Electronic control of a compressor, compressor and cooling equipment

The present invention refers to an electronic control (1) of a compressor (2), the electronic control (1) disposed in an encasement 5 (3), wherein the electronic control (1) comprises: a main board (4) associated to at least an auxiliary board (5,6,7), wherein one of the auxiliary boards (5,6,7) is a heat-generating board (7), wherein the heat-generating board (7) is disposed at a first distance (D1) in relation to a first wall of the encasement (P1), wherein the other auxiliary boards 0 (5.6) are disposed at least at a second distance (D2, D3) in relation to the first wall of the encasement (P1), wherein the first distance (D1) is less than the second distance (D2). A compressor (2) and a cooling equipment are also described.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a national stage entry of PCT Application No. PCT/BR2020/050074, filed on Mar. 9, 2020, which claims priority to Brazilian Application No. 102019006685-7, filed on Apr. 2, 2019.

The present invention refers to an electronic control device of a compressor, more specifically to a compact electronic control device and whose disposition of its elements enables efficient thermal dissipation. A compressor and a cooling equipment are also addressed.

DESCRIPTION OF THE STATE OF THE ART

Electronic control devices are commonly used in the state of the art in the control of compressors applied to cooling equipment. For example, in a variable capacity compressor, the electronic control device is, in general terms, responsible for sending commands for altering the rotation speed of the compressor motor and thus enable the temperature of the cooling equipment to be controlled.

One of the problems found in the state of the art lies in the lack of sufficient space for assembling the electronic control device and the compressor. So, there is a constant search for a set (electronic control device and compressor) of reduced size, obviously provided that efficiency and reliability are not lost.

Besides the reduced space, there are also problems linked to the generation of heat both from the compressor and from its electronic control device.

It is known that during the operation of a compressor used in cooling equipment said compressor tends to heat up, said generation of heat may compromise the operation of the electronic control device itself of the compressor, compromising the efficiency and reliability of its components (sensitive to temperature).

Similarly, the electronic control device itself of the compressor tends to generate heat during its operation, meaning that said energy is absorbed by elements sensitive to temperature and also compromising the operation of the electronic control device.

So, the search in the state of the art for a compact electronic control device having efficient heat characteristics is ongoing.

From the state of the art related to the present invention, it is known that electronic control devices applied to compressors are usually formed by a single printed circuit board endowed with two or more layers, wherein the electronic components are disposed in said layers.

The state of the art also discloses publications wherein the electronic control device is formed by a main board associated to auxiliary boards, as described in the prior art US 2018/0287466, wherein a circuit apt to control an electric motor is described. Possibly in an attempt to compact the proposed circuit, said prior art makes use of “daughter” electronic boards associated to a main board, wherein said association occurs by encasement, using the referenced slots for such.

It so happens that said prior art errs by disclosing means for improving the thermal efficiency of the electronic board and electric motor set, which compromises to a great extent the operation of the electric motor associated to the electronic circuit.

Additionally, said prior art shows no concern relating to the form of disposition of the so-called daughter boards in relation to main board, as well as the disposition of the electronic components of each one of the boards.

As seen from the teachings of the present invention, the form of disposition of an electronic control device and its components is essential for the compression and thermal efficiency thereof.

The state of the art also discloses prior art EP 1,617,081, describing a compressor wherein the circuit of the inverter (electronic control device) is disposed inside the shell of the compressor.

It so happens that said European prior art focuses on the description so that the compressor is apt to carry the inverter inside its shell, such that the inverter is hermetically disposed in the shell of the compressor.

On the other hand, document EP 1,617,081 errs in describing characteristics linked to the disposition of the boards of the inverter as well as forms of overcoming problems related to the dissipation of heat, and these problems definitely occurs when the objective is to dispose the inverter inside the shell of the compressor, as occurs in EP 1,617,081.

