A high-power inverter and its control method

Abstract

This invention discloses a high-power inverter and its control method, belonging to the field of power electronics technology. It includes a sensing-enhanced magnetic component, comprising a high thermal conductivity metal casing, a magnetic core disposed inside the high thermal conductivity metal casing, a main power coil, a high-precision sensing coil, and an integrated thermal probe. The high-precision sensing coil is wound close to the central post of the magnetic core, and the main power coil is coaxially wound around the outside of the high-precision sensing coil. The magnetic core, the main power coil, and the high-precision sensing coil together constitute the inductor core. This invention enables the controller to monitor the operating point of the magnetic core on the magnetization curve in real time, thereby directly determining its margin from magnetic saturation.

Description

Technical Field

[0001] This invention relates to the field of power electronics, specifically to a high-power inverter and its control method. Background Technology

[0002] In existing high-power inverter technologies, the core magnetic components are usually treated as integrated functional modules. This design approach makes it impossible to directly and in real time obtain the key physical states inside the components during inverter operation, especially the magnetic flux state inside the magnetic core and the internal hot spot temperature caused by power loss.

[0003] This limitation forces the inverter's 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 inherently involves uncertainties and delays; therefore, to ensure operational safety, the control strategy must employ a conservative design margin. Consequently, 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 conditions.

[0004] The information disclosed in the background section above is only intended to enhance the understanding of the background of this disclosure, and therefore may include information that does not constitute prior art known to those skilled in the art. Summary of the Invention

[0005] The purpose of this invention is to provide a high-power inverter and its control method to solve the problems mentioned in the background art.

[0006] The technical solution of this invention is a high-power inverter and its control method, comprising a sensing-enhanced magnetic component. The sensing-enhanced magnetic component includes a high thermal conductivity metal casing, a magnetic core disposed inside the high thermal conductivity metal casing, a main power coil, a high-precision sensing coil, and an integrated thermal probe. The high-precision sensing coil is wound close to the central post of the magnetic core, and the main power coil is coaxially wound around the outside of the high-precision sensing coil. The magnetic core, the main power coil, and the high-precision sensing coil together constitute an inductor core. The inductor core is encapsulated inside the high thermal conductivity metal casing. The integrated thermal probe is fixed at a preset monitoring point on the high thermal conductivity metal casing to obtain the casing temperature of the high thermal conductivity metal casing.

[0007] Preferably, the high thermal conductivity metal casing is provided with a mounting surface, which is used to be attached to and connected with an external liquid cooling 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 sidewall of the high thermal conductivity metal casing.

[0009] Preferably, the gaps inside the high thermal conductivity metal shell are filled with high thermal conductivity insulating adhesive 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 includes: acquiring an internal state characteristic list, wherein the internal state characteristic list is collected by a controller, and the list includes an induced voltage signal from a high-precision sensing coil and a casing temperature signal from an integrated thermal probe; based on the induced voltage signal, the controller reconstructs real-time magnetic state parameters and determines magnetic saturation margin according to the real-time magnetic state parameters; based on the real-time magnetic state parameters and real-time main current, the controller calculates heat source power; and combining the casing temperature signal as a boundary condition, the controller calculates a corrected internal hot spot temperature through a preset thermodynamic model; the controller compares the real-time magnetic state parameters and the corrected internal hot spot temperature with a preset safety threshold list in real time, and dynamically adjusts the 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 perform time accumulation calculation on the magnetic flux change rate to set the real-time magnetic state parameter as the instantaneous magnetic flux density characterizing the internal state of the magnetic core.

[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 hot spot 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, so as to set the corrected internal hot spot temperature as the sum of the reference hot spot temperature and the transient thermal shock temperature rise compensation value.

[0013] Preferably, when the real-time magnetic state parameter is close to the magnetic saturation limit, the controller is used to adjust the inverter operating parameters to an optimized switching frequency or modulation strategy; when the corrected internal hot spot temperature is close to 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 value.

