Integrated module of multi-way interleaved PFC and power supply and air conditioner

Abstract

The present invention discloses an integrated module of a multi-channel interleaved PFC, a power supply and an air conditioner, wherein the integrated module of the multi-channel interleaved PFC comprises a rectifier module, a PFC module, an inverter module, a parameter sampling module and a control module, wherein the parameter sampling module is used to collect parameters of the PFC module and the inverter module, and the control module controls the operation of the PFC module and the inverter module according to the collected parameters; the present invention has a highly integrated intelligent power module with complete functions and reduces the area of ​​a power board. Compared with a non-integrated power board, the board area is reduced by 10%, miniaturization is achieved, the control effect is significantly improved, and the cost is reduced by 20%.

Description

Technical Field

[0001] The invention relates to a power supply control circuit, in particular to an integrated module of a multi-path interleaved PFC, a power supply and an air conditioner. Background Art

[0002] The currently commonly used single-phase interleaved power factor correction circuit (Power Factor Correction, referred to as PFC) uses a symmetrical boost circuit to perform calculations by detecting the current of two IGBTs or other power devices or the total current. Since the PFC inductance is not completely consistent during the design process of the circuit and related components, it may cause current imbalance, which will eventually cause the IGBT of a certain circuit to share too much current. When the current error reaches a certain level, it may burn the corresponding power device, causing the entire PFC circuit to fail as a whole, and even cause damage to other devices of the unit, causing safety hazards.

[0003] At present, in the three-phase PFC circuit, IPM (Intelligent Power Module) is a key power device. In the actual operation process, the control part is controlled by MCU software. One or more IGBT failures cause system operation abnormalities. How to accurately detect the status of each IGBT inside the IPM, reduce the greater system failures caused by IPM defects, and reduce the overall loss of the system is an important research topic. However, in the existing control technology, there is no active detection technology for abnormal defects in a bridge arm inside the IPM, and it is impossible to effectively protect the power device in a timely and targeted manner before the power device is damaged, which in turn causes an increase in the equipment failure rate.

[0004] In view of the current national development concept of green environmental protection and energy saving, as well as the need for export certification requirements, both household appliances and commercial frequency conversion equipment must be mandatory to meet the relevant EMC (Electro Magnetic Compatibility, electromagnetic compatibility) standards, and power devices such as IGBT and IPM are the main sources of interference in EMC difficulties. In addition, more and more products are currently using frequency conversion motors to achieve more complex functions, such as fresh air air conditioners, clean air conditioners, washing machines, refrigerators, etc. In actual applications, the fully automatic frequency conversion drive system is usually composed of multiple modules with different functions, usually including PFC, drive circuits and IPM, etc. The independent design of each module makes the overall control board and electronic control larger in size, which is not conducive to improving the integration, miniaturization, and intelligent development.

[0005] Currently, power devices are assembled and locked with corresponding screws. However, in some after-sales processing, when used by non-professionals, or when the torque of the tools used is too large, abnormal transportation will cause damage to the packaging and internal devices of the IGBT or IPM, which will seriously shorten the service life of the power device and even cause unit abnormalities.

[0006] In response to the above problems, how to reduce the interference frequency amplitude of power devices, solve the current imbalance of digital power factor correction (PFC) circuit, and the problem of power device wave loss in software control circuit, especially in terms of harmonic control such as EMC, which may seriously lead to overall circuit failure and poor circuit reliability, and optimize the problems of excessive assembly torque of power devices and device abnormality caused by violent transportation.

[0007] Based on this, how to design a highly integrated intelligent power module and electronic device solution that supports analog controlled multi-way interleaved PFC, effectively solve the above problems and realize a highly intelligent and miniaturized solution, is a technical problem that the industry urgently needs to solve. Summary of the invention

[0008] In order to solve the defects of incomplete protection and large size in the prior art, the present invention proposes an integrated module of multi-path interleaved PFC, a power supply and an air conditioner.

[0009] The technical solution adopted by the present invention is to design an integrated module of multi-channel interleaved PFC, including a rectifier module, a PFC module, an inverter module, a parameter sampling module and a control module, wherein the parameter sampling module is used to collect parameters of the PFC module and the inverter module, and the control module controls the operation of the PFC module and the inverter module according to the collected parameters.