Additionally, document U.S. Pat. No. 6,704,202 discloses a compact-size as well as an inexpensive power controller. Highly heat-dissipating first board including an inverter circuit mounted thereon and second board including a control circuit mounted thereon are placed in parallel with each other and accommodated by case. Case has slits through which heat sink and connector can extend outside case, and further has fixing section for fixing case to a compressor. This structure allows the power controller to dissipate heat in an optimum manner and to be downsized, and also allows the compressor to integrate the controller thereinto. A capacity that the controller occupies in the refrigerating system can be substantially reduced. However, the physical layout of the temperature sensitive components7and54are in an unfavorable position from the thermal point of view, being subject to heating by both conduction and convection. In opposition, the great benefit of the present invention is the physical distance between heat sources and temperature sensitive components, improving the reliability of the product.

Document US2005/219827 discloses an electrical circuit device that includes a controller, drivers, auxiliary plates, and a case. The controller inputs driving signals to the drivers. The drivers have multiple semiconductor relays that turn on and off power supply to electrical loads based on the driving signals. The drivers are housed in the case. The driving signals are transmitted from the controller to the drivers via serial communication. With this configuration, the number of communication lines and the communication connectors and the size of the electrical circuit device are small with respect to parallel communication. When another driver is added, only software modification of the controller and addition of a serial communication line between the controller and the driver are required. Thus, the electrical circuit device can be easily modified for different models of vehicles. However, in opposition, the use of auxiliary plates is not the focus of the present invention. The present invention aims to protect the arrangement of these plates, offering the best thermal management.

Further, document US 2015/216089 discloses a control circuit with a power module fixed closer to a side wall of the casing than other circuit boards which produce less heat. This document addresses a liquid circulation cooling structure. This structure has several heat generating bodies, which are cooled by the same cooling body (metallic heatsink). However, in opposition, the present application does not require the cooling of different plates, but the thermal management between heat sources and sensitive components.

The present invention is intended to overcome the problems existing in the state of the art by way of an electronic control device whose disposition of its boards enables due compacting as well as efficient thermal dissipation.

More specifically, the present invention presents an electronic control device wherein the thermally most sensitive components are set aside from those components that generate more heat, therefore, the efficiency and reliability of the electronic control device will not be compromised.

Additionally, the electronic control device proposed in the present invention makes use of auxiliary boards associated to a main board, wherein the form of association proposed between the auxiliary boards and the main board boosts the compaction of the electronic control device that is the object of the present invention.

The advantages obtained from the teachings of the present invention will be addressed in detail during the course of the present specification.

OBJECTIVES OF THE INVENTION

The objective of the present invention is to provide an electronic control device of a compressor, wherein the electronic control device is formed by a main electronic board and by at least an auxiliary electronic board.

Another objective of the present invention is to provide an electronic control device whose disposition enables heat-generating elements of the electronic control device to be set aside from the elements sensitive to temperature.

An additional objective of the present invention lies in providing an electronic control device wherein one of its electronic boards is a board that concentrates most of the heat-generating elements, wherein the disposition of the heat-generating board in the electronic control device enables improved dissipation of the heat generated by said board.

It is also an objective of the present invention to provide an electronic control device wherein the heat-generating board is disposed at a first distance in relation to a wall of an encasement, wherein the other auxiliary boards are disposed at a second distance from this same wall, wherein the first distance is less than the second distance.

An additional objective of the present invention lies in providing an electronic control device wherein an operation face of the heat generating board faces (towards) a first wall of the encasement, such that the operation face of the other auxiliary boards faces a second wall of the encasement, such that the first wall is opposite the second wall.

It is also an objective of the present invention to provide an electronic control device endowed with a main board and three auxiliary boards.

Another objective of the present invention is to provide an electronic control device wherein the association of the auxiliary boards to the main board occurs by way of a soldering process.

An additional objective of the present invention consists of providing a compressor and a cooling equipment, the compressor comprising the electronic control device defined in the present invention.

It is a further objective of the present invention to provide a cooling equipment endowed with the electronic control device proposed in the present invention.

