High-power inverter and control method thereof

Abstract

The invention discloses a high-power inverter and a control method thereof, and belongs to the technical field of power electronics, the high-power inverter comprises a sensing enhanced magnetic assembly, the sensing enhanced magnetic assembly comprises a high-thermal-conductivity metal shell, a magnetic core arranged in the high-thermal-conductivity metal shell, a main power coil, a high-precision sensing coil and an integrated thermal probe; wherein the high-precision sensing coil is wound by clinging to a central column of the magnetic core, the main power coil is coaxially wound on the outer side of the high-precision sensing coil, and the magnetic core, the main power coil and the high-precision sensing coil jointly form an inductor core body. According to the invention, the controller can monitor the working point of the magnetic core on the magnetization curve in real time, so that the margin of the magnetic core away from the magnetic saturation state is directly judged.

Description

Technical Field

[0001] The present invention relates to the field of power electronics, and in particular to a high-power inverter and a control method thereof. Background Art

[0002] In existing high-power inverter technology, the core magnetic components are typically viewed as integrated functional modules. This design approach makes it impossible to directly and in real time obtain the critical physical states within the components during inverter operation, particularly the flux state within the magnetic core and the internal hotspot temperature generated by power loss.

[0003] This limitation forces the inverter control system to rely on externally measurable electrical parameters, such as input or output current and voltage, to indirectly estimate the internal state of the magnetic components. This estimation method has inherent uncertainty and delay, so to ensure operational safety, the control strategy must adopt a conservative design margin. As a result, the performance and reliability improvements of high-power inverters in practical applications are limited, making it difficult to achieve their optimal operating potential under complex or dynamically changing operating conditions.

[0004] The above information disclosed in this Background section is only for enhancement of understanding of the background of the present disclosure and therefore it may contain information that does not form the prior art that is already known to a person of ordinary skill in the art. Summary of the Invention

[0005] The object of the present invention is to provide a high-power inverter and a control method thereof to solve the problems raised in the above background technology.

[0006] The technical solution of the present invention is a high-power inverter and a control method thereof, including a perception-enhanced magnetic component, the perception-enhanced magnetic component including a high-thermal conductivity metal shell, a magnetic core arranged inside the high-thermal conductivity metal shell, a main power coil, a high-precision sensing coil and an integrated thermal probe; wherein the high-precision sensing coil is wound closely around the central column of the magnetic core, the main power coil is coaxially wound on the outside of the high-precision sensing coil, and the magnetic core, the main power coil and the high-precision sensing coil together constitute an inductor core body; the inductor core body is encapsulated inside the high-thermal conductivity metal shell; the integrated thermal probe is fixed to a preset monitoring point of the high-thermal conductivity metal shell to obtain the shell temperature of the high-thermal conductivity metal shell.

[0007] Preferably, a mounting surface is provided on the high thermal conductivity metal shell, and the mounting surface is used to be fitted and connected to an external liquid-cooled heat sink to form a main heat dissipation channel.

[0008] Preferably, the integrated thermal probe is a high-precision platinum resistance temperature sensor encapsulated at the end of a blind hole in the side wall of the high thermal conductivity metal shell.

[0009] Preferably, the gap inside the high thermal conductivity metal shell is filled with high thermal conductivity insulating glue, which is used to conduct the heat generated by the inductor core to the high thermal conductivity metal shell.

[0010] A control method for a high-power inverter comprises: obtaining an internal state feature list, the internal state feature list being collected by a controller, the list including an induced voltage signal from a high-precision sensing coil and a shell temperature signal from an integrated thermal probe; based on the induced voltage signal, the controller is used to reconstruct real-time magnetic state parameters and determine a magnetic saturation margin according to the real-time magnetic state parameters; based on the real-time magnetic state parameters and a real-time main current, the controller is used to calculate a heat source power; and in combination with the shell temperature signal as a boundary condition, the controller obtains a corrected internal hotspot temperature by solving a preset thermodynamic model; the controller is used to compare the real-time magnetic state parameters and the corrected internal hotspot temperature with a preset safety threshold list in real time, and dynamically adjust inverter operating parameters according to the comparison results.

