A control method for a DC-DC converter and the DC-DC converter

Abstract

This invention discloses a control method and a DC-DC converter for a DC-DC converter, belonging to the field of power electronics technology. The method includes: when a starting current is detected from the DC input power supply to the DC-DC converter, controlling the DC input power supply to charge a detection energy storage capacitor in a forward detection module; when the detection energy storage capacitor is detected to be charged to a preset detection voltage, disconnecting the DC-DC converter from the DC input power supply and controlling the detection energy storage capacitor to discharge and detect the discharge; obtaining the current overall power conversion efficiency of the DC-DC converter and the power change information of multiple lifespan-limiting components within the DC-DC converter; and generating current health status information and estimated lifespan information of the DC-DC converter based on the current overall conversion efficiency and power change information. This invention helps reduce the risks and troubleshooting difficulties associated with long-term converter use.

Description

Technical Field

[0001] This invention relates to the field of power electronics technology, and specifically to a control method for a DC-DC converter and a DC-DC converter. Background Technology

[0002] With the rapid development of electricity demand and various electronic devices, the demand for diverse power supply is also gradually increasing. In devices requiring direct current (DC), using a voltage converter to convert the DC voltage to the required operating voltage is a mature and stable voltage conversion technology. Commonly used DC-DC converters in existing technologies include Buck converters, Boost converters, flyback converters, and forward converters.

[0003] Many DC-DC converters utilize various lifespan-limiting components, such as switching transistors and isolation transformers. With prolonged use, the overall performance and lifespan-limiting components of a DC-DC converter may gradually age, manifesting as a gradual decline in conversion efficiency, increased contact impedance of critical components, or deterioration of insulation performance. However, in conventional technologies, it is often difficult to detect and understand the lifespan and health status of DC-DC converters in a timely manner, typically relying on periodic manual inspections. This approach has the following drawbacks: First, manual troubleshooting requires specialized technicians and equipment, making the process difficult and inefficient, especially when the converter is installed in a concealed location or the system is highly integrated, further complicating the disassembly and testing process. Second, manual troubleshooting typically only occurs after a significant fault or performance degradation has occurred, representing a reactive, post-event response. It is difficult to proactively intervene in the early stages of degradation and cannot provide timely warnings and maintenance for converters undergoing gradual aging. Third, manual troubleshooting struggles to accurately and independently assess and quantify the lifespan-limiting components within the converter, making it impossible to predict the converter's remaining lifespan or dynamically plan its load-bearing capacity based on the degree of aging.

[0004] Therefore, in the field of DC-DC converters, how to provide a technical means to automatically detect the health status and estimate the service life of the converter before it is put into operation, thereby reducing the risks of long-term use and the difficulty of manual inspection, is a technical problem that needs to be improved. Summary of the Invention

[0005] The purpose of this invention is to provide a control method and a DC-DC converter, which can detect and analyze the health status and lifespan of the converter before DC power is applied to the voltage modulation main module, thereby helping to reduce the risks and troubleshooting difficulties of long-term use of the converter.

[0006] To achieve the above objectives, the technical solution adopted by the present invention is as follows: A control method for a DC-DC converter, comprising: Step 1: When a startup current is detected in the DC-DC converter from the DC input power supply, control the DC input power supply to charge the detection energy storage capacitor in the forward detection module; Step 2: When the detection energy storage capacitor is detected to be charged to the preset detection voltage, disconnect the DC-DC converter from the DC input power supply and control the detection energy storage capacitor to discharge for detection; Step 3: Obtain the current overall power conversion efficiency of the DC-DC converter and the power change information of multiple life-limiting components within the DC-DC converter; Step 4: Based on the current overall conversion efficiency and power change information of the DC-DC converter, generate the current health status information and estimated service life information of the DC-DC converter.

[0007] Further, in step 4, based on the current overall conversion efficiency and power change information of the DC-DC converter, health status information and estimated lifespan information of the DC-DC converter are generated, specifically as follows: Step 401: Generate the current health status information of the DC-DC converter based on the preset estimated conversion efficiency threshold and the current overall conversion efficiency; Step 402: Based on the current overall conversion efficiency and the pre-stored overall efficiency experimental prediction data, generate the overall estimated remaining lifetime of the DC-DC converter; Step 403: Based on the power change information of multiple life-limited components in the DC-DC converter, generate the estimated remaining life of multiple life-limited components. Step 404: Filter out the estimated limit life from multiple estimated remaining life of components, and subtract the preset component nonlinear change duration from the estimated limit life to generate the estimated retention time. Step 405: Generate the estimated lifespan information of the DC-DC converter based on the overall estimated remaining lifespan and estimated warranty period.

[0008] Further, in step 401, based on the preset estimated conversion efficiency threshold and the current overall conversion efficiency, the current health status information of the DC-DC converter is generated, specifically as follows: Compare the current overall conversion efficiency of the DC-DC converter with the preset estimated conversion efficiency threshold; If the current overall conversion efficiency is greater than the estimated conversion efficiency threshold, then generate current health status information carrying a health identifier; If the current overall conversion efficiency is less than or equal to the estimated conversion efficiency threshold, then current health status information carrying an anomaly flag is generated.

[0009] Further, in step 402, based on the current overall conversion efficiency and pre-stored experimental prediction data of overall efficiency, the overall estimated remaining lifetime of the DC-DC converter is generated, specifically as follows: Based on the current overall conversion efficiency, the corresponding overall theoretical usage time and overall theoretical remaining lifespan are matched with the overall efficiency experimental prediction data. The actual reduction ratio of the overall lifespan is calculated by dividing the total actual usage time of the current DC-DC converter, which is recorded in advance, by the total theoretical usage time. The overall estimated remaining lifespan of the DC-DC converter is calculated by multiplying the actual reduction rate of the overall lifespan by the overall theoretical remaining lifespan.