BRIEF DESCRIPTION OF THE INVENTION

The objectives of the present invention are achieved by way of an electronic control device of a compressor, the electronic control device disposed in an encasement and comprising a main board associated to at least an auxiliary board, wherein one of the auxiliary boards is a heat generating board, wherein the heat-generating board is disposed at a first distance in relation to a first wall of the encasement, this first wall being related to the upper part of the encasement considering the final position of application of the electronic control device, and the other auxiliary boards are disposed at least at a second distance in relation to the first wall of the encasement, wherein the first distance is less than the second distance.

DETAILED DESCRIPTION OF THE DRAWINGS

The present invention initially describes an electronic control device1, as can be seen fromFIGS.1to5.

In a fully valid embodiment of the present invention, said electronic control device1can be applied to the control of a compressor2, more specifically, the electronic control device1can be used to control the speed of the electric motor of the compressor2.

In any case, it is emphasized that the application of the electronic control device1for the control of a compressor2should not be considered as a limitative characteristic of the present invention, such that the electronic control device1proposed herein could very well be used in various other applications, such as the control of motors in general and integrated controls for compressor and refrigerator.

In a valid embodiment of the present invention and in reference toFIGS.1and2, said electronic control device1is used in the control of a compressor2applied to a cooling equipment, such that cooling equipment is understood to be any refrigerator and/or freezer, be it domestic and/or commercial as well as any air-conditioning equipment, be it domestic, residential, portable, and applied to motor vehicles.

In any case, the application of the teachings of the present invention to a cooling equipment should not be considered as a limitative characteristic of the invention.

For due packaging and protection of the electronic control device1, it is proposed that it be disposed in an encasement3, as represented inFIGS.2and3.

It is emphasized that the illustration of the encasement3in the figures in question should not be considered as a limitative characteristic of the present invention, such that encasement3should be understood to be any element able to offer protection to the electronic control device1, and encasement3can also be understood to be any site for storing the control1, such as a plastic box, metal box, any type of cabinet, the very shell of the compressor, among others.

In this embodiment of the present invention illustrated inFIGS.2and3, the encasement3can be understood as a rectangular box of side walls P1, P2, P3and P4wherein the electronic control device1is disposed in the inner area of said encasement3.

In reference toFIGS.1to4, the present invention proposes that the electronic control device1be formed by an electronic board4(main board4) and by at least an auxiliary board5(auxiliary electronic board5).

In this embodiment of the present invention, it is proposed that three auxiliary boards5,6and7be used, as represented inFIGS.1to4. It is emphasized that the amount of auxiliary boards referred to in the present invention should not be considered as a limitative characteristic of the teachings proposed herein, such that any amount of auxiliary boards could be used.

The auxiliary electronic boards5,6and7can be respectively understood as a first auxiliary board5, a second auxiliary board6and a third auxiliary board7.

It is also understood that the main board4and each one of the auxiliary boards5,6and7comprises an operation face4a,5a,6a,7aand a track face4b,5b,6b,7b.

In specific reference toFIGS.1and3, the operation face4a,5a,6a,7aof the boards in question4,5,6and7should be under stood with the face of the electronic boards wherein most of the electronic components8(capacitors, resistors, diodes, transistors, varistors, among others) are disposed. Most electronic components8should be understood as the face of the boards4,5,6and7which comprises a greater quantity of electronic components when compared to the opposite face of the board in question.

So,FIG.3spotlights the operation face4a,5a,6a,7aof each one of the electronic boards4,5,6and7.

The track face4b,5b,6b,7bshould be understood as the face opposite the operation face4a,5a,6a,7a, so the track face4b,5b,6b,7bcan be understood as the face that comprises most of the conducting tracks of the board. In any case, it is emphasized that the track face4b,5b,6b,7bmay also contain some electronic components8on its surface.

