ABB frequency converter optimizing and upgrading device for wind turbine generator
By separating the gate drive board from the IGBT, adding a dedicated protection board, improving the control wiring, and upgrading the temperature rating of the control chip, the high-temperature fault problem of ABB frequency converters in wind turbine units was solved, achieving stable operation of the equipment and cost reduction.
Patent Information
- Application Number
- CN202520340634.5
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-02-28
- Publication Date
- 2026-02-03
- Estimated Expiration
- 2035-02-28
AI Technical Summary
ABB frequency converters have a high failure rate in wind turbines due to the high-temperature environment, especially the aging and failure of the gate drive board and IGBT, which affects the stable operation of the equipment and increases the consumption of spare parts.
The gate driver board is installed separately from the IGBT, a dedicated protection board is added, the control cable connection is improved, the temperature rating of the control chip is upgraded, and an external fan control circuit is connected to reduce the temperature.
It effectively reduces the failure rate, extends equipment life, reduces production costs, and improves wind turbine power generation efficiency.
Smart Images
Figure CN223872197U_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The utility model relates to wind power generation technical field, concretely relates to a kind of ABB frequency converter optimization upgrading device for wind turbine generator system. BACKGROUND
[0002] ABB frequency converter used by Bayin wind farm Huaxue SL1500 type wind turbine generator set, model is ACS800-67, is all put into operation on September 15, 2015.
[0003] Due to the compact structure of frequency converter, and limited by the particularity of wind turbine generator set operating environment and structural design, it cannot be equipped with separate purification room and air conditioner, and the operating temperature is high, with the increase of use time, electronic component aging, derive various faults, seriously affect the stable operation of fan, according to the existing data, frequency converter failure accounts for about 30% of annual failure rate of wind turbine, and power loss is about 4 million kWh.
[0004] Among them, under long-term high temperature condition, gate drive board aging leads to control invalidation of insulated gate bipolar transistor (IGBT), frequently reports SC fault or IGBT explosion, and the problem of associated damage to peripheral board card is particularly prominent, increases spare part consumption and production cost. UTILITY MODEL CONTENTS
[0005] The utility model aims at providing a kind of ABB frequency converter optimization upgrading device for wind turbine generator set to solve the problems raised in the above background.
[0006] To achieve the above object, the utility model provides the following technical scheme:
[0007] A kind of ABB frequency converter optimization upgrading device for wind turbine generator set, including gate drive board, insulated gate bipolar transistor, special protection board, cooling fan, control cable, control chip, fan control circuit;
[0008] Further, the gate drive board is separately arranged with insulated gate bipolar transistor, and the gate drive board is close to the air outlet of cooling fan;
[0009] Further, the insulated gate bipolar transistor after separation is arranged on special protection board;
[0010] Further, one end of the control cable is connected with gate drive board, while the other end of control cable is connected with power module control board and power board respectively, wherein, the installation position of one end of control cable and gate drive board is avoided from direct-current busbar;
[0011] Further, the control chip is connected with gate drive board, and the working temperature range of control chip is upgraded to 125 DEG C;
[0012] Further, for the ABB frequency converter of the wind turbine, the fan power supply board and the frequency conversion board of the original system are removed, and a fan control circuit is added; the fan control circuit sets the fan control system power frequency as 380V working frequency.
[0013] The control cable is fixed in a position away from the DC bus bar through a wire slot.
[0014] The fan control circuit comprises a frequency converter, a contactor and a power supply, and the contactor is connected between the frequency converter and the power supply.
[0015] The contactor is an AC contactor.
[0016] The power supply is a 380V AC power supply.
[0017] The gate drive board, the insulated gate bipolar transistor, the special protection board, the cooling fan, the control cable, the control chip and the fan control circuit are all installed inside the ABB frequency converter.
[0018] The utility model discloses the beneficial effect:
[0019] The utility model discloses through gate drive board and insulated gate bipolar transistor separate installation, install special protection board to insulated gate bipolar transistor, avoid DC bus bar of control cable connection mode, the upgrade of control chip temperature grade and the transformation of fan external power supply, effectively solve the high temperature problem in the operation of ABB frequency converter, reduce the failure rate, prolong the service life of equipment, reduce the production cost, improve the fan power generation efficiency. DETAILED DESCRIPTION
[0020] The description accompanying the drawings that form a part hereof is to provide a further understanding of the present application, and the illustrative embodiments of the present application and its description serve the purpose of explanations and are not to be construed as limiting the present application thereto.
[0021] Figure 1 It is the first schematic view of the ABB frequency converter optimization upgrading device for wind turbine of the utility model;
[0022] Figure 2 It is the structural schematic diagram of prior art;
[0023] Figure 3 It is the second schematic view of the ABB frequency converter optimization upgrading device for wind turbine of the utility model. DETAILED DESCRIPTION
[0024] In order to make the above-mentioned purposes, features and advantages of the utility model more apparent, obvious and easy to understand, the specific embodiments of the utility model will be described in detail below with reference to the drawings in the specification. Obviously, the described embodiments are part of the embodiments of the utility model, rather than all the embodiments. Based on the embodiments in the utility model, all other embodiments obtained by the ordinary person in the art without creative labor should belong to the protection scope of the utility model.