[0014] Preferably, the controller further includes: recording the temperature decay curve of the corrected internal hot spot temperature under a standard load sequence, and extracting its time constant as a heat dissipation performance benchmark; during long-term operation of the inverter, the controller calculates the deviation between the temperature decay time under the current operating condition 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] This invention provides a high-power inverter and its control method through improvements, which have the following improvements and advantages compared with the prior art:

[0016] 1. A high-precision sensing coil is set up and wound closely to the magnetic core. According to the law of electromagnetic induction, the controller can calculate the induced voltage signal output by this coil through time accumulation and accurately convert it into the core physical quantity characterizing the working state of the magnetic core, namely the instantaneous magnetic flux density. This allows the controller to monitor the working point of the magnetic core on the magnetization curve in real time, thereby directly determining its margin from the magnetic saturation state. This judgment method based on direct internal induction is far more direct and reliable than the traditional method of inference based on external current.

[0017] 2. An integrated thermal probe is used to obtain the shell temperature of the high thermal conductivity metal casing, which serves as a precise and dynamic boundary condition for the thermodynamic model. Simultaneously, the controller combines the reconstructed real-time magnetic state parameters and real-time main current to calculate the total heat source power. This calculation includes core losses caused by changes in the magnetic state, making it more comprehensive than traditional methods that only calculate coil copper losses. Based on this heat source power and shell temperature boundary condition, the controller uses a pre-defined thermodynamic model that includes a steady-state thermal resistance network model and a transient thermal impedance model to calculate the corrected internal hot spot temperature. This temperature value reflects both the average temperature rise under continuous load and compensates for transient temperature spikes under pulsed load, thus achieving accurate estimation of the most critical temperature points inside the component.

[0018] 3. When the controller determines that the real-time magnetic state parameters are close to the magnetic saturation limit, it does not passively wait for overcurrent protection to shut down. Instead, it actively adjusts the inverter operating parameters to an optimized switching frequency or modulation strategy. This proactively changes the volt-second product applied to the magnetic components, thereby pulling the core's operating point back to a safe linear region without interrupting operation. This significantly enhances the inverter's system stability under load shocks. When the controller determines that the corrected internal hotspot temperature is close to the material's upper operating temperature limit, it adopts targeted cooling strategies. For example, for overall temperature rise caused by continuous overload, the controller can adjust the inverter operating parameters to a reduced switching frequency to decrease 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 with minimal performance cost, helping to extend the component's lifespan. Attached Figure Description

[0019] The present invention will be further explained below with reference to the accompanying drawings and embodiments:

[0020] Figure 1 This is a schematic diagram of the main structure of the inverter;

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

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

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

[0024] In the diagram: 100, Sensing-enhanced magnetic component; 110, High thermal conductivity metal casing; 120, Magnetic core; 130, Main power coil; 140, High-precision sensing coil; 150, Integrated thermal probe. Detailed Implementation

[0025] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to specific embodiments.

[0026] Example 1

[0027] Please see Figures 1-4This invention provides a high-power inverter, including a sensing-enhanced magnetic component 100. The sensing-enhanced magnetic component 100 includes a high thermal conductivity metal casing 110, a magnetic core 120 disposed inside the high thermal conductivity metal casing 110, a main power coil 130, a high-precision sensing coil 140, and an integrated thermal probe 150. The high-precision sensing coil 140 is wound close to the central post of the magnetic core 120, and the main power coil 130 is coaxially wound around the outside of the high-precision sensing coil 140. The magnetic core 120, the main power coil 130, and the high-precision sensing coil 140 together constitute an inductor core. The inductor core is encapsulated inside the high thermal conductivity metal casing 110. The integrated thermal probe 150 is fixed at a preset monitoring point on the high thermal conductivity metal casing 110 to obtain the casing temperature of the high thermal conductivity metal casing 110.

[0028] Existing high-power inverters typically treat their core magnetic components as a single module, making it impossible to directly obtain information about their internal magnetic flux state and hotspot temperature during operation. This forces control strategies to be based on estimations and conservative designs using external electrical parameters, limiting further improvements in inverter performance and reliability. This high-power inverter changes this situation by incorporating a sensing-enhanced magnetic component 100. The structural design of the sensing-enhanced magnetic component 100 aims to provide the inverter's control system with auxiliary signals that directly reflect the internal physical state of the component. The high-precision sensing coil 140, due to its coaxial layout—closely attached to the magnetic core 120 and covered by the main power coil 130—can sensitively sense changes in the magnetic flux within the magnetic core 120, providing a physical basis for subsequent magnetic state reconstruction. Simultaneously, an integrated thermal probe 150 is housed within a high thermal conductivity metal casing. The specific monitoring point 110 is located based on the pre-determined analysis of the component's heat conduction path. Therefore, the measured casing temperature can effectively reflect the heat dissipation from the internal heat source to the outside. The selection principle for this monitoring point is to be on the main heat dissipation path and to minimize direct interference from the external ambient temperature. For example, it can be selected at a casing location close to the inductor core and in close contact with the external liquid cooling heat sink, thereby ensuring 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 allows the internal magnetic and thermal states, which were originally not directly measurable, to be correlated and calculated through externally measurable electrical and temperature signals. This creates conditions for accurate observation and adaptive control of the inverter's internal state, and helps to improve the inverter's operational stability and service life under complex operating conditions.