[0011] Preferably, the controller is used to convert the induced voltage signal into a magnetic flux change rate, and then set the real-time magnetic state parameter to an instantaneous magnetic flux density that characterizes the internal state of the magnetic core by performing time accumulation calculation on the magnetic flux change rate.

[0012] Preferably, the preset thermodynamic model includes a steady-state thermal resistance network model and a transient thermal impedance model; the controller is used to fuse the reference hotspot temperature calculated by the steady-state thermal resistance network model with the transient thermal shock temperature rise compensation value calculated by the transient thermal impedance model, thereby setting the corrected internal hotspot temperature to the sum of the reference hotspot temperature and the transient thermal shock temperature rise compensation value.

[0013] Preferably, when the real-time magnetic state parameter approaches the magnetic saturation limit, the controller is used to adjust the inverter operating parameters to the optimized switching frequency or modulation strategy; when the corrected internal hotspot temperature approaches the upper limit of the material operating temperature, the controller is used to adjust the inverter operating parameters to the reduced switching frequency or the reduced current pulse peak.

[0014] Preferably, it also includes: the controller is used to record the temperature decay curve of the corrected internal hot spot temperature under a standard load sequence, and extract its time constant as a heat dissipation performance benchmark; during long-term operation of the inverter, the controller is used to calculate the deviation between the temperature decay time under the current operating conditions and the heat dissipation performance benchmark to generate a health status index; when the health status index is lower than a preset maintenance threshold, the controller issues a predictive maintenance alarm.

[0015] The present invention provides a high-power inverter and a control method thereof through improvements, which have the following improvements and advantages compared with the prior art:

[0016] 1. A high-precision sensing coil is wound closely against the magnetic core. Based on the law of electromagnetic induction, the controller accurately converts the induced voltage signal output by this coil into the instantaneous magnetic flux density, a key physical quantity that characterizes the core's operating state, by accumulating it over time. This enables the controller to monitor the core's operating point on the magnetization curve in real time, thereby directly determining its margin to magnetic saturation. This judgment method, based on direct internal induction, is far more direct and reliable than traditional methods that rely on external current inference.

[0017] 2. An integrated thermal probe is set up to obtain the shell temperature of the high thermal conductivity metal shell, which serves as an accurate and dynamic boundary condition for the thermodynamic model. At the same time, the controller combines the reconstructed real-time magnetic state parameters and the real-time main current to calculate the total heat source power. This calculation includes the core loss caused by the change in magnetic state, so it is more comprehensive than the traditional method of only calculating the copper loss of the coil. Based on this heat source power and shell temperature boundary condition, the controller solves the corrected internal hot spot temperature through a preset thermodynamic model that includes a steady-state thermal resistance network model and a transient thermal impedance model. This temperature value reflects the average temperature rise under continuous load and compensates for the transient temperature spikes under pulse load, thereby achieving accurate estimation of the most critical temperature point inside the component.

[0018] 3. When the controller determines that the real-time magnetic state parameters are approaching the magnetic saturation limit, it does not passively wait for the overcurrent protection to shut down, but instead proactively adjusts the inverter operating parameters to the optimized switching frequency or modulation strategy. This can actively change the volt-second product applied to the magnetic component, thereby pulling the operating point of the magnetic core back to the safe linear region without interrupting operation, significantly enhancing the system stability of the inverter when subjected to load shocks. When the controller determines that the corrected internal hotspot temperature is close to the upper operating temperature limit of the material, it will adopt a targeted cooling strategy. For example, for the overall temperature rise caused by continuous overload, the controller can adjust the inverter operating parameters to a reduced switching frequency to reduce the total power loss; for temperature spikes caused by transient large current pulses, the operating parameters can be adjusted to moderately reduce the peak value of subsequent current pulses. This refined adjustment method can effectively alleviate internal thermal stress at a relatively low performance cost, helping to extend the service life of the components. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] The present invention will be further explained below in conjunction with the accompanying drawings and Examples:

