Abstract:
A power processing module for supplying power to a motion control device from a power source such as a utility power line, and related method of operation, are disclosed. The power processing module includes a first power input terminal, a first power output terminal, branch circuit protection circuitry coupled at least indirectly between the first power input terminal and the first power output terminal, and at least one bus bar coupling at least two of the first power input terminal, the first power output terminal, and the branch circuit protection circuitry.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
     FIELD OF THE INVENTION  
       [0001]     The present invention relates to motion control systems and, in particular, relates to systems for delivering power to motion control systems and related systems.  
       BACKGROUND OF THE INVENTION  
       [0002]     Motion control systems such as those employed in industrial environments typically require power from one or more power sources, in the form of primary and/or auxiliary power. Not uncommonly, different types or levels of power (e.g., DC or AC power), or powers having multiple different characteristics (e.g., different voltage levels, current levels, etc.) are required.  
         [0003]     Typically, the power that is provided to the motion control systems is received from one or more power lines (e.g., a utility grid) and then converted into the desired forms of power. However, in certain embodiments, power can be received from power sources other than power lines, such as local power generation sources (e.g., local generators or batteries).  
         [0004]     To provide the required forms of primary and/or auxiliary power to the motion control systems based upon the received power, many different front-end circuit components are often required. These front-end circuit components not only can provide power conversion, but also can serve other purposes as well, for example, circuit protection to protect against power spikes. For example, the National Electric Code requires that branch circuit protection be provided in connection with the delivery of power to motor controllers/motor drivers.  
         [0005]     Among the many different circuit components that can be utilized in any given system are power conversion components, switching components such as contactors, protective components such as circuit breakers and fuses, filtering components and even additional power sources. Traditionally, these circuit components have been implemented on an “ad hoc” basis when motion control systems are installed.  
         [0006]     The complexity, cost and inefficiency associated with identifying, purchasing and installing such front end components on such an ad hoc basis can be high. In particular, the installation, including wiring together, of circuit components can be difficult and costly. Further, the implementation of circuit components in this manner can result in the consumption of excessive panel space along or nearby the motion control systems. Indeed, because motor controllers/motor drivers often require high levels of power and current, the wiring used to connect the front end components must often be thick and consequently further increases the overall size of the assembly of front end components (for example, 3 gauge wire has an 8 inch bend radius).  
         [0007]     Therefore, it would be advantageous if there was available to customers an improved mechanism or manner of implementing the power-related functionality traditionally provided by such ad hoc agglomerations of front-end circuit components. In particular, it would be advantageous if such an improved mechanism or manner of implementing such functionality was less costly and complicated to implement than existing ad hoc circuit implementations, and took up less panel space along/nearby the motion control systems.  
       BRIEF SUMMARY OF THE INVENTION  
       [0008]     The present inventors have recognized that some or all of the front-end circuit components traditionally implemented in such an ad hoc manner in relation to motion control systems could instead be assembled into a single, standardized, and compact front-end power processing module. Further, the present inventors have recognized that such front-end circuit components implemented into such a module could in certain embodiments include a variety of components including circuit breakers and fuses, filtering components, and power conversion devices, for example.  
         [0009]     Additionally, the present inventors have recognized that certain of the components incorporated into the power processing module can be compactly assembled, despite the fact that high-levels of power/current may be communicated among those components, by utilizing bus bars rather than wires to connect those components. Among the components that can be compactly assembled through the use of bus bars, in at least some embodiments, are branch circuit protection circuit components.  
         [0010]     In particular, the present invention relates to a power processing module for supplying power to a motion control device. The power processing module includes a first power input terminal, a first power output terminal, branch circuit protection circuitry coupled at least indirectly between the first power input terminal and the first power output terminal, and at least one bus bar coupling at least two of the first power input terminal, the first power output terminal, and the branch circuit protection circuitry.  
         [0011]     Further, the present invention relates to a method of providing power to a motion control device. The method includes providing a power processing device having a first power input terminal, a first power output terminal, branch circuit protection circuitry coupled at least indirectly between the first power input terminal and the first power output terminal, and at least one bus bar coupling at least two of the first power input terminal, the first power output terminal, and the branch circuit protection circuitry. The method additionally includes substantially enclosing the power processing device within a housing, and coupling the power output terminal of the power processing device to an input terminal of the motion control device.  
