Intelligent control power module

Abstract

The utility model relates to the technical field of electronic information, and specifically discloses an intelligent control power module. Comprising a full-bridge circuit which comprises N on-off units, N is larger than or equal to 6, and conversion from direct current to alternating current is achieved through on and off of the N on-off units; the driving unit comprises a driving power supply and a driving circuit, and the driving circuit is connected with the driving power supply and the on-off unit and used for controlling on and off of the on-off unit; the logic circuit is used for correspondingly controlling PWM waves provided for a user according to the current, the voltage and the temperature which are acquired in real time; and the isolation power supply is connected with the driving circuit and the logic circuit. The full-bridge circuit, the driving circuit, the logic circuit and the isolation power supply are integrally arranged, so that the problem that in the prior art, each functional circuit is built by separated electronic components, and the circuit composition is relatively complex is effectively solved.

Description

Technical Field

[0001] The utility model relates to the technical field of electronic information, in particular to an intelligent control power module. Background Art

[0002] With the popularization of artificial intelligence and new energy concepts, robots on automated production lines, industrial robotic arms, solar and wind power grid-connected power generation, and new energy vehicles are widely used. As a result, motors or inverter power supplies have emerged as controlled objects, and inverters, servo drives, switching power supplies and other products as the "brains" of the controlled objects have also been promoted and applied in conjunction with them.

[0003] Power electronics, the core component for energy conversion and interaction in these products, directly impact and constrain the performance of drivers and power supplies, including their efficiency and reliability. Traditional development of these drivers and power supplies primarily consists of control circuits, drive circuits, isolated power supplies, main power circuits, and voltage and current signal detection and conditioning circuits, forming a closed-loop control system. These functional circuits are typically constructed from discrete electronic components, and key power electronics are primarily imported, such as IGBTs and IPM power semiconductor modules from Mitsubishi in Japan and Infineon in the United States.

[0004] The power modules currently used in inverters, servo drives, and switching power supplies are primarily based on imported insulated-gate bipolar transistors (IGBTs), intelligent power modules (IPMs, an integrated power switching device), or metal-oxide semiconductor field-effect transistors (MOSFETs). In actual product development, IGBTs, due to their high voltage resistance, are primarily used in high-voltage DC applications. MOSFETs, with their low voltage resistance, low on-resistance, and low saturation voltage drop, are primarily used in low-voltage DC applications. Because these two power devices have relatively limited functionality, a typical three-phase H-bridge circuit requires six IGBTs or MOSFETs. Popular IPM modules typically integrate these six power switches directly, resulting in a significantly smaller footprint and advantages over IGBTs or MOSFETs. However, all three applications require electronics engineers to design additional supporting circuits, including control circuits, multi-channel drivers, and isolated power supplies. This results in a relatively complex circuit structure, particularly with regard to PWM interlocking and dead-time settings. Designing the isolated power supply for interference immunity requires extensive experimentation, hindering rapid application circuit design, troubleshooting, and after-sales service support. Summary of the Invention

[0005] In view of this, the present application provides an intelligent control power module that integrates the PWM control (signal interlocking and dead time setting) circuit, drive circuit, and isolated power supply into an integrated design to solve the problem in the above-mentioned prior art that each functional circuit is constructed with separate electronic components, resulting in the need to design additional supporting circuits such as control circuits, multi-channel drives, and isolated power supplies, resulting in a relatively complex circuit structure. The specific solution is as follows:

[0006] An intelligent control power module, the power module comprising:

[0007] A full-bridge circuit comprising N switching units, where N is greater than or equal to 6, and converting direct current to alternating current by turning the N switching units on and off;

[0008] A driving unit, comprising a driving power supply and a driving circuit, wherein the driving circuit is connected to the driving power supply and the switching unit respectively and is used to control the switching unit to be turned on and off;

[0009] Protection circuit, used to control PWM wave output according to the current, voltage and temperature obtained in real time;

[0010] Logic circuit, used to control PWM wave output according to user needs;

[0011] an isolated power supply, located between the driving circuit and the logic circuit, the isolated power supply being connected to the driving circuit and the logic circuit respectively;

[0012] The full-bridge circuit, the driving unit, the protection circuit, the logic circuit and the isolated power supply are integrated into one.

