Power module test system

Abstract

The utility model provides a power module test system. The power module test system comprises a direct current power supply module, an auxiliary power supply module, a control module, an upper computer monitoring module, an IGBT power module and an alternating current output module, the DC power supply module is connected with the auxiliary power supply module, the auxiliary power supply module is connected with the control module, the control module is connected with the IGBT power module, and the IGBT power module is connected with the AC output module; the upper computer monitoring module is connected with the control module, the control module issues a driving signal to the IGBT power module during testing and receives current data and temperature data of the IGBT power module, and the upper computer monitoring module transmits the current data and the temperature data. Through the upper computer monitoring module and the control module, power module detection can be performed on an inverter of a three-level topological structure, and a driving signal is issued to the IGBT power module through the control module, so that different tests can be performed on the IGBT power module, the function and performance of the IGBT power module are detected, and the test cost is reduced.

Description

Technical Field

[0001] This application relates to the field of electronic technology, and in particular to a power module testing system. Background Technology

[0002] As a crucial component of energy storage converters, power modules are a vital part of the manufacturing process. Testing power modules is an essential part of factory testing for energy storage converters. The testing of energy storage converters mainly refers to the testing of their core components, namely the Insulated Gate Bipolar Transistor (IGBT) power modules. Therefore, a power module testing system is both important and necessary.

[0003] CN207408507U proposes an IGBT power module testing system, such as Figure 1 As shown, this power module testing system is powered by a DC power supply module. By connecting the control module, indicator lights, and resistors to the IGBT power module to be tested according to a specific connection relationship, this system can simultaneously test the IGBT module, IGBT driver board, and current sensor within the IGBT power module. However, its drawback is that it only supports traditional two-level topologies and cannot test three-level topologies. Three-level topologies produce PWM waveforms that are closer to a sine wave, with less ripple, lower switching losses, and the ability to achieve higher switching frequencies. Therefore, as the use of three-level topologies increases, this testing system cannot meet the testing requirements of power modules. CN114200234A provides a power module testing system including a host computer for sending control commands; a DSP chip for generating corresponding PWM pulse command signals based on the control commands; an FPGA chip for parsing the PWM pulse command signals to obtain parsed pulse signals; and a module control board for generating corresponding PWM waves based on the parsed pulse signals to control the target power module. However, this testing system is mainly designed for two-level topologies and lacks open-loop testing and non-functionality testing, making it unable to accurately detect the function and performance of IGBT modules.

[0004] Therefore, there is an urgent need for a power module testing system capable of testing three-level topologies. Utility Model Content

[0005] This application provides a power module testing system to solve the problem that existing power module testing systems cannot test the performance of three-level topologies.

[0006] This application provides a power module testing system, including: a DC power supply module, an auxiliary power supply module, a control module, a host computer monitoring module, an IGBT power module, and an AC output module;

[0007] The DC power supply module is connected to the auxiliary power supply module, the auxiliary power supply module is connected to the control module, the control module is connected to the IGBT power module, and the IGBT power module is connected to the AC output module.

[0008] The host computer monitoring module is connected to the control module. When the control module is conducting a test, it sends a drive signal to the IGBT power module and receives the current and temperature data of the IGBT power module. The host computer monitoring module transmits the current and temperature data.

[0009] In one embodiment, the IGBT power module is equipped with a current sensor and a temperature sensor;

[0010] The current sensor and the temperature sensor are connected to the control module.

[0011] In one embodiment, the IGBT power module includes: an IGBT driver board and an IGBT power board;

[0012] The IGBT driver board is connected to the IGBT power board.

[0013] In one embodiment, the power module test system further includes an RLC load module, and the AC output module is connected to the RLC load module.

[0014] In one embodiment, the IGBT power board is an interleaved parallel NPC three-level topology.

[0015] In one embodiment, the power module testing system further includes a cooling module;

[0016] The cooling module is connected to the control module.

