High-power igbt driving adaptive closed-loop control method and system

Abstract

This invention discloses an adaptive closed-loop control method and system for high-power IGBT drive. The control method includes: acquiring and processing the voltage and current output by the IGBT power module to generate a first feedback signal; acquiring and processing the collector-emitter voltage of the IGBT power module to generate a second feedback signal; and comprehensively processing all feedback signals, including the first and second feedback signals, to selectively send a corresponding first or second modulation drive signal to the IGBT drive module. The first modulation drive signal includes a PWM wave in its current state or a PWM wave with adjusted rise and fall times, and the second modulation drive signal includes a PFM wave. According to the above control method, the safety and service life of the IGBT power module can be effectively improved, and the IGBT power module can be adapted to more application scenarios, further improving its utilization rate, reducing equipment manufacturing costs, and the hardware structure is simpler and more adaptable to different scenarios.

Description

Technical Field

[0001] This invention relates to the field of high-power IGBT drive control technology, and in particular to a high-power IGBT drive adaptive closed-loop control method and system. Background Technology

[0002] Inverters are key components in electrical energy conversion, especially in clean energy generation, where high-power inverters are needed to convert other forms of energy, such as wind and solar power, into electrical energy. The application of IGBT power modules, a crucial component in inverters, is an important factor in determining the stability of equipment performance.

[0003] The operation of the IGBT power module needs to be controlled by the IGBT driver module to improve the stability and efficiency of the IGBT power module. However, existing IGBT driver waveform control strategies generally have the following shortcomings:

[0004] 1. Most existing inverters only use PI loop control to regulate the IGBT device drive waveform, such as voltage and current. The loop reference factor is singular, which cannot further free up the space for IGBT devices.

[0005] 2. Currently, the driving waveforms of IGBTs in inverters are driven by multi-sampling pulse width modulation (PWM) or pulse frequency modulation (PFM), and the adjustment method is fixed, which limits the efficiency of IGBT devices.

[0006] 3. Currently, the driving waveform of IGBTs is mostly adjusted by step switching to regulate the rising and falling edges of the driving waveform, resulting in complex driving circuits or poor adaptability. Summary of the Invention

[0007] The purpose of this invention is to provide a high-power IGBT drive adaptive closed-loop control method and system that can formulate different modulation drive strategies based on various factor parameters that reflect the working state of the IGBT power module to achieve hybrid modulation and reduce hardware complexity, thereby solving the above-mentioned technical problems.

[0008] To achieve the above objectives, this invention discloses a high-power IGBT driver adaptive closed-loop control method for performing closed-loop control on an IGBT driver module that drives the IGBT power module. The control method includes:

[0009] The voltage and current output by the IGBT power module are collected and processed to generate a first feedback signal;

[0010] The collector-emitter voltage of the IGBT power module is acquired and processed to generate a second feedback signal;

[0011] All feedback signals, including the first feedback signal and the second feedback signal, are processed in a comprehensive manner to selectively send a corresponding first modulation drive signal or a second modulation drive signal to the IGBT drive module. The first modulation drive signal includes a PWM wave in the current state or a PWM wave with adjusted rise and fall times. The second modulation drive signal includes a PFM wave.

[0012] Preferably, during the operation of the IGBT power module, the GE voltage of the IGBT power module is also acquired and processed in real time to generate a third feedback signal.

[0013] Preferably, during the operation of the IGBT power module, the temperature inside the IGBT power module is also collected and processed in real time to generate a fourth feedback signal.

[0014] Preferably, when the IGBT power module is in an abnormal state, a corresponding first modulation drive signal is sent to the IGBT drive module, and it is determined whether the duration of the first modulation drive signal exceeds a preset value. If so, the sending of the first modulation drive signal is stopped, and the second modulation drive signal is sent.

[0015] Preferably, a data processing controller and a programmable logic controller (PLC) electrically connected to the data processing controller are provided. The PLC is electrically connected to the IGBT drive module. The data processing controller processes each feedback signal, including the first feedback signal and the second feedback signal, and generates the PWM wave, PFM wave, and control signal for the PLC. The PLC processes the rise and fall times of the PWM wave according to the control signal.

[0016] Preferably, the IGBT drive module includes a drive circuit, a transformer isolation circuit, and a filter circuit connected in sequence. The input terminal of the drive circuit is electrically connected to the programmable logic controller, and the output terminal of the filter circuit is electrically connected to the control terminal of the IGBT power module.