[0010] Further, in step 403, based on the power change information of multiple lifespan-limited components within the DC-DC converter, the estimated remaining lifespan of the multiple lifespan-limited components is generated, specifically as follows: Based on the power change information of multiple life-limiting components in the DC-DC converter, the average unit power loss of the life-limiting components is obtained within a preset unit time after the energy storage capacitor discharges. For each life-limited component, the theoretical service life and theoretical remaining life of the component are matched with the corresponding power loss per unit of the component in the corresponding power loss change data. Obtain the actual usage time of each life-limited component, and calculate the actual life-limit reduction ratio of each component by dividing the actual usage time of the life-limited component by the theoretical usage time of the component. The estimated remaining lifespan of each life-limited component is calculated by multiplying its theoretical remaining lifespan by the actual reduction ratio of its lifespan.

[0011] Further, in step 404, the estimated limit lifetime is selected from multiple estimated remaining lifetimes of components, and the estimated limit lifetime is subtracted from the preset component nonlinear change duration to generate the estimated retention time, specifically as follows: By comparing the estimated remaining lifetime of multiple components, the component with the smallest estimated remaining lifetime is selected, which is the estimated limit lifetime. Obtain the duration of nonlinear change of the component, subtract the duration of nonlinear change of the component from the estimated limited life, and calculate the estimated hold-up time.

[0012] Further, in step 405, based on the overall estimated remaining lifespan and estimated warranty period, the estimated lifespan information of the DC-DC converter is generated, specifically as follows: Compare the overall estimated remaining lifespan with the estimated maintenance duration; If the estimated warranty period is longer than the overall estimated remaining lifespan, then the estimated lifespan information of the DC-DC converter is generated based on the overall estimated remaining lifespan. If the estimated duration of blessing is less than or equal to the overall estimated remaining lifespan, then the estimated limited lifespan will be compared with the overall estimated remaining lifespan. If the estimated limited lifespan is greater than the overall estimated remaining lifespan, then the lifespan between the estimated hold-up time after the current moment and the overall estimated remaining lifespan is obtained, which is the abnormal fluctuation lifespan of the component. If the estimated limited lifespan is less than or equal to the overall estimated remaining lifespan, then obtain the estimated hold-up time after the current moment and the lifespan between the estimated limited lifespan and the estimated lifespan, i.e., the abnormal fluctuation lifespan of the component. Within the estimated retention period after the current moment, generate the normal aging indicator of the DC-DC converter. Within the abnormal aging life of the components, generate the abnormal aging indicator of the internal components of the converter, and summarize and generate the estimated life of the converter.

[0013] Furthermore, step 4 also includes: Based on the unit power loss of multiple components and the corresponding estimated remaining lifespan, a fitting aging lifespan coefficient for the DC-DC converter is generated. Based on the overall estimated remaining lifespan and the fitted aging lifespan coefficient, the proportion of the fitted expected error is calculated. If the estimated hold-up time is longer than the overall estimated remaining lifespan, then from the current moment to the overall estimated remaining lifespan, the adaptable load power information of the DC-DC converter is generated based on the pre-acquired overall load power adjustment data. If the estimated warranty period is less than or equal to the overall estimated remaining lifespan, then from the current moment to the estimated warranty period, the first stage load power information will be generated based on the overall load power adjustment data. Within the estimated retention time and estimated limited life, estimated fitting life transformation data is generated based on the power loss transformation data corresponding to each life-limiting component model. Based on the estimated fitting lifetime transformation data and the expected fitting error ratio, the second-stage load power information is generated. Based on the load power information of the first stage and the load power information of the second stage, the adaptable load power information of the converter is generated.

[0014] The present invention also provides a DC-DC converter and a control method for the DC-DC converter according to any one of claims 1 to 7, comprising: a DC input power supply, a voltage modulation main module, a pre-detection module, a controller, and a detection load module, wherein the DC input power supply is connected to the pre-detection module, the pre-detection module is connected to the voltage modulation main module, the voltage modulation main module is connected to the detection load module, and the controller is connected to the pre-detection module; The voltage modulation main module is used to regulate the DC voltage input to the DC-DC converter from the DC input power supply. The pre-detection module is used to store electrical energy and perform discharge detection before the voltage modulation main module is put into use. The controller is used to perform data analysis, logical judgment, and detection process control. The detection load module is used to bear the detection load during the detection process.

[0015] Furthermore, the pre-detection module includes a detection energy storage capacitor, a fast switch, a relay, a detection power supply switch transistor, a linear voltage regulator submodule, and a detection power supply switch transistor. The positive terminal of the DC input power supply is connected to the drain of the fast switch and the detection power supply switch transistor. The source of the detection power supply switch transistor is connected to the linear voltage regulator submodule. The linear voltage regulator submodule is connected to the first terminal of the detection energy storage capacitor and the relay. The second terminal of the detection energy storage capacitor is connected to the negative terminal of the DC input power supply. The fast switch and the relay are both connected to the voltage modulation main module.