[0013] Preferably, the full-bridge circuit is a three-phase full-bridge circuit.

[0014] Preferably, the six on-off units are arranged in parallel, and the input ends are respectively connected to the DC bus. The six on-off units are respectively connected to the driving circuit, and their respective opening and closing are controlled by the driving circuit to convert the DC power input from the DC bus into AC power for output.

[0015] Preferably, the switching unit is a MOS tube.

[0016] Preferably, the rated operating voltage of the MOS tube is 600V, the rated operating current is adjusted according to the actual needs of the customer, and the switching frequency is 5 to 20kHz.

[0017] Preferably, the driving power supply is provided with at least two channels;

[0018] The two driving power supplies are independently provided and are connected to the driving circuits respectively.

[0019] Preferably, the full-bridge circuit, the driving unit, the logic circuit, and the isolated power supply are respectively integrated into a driving control board.

[0020] Preferably, the logic circuit is built with an internal upper and lower bridge interlocking unit, a level control unit, an overcurrent protection unit, an undervoltage protection unit, an overvoltage protection unit, a protection soft shutdown unit, and a protection hard shutdown unit;

[0021] The logic circuit has a built-in dead zone protection time.

[0022] Preferably, the power module further includes a carrier;

[0023] The carrier includes a power board, a control board and a housing;

[0024] The power board is located below the control board, and an aluminum plate is installed under the power board to dissipate heat;

[0025] The full-bridge circuit is installed on the power board, and the drive unit, the logic circuit, and the isolated power supply are installed on the control board;

[0026] The housing covers the control board and is connected to the control board. The power board is installed under the control board.

[0027] The beneficial effects of this application are:

[0028] The present application integrates the full-bridge circuit, the drive unit, the logic circuit, and the isolated power supply into an integrated configuration, thereby simplifying the traditional controller + isolated drive circuit + isolated power supply + main power circuit + logic control circuit + protection circuit into an "MCU + IPM" control mode. Engineers can use it directly without adding other circuits, effectively solving the problem in the prior art that each functional circuit is constructed by separate electronic components, resulting in the need to design additional supporting circuits such as control circuits, multi-channel drives and isolated power supplies, and a relatively complex circuit structure.

[0029] The present application integrates each functional circuit (i.e., the full-bridge circuit, the driving circuit, the driving power supply, the logic circuit, and the isolated power supply) on a control board, so that each functional circuit can still operate reliably under high temperature, high voltage, high frequency, and high power conditions. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1 This is a principle framework diagram of an intelligent control power module for this application;

[0031] Figure 2 This is a structural diagram of a full-bridge circuit in an embodiment of an intelligent control power module of the present application;

[0032] Figure 3 This is a structural diagram of a drive unit in an embodiment of an intelligent control power module of the present application;

[0033] Figure 4 This is a structural diagram of a logic circuit in an embodiment of an intelligent control power module of the present application;

[0034] Figure 5 An assembly diagram of an intelligent control power module for this application;

[0035] Figure 6 This is an exploded diagram of the assembly of an intelligent control power module for this application;

[0036] In the attached figure:

[0037] 1. Housing; 2. Control board; 3. Power board. DETAILED DESCRIPTION

[0038] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0039] See also Figure 1-6 The utility model provides an intelligent control power module, comprising:

[0040] An intelligent control power module, the power module comprising: various functional circuits (i.e., a full-bridge circuit, a drive unit, a logic circuit, and an isolated power supply) and a carrier for mounting the various functional circuits;

[0041] The carrier includes a power board 3, a control board 2 and a housing 1;

[0042] The power board is located below the control board;

[0043] The housing is a cover-shaped structure covering the outside of the control board, one end of the opening of the housing is connected to the power board, and a through-hole is provided on the side of the housing facing away from the power board for installing the control port in the control board 2;

[0044] In one embodiment of the present application, as shown in the attached Figure 6As shown, this application utilizes a top-down combination of a control board 2 and a power board 3. The lower power board 3 houses the power control unit, while the upper control board 2 houses the logic control unit, which includes the drive power supply isolation power supply, chip power supply, PWM control, and protection circuits. By separating the power and logic components, this application significantly reduces circuit interference signals caused by high voltage, while also outperforming existing products in terms of size.

