High-power IGBT flexible power supply control system

Abstract

The present invention relates to a high-power IGBT flexible power supply control system, and belongs to the field of electronic devices. The present invention carries out targeted system design for the problems of large-scale high-power IGBT flexible power supply devices, sudden load changes, and complex industrial field environments, so that the equipment can be applied to various industrial production scenarios. In order to solve the problem of large-scale high-power power electronic devices, the present invention formulates a clock synchronization strategy and carries out modular design of the device, so that the system can easily expand the power scale and the control effect can be guaranteed. All controllers form a ring communication redundancy, which greatly improves the safety of the system. For the problems of sudden load changes and complex industrial environments, a system fault self-healing function is added to improve the automation level of the equipment, and a Sigma-Delta sampling module is used to ensure the accuracy and rapidity of current sampling, thereby improving the performance of the equipment.

Description

Technical Field

[0001] The invention belongs to the field of electronic devices and relates to a high-power IGBT flexible power supply control system. Background Art

[0002] Industrial production has a strong demand for flexible power supply devices. Due to the limitations of the voltage and current resistance of power electronic devices, high-power industrial applications often use multi-stage series-parallel forms of IGBT power unit modules. As the power increases, the scale of the equipment increases accordingly, which requires more IGBTs and controllers to participate in the control. Therefore, the problem of synchronous control between multiple IGBT power units and multiple controllers is very important.

[0003] The operation of industrial production is complex and there are conditions of sudden load changes, which places high demands on the real-time performance of the device control system. It requires a fast control cycle and fault self-healing function to ensure control effect and equipment safety.

[0004] Industrial sites often have complex on-site environments. Dust and electromagnetic environments can interfere with devices, which requires the equipment to have good anti-interference capabilities and redundancy functions. Summary of the invention

[0005] In view of this, the purpose of the present invention is to provide a high-power IGBT flexible power supply control system, which has the characteristics of easy expansion of power scale, diverse external communication methods and high real-time control. A synchronous control strategy is adopted for the controller in the system, a new sampling method is used to ensure fast and stable current sampling, and targeted designs are made for load mutation conditions and complex industrial site environments to ensure stable, efficient and safe operation of the equipment.

[0006] In order to achieve the above object, the present invention provides the following technical solutions:

[0007] A high-power IGBT flexible power supply control system, the system includes a master controller and several slave controllers;

[0008] The plurality of slave controllers are all connected to the master controller via a network cable;

[0009] The main controller is connected to the digital input signal DI, the digital output signal DO, the analog input AI, the analog output AO and the communication module through the network cable;

[0010] The several slave controllers are all connected to the digital input signal DI, the digital output signal DO and the sampling signal through optical fibers;

[0011] The plurality of slave controllers are also connected to a plurality of power units via optical fibers;

[0012] The plurality of adjacent slave controllers are connected via network cables;

[0013] The plurality of power units are interconnected;

[0014] The main controller is connected to the human-machine interface and the industrial field controller respectively via Ethernet;

[0015] The master controller is connected to all slave controllers via real-time industrial Ethernet, and the links form a ring topology, allowing communication to be transmitted in both directions, providing communication redundancy for the system.

[0016] Optionally, the main controller is equipped with a Linux-RT real-time operating system, the system has an IEC 61131-3 programming language environment, and the task cycle reaches 100us.

[0017] Optionally, the master controller is responsible for all control calculations in the system program, and uses distributed clock technology to synchronize the clocks of the master controller and all slave controllers. The control system can complete the pulse download and sampling upload of all slave controllers within 100ns, ensuring the pulse control consistency of all IGBT power units.

[0018] Optionally, the sampling signal is composed of analog and digital parts, and provides a data stream output based on oversampling and noise shaping.

[0019] Optionally, the sampling signal is sampled by a high-speed analog signal sampler, and the sampled signal is compared with the digital signal to obtain an error signal; the error signal is passed through an integrator and a proportional amplifier to obtain a feedback signal, and the feedback signal is digitally filtered and digitally denoised through a digital signal processor to obtain a digital output.