[0016] In summary, the present invention has at least one of the following beneficial technical effects: First, a pre-emptive converter health status detection method is provided. This application adds a pre-detection module to the front end of the converter's voltage modulation main module. Before the DC input power supply officially supplies power to the voltage modulation main module, the detection energy storage capacitor is charged first, and then the detection energy storage capacitor is controlled to discharge and detect the voltage modulation main module. By analyzing the current overall power conversion efficiency and the power change information of multiple life-limiting components obtained during the discharge detection process, a pre-assessment of the converter's health status and service life can be achieved, avoiding the safety risks and potential hazards caused by directly putting the converter into operation when it already has serious aging.

[0017] Second, the health status assessment is comprehensive. This application employs a dual assessment approach, evaluating both the overall converter conversion efficiency and the individual lifespan-limiting components. The overall assessment compares the current overall conversion efficiency with the estimated conversion efficiency threshold, generating intuitive health or anomaly indicators to quickly determine the converter's macroscopic health status. The component-level assessment analyzes the power consumption changes of each lifespan-limiting component to calculate its estimated remaining lifespan, enabling the detection of abnormal aging trends in individual components at the microscopic level. This dual-dimensional cross-assessment makes the assessment results more reliable.

[0018] Third, it provides intelligent lifespan prediction capabilities. This application compares the overall estimated remaining lifespan calculated based on the overall conversion efficiency with the estimated hold-up time calculated based on the power loss of each component, taking the smaller one as the estimated lifespan of the converter. It further distinguishes between normal aging stages and abnormal component fluctuation stages, generating estimated lifespan information with stage-specific identifiers. This approach considers both the overall aging trend of the converter and the potential failure risks caused by the aging of internal key components, helping to reduce the probability of converter damage or excessive efficiency degradation during subsequent use.

[0019] Fourth, it can generate dynamically adaptable load power recommendations. After assessing the health status and lifespan of the converter, this application can also generate adaptable load power information that changes over time for different aging stages based on overall load power adjustment data and power loss conversion data of each lifespan-limiting component. This guides users to reasonably adjust the load intensity of the converter at different usage stages, helping to reduce the risk of the converter operating under overload conditions for a long time and slowing down the aging process of the converter.

[0020] Fifth, it has good compatibility and relatively controllable implementation costs. While retaining and maintaining compatibility with the original voltage modulation main module structure, the system of this application enhances functionality by connecting a front-end detection module and a detection load module at the front end. This eliminates the need for fundamental modifications to the internal topology of the existing voltage modulation main module, making it easy to add to or upgrade existing DC-DC converter systems. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the DC-DC converter structure of the present invention; Figure 2 This is a schematic diagram of the method flow of the present invention; Figure 3 A schematic diagram illustrating the process of generating current health status information and estimated lifespan information; Figure 4 This is a schematic diagram of the process for generating adaptable load power information. Detailed Implementation

[0022] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention. Furthermore, the technical features involved in the various embodiments of this invention described below can be combined with each other as long as they do not conflict with each other.

[0023] like Figure 1 As shown, the present invention provides a DC-DC converter, including: a DC input power supply, a voltage modulation main module, a pre-detection module, a controller, and a detection load module. The DC input power supply is connected to the pre-detection module, the pre-detection module is connected to the voltage modulation main module, the voltage modulation main module is connected to the detection load module, and the controller is connected to the pre-detection module. The voltage modulation main module is used to regulate the DC voltage input to the converter. It can be an isolated flyback voltage regulator or a non-isolated BUCK voltage regulator module, etc., to regulate the DC voltage input to the converter. The pre-detection module is used to store a certain amount of electrical energy and detect the health status and lifespan of the voltage modulation module before it is put into use. The controller is used to perform data analysis, logical judgment, and detection process control. The detection load module is used to perform the function of detecting the load during the detection process of the voltage modulation main module.

[0024] The pre-detection module includes a detection energy storage capacitor C, a fast switch K1, a relay KJ, a detection power supply switch Q2, and a linear voltage regulation submodule. The positive terminal of the DC input power supply is connected to the drain of the fast switch K1 and the detection power supply switch Q2. The source of the detection power supply switch Q2 is connected to the linear voltage regulation submodule. The linear voltage regulation submodule is connected to the first terminal of the detection energy storage capacitor C and the relay KJ. The second terminal of the detection energy storage capacitor C is connected to the negative terminal of the DC input power supply. Both the fast switch K1 and the relay KJ are connected to the voltage modulation main module.

[0025] The pre-detection module also includes a voltage sensor and a current sensor; The voltage sensor is connected in parallel with the detection energy storage capacitor C to monitor the voltage across the detection energy storage capacitor C in order to detect the voltage across the load module. The current sensor is connected between the linear voltage regulator submodule and the relay KJ to monitor the current flowing through the detection load module and the current flowing through each lifespan limiting element. It should also be noted that multiple control terminals of the controller are connected to the control terminals of the fast switch K1, the power supply detection switch Q2, and the relay KJ, respectively, to control the fast switch K1 and the relay KJ to open or close, and to control the power supply detection switch Q2 to turn on and off. Another control terminal of the controller is also connected to the control terminal of the voltage modulation main module, and is used to input PWM control signals to the switching transistors in the voltage modulation main module, so that the voltage modulation main module can regulate the DC voltage.

[0026] At the initial stage of the DC input power supply inputting current to the DC-DC converter, the controller first controls the fast switch K1 and the relay KJ to open, and controls the detection power supply switch Q2 to turn on; at this time, the DC input power supply first charges the detection energy storage capacitor C through the linear voltage regulation submodule, so that the voltage of the detection energy storage capacitor C reaches the preset detection voltage.