[0017] In one embodiment, the power module testing system further includes an oscilloscope connected to the AC output module;

[0018] When the control module performs a low-voltage open-loop test, the IGBT power board operates, and the AC output module outputs the test waveform of the IGBT power board.

[0019] In one embodiment, when the control module performs a high-voltage open-loop test, the IGBT power board operates, and the AC output module outputs the test waveform of the IGBT power board.

[0020] In one embodiment, when the control module performs a no-function test, the RLC load module is a three-phase load, the IGBT power board is running, and the RLC load module is adjusted so that the current flowing through the IGBT is the rated current for the system to operate at full power.

[0021] The cooling module cools down the IGBT power module.

[0022] In one embodiment, the auxiliary power module includes at least three voltage levels.

[0023] This application provides a power module testing system, including: a DC power supply module, an auxiliary power supply module, a control module, a host computer monitoring module, an IGBT power module, and an AC output module. The DC power supply module is connected to the auxiliary power supply module, the auxiliary power supply module is connected to the control module, the control module is connected to the IGBT power module, and the IGBT power module is connected to the AC output module. The host computer monitoring module is connected to the control module. During testing, the control module sends drive signals to the IGBT power module and receives current and temperature data from the IGBT power module. The host computer monitoring module transmits the current and temperature data. This application, through the host computer monitoring module and the control module, can perform power module testing on a three-level topology inverter. By sending drive signals to the IGBT power module through the control module, different tests can be performed on the IGBT power module to test its function and performance, reducing testing costs. Attached Figure Description

[0024] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments consistent with the present application and, together with the description, serve to explain the principles of the present application.

[0025] Figure 1 This is a schematic diagram of the structure of a power module testing system in the prior art;

[0026] Figure 2 This is a schematic diagram of the structure of a power module testing system provided in an embodiment of this application;

[0027] Figure 3 This is a schematic diagram of the structure of a power module testing system provided in another embodiment of this application;

[0028] Figure 4 A voltage diagram of an auxiliary power module provided in an embodiment of this application;

[0029] Figure 5 This is a schematic diagram of the structure of a three-level power module provided in one embodiment of this application;

[0030] Figure 6 This is a normal waveform diagram of an IGBT power module test provided in an embodiment of this application;

[0031] Figure 7 The image shows a normal waveform output by the AC output module during testing, as provided in an embodiment of this application.

[0032] The accompanying drawings have illustrated specific embodiments of this application, which will be described in more detail below. These drawings and descriptions are not intended to limit the scope of the concept in any way, but rather to illustrate the concept of this application to those skilled in the art through reference to specific embodiments. Detailed Implementation

[0033] Exemplary embodiments will now be described in detail, examples of which are illustrated in the accompanying drawings. When the following description relates to the drawings, unless otherwise indicated, the same numbers in different drawings denote the same or similar elements. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with this application. Rather, they are merely examples of apparatuses and methods consistent with some aspects of this application as detailed in the appended claims.

[0034] Traditional two-level inverter circuits can only output two levels: high and low. Three-level circuits are more complex in topology. These inverters can output high and low levels by turning on the upper and lower transistors, and output a zero level through the clamping effect of the middle diode, resulting in a total of three voltage levels. Existing power module testing systems are designed for two-level topologies and cannot test three-level topologies. This leads to low testing accuracy and fails to accurately reflect the function and performance of IGBT power modules.

[0035] This application provides a power module testing system, such as... Figure 2 As shown, Figure 2 This is a schematic diagram of the structure of a power module testing system provided in an embodiment of the present application. The power module testing system includes: a DC power supply module, an auxiliary power supply module, a control module, a host computer monitoring module, an IGBT power module, and an AC output module.

[0036] The DC power supply module is connected to the auxiliary power supply module, the auxiliary power supply module is connected to the control module, the control module is connected to the IGBT power module, and the IGBT power module is connected to the AC output module.