[0010] The parameter sampling module includes a PFC sampling circuit for sampling the PFC module and an IPM sampling circuit for sampling the inverter module.

[0011] The PFC sampling circuit includes a temperature sampling circuit, a current sampling circuit, an input voltage sampling circuit, and an output voltage sampling circuit.

[0012] The IPM sampling circuit includes a current monitoring circuit and a temperature sampling circuit.

[0013] The parameter sampling module also includes a phase loss detection module for detecting whether there is a phase loss on the input side of the rectifier module.

[0014] The parameter sampling module also includes a pressure acquisition circuit for detecting whether the installation force of the integrated module is appropriate.

[0015] The parameter sampling module also includes a fault detection module.

[0016] The inverter module also includes a dead time setting circuit.

[0017] The integrated module of the multi-path interleaved PFC also includes a shell, and the rectifier module, PFC module, inverter module, parameter sampling module, and control module are installed in the shell, and an AC input port, a DC output port, and an external inductor port are arranged on the shell; the rectifier module is connected to external AC power through the AC input port, the PFC module is connected to an external PFC inductor through the external inductor port, and the inverter module is connected to an external load through the DC output port.

[0018] The present invention also provides a power supply, which includes the integrated module of the multi-path interleaved PFC.

[0019] The present invention also provides an air conditioner, which comprises the power supply.

[0020] The above embodiments are for illustration only and are not intended to be limiting. Any equivalent modifications or changes made thereto without departing from the spirit and scope of the present application shall be included in the scope of the claims of the present application.

[0021] The beneficial effects of the technical solution provided by the present invention are:

[0022] 1. The module integrates an analog sampling circuit to control the feedback signal, which solves the circuit failure and power device damage caused by current imbalance due to device consistency, sampling signal transmission or processing interference during two-way or multi-way interleaved PFC software control;

[0023] 2. The module is equipped with an integrated fault monitoring chip, which can monitor the abnormal points of each power device and provide pre-protection, effectively reducing the failure rate of IGBT or IPM.

[0024] 3. Highly integrate the PFC module, rectifier module and inverter module to simplify the layout of the drive circuit, reduce the crosstalk effect of signal transmission, and improve EMC performance;

[0025] 4. Integrated pressure sensor to identify whether the installation torque of the intelligent power module is normal, improving the reliability of the unit or other electronic equipment;

[0026] The highly integrated intelligent power module of the present invention has complete functions and reduces the area of ​​the power board. Compared with the non-integrated power board, the board area is reduced by 10%, miniaturization is achieved, the control effect is significantly improved, and the cost is reduced by 20%. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] The present invention is described in detail below with reference to the embodiments and accompanying drawings, wherein:

[0028] Figure 1 This is a schematic diagram of the main power circuit of a preferred embodiment;

[0029] Figure 2 It is a schematic diagram of the integrated module of a preferred embodiment;

[0030] Figure 3 is a schematic diagram of a parameter sampling module of a preferred embodiment;

[0031] Figure 4 This is a schematic diagram of pressure detection in a preferred embodiment;

[0032] Figure 5 This is a circuit diagram of the inverter module dead time setting in a preferred embodiment. DETAILED DESCRIPTION

[0033] In order to make the purpose, technical solution and advantages of the present invention more clearly understood, the present invention is further described in detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0034] The present invention discloses an integrated module of a multi-path interleaved PFC, comprising a rectifier module, a PFC module, an inverter module, a parameter sampling module and a control module, wherein the parameter sampling module is used to collect parameters of the PFC module and the inverter module, and the control module controls the operation of the PFC module and the inverter module according to the collected parameters.

[0035] See also Figure 1 The schematic diagram of the interleaved PFC main power circuit is shown. The AC power input signal passes through the rectifier module, the external PFC inductor, the PFC module and the inverter module, which can simplify the layout of strong and weak currents in the drive circuit, reduce the crosstalk effect of signal transmission, and improve EMC performance.