[0045] The functional circuits include:

[0046] A full-bridge circuit, with its input connected to the DC bus and its output connected to the load, provides the three-phase voltages U, V, and W required by the load. The full-bridge circuit is used to convert the DC power input from the DC bus into the AC power required by the user;

[0047] In one embodiment of the present application, the full-bridge circuit is a three-phase full-bridge circuit, which converts the DC power input from the DC bus into a three-phase output of U, V, and W; Figure 2 The three-phase full-bridge circuit shown in the figure mainly consists of six on-off units connected in parallel (see the attached Figure 2 The six MOS tubes Q1, Q2, Q3, Q4, Q5 and Q6 shown in the figure and the unloading unit (see the attached figure) Figure 2 The MOS transistors Q8 and the unloading resistor shown in the figure are composed of MOS transistors Q8 and unloading resistors), wherein MOS transistors Q1, Q2, Q3, Q4, Q5 and Q6 are respectively connected in parallel at both ends of the series circuit of the unloading resistor and the unloading control MOS transistor Q8, and the G poles of the MOS transistors Q1, Q2, Q3, Q4, Q5 and Q6 are respectively connected to the PWM drive signal. The input ends of the MOS transistors Q1, Q2, Q3, Q4, Q5 and Q6 are connected to the DC bus, and the output ends are connected to the drive motor. The output of the PWM wave is controlled to control the on and off of the MOS transistors, and output the required U, V, and W three-phase voltages;

[0048] In this application, a three-phase full-bridge circuit controls the on and off state of each MOS transistor in the driver circuit by controlling the corresponding control circuit to convert DC power into the required AC power. By continuously alternating the on and off states of each MOS transistor, the load circuit can be switched back and forth between the positive and negative poles, thereby achieving DC to AC power conversion. In one embodiment of this application, the MOS transistor is a silicon carbide MOS transistor. The use of silicon carbide MOS transistors allows the power supply to achieve high efficiency and a small size, which has certain advantages in certain high-temperature and high-voltage environments.

[0049] The drive unit includes a drive circuit (specifically a drive control circuit) and a drive power supply. The drive control circuit is connected to the full-bridge circuit (i.e., the three-phase full-bridge power main circuit in this embodiment) and the drive power supply respectively. The number of drive power supplies can be determined according to actual needs, and each drive power supply is isolated from each other to avoid noise interference. In this embodiment, the drive power supply is an auxiliary power supply for the drive circuit. The drive power supply is independently provided with two channels, specifically Figure 3 The two power supplies for the isolated driving power supply and the 6-way PWM control signal are isolated from each other to improve the anti-interference capability and ensure the normal operation of the driving circuit.

[0050] Since false triggering is likely to occur when the filter capacitor at the output end of the drive circuit is too large, an isolated driver chip is used in this application to integrate the drive circuit to reduce the use of components, thereby reducing the size of the product while ensuring the functionality of the drive circuit.

[0051] Logic circuit. In this application, the logic circuit is respectively provided with protection status output, thermal protection status signal, overcurrent protection, enable signal (level control), undervoltage protection, overvoltage protection, and 6-channel PWM signals integrated on the logic device. The logic device has the characteristics of flexible programming, high integration, short design and development cycle, wide application range, advanced development tools, low design and manufacturing cost, low hardware experience requirements for designers, no need for testing of standard products, strong confidentiality, and popular price. It can realize large-scale circuit design, so it is used in the logic control of the entire power module of this product, such as Figure 4 As shown: the logic device has built-in overcurrent protection, undervoltage protection, overvoltage protection, overcurrent protection, internal upper and lower bridge interlocking unit and enable control unit. In the enable control unit: ENH and ENL are level control signals provided to the user.

[0052] Bus overcurrent protection control: When the current exceeds the set current value, the bus overcurrent feedback signal becomes high level, and PWM is locked and has no output.

[0053] Undervoltage protection control: When the bus voltage is lower than the set minimum voltage, the bus undervoltage feedback signal becomes high level, and the PWM is locked and has no output.

[0054] Overvoltage control: When the bus voltage is higher than the set maximum voltage, the bus overvoltage feedback signal becomes high level, and the PWM is locked and has no output.