Generally speaking, the operation face4a,5a,6a,7acan be understood as the face preferably used for housing the electronic components8, while the track face4b,5b,6b,7bcan be understood as being the preferred face for disposing the conducting tracks, the track face4b,5b,6b,7bmay also contain electronic components8.

Further and considering that a certain electronic component8is fastened to the main board4by means of a soldering process, the track face4bcan be understood as a face wherein the soldering points are visible.

Generally speaking, the track face should be understood as the face opposite the face that comprises most electronic components8.

In this sense,FIG.3illustrates the track face4b,5b,6b,7bof each one of the electronic boards4,5,6,7which make up the electronic control device1proposed in the present invention.

From the teachings described above, it is understood thatFIG.1respectively allows the visualization of the operation face4a,5aand6aof the main electronic board4and auxiliary boards5and6as well as the visualization of the track face7bof the third auxiliary electronic board7.

An important characteristic of the electronic control device1proposed in the present invention lies in the disposition and arrangement of the main electronic board4in addition to the auxiliary boards5,6, and7. More specifically, it is proposed that each auxiliary board5,6and7as well as the main board4represents a certain operation board of the electronic control device, wherein each operation board will comprise the specific and necessary electronic components for the operation of said board.

Further, and as described in detail ahead, the disposition site and arrangement of the auxiliary boards5,6and7and main board4(and its operation boards) also refer to an important characteristic of the present invention.

The main electronic board4can be understood as a mother board that concentrates all the PTH (pin through holej components of the electronic control device1, that is, those electronic components8whose terminals are inserted into the holes (orifices) of the electronic board4and are then fastened thereto, for example, by means of soldering.

In this embodiment of the present invention, the electronic board4comprises the following electronic components8: connectors, EMC filter, fuse, rectifier diodes, busbar capacitors, cables, jumpers, besides obviously comprising the auxiliary boards5,6and7as well.

So, the main board4can be understood as a fastening board, and this board is responsible for concentrating the PTH components of the electronic control device1, as described previously.

Similarly, the present invention proposes that the first auxiliary electronic board5be configured as a power board, more specifically, the electronic board5can be understood as an SMPS board (switched mode power supply), thus being responsible for providing low-voltage power to the other boards of the product.

Therefore, and in a configuration of the present invention, the auxiliary electronic board5comprises the following electronic components8: integrated SMPS circuit, inductor, voltage regulator, capacitors, diodes, and resistors.

Configuring the first auxiliary board5in a power board, as proposed, it is entirely possible to design various auxiliary boards5with different efficiencies, such that for each type of application desired, an auxiliary board5with the desired efficiency can be used.

So, if there is a need to change the efficiency of the electronic control device1, there is the possibility of replacing just the auxiliary board5, not making any alteration to the main board4or to the other auxiliary boards6and7either.

Similarly to that described above, the second auxiliary board6represents a control board of the electronic control device1. More specifically, the auxiliary board6concentrates the opto-communication couplers, microprocessor, microcontroller and its peripherals.

Therefore, it is possible to design only a new auxiliary board6if it is desirable to alter the microcontroller/microprocessor of the electronic control device1, thus not affecting the other boards of the control1. Similarly, should the need for repair and/or replacement arise, it is possible to substitute only the second board6, which ends up significantly reducing the costs involved.

The third auxiliary board7acts as an inverter board, said board7comprising the electronic keys responsible for driving the electric motor of the compressor2, and also for comprising drivers and peripheral circuits of the electronic control device1.

Therefore, and for effectively concentrating the components necessary for the operation of the electric motor of the compressor2, the inverter board (third board7) is understood to be the one that generates most heat in the electronic control device1. Put otherwise, when compared to the other boards of the electronic control device1(main board4and auxiliary boards5and6), the third auxiliary board7is the one that generates most heat (coming essentially from the operation of the electronic keys), and can thus be understood as a heat-generating board.

Therefore, heat-generating board7should be understood to be the board of the electronic control device1that generates most heat.

