A high-voltage generator and an electronic device to which the high-voltage generator is applied

Abstract

The application relates to the field of power electronics, in particular to a high-voltage generator and electronic equipment applying the same. The high-voltage generator comprises multiple DC-DC voltage-boosting channels, an FPGA controller, a driving circuit and a feedback bus. The FPGA controller generates multiple PWM control signals corresponding to the voltage-boosting channels; the driving circuit converts the PWM control signals into driving signals; the feedback bus collects the output voltage of the voltage-boosting channels and transmits the output voltage to the FPGA controller; and the FPGA controller adjusts the duty cycle of the PWM control signals according to the comparison result of the output voltage and a preset reference voltage. The application can reduce the difficulty and cost of production and manufacturing of the high-voltage generator, improve the output precision and stability of the high-voltage generator, and is easy to expand, thereby enhancing the expandability and flexibility of the high-voltage generator.

Description

Technical Field

[0001] This application relates to the field of power electronics technology, and in particular to a high-voltage generator and electronic devices thereof. Background Technology

[0002] In the field of industrial electronic automation, the development of high-power high-voltage generators is crucial. With the continuous growth of industrial production demands, these devices have been widely used in numerous products such as electroplating and plasma generators. They provide the necessary high-voltage power support for these industrial production processes, promoting the efficient development of related industries, improving production efficiency and product quality, and occupying an indispensable position in the modern industrial system.

[0003] In the past, to meet the high-voltage power requirements of industrial production, high-voltage generators generally used dedicated chips for boost control, typically employing forward or push-pull topologies. This approach could, to a certain extent, increase the voltage and provide the necessary high voltage for industrial production. However, this traditional technique also has limitations; its maximum output voltage and power depend on the selection of the boost control chip, and it usually only supports single or dual-channel boost output.

[0004] Existing high-voltage generators employ conventional methods with significant drawbacks. Because their maximum output voltage and power depend on chip selection and they typically only support single or dual-channel boost output, it is difficult to expand and precisely adjust the output voltage and power. In high-power applications, the power devices in single-channel DC-DC converters operate with high current and are large in size, making manufacturing difficult and costly. Summary of the Invention

[0005] In order to at least partially solve the above-mentioned technical problems in the related art, this application provides a high-voltage generator and an electronic device in which it is applied.

[0006] On the one hand, this application provides a high-voltage generator, which adopts the following technical solution: A high-voltage generator, comprising: Multiple DC-DC boost channels, each of which is configured to convert a low-voltage DC signal into a high-voltage DC signal according to a drive signal, and the multiple high-voltage DC signals are combined into a high-voltage output signal; The FPGA controller is configured to generate multiple PWM control signals, each of which corresponds to a different DC-DC boost channel. The driving circuit, connected to the input terminals of the FPGA controller and the plurality of DC-DC boost channels, is configured to generate a plurality of driving signals according to the plurality of PWM control signals, the driving signals being used to control the corresponding DC-DC boost channels; A feedback bus, connected to the output terminals of the FPGA controller and the plurality of DC-DC boost channels, is configured to feed back the high-voltage output signal to the FPGA controller, wherein the FPGA controller compares the high-voltage output signal with a preset reference voltage to adjust the duty cycle of the PWM control signal.

[0007] By adopting the above technical solution and setting up multiple DC-DC boost channels to aggregate the high-voltage output signals, the high-power boost task can be decomposed into multiple parallel low-power channel tasks. This reduces the operating current and size of the power devices in a single channel, thereby reducing the difficulty and cost of manufacturing. Simultaneously, by using an FPGA controller to generate control signals and acquiring the high-voltage output signal through a feedback bus, a closed-loop negative feedback control is formed. This allows for real-time adjustment of the duty cycle of the PWM control signal, thereby accurately and stably controlling the high-voltage output signal and improving the output accuracy and stability of the high-voltage generator. Furthermore, the FPGA-based solution makes it easy to expand the number of boost channels, enhancing the scalability and flexibility of the high-voltage generator.

[0008] Optionally, the DC-DC boost channel includes a power transistor, a transformer, and a rectifier. The power transistor has a control terminal, a power input terminal, and a power output terminal. The transformer has a primary coil and a secondary coil. The control terminal of the power transistor is connected to the drive circuit to receive the drive signal. The first end of the primary coil of the transformer is connected to the DC input terminal to receive a low-voltage DC signal. The second end of the primary coil of the transformer is connected to the power input terminal of the power transistor, and the power output terminal of the power transistor is grounded. The first end of the secondary coil of the transformer is connected to the DC output terminal through the rectifier to output a high-voltage DC signal. The second end of the secondary coil of the transformer is connected to ground.