[0027] Next, the controller controls the power supply switch Q2 to turn off and controls the relay KJ to close. At this time, the energy storage capacitor C is detected to release electrical energy to the voltage modulation main module. Then, by monitoring the working status of multiple life-limiting components in the voltage modulation main module and the overall working status of the DC-DC converter, the health status and lifespan of the DC-DC converter are analyzed.

[0028] After the DC-DC converter test is completed, the control power supply switch Q2 is turned off, the relay KJ is opened, and the fast switch K1 is closed, so that the voltage modulation main module is in working state.

[0029] Voltage sensors are used to monitor the voltage across the energy storage capacitor, and voltage transformers can also be used to monitor the voltage across the load module and the voltage across multiple lifespan-limiting components. Current sensors are used to monitor the current flowing through the load module and the current flowing through multiple lifespan-limiting components.

[0030] like Figure 2 As shown, the present invention also provides a control method for a DC-DC converter, comprising: Step 1: When a startup current is detected in the DC-DC converter from the DC input power supply, control the DC input power supply to charge the detection energy storage capacitor in the forward detection module; Step 2: When the detection energy storage capacitor is detected to be charged to the preset detection voltage, disconnect the DC-DC converter from the DC input power supply and control the detection energy storage capacitor to discharge for detection; Step 3: Obtain the current overall power conversion efficiency of the DC-DC converter and the power change information of multiple life-limiting components within the DC-DC converter; Step 4: Based on the current overall conversion efficiency and power change information of the DC-DC converter, generate the current health status information and estimated service life information of the DC-DC converter.

[0031] In step 1, when a startup current is detected flowing from the DC input power supply to the DC-DC converter, the DC input power supply is controlled to charge the detection energy storage capacitor in the forward detection module. Specifically: When the DC-DC converter is not powered on, the fast switch and relay remain open, while the power supply detection switch remains on. When the DC input power is initially connected to the DC-DC converter, the current sensor detects the starting current flowing through the pre-detection module. At this time, the DC input power is controlled to charge the energy storage capacitor in the pre-detection module, so as to facilitate subsequent discharge detection by detecting the energy storage capacitor.

[0032] In step 2, when the detection energy storage capacitor is detected to have charged to the preset detection voltage, the connection between the DC-DC converter and the DC input power supply is disconnected, and the detection energy storage capacitor is controlled to discharge for detection. Specifically: The linear voltage regulation submodule outputs DC power to charge the detection energy storage capacitor; When the voltage across the energy storage capacitor reaches the preset detection voltage, the controller controls the detection power supply switch to turn off and controls the relay to close. At this time, the energy storage capacitor discharges to the voltage modulation main module, and the controller identifies and judges the health status and service life of the DC-DC converter by detecting the status of the voltage modulation main module.

[0033] In step 3, the current overall power conversion efficiency of the DC-DC converter and the power change information of multiple lifespan-limited components within the DC-DC converter are obtained, specifically as follows: The controller acquires the power conversion efficiency of the converter during the entire discharge process of the detection energy storage capacitor, which is referred to here as the current overall power conversion efficiency. In addition, the controller acquires the voltage transformation information and current change information of multiple life-limiting components during the discharge process of the detection energy storage capacitor, and compiles the voltage change information and current change information into power change information for each life-limiting component.

[0034] like Figure 3 As shown, in step 4, based on the current overall conversion efficiency and power change information of the DC-DC converter, the health status information and estimated service life information of the DC-DC converter are generated, specifically as follows: Step 401: Generate the current health status information of the DC-DC converter based on the preset estimated conversion efficiency threshold and the current overall conversion efficiency; Step 402: Based on the current overall conversion efficiency and the pre-stored overall efficiency experimental prediction data, generate the overall estimated remaining lifetime of the DC-DC converter; Step 403: Based on the power change information of multiple life-limited components in the DC-DC converter, generate the estimated remaining life of multiple life-limited components. Step 404: Filter out the estimated limit life from multiple estimated remaining life of components, and subtract the preset component nonlinear change duration from the estimated limit life to generate the estimated retention time. Step 405: Generate the estimated lifespan information of the DC-DC converter based on the overall estimated remaining lifespan and estimated warranty period.

[0035] In step 401, based on the preset estimated conversion efficiency threshold and the current overall conversion efficiency, the current health status information of the DC-DC converter is generated, specifically as follows: Compare the current overall conversion efficiency of the DC-DC converter with the preset estimated conversion efficiency threshold; If the current overall conversion efficiency is greater than the estimated conversion efficiency threshold, then generate current health status information carrying a health identifier; If the current overall conversion efficiency is less than or equal to the estimated conversion efficiency threshold, then generate current health status information carrying an anomaly flag. The two situations described above will be explained separately: Scenario 1: If the current overall conversion efficiency is greater than the estimated conversion efficiency threshold, it means that the current converter is in a healthy state. The controller generates a current health status information carrying a health identifier, indicating that the converter is in a healthy state. Scenario 2: If the current overall conversion efficiency is less than or equal to the estimated conversion efficiency threshold, it indicates that the current converter is in an unhealthy state. The controller generates current health status information with an abnormality flag indicating that the converter is in an unhealthy state.

[0036] In step 402, based on the current overall conversion efficiency and the pre-stored overall efficiency experimental prediction data, the overall estimated remaining lifetime of the DC-DC converter is generated, specifically as follows: The controller has pre-stored overall efficiency experimental prediction data, which comes from the data measured by the staff in the laboratory during the aging test of the converter. It is used to reflect the correspondence between the overall aging of the converter and the overall conversion efficiency. The controller matches the corresponding overall theoretical usage time and overall theoretical remaining lifespan from the overall efficiency experimental prediction data based on the current overall conversion efficiency. The controller calculates the actual reduction ratio of the overall lifespan by dividing the total actual usage time of the current DC-DC converter by the total theoretical usage time, which is recorded in advance. The overall estimated remaining lifespan of the DC-DC converter is calculated by multiplying the actual reduction rate of the overall lifespan by the overall theoretical remaining lifespan.