[0020] Figure 1 It is a structural diagram of the inverter body;

[0021] Figure 2 It is a schematic diagram of the structure of a high thermal conductivity metal shell;

[0022] Figure 3 It is a schematic diagram of the overall connection structure of the magnetic core;

[0023] Figure 4 It is a schematic diagram of the structure of the main power coil and high-precision sensing coil;

[0024] In the figure: 100, sensing-enhanced magnetic component; 110, high thermal conductivity metal housing; 120, magnetic core; 130, main power coil; 140, high-precision sensing coil; 150, integrated thermal probe. DETAILED DESCRIPTION

[0025] In order to make the objectives, technical solutions and advantages of the present invention more clearly understood, the present invention is further described in detail below with reference to specific embodiments.

[0026] Example 1

[0027] See also Figures 1 to 4The present invention provides a high-power inverter, including a sensing-enhanced magnetic component 100, which includes a high-thermal-conductivity metal shell 110, a magnetic core 120 disposed inside the high-thermal-conductivity metal shell 110, a main power coil 130, a high-precision sensing coil 140, and an integrated thermal probe 150; wherein the high-precision sensing coil 140 is wound closely around the central column of the magnetic core 120, and the main power coil 130 is coaxially wound around the outside of the high-precision sensing coil 140, and the magnetic core 120, the main power coil 130, and the high-precision sensing coil 140 together constitute an inductor core body; the inductor core body is encapsulated inside the high-thermal-conductivity metal shell 110; the integrated thermal probe 150 is fixed to a preset monitoring point of the high-thermal-conductivity metal shell 110 for obtaining the shell temperature of the high-thermal-conductivity metal shell 110.

[0028] The high-power inverter in the prior art usually regards its core magnetic component as an integral module, and cannot directly know its internal magnetic flux state and hot spot temperature during operation, which results in the control strategy can only be estimated and conservatively designed based on external electrical parameters, limiting the further improvement of the inverter performance and reliability; the present high-power inverter changes this situation by setting a perception-enhanced magnetic component 100; the structural design of the perception-enhanced magnetic component 100 is intended to provide the inverter control system with an auxiliary signal that directly reflects the internal physical state of the component, and the high-precision sensing coil 140 is closely attached to the magnetic core 120 and is covered by the main power coil 130 in a coaxial layout, so that it can sensitively sense the changes in the magnetic flux inside the magnetic core 120, providing a physical basis for the subsequent magnetic state reconstruction; at the same time, the integrated thermal probe 150 is arranged in a high thermal conductivity metal shell. The specific monitoring point 110, the position of which is predetermined based on the analysis of the heat conduction path of the component, so that the shell temperature measured by it can effectively reflect the heat dissipation from the internal heat source to the outside; the principle of selecting this monitoring point is to be on the main heat dissipation path and to avoid direct interference from the external ambient temperature to the greatest extent. For example, the shell position can be selected close to the inductor core body and in a close contact area with the external liquid-cooled heat sink, so as to ensure that the measured temperature can stably and sensitively reflect the heat conducted from the internal heat source to the main heat dissipation channel; this structural combination makes it possible to correlate and infer the internal magnetic and thermal states that were originally not directly measurable through external measurable electrical signals and temperature signals, creating conditions for accurate observation and adaptive control of the internal state of the inverter, and helping to improve the operating stability and service life of the inverter under complex working conditions.

[0029] The high thermal conductivity metal housing 110 is provided with a mounting surface, which is used to be bonded and connected to an external liquid cooling heat sink to form a main heat dissipation channel.

