fastener being operative to clamp said second module member in a sealed relationship with said first module member.

4. The electronic control module according to claim 3, further comprises a first metallic bushing molded in said second module member adjacent to said first aperture such that said first fastener passes through said first aperture and said metallic bushing before engaging said first threaded bore.

5. The electronic control module according to claim 1, wherein:

said first fastener means comprises a first threaded fastener extending through a first aperture disposed on said second end of said positive supply blade to engage a first threaded bore in a brush card;

said second fastener means comprises a second threaded fastener extending through a second aperture disposed on said fourth end of said negative supply blade to engage a second threaded bore in said brush card, said first and second threaded fasteners being operative to clamp said second module member in a sealed relationship with said first module member;

said third fastener means comprises a third threaded fastener extending through a third aperture disposed on said sixth end of said positive motor blade to conductively engage said positive motor lead in a third bore; and

said fourth fastener means comprises a fourth threaded fastener extending through a fourth aperture disposed on said eighth end of said negative motor blade to conductively engage said negative motor lead disposed in a fourth bore.

6. The electronic control module according to claim 1, further comprises a plurality of upstanding walls disposed between each of said first, second, third and fourth ends.

7. The electronic control module according to claim 1, wherein said positive and negative motor blades are disposed between said positive and negative supply blades.

8. An electronic control module for an electric motor comprising:

a first module member attached to said electric motor;

a second module member defining an interior and including circuit board mounting means for securely mounting a circuit board within said interior;

control signal connector means on said second module member and having therein control signal terminals, said control signal connector means allowing quick attachment and release of a control signal wire set to said control signal terminals;

a positive supply blade molded in said second module member spaced apart from said control signal connector means and having a first end disposed within said interior and connected to said circuit board and a second end protruding externally from said interior;

a negative supply blade molded in said second module member spaced apart from said control signal connector means and having a third end disposed within said interior and connected to said circuit board and a fourth end protruding externally from said interior;

a positive motor blade molded in said second module member spaced apart from said control signal connector means and having a fifth end disposed within said interior and connected to said circuit board and a sixth end protruding externally from said interior;

a negative motor blade molded in said second module member spaced apart from said control signal connector means and having a seventh end disposed within said interior and connected to said circuit board and an eighth end protruding externally from said interior;

a first threaded fastener connected to a positive supply lead and extending through a first aperture disposed on said second end of said positive supply blade to engage a first threaded bore in a brush card;

a second threaded fastener connected to a negative supply lead and extending through a second aperture disposed on said fourth end of said negative supply blade to engage a second threaded bore in said brush card, said first and second threaded fasteners being operative to clamp said second module member in a sealed relationship with said first module member;

a third threaded fastener extending through a third aperture disposed on said sixth end of said positive motor blade to conductively engage a positive motor lead disposed in a third bore of said brush card; and

a fourth threaded fastener extending through a fourth aperture disposed on said eighth end of said negative motor blade to conductively engage a negative motor lead disposed in a fourth bore of said brush card.

9. The electronic control module according to claim 8, wherein said second module member is maintained in a sealed relationship with said first module member by at least one of said fastener means.

10. The electronic control module according to claim 8, wherein said first fastener means comprises a first threaded fastener extending through a first aperture disposed on said second end of said positive supply blade to engage a first threaded bore, said first threaded fastener being operative to clamp said second module member in a sealed relationship with said first module member.

11. The electronic control module according to claim 10, further comprises a first metallic bushing molded in said second module member adjacent to said first aperture such that said first fastener passes through said first aperture and said metallic bushing before engaging said first threaded bore.

12. The electronic control module according to claim 8, further comprises a plurality of upstanding walls disposed between each of said first, second, third and fourth ends.

13. The electronic control module according to claim 8, wherein said positive and negative motor blades are disposed between said positive and negative supply blades.

14. An electronic control module for an electric motor driven hydraulic pump comprising:

a hydraulic pump housing having a first module member portion integrally formed therewith;

a second module member defining an interior and including circuit board mounting means for securely mounting a circuit board within said interior;

control signal connector means on said second module member and having therein control signal terminals, said control signal connector means allowing quick attachment and release of a control signal wire set to said control signal terminals;

a positive supply blade molded in said second module member spaced apart from said control signal connector means and having a first end disposed within said interior and connected to said circuit board and a second end extending externally from said interior;

a negative supply blade molded in said second module member spaced apart from said control signal connector means and having a third end disposed within said interior and connected to said circuit board and a fourth end extending externally from said interior;

a positive motor blade molded in said second module member spaced apart from said control signal connector means and having a fifth end disposed within said interior and connected to said circuit board and a sixth end extending externally from said interior;

a negative motor blade molded in said second module member spaced apart from said control signal connector means and having a seventh end disposed within said interior and connected to said circuit board and a eighth end extending externally from said interior;

a first threaded fastener connected to a positive supply lead and extending through a first aperture disposed on said second end of said positive supply blade to engage a first threaded bore in a brush card;

a second threaded fastener connected to a negative supply lead and extending through a second aperture disposed on said fourth end of said negative supply blade to engage a second threaded bore in said brush card, said first and second threaded fasteners being operative to clamp said second module member in a sealed relationship with said first module member portion;

a third threaded fastener extending through a third aperture disposed on said sixth end of said positive motor blade to conductively engage a positive motor lead disposed in a third bore of said brush card; and

a fourth threaded fastener extending through a fourth aperture disposed on said eighth end of said negative motor blade to conductively engage a negative motor lead disposed in a fourth bore of said brush card.

15. The electronic control module according to claim 14, wherein said second module member is maintained in a sealed relationship with said first module member portion by at least one of said fastener means.

16. The electronic control module according to claim 14, wherein said first fastener means comprises a first threaded fastener extending through a first aperture disposed on said second end of said positive supply blade to engage a first threaded bore, said first threaded fastener being operative to clamp said second module member in a sealed relationship with said first module member portion.

17. The electronic control module according to claim 16, further comprises a first metallic bushing molded in said second module member adjacent to said first aperture such that said first fastener passes through said first aperture and said metallic bushing before engaging said first threaded bore.

18. The electronic control module according to claim 14, further comprises a plurality of upstanding walls disposed between each of said first, second, third and fourth ends.

19. The electronic control module according to claim 14, wherein said positive and negative motor blades are disposed between said positive and negative supply blades.