Considering the inverter board (third auxiliary board7) as the one that generates most heat in the electronic control device1, the disposition and arrangement of the auxiliary boards5,6and7assumes an important characteristic in the electronic control device1proposed in the pre sent invention.

Specifically, and viewing the best possible thermal performance for the electronic control device1, this embodiment of the present invention proposes that a heat-generating board7be distanced from the other components of the control device1, especially those components most sensitive to temperature. In an embodiment of the present invention, components most sensitive to temperature can be understood as the busbar capacitor80disposed on the main board4, the capacitor80′ disposed on the first auxiliary board5and the microprocessor80″ dis posed on the second auxiliary board6, as represented inFIG.3.

FIGS.2,3and4illustrate a valid arrangement for disposing the electronic control device1considering the teachings of the present invention. It is emphasized that theFIG.2illustrates a valid disposition of the control1in relation to the compressor2, since theFIGS.3and4only illustrate the electronic control device1and considering the arrangement form displayed inFIG.2.

As already described previously, it is proposed that the electronic control device1be disposed in an encasement3, such that said encasement should be associated to the compressor2, according to the illustration inFIG.2. In the embodiment represented in this figure, it is noted that the electronic control device1is disposed next to the compressor2such that the main board4be disposed vertically (with its operation face4atowards the compressor2) in any case, any other disposition arrangement would be fully acceptable.

Providing important thermal advantages for the electronic control device1described in the present invention, it is proposed that the board generating most heat in the control1, that is, the third auxiliary board7be distanced from the other boards of the electronic control device1.

Therefore, the present invention proposes that the heat generating board7be disposed at a first distance D1in relation to the first wall of the encasement P1, reference is made toFIG.4. Therefore, the other auxiliary boards5and6must be respectively disposed at a second D2and third distances D3in relation to the same wall P1.

As illustrated inFIG.4, it is proposed that the first distance D1be less than the second and third distances D2and D3, that is, the heat-generating board7is nearer the first wall P1than the other auxiliary boards5and6.

Another important characteristic of the electronic control device1proposed herein and viewing efficient thermal dissipation of the heat generated chiefly on the third auxiliary board7, it is proposed that the operation face7aof the heat-generating board7faces the first wall of the encasement P1, as represented inFIG.3.

So “to face” means that the operation face7aof the heat generating board7faces towards the first wall P1, as represented inFIGS.3and4.

Similarly, and still in reference toFIGS.3and4, the auxiliary boards5and6should preferably be disposed such that the operation face5a,6aof said boards faces towards the second wall of the encasement P2, wherein the first wall P1is opposite the second wall P2, as represented inFIG.3.

More specifically, and still in reference toFIG.3, it is noted that the operation face of the second auxiliary board6afaces the track face of the first auxiliary board5b, while the track face of the second auxiliary board6bfaces the track face7bof the heat-generating board7.

This form of disposition guarantees that the thermally most sensitive components, such as the busbar electrolyte capacitor80disposed on the main board4, the microprocessor80″ disposed on the auxiliary board6and the electrolyte capacitor80′ disposed on the auxiliary board5will undergo significantly less interference from the heat generated by the third auxiliary board7, thus improving the efficiency and reliability of the electronic control device1.

Further in relation to the disposition and arrangement proposed for the electronic control device1, it is noted that the operation face4aof the main board4faces a third wall P3of the encasement, the third wall P3being adjacent to the first wall P1and the second wall P2, as illustrated inFIGS.3and4. More specifically, and also based on the illustration ofFIG.2, it is noted that the operation face4aof the mother board (main board) faces the side portion of the compressor2.

The disposition of the electronic components8of the mother board on a lateral plane to the body of the compressor, as described above, hinders the thermal exchange with the environment via convection, which ultimately boosts the operation of the electronic control device1, since the main board4is the one that comprises one of the components8most sensitive to temperature (busbar capacitor80).

Therefore, the disposition proposed ends up distancing the heat-generating board7of the thermally most sensitive components and which are disposed on the main board4, in other words, with the arrangement in question the auxiliary boards5and6act as a shield, thus protecting the thermally most sensitive components and which are disposed on the main electronic board4.