[0037] In step 403, based on the power change information of multiple lifespan-limited components within the DC-DC converter, the estimated remaining lifespan of these components is generated, specifically as follows: The controller estimates the lifespan of multiple lifespan-limiting components based on the energy change information of these components. Here, a switching transistor is used as an example to illustrate this. Based on the power change information of multiple life-limiting components in the DC-DC converter, the average unit power loss of the life-limiting components is obtained within a preset unit time after the energy storage capacitor discharges. Based on the pre-stored power loss transformation data corresponding to various life-limited component models and the corresponding component unit power loss, the estimated remaining life of multiple life-limited components is generated. The power loss transformation data is used to reflect the mapping relationship between the usage time of life-limited components and the average power loss per unit time. The controller captures and calculates the average unit power loss of each lifetime-limiting element within a preset unit time after the energy storage capacitor is detected to discharge, based on multiple power change information. The controller also pre-stores power dissipation variation data for various life-limiting components of corresponding models. The power dissipation variation data here is used to record the mapping relationship between the life-limiting component, such as the switching transistor, and the average power dissipation per unit time. It should be noted that the unit power loss of the switching transistor is affected not only by aging, but also by the current flowing through it and the voltage across its terminals. Therefore, the power loss variation data here comes from the laboratory. By simulating the voltage and current at the initial stage of the energy storage capacitor discharge, aging tests were conducted in the same simulated environment to enhance the accuracy of the data. The controller uses the unit power loss of each life-limiting component to match the theoretical service life and theoretical remaining life of the component in the corresponding power loss change data. The controller obtains the actual usage time of each life-limiting component and calculates the actual life-limiting reduction ratio of each component by dividing the actual usage time of the life-limiting component by the theoretical usage time of the component. The estimated remaining lifespan of each life-limited component is calculated by multiplying its theoretical remaining lifespan by the actual reduction ratio of its lifespan.

[0038] In step 404, the estimated limit lifetime is selected from multiple estimated remaining lifetimes of components, and the estimated limit lifetime is subtracted from the preset component nonlinearity change duration to generate the estimated hold-up duration, specifically: The controller compares the estimated remaining lifespan of multiple components and selects the component with the smallest estimated remaining lifespan, which is referred to here as the estimated limit lifespan.

[0039] In addition, the controller also pre-stores the duration of non-linear changes of components. By setting the duration of non-linear changes of components, the possibility of converter burnout can be prevented when life-limited components generate large power loss changes at the end of their service life.

[0040] The controller estimates the limited lifespan and subtracts the duration of nonlinear changes in the components to calculate the estimated hold-up time.

[0041] In step 405, based on the overall estimated remaining lifespan and estimated warranty period, the estimated lifespan information of the DC-DC converter is generated, specifically as follows: Comparing the overall estimated remaining lifespan with the estimated maintenance duration, the following two scenarios emerge: Scenario 1: If the estimated warranty period is greater than the overall estimated remaining lifespan, it indicates that during the normal aging process of the converter, none of the multiple lifespan-limiting components are over-aged. In other words, the estimated lifespan information of the converter is generated based on the overall estimated remaining lifespan. Scenario 2: If the estimated warranty period is less than or equal to the overall estimated remaining lifespan, it indicates that the converter is in the normal aging process. The controller compares the estimated limited lifespan with the overall estimated remaining lifespan. When the estimated limited lifespan is greater than the overall estimated remaining lifespan, the lifespan between the estimated hold-up time after the current moment and the overall estimated remaining lifespan is called the component's abnormal fluctuation lifespan. When the estimated limited lifespan is less than or equal to the overall estimated remaining lifespan, the lifespan between the estimated hold-up time after the current moment and the estimated limited lifespan is called the component's abnormal fluctuation lifespan. Next, within the estimated retention period after the current time, a normal aging indicator for the converter is generated; within the abnormal aging lifespan of the components after the current time and the estimated retention period, an abnormal aging indicator for the internal components of the converter is generated, and the estimated lifespan information of the converter is summarized and generated.

[0042] By selecting the smaller of the overall estimated remaining lifespan and the estimated warranty period, the likelihood of converter damage or low efficiency can be reduced, both from the perspective of the converter as a whole and from the perspective of multiple lifespan-limiting components within the converter.

[0043] like Figure 4 As shown, step 4 also includes: S1: Based on the unit power loss of multiple components and the corresponding estimated remaining lifetimes, a fitted aging lifetime coefficient for the DC-DC converter is generated, specifically as follows: Since the aging of converters is mostly caused by the aging of life-limiting components, the aging status of multiple life-limiting components can also reflect the aging status of the converter.

[0044] Here, the controller extrapolates the relative aging state of the converter based on the states of multiple life-limiting components. For example, the aging state of the life-limiting components is identified by numbers from 0 to 1, and any number from 0 to 1 represents the aging life coefficient of the converter. In this way, the aging life coefficient of the converter is extrapolated based on the states of multiple life-limiting components, which is referred to here as the fitted aging life coefficient.

[0045] Based on the unit power loss of multiple life-limited components, a component proportion coefficient corresponding to the multiple life-limited components is generated.