[0030] The purpose of setting up the mounting surface is to establish a stable and efficient heat dissipation path for the sensor-enhanced magnetic component 100; as long as any structure can ensure a tight fit with low thermal resistance between the high thermal conductivity metal shell 110 and the external heat dissipation facility, it falls within the scope of protection of the present invention; for example, the mounting surface can be a flat surface that has been precisely milled, fastened to the external liquid-cooled heat sink by an additional bolt, and coated with thermal grease between the contact surfaces; alternatively, the mounting surface can also be designed as a structure with specific grooves or protrusions, forming an embedded fit with the corresponding structure on the external heat sink to increase the contact area; the connection between the mounting surface and the external liquid-cooled heat sink together constitutes the main heat dissipation channel, which enables the heat generated inside the component to be quickly discharged; this not only ensures the thermal stability of the inverter operating at high power density, but also provides reliable boundary conditions for the accuracy of the subsequent thermodynamic model, because the clear and efficient heat dissipation channel makes the heat transfer process more stable and predictable.

[0031] The integrated thermal probe 150 is a high-precision platinum resistance temperature sensor encapsulated at the end of a blind hole in the side wall of the high thermal conductivity metal housing 110 .

[0032] The specific structure of the integrated thermal probe 150 is intended to obtain accurate and representative shell temperature data; the integrated thermal probe 150 is concretized as a high-precision platinum resistance temperature sensor, such as a PT100 sensor, encapsulated at the end of a blind hole in the side wall of the high-thermal-conductivity metal shell 110, achieving this goal through a reliable engineering practice; the drilling depth of the blind hole is calculated to ensure that the temperature-sensing end of the sensor can be close to the critical path for internal heat conduction to the shell, while not damaging the sealing of the shell; the sensor is tightly attached to the bottom of the blind hole by thermal conductive adhesive, further reducing the contact thermal resistance; this setting enables the integrated thermal probe 150 to sensitively capture temperature changes transmitted from internal hot spots to the shell, and the temperature data it outputs has high fidelity, providing accurate and dynamically changing boundary conditions for the thermodynamic model, which is the basis for achieving accurate inversion calculation of internal hot spot temperatures.

[0033] The gap inside the high thermal conductivity metal housing 110 is filled with high thermal conductivity insulating glue for transferring heat generated by the inductor core to the high thermal conductivity metal housing 110 .

[0034] The high thermal conductivity metal shell 110 is filled with high thermal conductivity insulating glue in order to optimize the heat conduction path between the inductor core and the shell. During the assembly process, air gaps are inevitably present between the inductor core and the high thermal conductivity metal shell 110. The thermal conductivity of air is very low, which seriously hinders the transfer of heat. By filling the high thermal conductivity insulating glue by vacuum infusion, these air gaps can be completely eliminated, forming a continuous, low thermal resistance heat conducting medium from the main power coil 130 and the magnetic core 120 to the high thermal conductivity metal shell 110. This ensures that the heat generated by the inductor core can be efficiently and evenly transferred to the shell, which not only improves the heat dissipation capacity of the entire component, but also enables the temperature measured by the integrated thermal probe 150 on the shell to respond more realistically and quickly to changes in the internal heat source, thereby improving the accuracy of thermal state observation.

[0035] Example 2

[0036] A control method for a high-power inverter includes: obtaining an internal state feature list, the internal state feature list being collected by a controller, the list including an induced voltage signal from a high-precision sensing coil 140 and a shell temperature signal from an integrated thermal probe 150; based on the induced voltage signal, the controller is used to reconstruct real-time magnetic state parameters and determine a magnetic saturation margin based on the real-time magnetic state parameters; based on the real-time magnetic state parameters and the real-time main current, the controller is used to calculate a heat source power; and in combination with the shell temperature signal as a boundary condition, the controller obtains a corrected internal hotspot temperature by solving a preset thermodynamic model; the controller is used to compare the real-time magnetic state parameters and the corrected internal hotspot temperature with a preset safety threshold list in real time, and dynamically adjust inverter operating parameters based on the comparison results.