[0020] Optionally, the main controller has a fault self-healing function, and the specific steps are as follows:

[0021] S1: The system determines that a short circuit, open circuit or power unit failure occurs based on detection;

[0022] S2: The main controller immediately blocks the power unit pulse;

[0023] S3: After the pulse is blocked, the system determines whether a fault exists;

[0024] S4: The system determines that the fault is repaired, and the main controller generates pulse control again;

[0025] S5: The system determines that a fault exists and automatically shields the faulty components and power units;

[0026] S6: After shielding the faulty part, the system determines whether there is a fault in the remaining parts;

[0027] S7: After the fault is shielded, the system still has a fault and the device stops.

[0028] The beneficial effects of the present invention are as follows: the present invention carries out targeted system design for the problems of large-scale, sudden load change conditions and complex industrial field environment of high-power IGBT flexible power supply devices, so that the equipment can be applied to various industrial production scenarios. In order to solve the problem of large-scale high-power power electronic devices, the present invention has formulated a clock synchronization strategy and carried out modular design of the device, so that the system can easily expand the power scale and the control effect can be guaranteed. All controllers form a ring communication redundancy, which greatly improves the safety of the system. For the problems of sudden load change conditions and complex industrial environments, the system fault self-healing function is added to improve the automation level of the equipment, and the Sigma-Delta sampling module is used to ensure the accuracy and rapidity of current sampling and improve the performance of the equipment.

[0029] Other advantages, objectives and features of the present invention will be described in the following description to some extent, and to some extent, will be obvious to those skilled in the art based on the following examination and study, or can be taught from the practice of the present invention. The objectives and other advantages of the present invention can be realized and obtained through the following description. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] In order to make the purpose, technical solutions and advantages of the present invention more clear, the present invention will be described in detail below in conjunction with the accompanying drawings, wherein:

[0031] Figure 1 It is a structural diagram of a high-power IGBT flexible power supply control system;

[0032] Figure 2 This is a schematic diagram of the multi-controller synchronous control function in an embodiment of the present invention;

[0033] Figure 3 The figure is a flow chart of the system fault self-healing function in an embodiment of the present invention. DETAILED DESCRIPTION

[0034] The following describes the embodiments of the present invention by specific examples, and those skilled in the art can easily understand other advantages and effects of the present invention from the contents disclosed in this specification. The present invention can also be implemented or applied through other different specific embodiments, and the details in this specification can also be modified or changed in various ways based on different viewpoints and applications without departing from the spirit of the present invention. It should be noted that the illustrations provided in the following embodiments only illustrate the basic concept of the present invention in a schematic manner, and the following embodiments and features in the embodiments can be combined with each other without conflict.

[0035] Among them, the drawings are only used for illustrative explanations, and they only represent schematic diagrams rather than actual pictures, and should not be understood as limitations on the present invention. In order to better illustrate the embodiments of the present invention, some parts of the drawings may be omitted, enlarged or reduced, and do not represent the size of actual products. For those skilled in the art, it is understandable that some well-known structures and their descriptions in the drawings may be omitted.

[0036] The same or similar numbers in the drawings of the embodiments of the present invention correspond to the same or similar parts; in the description of the present invention, it should be understood that if the terms "upper", "lower", "left", "right", "front", "rear", etc. indicate the orientation or position relationship, they are based on the orientation or position relationship shown in the drawings, which is only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operate in a specific orientation. Therefore, the terms describing the position relationship in the drawings are only used for illustrative purposes and cannot be understood as limiting the present invention. For ordinary technicians in this field, the specific meanings of the above terms can be understood according to specific circumstances.

[0037] like Figure 1 As shown, the present invention provides a high-power IGBT flexible power supply control system, the system includes a network cable connection part and an optical fiber connection part; the network cable connection part is composed of a human-machine interface, an industrial field controller, a main controller, peripheral equipment DO, DI and communication modules, and a slave controller; the network cable connection part is the functional part of the device to realize control communication; the optical fiber connection part is composed of internal DI, DO, sampling module, and power unit; the optical fiber connection part is the functional part of the device to realize power output; the operator operates the industrial field controller through the human-machine interface to send instructions to the main controller, and the main controller indirectly controls the IGBT power unit through the slave controller, thereby generating power output.