[0046] In implementation, the controller sums the unit power loss of multiple life-limited components to calculate the total unit power loss. Then, it divides the unit power loss of each life-limited component by the total unit power loss to calculate the component proportion coefficient corresponding to each life-limited component.

[0047] Based on the power loss variation data and the corresponding estimated remaining life of multiple life-limited components, an aging factor for the components is generated.

[0048] The controller performs the same process for each life-limiting element, and here we take one of the life-limiting elements as an example, referred to here as the target life-limiting element.

[0049] The controller matches the theoretical usage time and theoretical remaining life of the corresponding component from the power loss conversion data corresponding to the target life-limited component, according to the method in the above steps. Then, it calculates the component aging coefficient by taking the ratio of the theoretical usage time of the component to the sum of the theoretical usage time and the theoretical remaining life of the component.

[0050] Based on the component proportion coefficient and component aging coefficient corresponding to multiple life-limited components, a fitted aging life coefficient is generated.

[0051] The controller accumulates the product of the component proportion coefficient and the component aging coefficient of multiple life-limited components, and calculates the fitted aging life coefficient.

[0052] S2: Based on the overall estimated remaining lifespan and the fitted aging lifespan coefficient, calculate and generate the fitted prediction error ratio, specifically: By using the above steps, the overall theoretical usage time and overall theoretical remaining lifespan of the current converter are obtained. Then, the overall aging lifespan coefficient is calculated by taking the proportion of the overall theoretical usage time to the sum of the overall theoretical usage time and the overall theoretical remaining lifespan.

[0053] Then, by dividing the overall aging coefficient by the fitted aging life coefficient, the expected error ratio of the fitted model is calculated.

[0054] In this application, since the output power of the converter is usually caused by multiple life-limiting components, the ratio difference between estimating the converter's lifespan through multiple life-limiting components and estimating the converter's lifespan through the overall conversion efficiency of the converter is adjusted by fitting the expected error ratio.

[0055] S3: If the estimated warranty period is longer than the overall estimated remaining lifespan, then from the current moment to the overall estimated remaining lifespan, based on the pre-acquired overall load power adjustment data, the adaptable load power information of the DC-DC converter is generated, specifically: The controller further compares the expected warranty duration with the overall estimated remaining lifespan, as explained in the above steps. It analyzes two cases: the expected warranty duration is longer than the overall estimated remaining lifespan, and the expected warranty duration is less than or equal to the overall estimated remaining lifespan. This allows for the analysis of the converter's corresponding adaptive power at different time periods.

[0056] The operation process is as follows: Based on the current overall conversion efficiency and experimental prediction data of the converter, the actual reduction ratio of the overall lifetime of the converter is calculated.

[0057] The controller uses the current overall conversion efficiency of the converter to match the corresponding overall theoretical usage time and overall theoretical remaining lifespan from the overall efficiency experimental prediction data.

[0058] The overall lifespan reduction ratio is calculated by dividing the overall actual usage time of the converter by the overall theoretical usage time, based on the overall actual usage time recorded in the controller.

[0059] Based on the overall estimated remaining lifespan after the current moment and the actual reduction rate of the overall lifespan, the estimated lifespan change information is calculated and generated.

[0060] The controller multiplies multiple time points in the overall remaining lifespan with the actual reduction ratio of the overall lifespan to calculate multiple estimated lifespan durations, and then summarizes these multiple estimated lifespan durations to generate estimated lifespan change information.

[0061] Based on multiple estimated lifetime durations in the estimated lifetime transformation information, the corresponding estimated adaptive load power is matched in the overall load power adjustment data.

[0062] The controller has preset overall load power adjustment data, which reflects the mapping relationship between theoretical usage time and the converter's expected output power.

[0063] The controller uses multiple estimated lifespan durations to match and obtain multiple estimated adaptive load powers from the overall load power adjustment data.

[0064] Based on multiple estimated adaptable load powers, the adaptable load power information of the converter is generated from the current moment to the overall estimated remaining lifetime.

[0065] The controller establishes a mapping relationship between multiple expected adaptable load powers and multiple estimated lifetime durations by establishing a correspondence between multiple expected adaptable load powers and multiple time points in the overall remaining lifetime, and summarizes and generates the adaptable load power information of the converter in the overall estimated remaining lifetime after the current moment.

[0066] By calculating the adaptable load power of the converter, the operating load intensity of the converter can be adjusted first, reducing the converter from operating under overload conditions for a long time and reducing the possibility of converter damage.

[0067] S4: If the estimated warranty period is less than or equal to the overall estimated remaining lifespan, then from the current moment to the estimated warranty period, the first stage load power information is generated based on the overall load power adjustment data, specifically as follows: When the estimated warranty period is less than or equal to the overall estimated remaining lifespan, the estimated power of multiple adapted loads corresponding to the converter within the estimated warranty period after the current moment is calculated in the same way as in step S3. Then, the first-stage load power information corresponding to the converter within the estimated warranty period after the current moment is generated by summarizing the results.

[0068] S5: Within the estimated retention period and estimated limited lifespan, generate estimated fitted lifespan transformation data based on the power loss transformation data corresponding to each lifespan-limiting component model, specifically: When the estimated warranty period is less than the overall estimated remaining lifespan, further processing is required. Specifically, referring to the method described above, the abnormal fluctuation lifespan of the component should be calculated first.

[0069] Then, during the period from the current moment until the estimated warranty period ends, multiple component turbulence sampling time points are captured at the same intervals within the component's abnormal turbulence lifespan. This example uses a component with a target lifespan limitation for illustration.