[0009] By employing the above technical solution, a specific, effective, and structurally simple circuit topology is provided to realize each DC-DC boost channel through a combination of power transistors, transformers, and rectifier components. This solution utilizes the high-speed switching function of the power transistors, combined with the transformer to achieve voltage boosting and electrical isolation, and then obtains a stable high-voltage DC output through rectifier components, ensuring the reliability and safety of each boost channel.

[0010] Optionally, the power transistor may include a MOSFET or an IGBT.

[0011] By adopting the above technical solution and specifying that the power transistor is a MOSFET or an IGBT, the advantages of these two types of devices, such as fast switching speed, low drive power, low on-state voltage drop, and large power capacity, are utilized. This helps to improve the switching frequency and conversion efficiency of the DC-DC boost channel, reduce power loss, and thus improve the overall performance of the high-voltage generator.

[0012] Optionally, the FPGA controller includes multiple PWM modules, each corresponding to a different DC-DC boost channel; wherein, the PWM module is connected to the drive circuit and the feedback bus, and is used to generate a PWM control signal and compare the high-voltage output signal with a preset reference voltage to adjust the duty cycle of the PWM control signal.

[0013] By employing the above technical solution, multiple PWM modules corresponding one-to-one with the DC-DC boost channels are set up inside the FPGA controller, realizing modular and parallel processing of the control logic. Each PWM module is independently responsible for the generation of PWM signals and closed-loop feedback regulation of its corresponding channel, simplifying the internal logic design of the FPGA, improving the real-time performance and response speed of the control, and making the system more flexible and scalable when increasing or decreasing the number of boost channels.

[0014] Optionally, the plurality of PWM modules are configured to generate a plurality of PWM control signals with phase differences uniformly distributed within a preset range.

[0015] By employing the above technical solution, multi-channel interleaved parallel control is achieved by uniformly distributing the phase differences of multiple PWM control signals. This method effectively smooths the total current drawn from the input terminal, significantly reduces input current ripple, thereby reducing the requirements for the input filter capacitor, reducing capacitor heating, and helping to suppress electromagnetic interference, thus improving the power quality and stability of the entire system.

[0016] Optionally, the FPGA controller includes three PWM modules, and the phase difference between the multiple PWM control signals is 120 degrees.

[0017] Using the above technical solution, taking three PWM modules and a 120-degree phase difference as an example, a specific and optimized multiphase interleaved control implementation method is provided. Three-phase interleaving can effectively cancel some input current harmonics, achieving lower input current ripple, and further enhancing the technical solution's effectiveness in reducing ripple and electromagnetic interference.

[0018] Optionally, the FPGA controller further includes an I2C bus and a configuration register group; wherein, the I2C bus is used to connect to a host computer or MCU to receive configuration instructions; the configuration register group is connected to the I2C bus and is used to set the preset reference voltage according to the configuration instructions.

[0019] By adopting the above technical solution and adding an I2C bus and configuration register group, an interface for communication and interaction between the high-voltage generator and a host computer or microcontroller is provided. Users or the main control system can easily send configuration commands through this interface to dynamically set or adjust the preset reference voltage, thereby achieving remote, precise, and flexible programmable control of the output voltage, greatly enhancing the applicability and intelligence level of the high-voltage generator.

[0020] Optionally, the driving circuit includes multiple driving units, each of which is connected to the corresponding PWM module and the DC-DC boost channel.

[0021] By employing the above technical solution and equipping each DC-DC boost channel with an independent drive unit, it is ensured that each PWM control signal generated by the FPGA controller can be effectively amplified, providing a sufficiently strong and stable drive capability for the corresponding power transistor. This one-to-one drive method avoids signal crosstalk between channels, ensuring that each power transistor can be turned on and off quickly and reliably, thereby guaranteeing the efficient operation of each boost channel.

[0022] Optionally, the feedback bus has multiple feedback terminals, each of which is connected to a corresponding PWM module.

[0023] By adopting the above technical solution, and connecting the feedback bus to each corresponding PWM module, it is ensured that all parallel control loops are regulated based on the same final, aggregated high-voltage output signal. This enables all boost channels to work together to maintain stable output voltage, avoiding channel imbalances that may result from independent feedback, and ensuring the stability and consistency of the entire system.

[0024] On the other hand, this application also provides an electronic device that adopts the following technical solution: An electronic device having the high-voltage generator.