[0037] The core purpose of this control method is to use the signals provided by the perception-enhanced magnetic component 100 to achieve deep perception and active adjustment of the inverter's internal state. The list of internal state features obtained by the controller is the data foundation for achieving this goal. The controller reconstructs real-time magnetic state parameters based on the induced voltage signal. This process enables the controller to monitor the operating point of the magnetic core 120 in real time and determine its margin to magnetic saturation, thereby foreseeing potential risk of loss of control. At the same time, the controller calculates the heat source power based on the known real-time magnetic state parameters and the collected real-time main current. The real-time main current is usually measured in real time by a Hall effect current sensor or shunt resistor set in the inverter's main circuit. This method is more accurate than simply relying on current to calculate copper loss because it takes into account the loss of the magnetic core 120 caused by changes in the magnetic state. Then, using the calculated heat source power as input and the shell temperature signal as the boundary condition, the controller solves the corrected internal hot spot temperature through a preset thermodynamic model, obtaining an estimate of the most critical temperature point within the component. The controller continuously compares these two reconstructed internal parameters—the real-time magnetic state parameter and the corrected internal hotspot temperature—with preset safety thresholds and dynamically adjusts the inverter operating parameters based on the comparison results. This series of operations transforms inverter control from passive protection to active management. While ensuring safety, it can adjust the operating strategy based on the actual internal margin, helping to strike a balance between performance and reliability under different operating conditions.

[0038] The controller is used to convert the induced voltage signal into a magnetic flux change rate, and then set the real-time magnetic state parameter to the instantaneous magnetic flux density that characterizes the internal state of the magnetic core 120 by performing time accumulation calculation on the magnetic flux change rate.

[0039] The specific calculation process for setting the real-time magnetic state parameters is aimed at extracting more physically meaningful magnetic field information from the original induced voltage signal. After the controller collects the induced voltage signal output by the high-precision sensing coil 140, according to the law of electromagnetic induction, the voltage value is proportional to the rate of change of the magnetic flux passing through the coil. Therefore, the controller directly converts the induced voltage signal into the rate of change of the magnetic flux of the magnetic core 120 through a preset proportional coefficient. The controller accumulates and calculates this rate of change signal over time, i.e., numerically integrates it. The result of this accumulation is the instantaneous magnetic flux density inside the magnetic core 120. The real-time magnetic state parameter is set to the instantaneous magnetic flux density because the magnetic flux density is the most core physical quantity that describes the working state of the magnetic material. It directly corresponds to the working point on the material's magnetization curve, allowing the controller to accurately determine whether the magnetic core 120 is close to saturation. The basis for this judgment is more direct and reliable than inferring only from the external current.

[0040] The controller performs this calculation based on Faraday's law of electromagnetic induction; the induced voltage of the coil is sensed with high precision. and the magnetic flux in the core The relationship is: ;

[0041] in, is the number of turns of the high-precision sensing coil, which is a known constant; : Indicates the instantaneous induced voltage of the high-precision sensing coil, which is the time function; : Voltage symbol; subscript : Refers to perception; : Indicates that over time change; : The sign of the number of turns;

[0042] Therefore, the rate of change of magnetic flux can be directly derived from the induced voltage: ;

[0043] in, : differential symbol; :Over time Changing magnetic flux;

[0044] The controller reconstructs the instantaneous magnetic flux by performing discrete time integration and time accumulation calculation on the rate of change of magnetic flux. : ;

[0045] in, : Indicates that at the current discrete time point Magnetic flux; : the sign of magnetic flux; : represents the current discrete time step; : Indicates the previous discrete time point Magnetic flux; : Indicates that at the current discrete time point The induced voltage; : Indicates the sampling time interval of the controller;

[0046] Real-time magnetic state parameters, i.e. instantaneous magnetic flux density , by dividing the magnetic flux by the effective cross-sectional area of ​​the core get: ;

[0047] in, is the instantaneous magnetic flux density at the current moment, is the current discrete time point The magnetic flux, is the effective cross-sectional area of ​​the core, which is a known design parameter. Through this method, the controller can accurately obtain the instantaneous magnetic flux density that characterizes the internal state of the core.