[0070] At the same time, the actual reduction ratio of the lifespan of the target lifespan-limited component is calculated by combining the theoretical and actual usage time of the component with the current target lifespan limitation.

[0071] Then, by multiplying the sampling time points of multiple components with the actual reduction ratio of component lifespan, multiple component sampling time points are calculated. And by matching the power loss change data corresponding to the target lifespan-limited component with multiple component sampling time points, the estimated damage power of multiple components is obtained.

[0072] By taking the estimated damage power of multiple life-limited components at each sampling time point corresponding to the same component, and following the method described in step S1, the corresponding fitted aging life coefficient is calculated, and the estimated fitted life transformation data is generated.

[0073] S6: Based on the estimated fitted lifetime transformation data and the expected fitting error ratio, generate the second-stage load power information, specifically: In implementation, the controller calculates the overall estimated lifespan coefficient by multiplying multiple fitted aging lifespan coefficients and the fitted expected error ratio in the fitted lifespan change data. Then, using the same method as in step S4 above, it calculates multiple estimated adapted load powers corresponding to the converters during the abnormal fluctuation lifespan of the components from the current time to the estimated retention time, and summarizes them to generate the second stage load power information.

[0074] S7: Based on the load power information of the first stage and the load power information of the second stage, generate the adaptable load power information of the converter, specifically: The controller will summarize the first-stage load power information and the second-stage load power information when the estimated warranty duration is less than or equal to the overall estimated remaining lifespan, and generate the adaptable load power information corresponding to the converter.

[0075] Embodiments of the present invention may be provided as methods, systems, or computer program products. Therefore, the present invention may take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, the present invention may take the form of a computer program product embodied on one or more computer-usable storage media (including, but not limited to, disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0076] This invention is described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, generate instructions for implementing the flowchart illustrations and / or block diagrams. Figure 1 One or more processes and / or boxes Figure 1 A device that provides the functions specified in one or more boxes.

[0077] These computer program instructions may also be stored in a computer-readable storage medium that can direct a computer or other programmable data processing device to function in a particular manner, such that the instructions stored in the computer-readable storage medium produce an article of manufacture including instruction means, which are implemented in a process Figure 1 One or more processes and / or boxes Figure 1 The function specified in one or more boxes.

[0078] These computer program instructions may also be loaded onto a computer or other programmable data processing equipment to cause a series of operational steps to be performed on the computer or other programmable equipment to produce a computer-implemented process, thereby providing instructions that execute on the computer or other programmable equipment for implementing the process. Figure 1 One or more processes and / or boxes Figure 1 The steps of the function specified in one or more boxes.

[0079] Contents not described in detail in this specification are prior art known to those skilled in the art. It is hereby indicated that the above description is intended to help those skilled in the art understand this invention, but does not limit the scope of protection of this invention. Any equivalent substitutions, modifications, improvements, or simplifications of the above descriptions that do not depart from the essential content of this invention fall within the scope of protection of this invention.

Claims

1. A control method for a DC-DC converter, characterized in that, include: Step 1: When a startup current is detected in the DC-DC converter from the DC input power supply, control the DC input power supply to charge the detection energy storage capacitor in the forward detection module; Step 2: When the detection energy storage capacitor is detected to be charged to the preset detection voltage, disconnect the DC-DC converter from the DC input power supply and control the detection energy storage capacitor to discharge for detection; Step 3: Obtain the current overall power conversion efficiency of the DC-DC converter and the power change information of multiple life-limiting components within the DC-DC converter; Step 4: Based on the current overall conversion efficiency and power change information of the DC-DC converter, generate the current health status information and estimated service life information of the DC-DC converter.

2. The control method for a DC-DC converter according to claim 1, characterized in that, In step 4, based on the current overall conversion efficiency and power change information of the DC-DC converter, health status information and estimated lifespan information of the DC-DC converter are generated, specifically as follows: Step 401: Generate the current health status information of the DC-DC converter based on the preset estimated conversion efficiency threshold and the current overall conversion efficiency; Step 402: Based on the current overall conversion efficiency and the pre-stored overall efficiency experimental prediction data, generate the overall estimated remaining lifetime of the DC-DC converter; Step 403: Based on the power change information of multiple life-limited components in the DC-DC converter, generate the estimated remaining life of multiple life-limited components. Step 404: Filter out the estimated limit life from multiple estimated remaining life of components, and subtract the preset component nonlinear change duration from the estimated limit life to generate the estimated retention time. Step 405: Generate the estimated lifespan information of the DC-DC converter based on the overall estimated remaining lifespan and estimated warranty period.

3. The control method for a DC-DC converter according to claim 2, characterized in that, In step 401, based on the preset estimated conversion efficiency threshold and the current overall conversion efficiency, the current health status information of the DC-DC converter is generated, specifically as follows: Compare the current overall conversion efficiency of the DC-DC converter with the preset estimated conversion efficiency threshold; If the current overall conversion efficiency is greater than the estimated conversion efficiency threshold, then generate current health status information carrying a health identifier; If the current overall conversion efficiency is less than or equal to the estimated conversion efficiency threshold, then current health status information carrying an anomaly flag is generated.

4. The control method for a DC-DC converter according to claim 2, characterized in that, In step 402, based on the current overall conversion efficiency and the pre-stored overall efficiency experimental prediction data, the overall estimated remaining lifetime of the DC-DC converter is generated, specifically as follows: Based on the current overall conversion efficiency, the corresponding overall theoretical usage time and overall theoretical remaining lifespan are matched with the overall efficiency experimental prediction data. The actual reduction ratio of the overall lifespan is calculated by dividing the total actual usage time of the current DC-DC converter, which is recorded in advance, by the total theoretical usage time. The overall estimated remaining lifespan of the DC-DC converter is calculated by multiplying the actual reduction rate of the overall lifespan by the overall theoretical remaining lifespan.