[0037] The host computer monitoring module is connected to the control module. When the control module is testing, it sends drive signals to the IGBT power module and receives the current and temperature data from the IGBT power module. The host computer monitoring module transmits the current and temperature data.

[0038] This application uses a host computer monitoring module and a control module to perform power module testing on a three-level topology inverter. The control module sends drive signals to the IGBT power module to perform different tests on the IGBT power module, thereby testing the function and performance of the IGBT power module and reducing testing costs.

[0039] In one embodiment, the control module includes a decoding unit that converts digital signals into specific output signals to control the IGBT power module to perform corresponding functional tests when different tests are required. The power module testing system also includes a data transmission module. This module transmits current and temperature data of the IGBT power module to the control module during testing; and transmits different control signals to the IGBT power module during different tests, enabling the IGBT power module to perform the corresponding tests.

[0040] In one embodiment, Figure 1 As shown, the IGBT power module is equipped with a current sensor and a temperature sensor;

[0041] The current sensor and temperature sensor are connected to the control module.

[0042] In one embodiment, the IGBT power module includes: an IGBT driver board and an IGBT power board;

[0043] The IGBT driver board is connected to the IGBT power board.

[0044] In one embodiment, Figure 3 As shown, Figure 3 This is a schematic diagram of the structure of a power module testing system provided in an embodiment of this application. The power module testing system also includes an RLC load module, and the AC output module is connected to the RLC load module.

[0045] Specifically, the DC power supply module supplies power to the auxiliary power supply, which in turn supplies power to the control module. The control module is connected to both the IGBT power module and the host computer monitoring module, providing power to both. Furthermore, the control module monitors the temperature and current of the IGBT power module. The IGBT power module is connected to the AC output module, which in turn connects to the RLC load module. During reactive power testing of the IGBT power module, the control module controls the cooling module to lower its temperature. During testing, the control module supplies power to the IGBT power module and simultaneously sends drive signals via the data transmission module. These drive signals control the IGBT module's conduction. Upon receiving the drive signals, the IGBT driver board activates the IGBT power module, providing it with IGBT current and temperature information. These parameters are observed in the host computer monitoring module. The control module monitors the system in real-time during testing. If a fault occurs, it will be displayed on the host computer monitoring module. In the event of a system fault, protection mechanisms will activate, preventing system operation. Once the fault is resolved, the system will return to normal. The power module testing system of this application can not only perform functional testing of three-level IGBT modules, drive capability testing of drive units, IGBT temperature detection, and IGBT current detection, but also perform non-functional testing of IGBTs and performance testing of IGBTs under high current conditions.

[0046] In one embodiment, the auxiliary power module can provide multiple voltage levels. For example... Figure 4 As shown, Figure 4 This diagram illustrates the voltage provided by an auxiliary power module according to an embodiment of this application. When the auxiliary power module provides operating power to the control module, the voltage supplied to each component is determined based on the operating voltage requirements of the power supply section. In this embodiment, the auxiliary power module provides three voltage levels: 12V, 15V, and 24V. Optionally, the auxiliary power module can be configured with different voltage levels according to power supply requirements; this application does not impose any limitations on this.

[0047] In one embodiment, the IGBT power board has a three-level topology, such as... Figure 5 As shown, Figure 5 This is a schematic diagram of a three-level power module provided in one embodiment of this application. Three-level topologies include interleaved parallel NPC-type three-level topologies, ANPC-type three-level topologies, T-type three-level topologies, etc. The power module testing system provided in this application can test power modules with three-level topologies and is not limited to any particular type of three-level topology.

[0048] In one embodiment, the power module testing system further includes a cooling module; this cooling module is connected to the control module, such as... Figure 3 , Figure 4 As shown. This cooling module can reduce the temperature when the power module is running at full power, avoiding an increase in the internal resistance and losses of the components in the power module, reducing the efficiency of the power module, and affecting the accuracy of the test results.