[0038] like Figure 2 As shown in the figure, it is the synchronous control principle of the master controller and the slave controller in the system. The master controller sends out a command data frame carrying its clock information, which passes through each slave controller in turn to transmit the pulse control instruction at the same time. After the pulse instruction is sent, the feedback data frame is sent from the last slave controller, and it passes through each slave controller in the reverse direction to upload the sampled data at the same time. Finally, each controller performs clock calibration through the master controller clock, local clock and delay compensation to complete the clock synchronization. The whole process is completed within 100ns. The IGBT power unit adopts a modular design, and the modules are connected in parallel. The number can be freely set according to the production capacity requirements.

[0039] like Figure 3 The following is a flowchart of the system fault self-healing function, which is divided into the following 7 steps:

[0040] S1: The system determines based on detection that a short circuit, open circuit or power unit failure has occurred.

[0041] S2: The main controller immediately blocks the power unit pulses.

[0042] S3: After the pulse is blocked, the system determines whether a fault exists.

[0043] S4: The system determines that the fault is repaired and the main controller regenerates pulse control.

[0044] S5: The system determines that a fault exists and automatically shields the faulty components and power units.

[0045] S6: After shielding the faulty part, the system determines whether there is a fault in the remaining parts.

[0046] S7: After the fault is shielded, the system still has a fault and the device stops.

[0047] Finally, it should be noted that the above embodiments are only used to illustrate the technical solution of the present invention rather than to limit it. 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 solution of the present invention can be modified or replaced by equivalents without departing from the purpose and scope of the technical solution, which should be included in the scope of the claims of the present invention.

Claims

1. High-power IGBT flexible power supply control system, characterized by: The system includes a master controller and a number of slave controllers; The plurality of slave controllers are all connected to the master controller via a network cable; The main controller is connected to the digital input signal DI, the digital output signal DO, the analog input AI, the analog output AO and the communication module through the network cable; The several slave controllers are all connected to the digital input signal DI, the digital output signal DO and the sampling signal through optical fibers; The plurality of slave controllers are also connected to a plurality of power units via optical fibers; The plurality of adjacent slave controllers are connected via network cables; The plurality of power units are interconnected; The main controller is connected to the human-machine interface and the industrial field controller respectively via Ethernet; The master controller is connected to all slave controllers via real-time industrial Ethernet, and the links form a ring topology, so that communication is transmitted in both directions, providing communication redundancy for the system; The main controller is equipped with a Linux-RT real-time operating system, the system has an IEC 61131-3 programming language environment, and the task cycle reaches 100us; The master controller is responsible for all control calculations in the system program. It uses distributed clock technology to synchronize the clocks of the master controller and all slave controllers. The control system can complete the pulse download and sampling upload of all slave controllers within 100ns, ensuring the consistency of pulse control of all IGBT power units. The sampling signal is composed of analog and digital parts, and provides a data stream output based on oversampling and noise shaping; The sampling signal is sampled by a high-speed analog signal sampler, and the sampled signal is compared with the digital signal to obtain an error signal; The error signal is passed through an integrator and a proportional amplifier to obtain a feedback signal, and the feedback signal is digitally filtered and digitally noise-reduced through a digital signal processor to obtain a digital output; The main controller has a fault self-healing function, and the specific steps are as follows: S1: The system determines that a short circuit, open circuit or power unit failure occurs based on detection; S2: The main controller immediately blocks the power unit pulse; S3: After the pulse is blocked, the system determines whether a fault exists; S4: The system determines that the fault is repaired, and the main controller generates pulse control again; S5: The system determines that a fault exists and automatically shields the faulty components and power units; S6: After shielding the faulty part, the system determines whether there is a fault in the remaining parts; S7: After the fault is shielded, the system still has a fault and the device stops.

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