[0048] The preset thermodynamic model includes a steady-state thermal resistance network model and a transient thermal impedance model; the controller is used to fuse the reference hotspot temperature obtained by solving the steady-state thermal resistance network model with the transient thermal shock temperature rise compensation value obtained by solving the transient thermal impedance model, thereby setting the corrected internal hotspot temperature to the sum of the reference hotspot temperature and the transient thermal shock temperature rise compensation value.

[0049] The calculation method for the corrected internal hotspot temperature is set to fully and accurately reflect the thermal effects caused by different load characteristics inside the component. The preset thermodynamic model consists of two parts, each of which responds to different thermal dynamic processes. The steady-state thermal resistance network model is established based on the macroscopic structure of the component, and the component is equivalent to a thermal resistance network composed of several key nodes. By solving this network, a baseline hotspot temperature that reflects the overall temperature rise distribution of the component under continuous load can be obtained. When the inverter is subjected to a high-dynamic pulse load, the heat will be concentrated at the heat source in a short period of time and will not have time to be transferred to the outer casing, forming a transient temperature spike, which cannot be captured by the steady-state model. The transient thermal impedance model is introduced. This model establishes the relationship between the pulse power characteristics and the transient temperature rise through offline calibration. The controller calls this model to calculate a transient thermal shock temperature rise compensation value based on the real-time load characteristics. The controller adds this compensation value to the baseline hotspot temperature to obtain a corrected internal hotspot temperature, which not only includes the average temperature rise information of the component, but also superimposes the transient temperature peak information that has a significant impact on the device life, thereby providing the controller with a more complete view of the internal thermal state.

[0050] The preset thermodynamic model is specified as follows:

[0051] Steady-state thermal resistance network model: This model simplifies the component into a node network. For example, it can contain three nodes: heat source node, shell node, and ambient node; the thermal resistance between each node, such as represents the thermal resistance from the heat source node to the shell node, Indicates the thermal resistance from the shell node to the ambient node, which is predetermined by experimental calibration or finite element simulation; the reference hot spot temperature The calculation formula is: ;

[0052] in, is the real-time shell temperature measured by the integrated thermal probe 150, is the total heat source power calculated above. The subscripts of the parameters have the following meanings: Refers to the heat source node, which is the point with the highest temperature inside the component; Refers to a metal housing with high thermal conductivity; refers to the baseline value; therefore, represents the reference hot spot temperature, represents the thermal resistance from the heat source node to the shell node;

[0053] Transient thermal impedance model: This model usually uses a function composed of a multi-order RC network, a Foster network or a Kaul network. To express it, this function describes the change of hot spot temperature rise with time after applying unit power pulse; transient thermal shock temperature rise compensation value The controller obtains the corrected internal hotspot temperature by convolving the real-time power pulse with the transient thermal impedance model. The controller combines the calculated transient thermal shock temperature rise compensation value with the reference hotspot temperature to obtain the corrected internal hotspot temperature. : ;

[0054] When the real-time magnetic state parameters approach the magnetic saturation limit, the controller is used to adjust the inverter operating parameters to the optimized switching frequency or modulation strategy; when the corrected internal hotspot temperature approaches the upper limit of the material operating temperature, the controller is used to adjust the inverter operating parameters to a reduced switching frequency or a reduced current pulse peak.