[0017] The present invention also discloses a high-power IGBT drive adaptive closed-loop control system, which includes a data processing controller, a programmable logic controller, a first feedback network, a second feedback network, and an IGBT drive module.

[0018] The data processing controller is electrically connected to the IGBT drive module through the programmable logic controller, and the IGBT drive module is electrically connected to the IGBT power module;

[0019] The first feedback network is used to collect and process the voltage and current output by the IGBT power module to generate a first feedback signal provided to the data processing controller;

[0020] The second feedback network is used to acquire and process the CE voltage of the IGBT power module to generate a second feedback signal for the data processing controller.

[0021] The data processing controller is used to output a drive modulation wave and a control signal to the programmable logic controller based on the comprehensive feedback of the various received feedback signals. The drive modulation wave can switch between PWM wave and PFM wave.

[0022] The programmable logic controller is used to change the rise and fall times of the PWM wave according to the control signal.

[0023] Preferably, it also includes a third feedback network, which is used to acquire and process the GE voltage of the IGBT power module to generate a third feedback signal provided to the data processing controller.

[0024] Preferably, it also includes a fourth feedback network, which is used to acquire and process the temperature within the IGBT power module to generate a fourth feedback signal provided to the data processing controller.

[0025] Preferably, when the IGBT power module is in an abnormal state, the data processing controller outputs a PWM wave and issues a control signal that causes the programmable logic controller to process the rise and fall times of the PWM wave to adjust the operating state of the IGBT power module. If the adjustment time of the IGBT power module is greater than a preset value, the data processing controller outputs a PFM wave and stops issuing the control signal.

[0026] Preferably, the IGBT drive module includes a drive circuit, a transformer isolation circuit, and a filter circuit connected in sequence. The input terminal of the drive circuit is electrically connected to the programmable logic controller, and the output terminal of the filter circuit is electrically connected to the control terminal of the IGBT power module.

[0027] Compared with existing technologies, the high-power IGBT drive adaptive closed-loop control method and system of the present invention have the following beneficial technical effects:

[0028] 1. For the closed-loop control of IGBT power modules, the control strategy is formulated by comprehensively considering the influence of various feedback signals on the IGBT power modules, thereby effectively improving the safety and service life of the IGBT power modules;

[0029] 2. The drive signal can switch between PWM and PFM waves according to the current situation, thereby realizing hybrid modulation of the IGBT power module, making the IGBT power module adaptable to more application scenarios, further improving its utilization rate, and reducing equipment manufacturing costs.

[0030] 3. The rise and fall times of the PWM wave are processed by software. Compared with the existing technology that adjusts the rise and fall times of the PWM wave by selecting different drive resistors or adding different levels of power supply to adjust the rise and fall times, the hardware structure is simpler and more adaptable to different scenarios. Attached Figure Description

[0031] Figure 1 This is a schematic diagram of the adaptive closed-loop control signal flow for high-power IGBT driving in an embodiment of the present invention.

[0032] Figure 2 This is a structural block diagram of the high-power IGBT drive adaptive closed-loop control system in an embodiment of the present invention.

[0033] Figure 3 This is a schematic diagram of the working process of the high-power IGBT drive adaptive closed-loop control system in an embodiment of the present invention. Detailed Implementation

[0034] To illustrate the technical content, structural features, objectives, and effects of the present invention in detail, the following description is provided in conjunction with the embodiments and accompanying drawings.

[0035] like Figure 1 and Figure 2 This embodiment discloses a high-power IGBT drive adaptive closed-loop control method for performing closed-loop control on the IGBT drive module 11 that drives the IGBT power module 10, thereby adaptively adjusting the operating state of the IGBT power module 10 according to the current state, improving the safety and multi-scenario adaptability of the IGBT power module 10. The control method includes the following steps:

[0036] The voltage and current output by the IGBT power module 10 are collected and processed to generate the first feedback signal F1;

[0037] The collector-emitter voltage of the IGBT power module 10 is collected and processed to generate a second feedback signal F2;

[0038] All feedback signals, including the first feedback signal F1 and the second feedback signal F2, are processed in a comprehensive manner to selectively send a corresponding first modulation drive signal or a second modulation drive signal to the IGBT drive module 11. The first modulation drive signal includes a PWM wave in the current state or a PWM wave with adjusted rise and fall times. The second modulation drive signal includes a PFM wave.