[0049] In one embodiment, the power module test system further includes an oscilloscope connected to the AC output module;

[0050] When the control module performs a low-voltage open-loop test, the IGBT power board operates, and the AC output module outputs the test waveform of the IGBT power board.

[0051] Specifically, when the control module performs a low-voltage open-loop test on the IGBT power module, such as Figure 2 As shown, the DC power supply module supplies power to the control module and the IGBT power module. The control module activates the corresponding relays, and then sends drive signals to the IGBT power module through the data transmission module to control the IGBT power board to conduct. The waveform of the IGBT power module is checked using an oscilloscope. During IGBT power board testing, the normal test waveform is shown as follows. Figure 6 As shown, Figure 6 This is a normal waveform diagram for testing an IGBT power module according to an embodiment of this application. After confirming that the waveform during the IGBT power module test is normal, an oscilloscope is used to check the output waveform at the rear end of the AC output module. The normal waveform diagram is shown below. Figure 7 As shown, Figure 7 This is a normal waveform diagram of the AC output module output during testing according to an embodiment of this application, indicating the end of the low-voltage open-loop test.

[0052] The driving principle of the IGBT power board is to drive the power board using an IGBT driver board. Specifically, it uses 4 isolated drive signals. The primary and secondary side signals are isolated by optocouplers, and the secondary side drives the IGBT through a push-pull circuit. Each channel drives one IGBT device. If the IGBT is abnormal, the primary side driving device will react, allowing for timely troubleshooting and resolution, thus avoiding IGBT damage or greater losses during high-voltage testing.

[0053] In one embodiment, when the control module performs a high-voltage open-loop test, the IGBT power board operates, and the AC output module outputs the test waveform of the IGBT power board.

[0054] Specifically, the control module performs a high-voltage open-loop test on the IGBT power module. The DC power supply module supplies power to the auxiliary power supply module, which in turn provides the operating voltage for the control module. During the test, the IGBT current and temperature are observed. The main controller controls the system to activate the corresponding relays and then sends drive signals to the IGBT power module according to the program to control the IGBT conduction. The waveform of the IGBT power module is checked using an oscilloscope. A normal test waveform is shown as follows: Figure 6 As shown, after confirming that the waveform during the IGBT power module test was normal, an oscilloscope was used to check the output waveform at the rear end of the AC output module. A normal waveform is shown below. Figure 7 As shown, after confirming the waveform is normal, the high-voltage open-loop test is complete. The test passing indicates that the IGBT is functioning correctly and the system is capable of complete system testing.

[0055] In one embodiment, when the control module performs a no-function test, the RLC load module is a three-phase load, the IGBT power board is running, and the RLC load module is adjusted so that the current flowing through the IGBT is the rated current for the system to operate at full power.

[0056] The cooling module cools and reduces the temperature of the IGBT power module.

[0057] Specifically, when the control module performs a non-functionality test on the IGBT power module, the DC power supply module supplies power to the auxiliary power supply module, which provides the operating voltage for the control module. The IGBT power module is connected to the AC output module, which in turn is connected to the RLC load module, which provides a three-phase load. The RLC load module is a circuit load composed of resistors, inductors, and capacitors. In a circuit, the RLC load module can simulate various electrical loads for testing and analyzing circuit performance and response. By adjusting the values ​​and connections of the resistors, inductors, and capacitors, different circuit load conditions can be simulated.

[0058] During the reactive power capability test of the IGBT power module, the decoding unit inside the controller operates, controlling the entire test system, activating relevant relays, and sending drive signals to the IGBT power module. The IGBT power module then runs. By adjusting the RLC load module, reactive power is used instead of active power to verify the performance of the IGBT power module, ensuring that the current flowing through the IGBT power board is the rated current for full-power operation of the system. This tests the performance of the IGBT power board under high current flow. During the test, the control module controls the cooling module to cool the IGBT power module. The test is considered passed if the current flowing through the IGBT is the full-power operating current and the system runs continuously for 20 minutes without abnormalities, indicating that the IGBT is fault-free and meets the usage requirements.