[0029] The high thermal conductivity metal casing 110 is provided with a mounting surface, which is used to fit and connect with the external liquid cooling heat sink to form the main heat dissipation channel.

[0030] The purpose of the mounting surface is to establish a stable and efficient heat dissipation path for the sensing-enhanced magnetic component 100. Any structure that can ensure a tight fit with low thermal resistance between the high thermal conductivity metal casing 110 and the external heat dissipation facility falls within the scope of protection of this invention. For example, the mounting surface can be a flat surface that has been precision milled and fastened to the external liquid cooling heat sink with an additional bolt, and thermally conductive silicone grease is applied between the contact surfaces. Alternatively, the mounting surface can be designed with a structure with specific grooves or protrusions to form 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 cooling heat sink together constitutes the main heat dissipation channel, which allows the heat generated inside the component to be quickly dissipated. This not only ensures the thermal stability of the inverter when operating at high power density, but also provides reliable boundary conditions for the accuracy of the subsequent thermodynamic model, because a 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 in the blind hole end of the side wall of the high thermal conductivity metal housing 110.

[0032] The integrated thermal probe 150 is specifically designed to acquire accurate and representative shell temperature data. This is achieved through a reliable engineering practice by encapsulating the integrated thermal probe 150 as a high-precision platinum resistance temperature sensor, such as a PT100 sensor, at the end of a blind hole in the sidewall of a high thermal conductivity metal shell 110. The drilling depth of the blind hole is calculated to ensure that the sensor's sensing endpoint is close to the critical path of heat conduction from the interior to the shell, without compromising the shell's seal. Thermally conductive adhesive is used to tightly bond the sensor to the bottom of the blind hole, further reducing contact thermal resistance. This configuration allows the integrated thermal probe 150 to sensitively capture temperature changes conducted from internal hot spots to the shell, providing high-fidelity output temperature data. This provides accurate and dynamically changing boundary conditions for thermodynamic models, forming the basis for accurate inversion calculations of internal hot spot temperatures.

[0033] The gaps inside the high thermal conductivity metal casing 110 are filled with high thermal conductivity insulating adhesive to conduct the heat generated by the inductor core to the high thermal conductivity metal casing 110.

[0034] Filling the interior of the high thermal conductivity metal casing 110 with high thermal conductivity insulating adhesive aims to optimize the heat conduction path between the inductor core and the casing. During assembly, air gaps inevitably exist between the inductor core and the high thermal conductivity metal casing 110. Air has very low thermal conductivity, which severely hinders heat transfer. Vacuum-filling with high thermal conductivity insulating adhesive completely eliminates these air gaps, forming a continuous, low thermal resistance thermally conductive medium from the main power coil 130 and magnetic core 120 to the high thermal conductivity metal casing 110. This ensures that the heat generated by the inductor core is efficiently and uniformly conducted to the casing, improving the overall heat dissipation capacity of the component. Furthermore, it allows the integrated thermal probe 150 to more accurately and quickly respond to changes in the internal heat source, improving the accuracy of thermal state observation.

[0035] Example 2

[0036] A control method for a high-power inverter includes: acquiring an internal state characteristic list, which is collected by a controller and includes an induced voltage signal from a high-precision sensing coil 140 and a casing temperature signal from an integrated thermal probe 150; based on the induced voltage signal, the controller reconstructs real-time magnetic state parameters and determines the magnetic saturation margin according to the real-time magnetic state parameters; based on the real-time magnetic state parameters and real-time main current, the controller calculates the heat source power; combined with the casing temperature signal as a boundary condition, the controller calculates the corrected internal hot spot temperature through a preset thermodynamic model; the controller compares the real-time magnetic state parameters and the corrected internal hot spot temperature with a preset safety threshold list in real time, and dynamically adjusts the inverter operating parameters according to the comparison results.