[0039] Specifically, taking the IGBT power module 10 that outputs three-phase AC power as an example, during operation, the three-phase voltage and three-phase current output by the IGBT power module 10 are collected in real time, and after Parker transformation (DQ transformation for short), the output sampling voltage Vout_s and the output sampling current Iout_s are obtained. Then, the output sampling voltage Vout_s is sent to the PI controller, which compares the output sampling voltage Vout_s with the given reference output voltage Vref_out, and outputs the reference output current Iref after passing through the PI loop. Then, the output sampling current Iout_s is sent to the PI controller again, which compares the output sampling current Iout_s with the reference output current Iref, and generates the first feedback signal F1 through the PI loop. The first feedback signal F1 forms the driving waveform (PWM wave) of the IGBT power module 10, thereby realizing the closed-loop control strategy of voltage outer loop control and current inner loop control.

[0040] During the operation of the IGBT power module 10, the CE voltage of the IGBT power module 10 is simultaneously acquired as the CE sampling voltage Vce_s, and this CE sampling voltage Vce_s is sent to the PI controller. It is compared with a given reference CE voltage Vref_ce, and the comparison result is passed through the PI loop to obtain the second feedback signal F2. Based on the second feedback signal F2, a PWM wave or a PFM wave can be selected for output. When outputting a PWM wave, the rise and fall times of the PWM wave can be adjusted by software.

[0041] Furthermore, during the operation of the IGBT power module 10, the GE terminal voltage of the IGBT power module 10 can be acquired and processed in real time to generate a third feedback signal F3. In this embodiment, the acquired GE terminal voltage is sent as the GE sampling voltage Vge_s to the PI controller, compared with a given reference GE voltage Vref_ge, and the comparison result is passed through the PI loop to obtain the third feedback signal F3. Based on the third feedback signal F3, a PWM wave or a PFM wave can be selected for output. When outputting a PWM wave, the rise and fall times of the PWM wave can be adjusted by software.

[0042] Furthermore, during the operation of the IGBT power module 10, the temperature inside the IGBT power module 10 can be collected and processed in real time to generate a fourth feedback signal F4. In this embodiment, the collected temperature value inside the IGBT power module 10 is sent to the PI controller as the sampling temperature Tntc_s, compared with a given reference temperature Vref_t, and the comparison result is passed through the PI loop to obtain the fourth feedback signal F4. Based on the fourth feedback signal F4, a PWM wave or a PFM wave can be selected for output. When outputting a PWM wave, the rise and fall times of the PWM wave can be adjusted by software.

[0043] like Figure 2 To facilitate the implementation of the above control method, another preferred embodiment of the present invention discloses a high-power IGBT drive adaptive closed-loop control system, which includes a data processing controller 20, a programmable logic controller 21, a first feedback network W1, a second feedback network W2, a third feedback network W3, a fourth feedback network W4, and an IGBT drive module 11.

[0044] The data processing controller 20 is electrically connected to the IGBT drive module 11 via the programmable logic controller 21, and the IGBT drive module 11 is electrically connected to the IGBT power module 10.

[0045] The first feedback network W1 is used to collect and process the voltage and current output by the IGBT power module 10 to generate a first feedback signal F1 provided to the data processing controller 20.

[0046] The second feedback network W2 is used to acquire and process the CE voltage of the IGBT power module 10 to generate a second feedback signal F2 provided to the data processing controller 20.

[0047] The third feedback network W3 is used to acquire and process the GE voltage of the IGBT power module 10 to generate a third feedback signal F3 provided to the data processing controller 20.

[0048] The fourth feedback network W4 is used to collect and process the temperature inside the IGBT power module 10 to generate a fourth feedback signal F4 provided to the data processing controller 20.

[0049] The data processing controller 20 is used to output a drive modulation wave and a control signal to the programmable logic controller 21 based on the comprehensive feedback of the various received feedback signals. The drive modulation wave can switch between PWM wave and PFM wave.

[0050] The programmable logic controller 21 is used to change the rise and fall times of the PWM wave according to the control signal. In this embodiment, the programmable logic controller 21 is preferably a CPLD, but an FPGA can also be used.

[0051] Specifically, the first feedback network W1 is set between the output terminal of the IGBT power module 10 and the data processing controller 20. The first feedback network W1 includes an output voltage acquisition module 31, an output current acquisition module 30, and a first PI controller 32 electrically connected to the output voltage acquisition module 31 and the output current acquisition module 30. The output voltage acquisition module 31 is used to acquire the output voltage of the IGBT power module 10, the output current acquisition module 30 is used to acquire the output current of the IGBT power module 10, and the first PI controller 32 is used to perform PI calculation based on the output voltage and the output current to generate a first feedback signal F1.