         [0012]     Additionally, the present invention relates to a three-phase power processing device. The power processing device includes first, second and third power input terminals, and first, second and third power output terminals. The power processing device further includes first, second and third bus bars coupling the first, second and third power input terminals to first, second and third input ports of a component including a branch circuit protection device, respectively. The power processing device additionally includes fourth, fifth and sixth bus bars coupling first, second and third output ports of the component to the first, second and third power output terminals, respectively. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0013]      FIG. 1  is a schematic showing electronic components of a first exemplary embodiment of a power processing module;  
         [0014]      FIG. 2  is a perspective view of the power processing module of  FIG. 1 ;  
         [0015]      FIG. 3  is an exploded, perspective view of the power processing module of  FIG. 2 ;  
         [0016]      FIG. 4  is a schematic showing electronic components of a second exemplary embodiment of a power processing module, in contrast to that of  FIG. 1 ; and  
         [0017]      FIG. 5  is a schematic showing electronic components of a third exemplary embodiment of a power processing module, in contrast to that of  FIGS. 1 and 4 .  
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0018]     Referring to  FIG. 1 , electronic components of a first exemplary embodiment of a power processing module or device  10  in accordance with one embodiment of the present invention are shown. The power processing device  10  is designed to allow for conversion of power from, in this embodiment, line power (e.g., from a utility) into power having appropriate level(s) and characteristic(s) for use by a motion control system such as a motor controller or motor driver (not shown), and thus the power processing device in the present embodiment can also be termed a “line interface module”.  
         [0019]     Depending upon the embodiment, the power processing device  10  can also provide power to other portions of a motion control system besides (or instead of) a motion controller/driver, for example, components such as programmable logic controllers (PLCs) or other devices that are commonly mounted on panels along with motion controllers/drivers. To the extent the claims set forth below refer to a “motion control device”, this term is intended to encompass not merely a motor controller or motor driver, but rather is intended to encompass more broadly any one or more of the aforementioned devices or components that can be implemented in relation to a motion control system and/or related panel.  
         [0020]     As shown, the power processing device  10  includes a power input terminal  12  that, in the present embodiment, is configured to be connected to a power line (e.g., from a utility) to receive line power. Additionally, the power processing device has first, second, third, fourth and fifth power output terminals  14 ,  16 ,  18 ,  20  and  22 , respectively. The power processing device  10  allows for, therefore, output power of five different types (or otherwise having different characteristics) to be generated based upon the single type of power received at the power input terminal  12 .  
         [0021]     Further as shown in  FIG. 1 , the first power output terminal  14  provides high-voltage (e.g., either 230 or 460V), high-current (e.g., up to 75 A) power, and thus is a high-power output. This would typically be the primary high-power output of the power processing device  10 , and be applicable, for example, toward providing power to a servo drive that will then drive a motor or the like. As shown, in order to provide this high-power at the power output terminal  14 , input power from the power input terminal  12  is first provided through a circuit breaker  24  and then communicated further through a contactor  26 , before then being communicated to the first power output terminal  14 . The circuit breaker  24  can be a high-current (e.g., 125 A), 3-phase thermal and magnetic molded case circuit breaker such as the 140U-H6C3-D12-D circuit breaker available from Rockwell Automation of Milwaukee, Wis., the beneficial assignee of the present application. The contactor  26  can be also a high-current (e.g., 85 A), 3-phase contactor with auxiliary control. In certain embodiments, the contactor  26  could have one normally closed contact and four normally open contacts. The molded case circuit breaker  24  in certain embodiments is designed to provide branch circuit protection that would satisfy National Electric Code requirements for certain motor controllers/motor drivers.  