[0037] The core objective of this control method is to utilize the signals provided by the sensing-enhanced magnetic component 100 to achieve deep sensing and proactive adjustment of the inverter's internal state. The list of internal state characteristics acquired by the controller forms the data foundation for achieving this objective. 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 from magnetic saturation, thereby anticipating potential runaway risks. Simultaneously, the controller calculates the heat source power based on the known real-time magnetic state parameters and the acquired real-time main current. This real-time main current is typically measured in real time by a Hall effect current sensor or shunt resistor installed in the inverter's main circuit. This method is more accurate than simply relying on current to calculate copper losses because it incorporates the losses of the magnetic core 120 caused by changes in magnetic state. Subsequently, the calculated heat source power is used as input, and the casing temperature signal is used as a boundary condition. The corrected internal hot spot temperature is calculated using a preset thermodynamic model, thus obtaining an estimate of the most critical temperature point inside the component. The controller continuously compares the two reconstructed internal parameters, namely the real-time magnetic state parameters and the corrected internal hot spot temperature, with the preset safety thresholds, and dynamically adjusts the inverter operating parameters based on the comparison results. This series of operations transforms the inverter control from passive protection to active management, enabling the adjustment of operating strategies based on actual internal margins while ensuring safety, which helps to find a balance between performance and reliability under different operating conditions.

[0038] The controller is used to convert the induced voltage signal into the rate of change of magnetic flux, and then to calculate the rate of change of magnetic flux over time, thereby setting the real-time magnetic state parameter as the instantaneous magnetic flux density characterizing the internal state of the magnetic core 120.

[0039] The specific calculation process for setting the real-time magnetic state parameters aims to extract more physically meaningful magnetic field information from the original induced voltage signal. After the controller acquires the induced voltage signal output by the high-precision sensing coil 140, according to the law of electromagnetic induction, this voltage value is proportional to the rate of change of magnetic flux passing through the coil. Therefore, the controller directly converts the induced voltage signal into the rate of change of magnetic flux of the magnetic core 120 through a preset proportional coefficient. The controller performs a cumulative calculation on this rate of change of magnetic flux signal over time, i.e., numerical integration. 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 magnetic flux density is the most core physical quantity describing the working state of magnetic materials. It directly corresponds to the operating point on the material's magnetization curve, thus enabling the controller to accurately determine whether the magnetic core 120 is close to saturation. This judgment is more direct and reliable than inference based solely on external current.

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

[0041] ;

[0042] in, It is the number of turns of the high-precision sensing coil, which is a known constant; : Represents the instantaneous induced voltage of a high-precision sensing coil; it is time-dependent. The function; : Symbol for voltage; subscript : refers to perception; : indicates over time change; : The symbol for the number of turns;

[0043] Therefore, the rate of change of magnetic flux can be directly derived from the induced voltage:

[0044] ;

[0045] in, Differential symbol; Over time Changing magnetic flux;

[0046] The controller reconstructs the instantaneous magnetic flux by performing discrete-time integration and time-accumulation on the rate of change of magnetic flux. :

[0047] ;

[0048] in, : Represents the current discrete time point Magnetic flux; : Symbol for magnetic flux; : Represents the current discrete time step; : indicates at the previous discrete time point Magnetic flux; : Represents the current discrete time point The induced voltage; : Indicates the sampling time interval of the controller;

[0049] Real-time magnetic state parameters, i.e., instantaneous magnetic flux density By dividing the magnetic flux by the effective cross-sectional area of ​​the magnetic core get:

[0050] ;

[0051] in, The instantaneous magnetic flux density at the current moment, For the current discrete time point The magnetic flux, It is the effective cross-sectional area of ​​the magnetic 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 magnetic core.

[0052] The preset thermodynamic model includes a steady-state thermal resistance network model and a transient thermal impedance model. The controller is used to merge the reference hot spot 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, so as to set the corrected internal hot spot temperature as the sum of the reference hot spot temperature and the transient thermal shock temperature rise compensation value.