[0052] The second feedback network W2 includes a CE voltage acquisition module 40 and a second PI controller 41. The CE voltage acquisition module 40 is used to acquire the CE voltage of the IGBT power module 10, and the second PI controller 41 is used to process the CE voltage according to the reference CE voltage to obtain the second feedback signal F2.

[0053] The third feedback network W3 includes a GE voltage acquisition module 50 and a third PI controller 51. The GE voltage acquisition module 50 is used to acquire the GE voltage of the IGBT power module 10, and the third PI controller 51 is used to process the GE voltage according to the reference GE voltage to obtain the third feedback signal F3.

[0054] The fourth feedback network W4 includes a temperature acquisition module 60 and a fourth PI controller 61. The temperature acquisition module 60 is used to acquire the temperature inside the IGBT power module 10, and the fourth PI controller 61 is used to process the sampled temperature according to the reference temperature to obtain the fourth feedback signal F4.

[0055] It should also be noted that in the second feedback network W2, after obtaining the second feedback signal F2, it can be compared with the third feedback signal F3 and the fourth feedback signal F4 respectively before being output to the data processing controller 20. Similarly, in the third feedback network W3, after obtaining the third feedback signal F3, it can be compared with the second feedback signal F2 and the fourth feedback signal F4 respectively before being output to the data processing controller 20. In the fourth feedback network W4, after obtaining the fourth feedback signal F4, it can be compared with the second feedback signal F2 and the third feedback signal F3 respectively before being output to the data processing controller 20.

[0056] Combining the above control methods, and Figures 1 to 3 The workflow of the control system in this embodiment includes:

[0057] S1: Read the preset parameters of the IGBT power module 10, including reference output voltage, reference output current, reference CE voltage, reference GE voltage, reference temperature, and warning values ​​of related parameters.

[0058] S2: After the device is started, a closed-loop control process of voltage outer loop control and current inner loop control is established through the first feedback network W1, and a drive modulation wave is formed in the data processing controller 20 and sent to the programmable logic controller 21. The programmable logic controller 21 then loads the drive modulation wave into the IGBT power module 10 through the IGBT drive module 11.

[0059] S3: During the operation of the IGBT power module 10, the system detects in real time whether the IGBT power module 10 is in a normal state, that is, detects the CE voltage, GE voltage and internal temperature, and determines whether the detected values ​​are within the preset range. If yes, then execute S4; otherwise, execute S5.

[0060] S4: Disable the function of adjusting the drive modulation wave (which is PWM wave at this time);

[0061] S5: Start the timer and check if the timer has overflowed. If not, proceed to S6; if yes, proceed to S7.

[0062] S6: Enable the function of adjusting the drive modulation wave. The data processing controller 20 outputs a PWM wave and a control signal to the programmable logic controller 21. The programmable logic controller 21 adjusts the rise and fall times of the PWM wave according to the control signal and then outputs it to adjust the working state of the IGBT power module 10.

[0063] S7: Change the adjustment strategy of the drive adjustment wave, that is, the data processing controller 20 is adjusted to output a PFM wave to the programmable logic controller 21, and the working state of the IGBT power module 10 is adjusted by the PFM wave, and the timer is turned off until the IGBT power module 10 is in normal working state.

[0064] Furthermore, the IGBT drive module 11 includes a drive circuit, a transformer isolation circuit, and a filter circuit that are electrically connected in sequence. The input terminal of the drive circuit is electrically connected to the programmable logic controller 21, and the output terminal of the filter circuit is electrically connected to the control terminal of the IGBT power module 10.

[0065] In summary, the control system and control method disclosed in the above embodiments, firstly, based on the first feedback network W1 for establishing voltage outer loop control and current inner loop control, also include a second feedback network W2 for feedback based on the CE voltage of the IGBT power module 10, a third feedback network W3 for feedback based on the GE voltage of the IGBT power module 10, and a fourth feedback network W4 for feedback based on the temperature of the IGBT power module 10. This allows the data processing controller 20 to formulate a control strategy based on the feedback signals from multiple feedback networks, effectively improving the safety and service life of the IGBT power module 10.

[0066] Secondly, the adjustment drive wave that drives the IGBT drive module 11 can switch between PWM wave and PFM wave according to the current situation, thereby realizing the hybrid modulation of the IGBT power module 10, which makes the IGBT power module 10 adaptable to more application scenarios, further improves its utilization rate, and reduces equipment manufacturing costs.