         [0022]     Initially as shown in  FIG. 1 , the second power output terminal  16  provides non-filtered control power while the third power output terminal  18  provides filtered control power. Each of these power output terminals  16  and  18  is provided with its power from the power input terminal  12  by way of a fuse block  28  and a circuit breaker  30  that are coupled in series between the power input terminal and each of the power output terminals. Additionally, between the circuit breaker  30  and the third power output terminal  18  (but not between the circuit breaker  30  and the second power output terminal  16 ) is a filter  32 , such that the power at the third power output terminal is filtered. In the embodiment shown, the power provided at the second and third power output terminals  16 ,  18  is high-voltage power (e.g., 230V) but is of moderate current. In particular, the fuse block  28  limits current to a low or moderate level (e.g., to 3.5 A) and in the present embodiment is a 1492-FB2C30-L fuse block available from Rockwell Automation. The circuit breaker  30  in the present embodiment is a 1492-SP2D040 circuit breaker also available from Rockwell Automation, which is a 4 A, two pole, 20 KA-interrupt-rated circuit breaker. The filter  32  in the present embodiment is a single-phase, one-stage line filter rated at 230 VAC.  
         [0023]     As shown, the circuit breaker  30  is also coupled to the coil of contactor  26  via a changeover contact in the present embodiment. This ensures that a secondary control device must be operational for the contactor to engage. Although not shown, the circuit breaker  30  more particularly is mechanically linked to an auxiliary contact (e.g., a 1492-ASPH3 auxiliary contact available from Rockwell Automation), which in turn is wired to the input of the actuating coil of the contactor  26 . If the circuit breaker  30  is tripped, the auxiliary contact will disengage the signal to the contactor, the contactor coil will de-energize and the contactor will open, cutting high current power. This ensures that the main power to a drive/motor is removed when the motion control system loses control power.  
         [0024]     Still referring to  FIG. 1 , the fourth power output terminal  20  provides low voltage (e.g., 24V) filtered power. This power is provided from the power input terminal  12  by way of an additional circuit breaker  34 , followed by an additional filter  36 , followed by a power converter  38  and a filter  40 . In the embodiment shown, the power output at the fourth output terminal  20  is DC power. The DC power is generated from the AC line power received at the power input terminal  12  by way of the power converter  38 , which is an AC to DC power converter or rectifier. In the embodiment shown, the power converter  38  specifically can be a 24V rated power supply that converts 460V (or in alternate embodiments  230 V or  120 V) AC power into 224V DC power, such as the 1606-XL480EP power supply available from Rockwell Automation. With respect to the other components  34 ,  36  and  40 , the circuit breaker  34  in the present embodiment is a 16 A general purpose circuit breaker having a 10 KA-interrupt-rating, such as the 1492-SP2C160 circuit breaker available from Rockwell Automation. The filter  36  in the present embodiment, which is positioned between the circuit breaker  34  and the power converter  38 , is a 3-phase, 1-stage line filter (in this case rated at 460 VAC). As for the other filter  40 , that filter in the present embodiment is a 24V low pass filter.  
         [0025]     Finally, additionally as shown in  FIG. 1 , the fifth power output terminal  22  is an interface signal power terminal having first and second sets of pins  42  and  44 , respectively. The first set of pins  42  receives signals from the auxiliary contacts of the contactor  26 , providing status of the contactor to the motion system through three normally open contacts and one normally closed contacts. These auxiliary contacts are mechanically linked to the main contacts of the contactor  26 . The second set of pins  44  is coupled to a junction  46  between the power converter  38  and the filter  40 , and consequently outputs DC power from the power converter  38 .  
         [0026]     Turning to  FIGS. 2 and 3 , perspective views of the power processing device  10  when fully-assembled and disassembled (exploded) are shown. In particular, the power input terminal  12  is shown to extend out of a top surface  48  of a housing  50  of the power processing device  10 . The power input terminal  12  is coupled to the circuit breaker  24  by way of a first set of three bus bars  52 . The first power output terminal  14  is coupled to the contactor  26  by a second set of three bus bars  54 . Further, the circuit breaker  24  is coupled to the contactor  26  by a third set of three bus bars  56 . The first, second and third sets of three bus bars  52 ,  54  and  56  can also be termed line bus bars, load bus bars and jumper bus bars, respectively. Through the use of the bus bars, instead of wires, the compactness of the power processing device  10  is enhanced insofar as the bus bars can make sharp turns (e.g., 90 degree turns) that would not be possible if wire of the appropriate gauge was used. Insofar as the bus bars in the present embodiment are used to connect the power input terminal  12  to the first power output terminal  14  by way of the circuit breaker  24  and contactor  26 , the bus bars in particular facilitate the branch circuit protection afforded by the circuit breaker  24 .  