[0036] See also Figure 2The present invention integrates a rectifier module, a PFC module, an inverter module, a parameter sampling module and a control module, and has the following functions: 1. It solves the circuit failure and power device damage caused by the current imbalance problem caused by the interference of the sampling signal transmission and processing process due to the consistency of the device during the two-way or multi-way interleaved PFC software control process. 2. It solves the problem that each power unit inside the integrated power device IPM / IGBT module cannot actively monitor faults and perform pre-protection, which can effectively reduce the failure rate of IGBT or IPM. 3. It solves the problem that the separate design of the PFC module and the inverter module in the design of the PFC circuit makes the layout of the drive circuit difficult and the crosstalk of the signal transmission is affected, thereby reducing the risk of EMC. 4. It solves the problem that the unit uses an intelligent power module with no obvious damage due to abnormal torque or transportation, resulting in poor reliability of the unit or other electronic equipment.

[0037] In a preferred embodiment, the parameter sampling module includes a PFC sampling circuit for sampling the PFC module and an IPM sampling circuit for sampling the inverter module.

[0038] See also Figure 3 The PFC sampling circuit includes a temperature sampling circuit, a current sampling circuit, an input voltage sampling circuit, and an output voltage sampling circuit. The controller controls the interleaved PFC according to the current, input voltage, and output voltage signals sampled by the PFC sampling circuit to solve the circuit failure and power device damage caused by the current imbalance problem caused by the device consistency, the interference of the sampling signal transmission and processing process in the two-way or multi-way interleaved PFC software control process.

[0039] See also Figure 3 The IPM sampling circuit includes a current monitoring circuit and a temperature sampling circuit. The controller implements driving over / under voltage protection and dead zone protection according to the signal sampled by the IPM sampling circuit.

[0040] The parameter sampling module also includes a phase loss detection module for detecting whether the input side of the rectifier module is phase-lost. The phase loss detection circuit collects the input side AC signal, and if a phase loss signal is identified, controls the IPM inverter input to stop working and protect the drive circuit.

[0041] The inverter module also includes a dead time setting circuit. Figure 5Setting: IPM inverter control input is effective at low level. When the DSP output signal controls the OR gate pin 1 at high level, the logic OR gate outputs high level, and the IPM inverter input is locked; when the DSP output signal is low level, the high-frequency ceramic capacitor C discharges through the resistor R, the logic gate input pin 2 is still high level, the logic OR gate outputs high level, and the IPM inverter output is locked; when the high-frequency ceramic capacitor C is discharged, the logic OR gate input pin 2 becomes low level, the logic output is low level, and the IPM input control is effective. Therefore, the capacitor discharge time is the effective delay time from the DSP control output to the IPM. The IPM delay time can be set by setting the size of R and C to ensure that the upper and lower bridge arms of the IPM will not be turned on at the same time.

[0042] The parameter sampling module also includes a pressure acquisition circuit to detect whether the installation force of the integrated module is appropriate. The intelligent power module integrates a pressure sensor to identify whether the screws are properly tightened during IPM installation, whether the torque of the screws is too large or too small, and collects the signal to control whether the chip starts working, thereby improving the reliability of the unit or other electronic equipment. The pressure acquisition process is as follows Figure 4 As shown. S1 detects whether the screws of the inverter module are installed. If the screws are not installed, go to step S2, otherwise go to step S4; S2 The controller controls the red light to flash once every second; S3 The operator installs the screws according to the prompt, and then goes to step S4; S4 detects whether the screw installation torque is too large. If the installation torque is not large, go to step S5, and if the installation torque is large, go to step S8; S5 detects whether the screw installation torque is too small. If the installation torque is too small, go to step S6, and if the installation torque is not small, go to step S7; S6 The operator increases the screw to increase the installation torque, and then go to step S4; S7 The detection is completed, and the IPM chip can work normally; S8 The controller controls the red light to flash twice every second; S9 The operator reduces the screw installation torque according to the prompt, and then goes to step S4.

[0043] The parameter sampling module also includes a fault detection module. The integrated power device IPM / IGBT module has an integrated fault monitoring chip, which can monitor the abnormal points of each power device and perform pre-protection, effectively reducing the failure rate of IGBT or IPM.