[0025] By adopting the above technical solution, the electronic equipment utilizes the aforementioned high-voltage generator, enabling it to possess high-power, high-efficiency, high-stability, and easily expandable high-voltage power supply capabilities. This makes it well-suited for applications such as plasma welders, high-frequency induction furnaces, and ozone generators. This helps improve the overall performance of the electronic equipment, reduce its production cost and size, and enhance its operational reliability and control flexibility.

[0026] In summary, this application includes at least one of the following beneficial technical effects: 1. By setting up multiple DC-DC boost channels and aggregating the high-voltage output signals, the high-power boost task can be decomposed into multiple parallel low-power channel tasks, reducing the operating current and size of power devices in a single channel, thereby reducing manufacturing difficulty and cost. Simultaneously, using an FPGA controller to generate control signals and acquiring high-voltage output signals via a feedback bus forms a closed-loop negative feedback control, enabling real-time adjustment of the PWM control signal's duty cycle. This allows for precise and stable control of the high-voltage output signal, improving the output accuracy and stability of the high-voltage generator. Furthermore, the FPGA-based solution makes it easy to expand the number of boost channels, enhancing the scalability and flexibility of the high-voltage generator.

[0027] 2. By setting up multiple PWM modules within the FPGA controller, each corresponding to a DC-DC boost channel, modular and parallel processing of the control logic is achieved. Each PWM module is independently responsible for generating the PWM signal and adjusting the closed-loop feedback for its corresponding channel. This simplifies the internal logic design of the FPGA, improves the real-time performance and response speed of the control, and makes the system more flexible and scalable when increasing or decreasing the number of boost channels.

[0028] 3. By uniformly distributing the phase differences of multiple PWM control signals, multi-channel interleaved parallel control is achieved. This method effectively smooths the total current drawn from the input, significantly reduces input current ripple, thereby reducing the requirements for the input filter capacitor, reducing capacitor heating, and helping to suppress electromagnetic interference, thus improving the power quality and stability of the entire system. Attached Figure Description

[0029] Figure 1 A schematic diagram of the circuit structure of a high-voltage generator according to an embodiment of this application is shown.

[0030] Figure labeling: 10, DC-DC boost channel; 11, power transistor; 12, transformer; 13, rectifier element; 20, FPGA controller; 21, PWM module; 22, I2C bus; 23, configuration register group; 30, drive circuit; 31, drive unit; 40, feedback bus. Detailed Implementation

[0031] The present application will be further described in detail below with reference to the accompanying drawings.

[0032] Figure 1 A circuit structure diagram of a high-voltage generator according to an embodiment of this application is shown. (Refer to...) Figure 1The high-voltage generator includes multiple DC-DC boost channels 10, a field-programmable gate array (FPGA) controller 20, a drive circuit 30, and a feedback bus 40. The multiple DC-DC boost channels 10 are responsible for boosting the input DC voltage. Each DC-DC boost channel 10 includes a power transistor 11, a transformer 12, and a rectifier element 13 connected in sequence. The FPGA controller 20 generates at least three PWM control signals in parallel, each corresponding to a specific DC-DC boost channel, to control the boosting process. The drive circuit 30 is connected between the FPGA controller 20 and the power transistor 11, converting the PWM control signals into drive signals that can drive the power transistor 11. The feedback bus 40 is used to collect the output voltage information of the DC-DC boost channels 10 and transmit it to the FPGA controller 20. The FPGA controller 20 adjusts the duty cycle of the PWM control signals in real time based on the comparison between the output voltage information and a preset reference voltage to achieve a stable output voltage. Because of the use of a multi-channel parallel connection, high-power tasks can be decomposed into multiple low-power channel tasks, which reduces the operating current and size of power devices. At the same time, by adjusting the duty cycle in real time, the output voltage can be accurately stabilized.

[0033] In some embodiments, each DC-DC boost channel 10 includes a power transistor 11, a transformer 12, and a rectifier element 13.

[0034] Power transistor 11 can be either a MOSFET or an IGBT. Taking a MOSFET as an example, it features fast switching speed and high input impedance. A MOSFET has three terminals: gate, source, and drain. The gate serves as the control terminal, receiving the drive signal from the drive circuit 30. When the drive signal turns on the MOSFET, the power supply current can flow through the primary coil of transformer 12 and the MOSFET; when the drive signal turns off the MOSFET, the current in the primary coil of transformer 12 is cut off. Besides MOSFETs, IGBTs are also a suitable choice. IGBTs combine the advantages of MOSFETs and bipolar transistors, offering high voltage and high current carrying capacity.