5. The control method for a DC-DC converter according to claim 2, characterized in that, In step 403, based on the power change information of multiple lifespan-limited components within the DC-DC converter, the estimated remaining lifespan of these components is generated, specifically as follows: Based on the power change information of multiple life-limiting components in the DC-DC converter, the average unit power loss of the life-limiting components is obtained within a preset unit time after the energy storage capacitor discharges. For each life-limited component, the theoretical service life and theoretical remaining life of the component are matched with the corresponding power loss per unit of the component in the corresponding power loss change data. Obtain the actual usage time of each life-limited component, and calculate the actual life-limit reduction ratio of each component by dividing the actual usage time of the life-limited component by the theoretical usage time of the component. The estimated remaining lifespan of each life-limited component is calculated by multiplying its theoretical remaining lifespan by the actual reduction ratio of its lifespan.

6. The control method for a DC-DC converter according to claim 2, characterized in that, In step 404, the estimated limit lifetime is selected from multiple estimated remaining lifetimes of components, and the estimated limit lifetime is subtracted from the preset component nonlinearity change duration to generate the estimated hold-up time, specifically as follows: By comparing the estimated remaining lifetime of multiple components, the component with the smallest estimated remaining lifetime is selected, which is the estimated limit lifetime. Obtain the duration of nonlinear change of the component, subtract the duration of nonlinear change of the component from the estimated limited life, and calculate the estimated hold-up time.

7. The control method for a DC-DC converter according to claim 2, characterized in that, In step 405, based on the overall estimated remaining lifespan and estimated warranty period, the estimated lifespan information of the DC-DC converter is generated, specifically as follows: Compare the overall estimated remaining lifespan with the estimated maintenance duration; If the estimated warranty period is longer than the overall estimated remaining lifespan, then the estimated lifespan information of the DC-DC converter is generated based on the overall estimated remaining lifespan. If the estimated duration of blessing is less than or equal to the overall estimated remaining lifespan, then the estimated limited lifespan will be compared with the overall estimated remaining lifespan. If the estimated limited lifespan is greater than the overall estimated remaining lifespan, then the lifespan between the estimated hold-up time after the current moment and the overall estimated remaining lifespan is obtained, which is the abnormal fluctuation lifespan of the component. If the estimated limited lifespan is less than or equal to the overall estimated remaining lifespan, then obtain the estimated hold-up time after the current moment and the lifespan between the estimated limited lifespan and the estimated lifespan, i.e., the abnormal fluctuation lifespan of the component. Within the estimated retention period after the current moment, generate the normal aging indicator of the DC-DC converter. Within the abnormal aging life of the components, generate the abnormal aging indicator of the internal components of the converter, and summarize and generate the estimated life of the converter.

8. The control method for a DC-DC converter according to claim 2, characterized in that, Step 4 also includes: S1: Generate the fitting aging life coefficient of the DC-DC converter based on the unit loss power of multiple components and the corresponding estimated remaining life. S2: Calculate the expected error ratio of the fit based on the overall estimated remaining life and the fitted aging life coefficient; S3: If the estimated warranty period is longer than the overall estimated remaining lifespan, then from the current moment to the overall estimated remaining lifespan, the adaptable load power information of the DC-DC converter is generated based on the pre-acquired overall load power adjustment data. S4: If the estimated warranty period is less than or equal to the overall estimated remaining lifespan, then within the time frame from the current moment to the estimated warranty period, the first stage load power information is generated based on the overall load power adjustment data. S5: Within the estimated retention time and estimated limited life, generate estimated fitting life transformation data based on the power consumption transformation data corresponding to each life-limiting component model; S6: Generate the second-stage load power information based on the estimated fitting lifetime transformation data and the fitting expected error ratio; S7: Generate the adaptable load power information of the converter based on the first-stage load power information and the second-stage load power information.

9. A DC-DC converter, and a control method for the DC-DC converter according to any one of claims 1 to 8, characterized in that, include: The system includes a DC input power supply, a voltage modulation main module, a pre-detection module, a controller, and a detection load module. The DC input power supply is connected to the pre-detection module, the pre-detection module is connected to the voltage modulation main module, the voltage modulation main module is connected to the detection load module, and the controller is connected to the pre-detection module. The voltage modulation main module is used to regulate the DC voltage input to the DC-DC converter from the DC input power supply. The pre-detection module is used to store electrical energy and perform discharge detection before the voltage modulation main module is put into use. The controller is used to perform data analysis, logical judgment, and detection process control. The detection load module is used to bear the detection load during the detection process.

10. A DC-DC converter according to claim 9, characterized in that, The pre-detection module includes a detection energy storage capacitor, a fast switch, a relay, a detection power supply switch transistor, a linear voltage regulator submodule, and a detection power supply switch transistor. The positive terminal of the DC input power supply is connected to the drain of the fast switch and the detection power supply switch transistor. The source of the detection power supply switch transistor is connected to the linear voltage regulator submodule. The linear voltage regulator submodule is connected to the first terminal of the detection energy storage capacitor and the relay. The second terminal of the detection energy storage capacitor is connected to the negative terminal of the DC input power supply. The fast switch and the relay are both connected to the voltage modulation main module.

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