         [0027]     Other components of the power processing device  10  are further evident from  FIGS. 2 and 3 . In particular, the fuse block  28 , circuit breaker  30 , filter  32 , circuit breaker  34 , filter  36 , power converter  38  and filter  40 , as well as the second, third, fourth and fifth power output terminals  16 ,  18 ,  20  and  22  respectively are all shown in one or both of  FIGS. 2 and 3 . The fifth power output terminal  22  in particular is mounted on a circuit board  23  that also supports the filter  40 . Additionally as shown, all of these components are compactly fit within the housing  50 , and front and rear panels  58  and  60  are assembled onto the housing to complete the overall device  10 . Assembled to the rear panel  60  is a bracket  61  that extends perpendicularly from the rear panel. An input power circuit board  62  on which is mounted the power input terminal  12  is fastened to, and supported by, the bracket  61 .  
         [0028]     The bracket  61  includes orifices  63  for the power input terminal  12  and the first power output terminal  14 , the top surface  48  of the housing  50  also includes orifices  64  for the second, third and fourth power output terminals  16 ,  18  and  20 . The front panel  58  includes additional orifices  66  and  68  to allow for user access to the circuit breaker  24  and to an assembly  69  of the circuit breaker  34 , fuse block  28  and circuit breaker  30 . Also, the front panel  58  includes an access door  70  allowing access to the fifth power output terminal  22 . The rear panel  60  includes mounting orifices  72  by which the power processing device  10  when assembled can be mounted to a panel or other structural component(s) associated with or nearby motion control devices (not shown).  
         [0029]     Turning to  FIGS. 4 and 5 , two alternate embodiments  80 ,  90  of power processing devices that differ in certain regards from the power processing device  10  are shown. The power processing device  80  shown in  FIG. 4  in particular differs from the power processing device  10  in that it has not only a first or primary power input terminal  12  but also an auxiliary power input terminal  82 . While the primary power input terminal  12  remains connected to the circuit breaker  24 , as in the case of the power processing device  10 , it is the auxiliary power input terminal  82  that is coupled to the fuse block  28  and to the circuit breaker  34 . As for the power processing device  90  shown in  FIG. 5 , that power processing device is the same as that shown in  FIG. 1  except insofar as it includes an additional voltage step-down (or step-up) device  92  that converts 460V power from the fuse block  28  into 230V power before it is provided to the circuit breaker  30 . Otherwise the power processing devices  80 ,  90  are identical to the power processing device  10 .  
         [0030]     At the same time, depending upon the embodiment, the particular components that are used as the fuse block  28 , circuit breakers  24 ,  30 , contactor  26  and other components of these power processing devices  10 ,  80  and  90  can vary considerably in their particular identifies. For example, while in the discussion concerning  FIG. 1 , the fuse block  28  was specified to be a 1492-FB2C30-L fuse block having a 3.5 A fuse, in alternate embodiments, fuse blocks having  15 A or  8 A fuses could be used. Also for example, while the earlier discussion concerning the circuit breaker  30  indicated that it is a 1492-SP2D040 circuit breaker, the circuit breaker also could be a 1492-SP2D060 circuit breaker or a 1492-SP2D130 circuit breaker. Further, while the contactor  26  in  FIG. 1  was indicated to be a 100S-C85KL14C contactor, in alternate embodiments it also could be 100S-C85KD14C contactor. Further, the circuit breaker  34 , which was indicated previously to be a 1492-SP2C160 circuit breaker could also be a 1492-SP3C060 circuit breaker and the power converter  38 , which was previously indicated to be a 1606-XL480EP 20 A power supply, could also be a 1606-XL480E-3W 20 A power supply. Additionally, in further alternate embodiments still other components could be utilized. Thus, the present invention is intended to encompass a variety of embodiments of power processing devices employing any of a variety of different components and component types, and the present invention is not intended to be limited to any particular one or more of the embodiments specifically shown in the figures and/or discussed herein.  
         [0031]     It is specifically intended that the present invention not be limited to the embodiments and illustrations contained herein, but that modified forms of those embodiments including portions of the embodiments and combinations of elements of different embodiments also be included as come within the scope of the following claims.