[0035] Transformer 12 is generally a step-up transformer, which consists of a primary coil and a secondary coil. The first end of the primary coil is connected to a DC power supply, and the second end is connected to the drain of the power transistor 11. When the power transistor 11 is turned on, the power supply provides current to the primary coil, and energy is stored in the transformer 12 in the form of a magnetic field; when the power transistor 11 is turned off, according to the principle of electromagnetic induction, a high voltage will be induced in the secondary coil.

[0036] The rectifier element 13 is typically a diode, which converts the high-voltage alternating current induced in the secondary coil of transformer 12 into direct current. The anode of the diode is connected to the secondary coil of transformer 12, and the cathode outputs the rectified direct current.

[0037] The combinational logic of the DC-DC boost channel 10 is as follows: the power transistor 11 acts like a high-speed switch, chopping the DC input from the DC power supply into a high-frequency square wave, which is then input to the transformer 12. The transformer 12 boosts the voltage, and finally, the AC power is converted back to DC power by the rectifier element 13. This combination enables voltage boosting, and each boost channel can complete this process independently. Multiple channels connected in parallel can achieve high-power output.

[0038] In some embodiments, the FPGA controller 20 includes multiple PWM modules 21, an I2C bus 22, and a configuration register group 23. Each PWM module 21 corresponds to a boost channel, and each PWM module 21 integrates an analog-to-digital converter (ADC) and a slope generator. An external host computer or MCU (not shown) is connected to the FPGA controller 20 via the I2C bus 22, writing instructions to the configuration register group 23 inside the FPGA controller 20 to set a reference voltage value. The DC high-voltage signal from the DC-DC boost channel 10 is fed back to the feedback terminal (Feedback, FB) of the FPGA controller 20 via the feedback bus 40. The feedback DC high-voltage signal is sampled by the ADC of each PWM module 21. The ADC converts the analog voltage into a digital value and compares it with the reference voltage value. The slope generator adjusts the duty cycle of the PWM control signal of the PWM module 21 in real time based on the comparison result. Optionally, the FPGA controller 20 is configured to uniformly distribute the phase difference of the PWM control signal within a preset range. For example, three PWM modules 21 can be configured to form three outputs. With three outputs, the phase difference between the three PWM control signals is exactly 120 degrees. This design reduces input ripple, decreases filter capacitor heating, and reduces EMC electromagnetic radiation. Due to the phase difference, each boost channel performs power conversion at different times, resulting in a smoother total current drawn from the DC power supply. This application uses an FPGA controller 20 as the boost controller. The number of boost channels is related to the number of input / output ports and internal logic gate resources (i.e., the number of PWM modules 21) of the FPGA controller 20. The FPGA controller 20 is programmable; the more input / output ports and internal logic gate resources it has, the more boost channels it can support, thus enabling scalability. This allows for easily achieving four to dozens of boost channels, featuring high output power, low ripple, and easy scalability, making it ideal for applications such as plasma welding, high-frequency induction furnaces, and ozone generators.

[0039] In some embodiments, the driving circuit 30 includes a plurality of independent driving units 31, each driving unit 31 being electrically connected to the output terminal of the FPGA controller 20 and the control terminal of the power transistor 11. The main function of the driving unit 31 is to amplify the low-power PWM control signal from the FPGA controller 20 and convert it into a driving signal sufficient to quickly and completely turn the power transistor 11 on and off.

[0040] In some embodiments, the feedback bus 40 is a common signal line. The feedback bus 40 collects the output voltage signals of each DC-DC boost channel 10 and transmits them to the FPGA controller 20, so that the FPGA controller 20 can fully understand the status of the output voltage and make real-time adjustments.

[0041] Through actual testing, with an output power of 50KW, a switching frequency of 50KHz for the DC-DC boost channel 10, and using ten DC-DC boost channels 10 for conversion, combined with real-time calculation and synchronous rectification by the FPGA controller 20, this multi-channel parallel scheme effectively reduces the operating current of a single channel, making the manufacturing process of the entire circuit simpler and more controllable. The efficiency of this high-voltage generator reaches 98%, which is 3%-5% higher than traditional single-channel or dual-channel parallel technologies. Compared to using expensive high-power transformers and power transistors, this solution has lower manufacturing costs, saving more than 25% in costs.