Furthermore, the proposal in question of disposition of the heat-generating board7, such that its operation face7afaces the first wall P1ultimately improves the thermal efficiency of the system. In a non-limitative manner, the first wall P1should be understood as the upper wall of the encasement3which stores the electronic control device1, the electronic control device1and the encasement3being mounted in their final use position. This final use position is illustrated inFIG.2.

In this sense, and with a view to further boost the characteristics linked to the thermal dissipation of the electronic control device1, it is proposed that the first wall Pi of the encasement3comprise a heat dissipator10, as represented inFIG.5.

Generally speaking, the heat dissipator10can be under stood as a board made of metal material, such as aluminum, the objective of which is to transfer the heat generated by the third auxiliary board7directly to the environment.

In one configuration, the very wall of the encasement (first wall P1) may configure the heat dissipator10, so it is understood that the very wall P1can be made of metal material, thus acting as the heat dissipator10. In another fully valid configuration, the heat dissipator10can be associated to the first wall P1, and said wall may be made of any material, such as a polymer material.

Furthermore, and in reference toFIG.4, it is proposed that the electronic control device1further comprise a conducting adhesive9associated to the operation face7aof the heat-generating board7, specifically, the conducting adhesive9is responsible for transmitting, by conduction, the heat generated in the components of the auxiliary board7to the heat dissipator10, so subsequently the heat is dissipated to the environment, by convection and irradiation.

It is emphasized that the form and the disposition site of the conducting adhesive9, as represented inFIG.4, should not represent a limitative characteristic of the present invention.

In a non-limitative characteristic of the present invention, it is proposed that the association between the auxiliary boards5,6and7and the main board4occur by way of a soldering process. Preferably, said association occurs by way of a wave soldering process which results in an electronic control device1endowed with sufficient mechanical stress and vibration.

In any case, it is emphasized that in the use of the soldering process, the wave should not be considered as a limitation of the pre sent invention, to the extent that other forms of association would be fully acceptable, such as the use of selective soldering or soldering by robot.

So what is proposed here is an electronic control device1wherein the auxiliary boards5,6and7are disposed concurrently to the main electronic board4, that is, it is understood that the plans defined by each one of the auxiliary boards5,6and7are concurrent to the plane defined by the main board4, as represented inFIGS.1to4.

In a non-limitative characteristic of the present invention, and as represented inFIGS.1to4, the auxiliary boards5,6and7are disposed perpendicularly to the main board4, in any case, it is under lined that other forms of disposition would be acceptable, such as the disposition of at least one of the boards5,6and7slantedly in relation to the main board4.

In another valid configuration, at least one of the auxiliary boards5,6and7could be disposed perpendicularly in relation to the main board4, such that the other boards of the electronic control device could be disposed slantedly in relation to the board4.

Furthermore, the disposition of the auxiliary boards5,6and7in parallel to each other should not represent a limitation of the present invention either.

So, what is proposed is an electronic control device1with efficient operation and excellent thermal and electromagnetic characteristics, also being compact, able to be disposed in an encasement3with dimensions preferably in the range of 120 (L)×90 (A)×45 (P) mm.

Further, and without entailing limitations to the teachings of the present invention, it is proposed that the main board4be configured as a single layer board and as daughter boards5,6and7be con figured as dual layer boards, that is, boards that enable the disposition of electronic components on the two faces of the board. It is under lined that this characteristic does not refer to a limitation of the present invention.

The present invention further proposes a compressor2used in a cooling equipment, wherein the compressor2comprises an electronic control device1as previously described.

Lastly, a cooling equipment is further proposed, endowed with an electronic control device1as proposed in the present invention.

Having described an example of a preferred embodiment, it should be understood that the scope of the present invention encompasses other possible variations, being limited solely by the content of the accompanying claims, potential equivalents being included therein.