[0067] Furthermore, by using a programmable logic controller 21 to process the rise and fall times of the PWM wave, compared with the existing technology that adjusts the rise and fall times of the PWM wave by selecting different drive resistors or adding different levels of power supply to the stage of shutdown, the hardware structure is simpler and more adaptable to different scenarios.

[0068] The above-disclosed embodiments are merely preferred embodiments of the present invention and should not be construed as limiting the scope of the present invention. Therefore, any equivalent variations made in accordance with the claims of the present invention are still within the scope of the present invention.

Claims

1. A high-power IGBT driver adaptive closed-loop control method for closed-loop control of the IGBT driver module that drives the IGBT power module, characterized in that, The control method includes: The voltage and current output by the IGBT power module are collected and processed to generate a first feedback signal; The collector-emitter voltage of the IGBT power module is acquired and processed to generate a second feedback signal; The GE terminal voltage of the IGBT power module is acquired and processed to generate a third feedback signal; The temperature inside the IGBT power module is collected and processed to generate a fourth feedback signal; The system performs comprehensive processing on all feedback signals, including the first feedback signal, the second feedback signal, the third feedback signal, and the fourth feedback signal. This comprehensive processing includes cross-comparing the second feedback signal, the third feedback signal, and the fourth feedback signal pairwise to selectively send a corresponding first modulation drive signal or a second modulation drive signal to the IGBT drive module. The first modulation drive signal includes a PWM wave in the current state or a PWM wave with adjusted rise and fall times. The second modulation drive signal includes a PFM wave. When the IGBT power module is in an abnormal state, it sends a corresponding first modulation drive signal to the IGBT drive module and determines whether the duration of the first modulation drive signal exceeds a preset value. If not, the first modulation drive signal is adjusted and resent. If so, the transmission of the first modulation drive signal is stopped and the second modulation drive signal is sent.

2. The high-power IGBT drive adaptive closed-loop control method according to claim 1, characterized in that, A data processing controller and a programmable logic controller (PLC) electrically connected to the data processing controller are provided. The PLC is electrically connected to the IGBT drive module. The data processing controller processes each feedback signal, including the first feedback signal and the second feedback signal, and generates the PWM wave, PFM wave, and control signal for the PLC. The PLC processes the rise and fall times of the PWM wave according to the control signal.

3. The high-power IGBT drive adaptive closed-loop control method according to claim 2, characterized in that, The IGBT drive module includes a drive circuit, a transformer isolation circuit, and a filter circuit that are electrically connected in sequence. The input terminal of the drive circuit is electrically connected to the programmable logic controller, and the output terminal of the filter circuit is electrically connected to the control terminal of the IGBT power module.

4. A high-power IGBT drive adaptive closed-loop control system, characterized in that, It includes a data processing controller, a programmable logic controller, a first feedback network, a second feedback network, a third feedback network, a fourth feedback network, and an IGBT driver module; The data processing controller is electrically connected to the IGBT drive module through the programmable logic controller, and the IGBT drive module is electrically connected to the IGBT power module; The first feedback network is used to collect and process the voltage and current output by the IGBT power module to generate a first feedback signal provided to the data processing controller; The second feedback network is used to acquire and process the CE voltage of the IGBT power module to generate a second feedback signal for the data processing controller. The third feedback network is used to collect and process the GE voltage of the IGBT power module to generate a third feedback signal for the data processing controller. The fourth feedback network is used to collect and process the temperature inside the IGBT power module to generate a fourth feedback signal for the data processing controller. The data processing controller is configured to output a drive modulation wave and a control signal to the programmable logic controller based on the comprehensive feedback of the received feedback signals. The drive modulation wave can switch between PWM wave and PFM wave. The comprehensive feedback includes pairwise cross comparison of the second feedback signal, the third feedback signal and the fourth feedback signal. The programmable logic controller is used to change the rise and fall times of the PWM wave according to the control signal; When the IGBT power module is in an abnormal state, the data processing controller outputs a PWM wave and sends a control signal that causes the programmable logic controller to process the rise and fall times of the PWM wave in order to adjust the operating state of the IGBT power module. If the adjustment time of the IGBT power module is greater than a preset value, the data processing controller outputs a PFM wave and stops sending the control signal.

5. The high-power IGBT drive adaptive closed-loop control system according to claim 4, characterized in that, The IGBT drive module includes a drive circuit, a transformer isolation circuit, and a filter circuit that are electrically connected in sequence. The input terminal of the drive circuit is electrically connected to the programmable logic controller, and the output terminal of the filter circuit is electrically connected to the control terminal of the IGBT power module.

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