[0044] The integrated module of the multi-path interleaved PFC also includes a shell, and the rectifier module, PFC module, inverter module, parameter sampling module, and control module are installed in the shell, and an AC input port, a DC output port, and an external inductor port are arranged on the shell; the rectifier module is connected to external AC power through the AC input port, the PFC module is connected to an external PFC inductor through the external inductor port, and the inverter module is connected to an external load through the DC output port.

[0045] The present invention also discloses a power supply, which comprises the integrated module of the multi-path interleaved PFC.

[0046] The invention also discloses an air conditioner, which comprises the power supply.

[0047] The above embodiments are for illustration only and are not intended to be limiting. Any equivalent modifications or changes made thereto without departing from the spirit and scope of the present application shall be included in the scope of the claims of the present application.

Claims

1. An integrated module of multi-channel interleaved PFC, comprising a rectifier module, a PFC module, and an inverter module, characterized in that: It also includes a parameter sampling module and a control module, wherein the parameter sampling module is used to collect parameters of the PFC module and the inverter module, and the control module controls the operation of the PFC module and the inverter module according to the collected parameters; The rectifier module, PFC module, inverter module, parameter sampling module and control module are integrated together; The parameter sampling module includes a pressure acquisition circuit for detecting whether the installation force of the integrated module of the multi-channel interleaved PFC is appropriate. The working process of the pressure acquisition circuit includes: Step S1: Check whether the screws of the inverter module are installed. If the screws are not installed, go to step S2, otherwise go to step S4; The S2 controller controls the red light to flash once every second; S3: The operator installs the screws according to the prompts, and then goes to step S4; S4 detects whether the screw installation torque is too large. If the installation torque is not large, go to step S5; if the installation torque is large, go to step S8; S5 detects whether the screw installation torque is too small. If the installation torque is too small, go to step S6; if the installation torque is not small, go to step S7; S6 The operator increases the screw to increase the installation torque, and then goes to step S4; S7 detection is completed, and the IPM chip can work normally; The S8 controller controls the red light to flash twice every second; S9: The operator reduces the screw installation torque according to the prompt, and then goes to step S4.

2. The integrated module of multi-way interleaved PFC according to claim 1, characterized in that: The parameter sampling module includes a PFC sampling circuit for sampling the PFC module and an IPM sampling circuit for sampling the inverter module.

3. The integrated module of multi-way interleaved PFC as claimed in claim 2, characterized in that: The PFC sampling circuit includes a temperature sampling circuit, a current sampling circuit, an input voltage sampling circuit, and an output voltage sampling circuit.

4. The integrated module of multi-way interleaved PFC as claimed in claim 3, characterized in that: The IPM sampling circuit includes a current monitoring circuit and a temperature sampling circuit.

5. The integrated module of multi-way interleaved PFC as claimed in claim 4, characterized in that: The parameter sampling module also includes a phase loss detection module for detecting whether there is a phase loss on the input side of the rectifier module.

6. The integrated module of multi-way interleaved PFC as claimed in claim 5, characterized in that: The parameter sampling module also includes a pressure acquisition circuit for detecting whether the installation force of the integrated module is appropriate.

7. The integrated module of multi-channel interleaved PFC according to claim 6, characterized in that: The parameter sampling module also includes a fault detection module.

8. The integrated module of multi-channel interleaved PFC according to claim 1, characterized in that: The inverter module also includes a dead time setting circuit.

9. The integrated module of multi-way interleaved PFC according to any one of claims 1 to 8, characterized in that: The integrated module of the multi-path interleaved PFC also includes a shell, and the rectifier module, PFC module, inverter module, parameter sampling module, and control module are installed in the shell, and an AC input port, a DC output port, and an external inductor port are arranged on the shell; the rectifier module is connected to external AC power through the AC input port, the PFC module is connected to an external PFC inductor through the external inductor port, and the inverter module is connected to an external load through the DC output port.

10. A power supply, characterized in that: The power supply comprises an integrated module of the multi-way interleaved PFC according to any one of claims 1 to 9.

11. An air conditioner, characterized in that: The air conditioner comprises the power supply according to claim 10.

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