[0042] The implementation principle of a high-voltage generator according to an embodiment of this application is as follows: Utilizing the powerful digital processing capabilities of the FPGA controller 20, the high-power high-voltage output task is decomposed into multiple parallel, easily controllable low-power channels. The FPGA controller 20 controls the operation of each boost channel by generating PWM control signals. The feedback bus 40 acquires the output voltage in real time, and the FPGA controller 20 adjusts the duty cycle of the PWM signal in real time based on the comparison result between the output voltage and the preset reference voltage to ensure the stability and accuracy of the output voltage. Simultaneously, the parallel connection of multiple channels and the differential phase control of the PWM signal reduce the operating current of single-channel power devices, reduce input ripple and electromagnetic radiation, improve circuit efficiency, reduce production costs, and facilitate scalability. Compared with traditional high-voltage generators, it has significant advantages and promising application prospects in the field of industrial electrical automation.

[0043] This application also discloses an electronic device comprising the high-voltage generator described in the foregoing embodiments. This electronic device may be, for example, a plasma welder, a high-frequency induction furnace, an ozone generator, etc.

[0044] The implementation principle of an electronic device according to an embodiment of this application is as follows: Because the electronic device employs the aforementioned high-voltage generator, it possesses high-power, high-efficiency, high-stability, and easily expandable high-voltage power supply capabilities, making it well-suited for applications such as plasma welders, high-frequency induction furnaces, and ozone generators. This helps improve the overall performance of the electronic device, reduce its production cost and size, and enhance its operational reliability and control flexibility.

[0045] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A high-voltage generator, characterized in that, include: Multiple DC-DC boost channels (10), each of the DC-DC boost channels (10) is configured to convert a low-voltage DC signal into a high-voltage DC signal according to a drive signal, and the multiple high-voltage DC signals are combined into a high-voltage output signal; The FPGA controller (20) is configured to generate multiple PWM control signals, each of which corresponds to a different DC-DC boost channel (10). The driving circuit (30) is connected to the input terminals of the FPGA controller (20) and the plurality of DC-DC boost channels (10), and is configured to generate a plurality of driving signals according to the plurality of PWM control signals, the driving signals being used to control the corresponding DC-DC boost channels (10). Feedback bus (40), connected to the output of the FPGA controller (20) and the plurality of DC-DC boost channels (10), is configured to feed back the high voltage output signal to the FPGA controller (20), wherein the FPGA controller (20) compares the high voltage output signal with a preset reference voltage to adjust the duty cycle of the PWM control signal.

2. The high-voltage generator according to claim 1, characterized in that, The DC-DC boost channel (10) includes a power transistor (11), a transformer (12), and a rectifier (13). The power transistor (11) has a control terminal, a power input terminal, and a power output terminal. The transformer (12) has a primary coil and a secondary coil. The control terminal of the power transistor (11) is connected to the drive circuit (30) to receive the drive signal. The first end of the primary coil of the transformer (12) is connected to the DC input terminal to receive a low-voltage DC signal. The second end of the primary coil of the transformer (12) is connected to the power input terminal of the power transistor (11), and the power output terminal of the power transistor (11) is grounded. The first end of the secondary coil of the transformer (12) is connected to the DC output terminal through the rectifier (13) to output a high-voltage DC signal. The second end of the secondary coil of the transformer (12) is connected to ground.

3. The high-voltage generator according to claim 2, characterized in that, The power transistor (11) includes a MOSFET or an IGBT.

4. The high-voltage generator according to claim 1, characterized in that, The FPGA controller (20) includes multiple PWM modules (21), each of which corresponds to a different DC-DC boost channel (10). The PWM module (21) is connected to the drive circuit (30) and the feedback bus (40) to generate a PWM control signal and compare the high voltage output signal with a preset reference voltage to adjust the duty cycle of the PWM control signal.

5. The high-voltage generator according to claim 4, characterized in that, The plurality of PWM modules (21) are configured to generate a plurality of PWM control signals with phase differences uniformly distributed within a preset range.

6. The high-voltage generator according to claim 5, characterized in that, The FPGA controller (20) includes three PWM modules (21), and the phase difference between the multiple PWM control signals is 120 degrees.

7. The high-voltage generator according to claim 4, characterized in that, The FPGA controller (20) further includes an I2C bus (22) and a configuration register group (23); wherein, the I2C bus (22) is used to connect to a host computer or MCU to receive configuration instructions; the configuration register group (23) is connected to the I2C bus (22) and is used to set the preset reference voltage according to the configuration instructions.

8. The high-voltage generator according to claim 4, characterized in that, The driving circuit (30) includes multiple driving units (31), each of which is connected to the corresponding PWM module (21) and the DC-DC boost channel (10).

9. The high-voltage generator according to claim 4, characterized in that, The feedback bus (40) has multiple feedback terminals, each of which is connected to the corresponding PWM module (21).

10. An electronic device, characterized in that, It has a high-voltage generator as described in any one of claims 1-9.

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