[0059] By controlling the switching devices, we can control the equivalent voltage, while the current is actually controlled indirectly. Current and voltage generally correspond to four states: positive output voltage, midpoint voltage, negative voltage, and the high-impedance state when all are off, totaling four main switching states. In addition, a transition process is required when switching between the main switching states.

[0060] This testing system can comprehensively reflect the performance and test results of power modules under low voltage, high voltage, and high current conditions. Using an RLC load module, it provides reactive power capability detection and tests the three-level topology. While using active power to test IGBT power modules places high demands on the DC power source, using reactive power to simulate full-load active power operation, with an RLC load module, eliminates the need for such a high-performance DC power source. Furthermore, according to national standards, converters should have reactive power regulation capabilities. Therefore, the power module testing system provided in this application can ensure that the performance of IGBT power modules is fully and accurately verified.

[0061] The division of units is merely a logical functional division; in actual implementation, there may be other division methods. For example, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed. Furthermore, the coupling or direct coupling or communication connection shown or discussed may be indirect coupling or communication connection through some interfaces, devices, or units, and may be electrical, mechanical, or other forms.

[0062] The units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of this embodiment according to actual needs.

[0063] In addition, each functional unit in each embodiment of the present application may be integrated into one processing unit, or each unit may exist physically separately, or two or more units may be integrated into one unit.

[0064] Finally, it should be noted that other embodiments of this application will readily conceive of by those skilled in the art upon consideration of the specification and practice of the disclosed embodiments. This application is intended to cover any variations, uses, or adaptations of this application that follow the general principles of this application and include common knowledge or customary techniques in the art not disclosed herein, and is not limited to the precise structures described above and shown in the accompanying drawings, and various modifications and alterations may be made without departing from its scope. The scope of this application is limited only by the appended claims.

Claims

1. A power module testing system, characterized in that: include: DC power supply module, auxiliary power supply module, control module, host computer monitoring module, IGBT power module and AC output module; The DC power supply module is connected to the auxiliary power supply module, the auxiliary power supply module is connected to the control module, the control module is connected to the IGBT power module, and the IGBT power module is connected to the AC output module; The host computer monitoring module is connected to the control module. When testing, the control module sends a driving signal to the IGBT power module and receives current data and temperature data of the IGBT power module. The host computer monitoring module transmits the current data and the temperature data.

2. The power module testing system according to claim 1, characterized in that: The IGBT power module is provided with a current sensor and a temperature sensor; The current sensor and the temperature sensor are connected to the control module.

3. The power module testing system according to claim 1, characterized in that: The IGBT power module comprises: an IGBT driving board and an IGBT power board; The IGBT driving board is connected to the IGBT power board.

4. The power module testing system according to claim 3, characterized in that: The power module testing system further comprises an RLC load module, and the AC output module is connected to the RLC load module.

5. The power module testing system according to claim 3, characterized in that: The IGBT power board is an interleaved parallel NPC three-level topology structure.

6. The power module testing system according to claim 4, characterized in that: The power module testing system also includes a cooling module; The cooling module is connected to the control module.

7. The power module testing system according to claim 6, characterized in that: The power module testing system further comprises an oscilloscope, which is connected to the AC output module; When the control module performs the low-voltage open-loop test, the IGBT power board operates, and the AC output module outputs the test waveform of the IGBT power board.

8. The power module testing system according to claim 7, characterized in that: When the control module performs the high-voltage open-loop test, the IGBT power board operates, and the AC output module outputs the test waveform of the IGBT power board.

9. The power module testing system according to claim 8, characterized in that: When the control module performs the non-functional capacity test, the RLC load module is a three-phase load, the IGBT power board is running, and the RLC load module is adjusted so that the current flowing through the IGBT is the rated current of the system running at full power; The cooling module cools down the IGBT power module.

10. The power module testing system according to claim 1, characterized in that: The auxiliary power supply module includes at least three voltage levels.

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