[0055] The specific strategy for adjusting the inverter operating parameters is intended to take targeted preventive measures based on different internal state risks. When the controller determines that the real-time magnetic state parameters are approaching the magnetic saturation limit, for example, when the load current suddenly increases, it will actively adjust the inverter operating parameters, such as appropriately increasing the switching frequency or changing the modulation waveform, so as to actively change the volt-second product applied to the magnetic component. For example, the controller can switch from conventional sinusoidal pulse width modulation to space vector pulse width modulation, or actively insert a specific zero vector action time into the existing modulation strategy. These adjustments can effectively reduce the volt-second product applied to the magnetic core during each switching cycle without significantly affecting the output performance, thereby pulling the magnetic core back to the safe operating zone. In this way, the operating point of the magnetic core 120 is pulled back to the linear zone without triggering the overcurrent protection shutdown, thereby ensuring the system stability of the inverter when it is subjected to load shocks. On the other hand, when the controller determines that the corrected internal hot spot temperature is close to the upper limit of the material's allowable operating temperature, it will perform graded adjustment based on the temperature rise characteristics. If the overall temperature rise is caused by continuous overload, the controller may choose to adjust the inverter operating parameters to a lower switching frequency to reduce core 120 losses and switching losses. If the temperature spike is caused by transient pulse current, the controller may choose to adjust the inverter operating parameters to moderately reduce the subsequent current pulse peak value. This refined adjustment can alleviate internal magnetic stress and thermal stress at a relatively low performance cost, helping to extend the service life of the components.

[0056] It also includes: the controller is used to record the temperature decay curve of the corrected internal hot spot temperature under a standard load sequence, and extract its time constant as a heat dissipation performance benchmark; during long-term operation of the inverter, the controller is used to calculate the deviation between the temperature decay time under the current operating conditions and the heat dissipation performance benchmark to generate a health status index; when the health status index is lower than the preset maintenance threshold, the controller issues a predictive maintenance alarm.

[0057] Generate a health status index and issue an alarm, the purpose of which is to achieve long-term tracking and predictive maintenance of the health status of the perception-enhanced magnetic component 100; the controller needs to apply a standard load sequence in the initial state of the component or under controlled conditions. The standard load sequence can be a preset program, for example, first let the inverter run at rated power for a period of time sufficient to allow the component temperature to reach a steady state, such as 30 minutes, and then immediately remove the load completely to enter the no-load or standby state, and then record the temperature decay curve of the corrected internal hot spot temperature during the natural cooling process after the load is removed, and calculate and store a time constant from the curve, which is the heat dissipation performance benchmark, representing the component The controller measures the heat dissipation capacity of the component in a healthy state. During the inverter's subsequent long-term operation, the controller uses periods of equipment downtime or low load to monitor similar cooling processes and calculate the current temperature decay time. By comparing the current decay time with the heat dissipation performance benchmark, the degree of aging of the heat dissipation path can be quantified. For example, cracking of the thermal adhesive or loose contact surfaces can lead to slower heat dissipation and longer decay times. The controller converts this deviation into a health status index. When this index drops below a preset maintenance threshold due to component aging, the controller issues a predictive maintenance alert. This prompts management personnel to inspect or replace components before serious failure occurs, reducing losses caused by unplanned downtime.

[0058] The algorithm for generating the health status index is as follows:

[0059] In order to quantify the health status, the following parameters are defined: It is the heat dissipation performance benchmark, i.e. the temperature decay time constant of the component measured by a standard load sequence in its initial state; is the current temperature decay time constant monitored during the long-term operation of the inverter; the health status index can be quantified as a percentage: ;

[0060] in, : represents the health status index;

[0061] Ideally, , When the heat dissipation path ages, such as the thermal adhesive drying up or the contact surface loosening, resulting in poor heat dissipation, will increase, leading to The preset maintenance threshold can be set to, for example, 70%. When it falls below this value, the controller issues a predictive maintenance alert.

[0062] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solutions of the present invention may be modified or replaced by equivalents without departing from the spirit and scope of the technical solutions of the present invention, which should all be included in the scope of the claims of the present invention.