[0053] The purpose of setting the calculation method for the corrected internal hot spot temperature is to comprehensively and accurately reflect the thermal effects caused by different load characteristics within the component. The preset thermodynamic model consists of two parts, each addressing different thermal dynamic processes. The steady-state thermal resistance network model is established based on the macroscopic structure of the component, equating the component to a thermal resistance network composed of several key nodes. By solving this network, a reference hot spot temperature reflecting the overall temperature rise distribution of the component under continuous load can be obtained. When the inverter is subjected to a highly dynamic pulse load, heat will concentrate at the heat source in a short time, unable to be conducted to the casing, forming an instantaneous temperature spike, which the steady-state model cannot capture. A transient thermal impedance model is introduced, which establishes the relationship between pulse power characteristics and instantaneous temperature rise through offline calibration. The controller calls this model to calculate a transient thermal shock temperature rise compensation value based on real-time load characteristics. The controller adds this compensation value to the reference hot spot temperature to obtain the corrected internal hot spot temperature, which includes both the average temperature rise information of the component and the instantaneous temperature peak information that has an important impact on the device's lifespan, thus providing the controller with a more complete view of the internal thermal state.

[0054] The pre-defined thermodynamic model is specified as follows:

[0055] Steady-state thermal resistance network model: This model simplifies the component into a node network, for example, it may contain three nodes: a heat source node, a shell node, and an environment node; the thermal resistance between each node, such as... This represents the thermal resistance from the heat source node to the shell node. The thermal resistance from the shell node to the ambient node is determined in advance through experimental calibration or finite element simulation; the reference hot spot temperature. The calculation formula is:

[0056] ;

[0057] in, The real-time shell temperature was measured by the integrated thermal probe 150. This refers to the total heat source power calculated above. The meanings of the subscripts for each parameter are as follows: Refers to the heat source node, that is, the point with the highest temperature inside the component; Refers to a metal casing with high thermal conductivity; Refers to the benchmark value; therefore, Indicates the reference hot spot temperature. This represents the thermal resistance from the heat source node to the shell node;

[0058] Transient thermal impedance model: This model typically uses a function composed of a multi-order RC network, Foster network, or Caul network. This function describes the change in hotspot temperature rise over time after a unit power pulse is applied; transient thermal shock temperature rise compensation value. The temperature is obtained by convolving the real-time power pulse with the transient thermal impedance model. The controller then fuses the calculated transient thermal shock temperature rise compensation value with the reference hotspot temperature to obtain the corrected internal hotspot temperature. :

[0059] ;

[0060] When the real-time magnetic state parameters approach the magnetic saturation limit, the controller adjusts the inverter operating parameters to the optimized switching frequency or modulation strategy; when the corrected internal hot spot temperature approaches the upper limit of the material's operating temperature, the controller adjusts the inverter operating parameters to the reduced switching frequency or the reduced current pulse peak value.

[0061] The specific strategies for adjusting inverter operating parameters aim to take targeted preventative measures based on different internal state risks. When the controller determines that the real-time magnetic state parameters are approaching the magnetic saturation limit, such as when the load current suddenly increases, it will proactively adjust the inverter operating parameters, such as appropriately increasing the switching frequency or changing the modulation waveform, to actively change the volt-second product applied to the magnetic components. For example, the controller can switch from conventional sinusoidal pulse width modulation to space vector pulse width modulation, or proactively 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 in each switching cycle without significantly affecting the output performance, thereby pulling the magnetic core back to the safe operating area. This brings the operating point of the magnetic core 120 back to the linear region without triggering overcurrent protection shutdown, ensuring the system stability of the inverter under load impact. 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 adjustments 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 reduced 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 peak value of subsequent current pulses. This fine-tuning can alleviate internal magnetic and thermal stress with a small performance cost, which helps to extend the service life of the components.

[0062] It also includes: the controller is used to record the temperature decay curve of the corrected internal hot spot temperature under 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 condition 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.