[0055] Since the upper and lower half bridges of each bridge must not be turned on at the same time, the high-speed PWM drive signal will often produce a delay effect due to various reasons when reaching the control electrode of the power element, causing a half-bridge element to not turn off when it should be turned off, causing the power element to burn. In response to this situation, the present application sets a logical dead zone in the logic device, uses the logic device to control the input PWM, and sets the dead zone time according to user needs to prevent the power element from burning due to the simultaneous opening of the upper and lower tubes. When it is detected that the upper and lower interlocked PWMs are high at the same time, the output PWM is turned off to protect the power element. This greatly improves the reliability of the product;

[0056] This allows the control of the PWM output waveform to be achieved through logic devices, the required dead time to be set through the CPLD software program, and the PWM wave output to be controlled to prevent the upper and lower tubes from being connected and exploding; protection control for over-temperature, over-current, over-voltage, and under-voltage; the user end can independently control the enable signal to control the PWM wave output and independently control the shutdown or opening of the MOS tube.

[0057] It should be noted that:

[0058] In one embodiment of the present application, the rated operating voltage of the MOS tube is set to 600V, the rated operating current is adjusted according to the actual needs of the customer, and the switching frequency is 5 to 20kHz.

[0059] The MOS transistors used in three-phase full-bridge circuits are driven and controlled by corresponding driver circuits, and each driver requires an isolated power supply. This makes the design complex for engineers and is prone to interference, resulting in unclean drive waveforms and impracticality. This application integrates the driver power supply into the product, ensuring a stable and anti-interference power supply system. The driver control circuit has isolation protection, stable output, and strong drive capability.

[0060] Existing silicon carbide power modules only have power output functions and lack intelligent control functions, requiring users to build their own peripheral circuits. This product not only uses silicon carbide MOS tubes but also has intelligent control functions.

Claims

1. An intelligent control power module, characterized in that: The power module includes: A full-bridge circuit comprising N switching units, where N is greater than or equal to 6, and converting direct current to alternating current by turning the N switching units on and off; A driving unit, comprising a driving power supply and a driving circuit, wherein the driving circuit is connected to the driving power supply and the switching unit respectively and is used to control the switching unit to be turned on and off; Protection circuit, used to control PWM wave output according to the current, voltage and temperature obtained in real time; Logic circuit, used to control PWM wave output according to user needs; an isolated power supply, located between the drive circuit and the logic circuit, the isolated power supply being connected to the drive circuit and the logic circuit respectively; The full-bridge circuit, the driving unit, the logic circuit and the isolated power supply are integrated into one unit.

2. The intelligent control power module according to claim 1, characterized in that: The full-bridge circuit is a three-phase full-bridge circuit.

3. The intelligent control power module according to claim 1, characterized in that: The six on-off units are arranged in parallel, and the input ends are respectively connected to the DC bus. The six on-off units are respectively connected to the driving circuit. The driving circuit controls their respective opening and closing to convert the DC power input from the DC bus into the required AC power for output.

4. The intelligent control power module according to claim 1, characterized in that: The switching unit is a MOS tube.

5. The intelligent control power module according to claim 4, characterized in that: The rated operating voltage of the MOS tube is 600V, the rated operating current is adjusted according to the actual needs of the customer, and the switching frequency is 5-20kHz.

6. The intelligent control power module according to claim 1, characterized in that: The driving power supply is provided with at least two channels; The two driving power supplies are independently provided and connected to the driving circuits respectively.

7. The intelligent control power module according to claim 6, characterized in that: The full-bridge circuit is integrated on a power board; the driving unit, the logic circuit, and the isolated power supply are respectively integrated on the driving board.

8. The intelligent control power module according to claim 1, characterized in that: The logic circuit has an internal upper and lower bridge interlocking unit, a level control unit, an overcurrent protection unit, an undervoltage protection unit, an overvoltage protection unit, a protection soft shutdown unit and a protection hard shutdown unit. The logic circuit has a built-in programmable dead zone control time.

9. The intelligent control power module according to claim 1, characterized in that: The power module further includes a carrier; The carrier includes a power board, a control board and a housing; The power board is located below the control board, and an aluminum plate is installed under the power board to dissipate heat; The full-bridge circuit is installed on the power board, and the drive unit, the logic circuit, and the isolated power supply are installed on the control board; The housing covers the control board and is connected to the control board. The power board is installed under the control board.

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