Claims

1. A high power inverter, characterized in that: The invention comprises a perception-enhanced magnetic component (100), wherein the perception-enhanced magnetic component (100) comprises a high thermal conductivity metal shell (110), a magnetic core (120) arranged inside the high thermal conductivity metal shell (110), a main power coil (130), a high-precision perception coil (140) and an integrated thermal probe (150); wherein the high-precision perception coil (140) is wound closely to the central column of the magnetic core (120), the main power coil (130) is coaxially wound on the outside of the high-precision perception coil (140), and the magnetic core (120), the main power coil (130) and the high-precision perception coil (140) together constitute an inductor core body; the inductor core body is encapsulated inside the high thermal conductivity metal shell (110); and the integrated thermal probe (150) is fixed to a preset monitoring point of the high thermal conductivity metal shell (110) and is used to obtain the shell temperature of the high thermal conductivity metal shell (110).

2. The high power inverter according to claim 1, characterized in that: The high thermal conductivity metal shell (110) is provided with a mounting surface, and the mounting surface is used for being fitted and connected with an external liquid cooling heat sink to form a main heat dissipation channel.

3. The high power inverter according to claim 1, characterized in that: The integrated thermal probe (150) is a high-precision platinum resistance temperature sensor encapsulated at the end of a blind hole on the side wall of the high-thermal-conductivity metal housing (110).

4. The high power inverter according to claim 1, characterized in that: The gap inside the high thermal conductivity metal shell (110) is filled with high thermal conductivity insulating glue, which is used to conduct heat generated by the inductor core to the high thermal conductivity metal shell (110).

5. A control method for a high power inverter, applied to the high power inverter according to any one of claims 1 to 4, characterized in that: include: An internal state feature list is obtained, the internal state feature list being collected by a controller, the list including an induced voltage signal from the high-precision sensing coil (140) and a shell temperature signal from the integrated thermal probe (150); based on the induced voltage signal, the controller is used to reconstruct real-time magnetic state parameters and determine magnetic saturation margin based on the real-time magnetic state parameters; based on the real-time magnetic state parameters and the real-time main current, the controller is used to calculate heat source power; and in combination with the shell temperature signal as a boundary condition, the controller obtains a corrected internal hotspot temperature by solving a preset thermodynamic model; the controller is used to compare the real-time magnetic state parameters and the corrected internal hotspot temperature with a preset safety threshold list in real time, and dynamically adjust inverter operating parameters according to the comparison result.

6. The control method of a high power inverter according to claim 5, characterized in that: The controller is used to convert the induced voltage signal into a magnetic flux change rate, and then perform a time accumulation calculation on the magnetic flux change rate, thereby setting the real-time magnetic state parameter to an instantaneous magnetic flux density representing the internal state of the magnetic core (120).

7. The control method of a high power inverter according to claim 5, characterized in that: The preset thermodynamic model includes a steady-state thermal resistance network model and a transient thermal impedance model; the controller is used to fuse the reference hotspot temperature obtained by solving the steady-state thermal resistance network model with the transient thermal shock temperature rise compensation value obtained by solving the transient thermal impedance model, thereby setting the corrected internal hotspot temperature to the sum of the reference hotspot temperature and the transient thermal shock temperature rise compensation value.

8. The control method of a high power inverter according to claim 5, characterized in that: When the real-time magnetic state parameter approaches the magnetic saturation limit, the controller is used to adjust the inverter operating parameters to the optimized switching frequency or modulation strategy; when the corrected internal hotspot temperature approaches the upper limit of the material operating temperature, the controller is used to adjust the inverter operating parameters to the reduced switching frequency or the reduced current pulse peak.

9. The control method of a high power inverter according to claim 5, characterized in that: Also includes: The controller is used to record the temperature decay curve of the corrected internal hotspot temperature under a standard load sequence and extract its time constant as a heat dissipation performance benchmark; during long-term operation of the inverter, the controller is used to calculate the deviation between the temperature decay time under the current operating conditions and the heat dissipation performance benchmark to generate a health status index; when the health status index is lower than a preset maintenance threshold, the controller issues a predictive maintenance alarm.

Images