[0063] The purpose of generating a health status index and issuing alarms is to achieve long-term tracking and predictive maintenance of the health status of the sensing-enhanced magnetic module 100. The controller needs to apply a standard load sequence under the initial state or controlled conditions of the module. This standard load sequence can be a preset program, for example, first allowing the inverter to run at rated power for a period sufficient to allow the module temperature to reach a steady state, such as 30 minutes, and then immediately removing the load completely to enter an unloaded or standby state. Then, the temperature decay curve of the corrected internal hot spot temperature during the natural cooling process after the load is removed is recorded, and a time constant is calculated and stored from this curve. This is the heat dissipation performance benchmark, representing the group's... The controller measures the heat dissipation capacity of components in a healthy state. During the long-term operation of the inverter, the controller monitors similar cooling processes during equipment shutdowns or low-load periods, calculating the current temperature decay time. By comparing the current decay time with a heat dissipation performance benchmark, the aging degree of the heat dissipation path can be quantified. For example, cracked thermal adhesive or loose contact surfaces will slow down heat dissipation and lengthen the decay time. 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 will issue a predictive maintenance alarm. This can prompt managers to inspect or replace components before serious failures occur, reducing losses caused by unplanned downtime.

[0064] The algorithm for generating the health status index is as follows:

[0065] To quantify health status, the following parameters are defined: It serves as a benchmark for heat dissipation performance, namely the temperature decay time constant measured by the component under a standard load sequence in its initial state; The current temperature decay time constant is the value monitored during long-term operation of the inverter; the health status index can be quantified as a percentage:

[0066] ;

[0067] in, : Represents a health status index;

[0068] In an ideal situation, , When the heat dissipation path ages, such as when the thermal adhesive cracks or the contact surface becomes loose, leading to poor heat dissipation, It will increase, thus leading to The value decreases; the preset maintenance threshold can be set, for example, 70%, when... When the value falls below this level, the controller issues a predictive maintenance alarm.

[0069] 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 it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

Claims

1. A high-power inverter, characterized in that, The system includes a sensing-enhanced magnetic component (100), comprising a high thermal conductivity metal casing (110), a magnetic core (120) disposed inside the high thermal conductivity metal casing (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 close to the center post of the magnetic core (120) for acquiring induced voltage signals, and the main power coil (130) is coaxially wound around the outside of the high-precision sensing coil (140); the magnetic core (120), the main power coil (130), and the high-precision sensing coil (140) together constitute an inductor core; the inductor core is encapsulated within the high thermal conductivity metal casing (110). 10) Inside; The integrated thermal probe (150) is fixed on a preset monitoring point of the high thermal conductivity metal shell (110) to acquire the shell temperature signal of the high thermal conductivity metal shell (110). It also includes a controller, which reconstructs real-time magnetic state parameters based on the induced voltage signal and determines the 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 the heat source power; Combined with the shell temperature signal as a boundary condition, the controller calculates the corrected internal hot spot temperature through a preset thermodynamic model; The controller is used to compare the real-time magnetic state parameters and the corrected internal hot spot temperature with a preset safety threshold list in real time, and dynamically adjust the inverter operating parameters according to the comparison results.

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, which is used to be attached to an external liquid cooling heat sink to form a main heat dissipation channel.

3. A 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 shell (110).

4. A high-power inverter according to claim 1, characterized in that, The gaps inside the high thermal conductivity metal shell (110) are filled with high thermal conductivity insulating adhesive to conduct the 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 as described in any one of claims 1 to 4, characterized in that, include: An internal state feature list is acquired by the controller. This list includes the induced voltage signal from the high-precision sensing coil (140) and the shell temperature signal from the integrated thermal probe (150). Based on the induced voltage signal, the controller reconstructs the real-time magnetic state parameters and determines the magnetic saturation margin according to the real-time magnetic state parameters. Based on the real-time magnetic state parameters and the real-time main current, the controller calculates the heat source power. Combining the shell temperature signal as a boundary condition, the controller calculates the corrected internal hot spot temperature through a preset thermodynamic model. The controller compares the real-time magnetic state parameters and the corrected internal hot spot temperature with a preset safety threshold list in real time and dynamically adjusts the inverter operating parameters according to the comparison results.

6. The control method for 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 to calculate the magnetic flux change rate over time, thereby setting the real-time magnetic state parameter as the instantaneous magnetic flux density characterizing the internal state of the magnetic core (120).

7. The control method for 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 hot spot 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, so as to set the corrected internal hot spot temperature as the sum of the reference hot spot temperature and the transient thermal shock temperature rise compensation value.

8. The control method for 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 adjusts the inverter operating parameters to an optimized switching frequency or modulation strategy; when the corrected internal hot spot temperature approaches the upper limit of the material operating temperature, the controller adjusts the inverter operating parameters to a reduced switching frequency or a reduced current pulse peak value.

9. The control method for 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 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 condition 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.

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