[0025] Embodiment 1
[0026] The gate drive board is a circuit module for controlling the turn-on and turn-off of an insulated gate bipolar transistor (IGBT). The following content collectively refers to the insulated gate bipolar transistor as IGBT. The insulated gate bipolar transistor itself needs a specific electrical signal to realize conduction and cutoff to complete its power conversion and control function in the circuit. The role of the gate drive board is to provide accurate and appropriate driving voltage and current for the gate of the insulated gate bipolar transistor to ensure that the insulated gate bipolar transistor can quickly and reliably switch on and off and work normally under various working conditions.
[0027] The embodiment provides an ABB frequency converter optimization upgrading device for a wind turbine. First, the gate drive board and the insulated gate bipolar transistor are separated, and a special protection board is designed for the separated insulated gate bipolar transistor, so that the gate drive board is away from the heat source insulated gate bipolar transistor, and the gate drive board is arranged at the air outlet close to the cooling fan, so that the gate drive board is well cooled and the service life is prolonged. The special protection board designed above adopts a program chip, and the gate trigger signal is more reliable.
[0028] Secondly, the mounting position of the control cable is changed: one end of the control cable is connected with the gate drive board, and the other end of the control cable is connected with the power module control board and the power supply board respectively, wherein the mounting position of the one end of the control cable connected with the gate drive board avoids the direct current busbar; it should be noted that the connection position of the original drive board control cable is only about 5cm away from the direct current busbar, and the insulated gate bipolar transistor is in close contact with the insulated gate bipolar transistor. When the machine explodes, high-voltage direct current will burn the power module control board and the power supply board through the control cable. Therefore, by changing the mounting position of the control cable, the embodiment can avoid such situations, indirectly reduce the cost of spare parts, and the control cable is a flat cable.
[0029] Then, the performance level of the control chip is upgraded: the working temperature range is upgraded from the original 85 DEG C to 125 DEG C, and the stability of the chip in a high-temperature environment is enhanced.
[0030] Furthermore, the external power supply for the inverter fan is modified: the original fan power board and inverter board are removed and used as spare parts, reducing spare parts procurement costs and subsequent maintenance costs, while also reducing the failure rate; the fan control circuit is added, that is, an external contactor coil and contactor main contacts are added, and the fan control system is changed to operate at 380V, which extends the service life of the fan, increases the ventilation volume, and reduces the operating temperature of the inverter.
[0031] Finally, after the technical upgrade was completed, converter charging tests, zero-speed tests, and grid connection tests were conducted.
[0032] The converter charging experiment, conducted under the premise of applying a certain power supply voltage and current to a full-power converter, tests and evaluates the topology, current, voltage, and other parameters of the converter's internal circuitry to verify the converter's performance and reliability. In simple terms, it involves: during converter startup, a resistor limits the current while charging the capacitor. Once the capacitor is fully charged, the resistor is automatically disconnected, allowing the high-voltage DC power supply to conduct, causing the electromagnet to actuate and thus starting the converter. This reduces the peak high-voltage voltage generated at startup to a lower level, protecting the circuit components for safe operation.
[0033] The inverter zero-speed test refers to the process where, when the inverter frequency is zero, one of its multi-function output terminals has an output signal. This output signal is then used to drive the host computer to perform the next action, in order to ensure that the voltage and current waveforms are stable and free from distortion.
[0034] The converter grid connection experiment involves adjusting the frequency and phase of the converter's output voltage to synchronize it with the grid, then performing a soft start, gradually increasing the converter's output power until it reaches the set value, and finally locking out the connection. This means that during the grid connection process, the grid status is continuously monitored, and if any abnormality is detected, the connection is immediately disconnected to prevent damage to the grid or the converter. Results show that the operating temperature of the insulated-gate bipolar transistor and driver board decreased by approximately 10-20°C compared to before the modification.
[0035] The above provides a detailed description of an ABB frequency converter optimization and upgrade device for wind turbine units provided by this utility model. Although specific embodiments of this utility model have been described in conjunction with the accompanying drawings, this is not intended to limit the scope of protection of this utility model. It should be noted that those skilled in the art can make several improvements and modifications to this application without departing from the principles of this application, and these improvements and modifications also fall within the protection scope of the claims of this application.
Claims
1. An ABB frequency converter optimization and upgrade device for wind turbine units, characterized in that, include: Gate driver board, insulated gate bipolar transistor, dedicated protection board, cooling fan and control cable; The gate drive board is separated from the insulated gate bipolar transistor, and the gate drive board is close to the air outlet of the cooling fan. The separated insulated gate bipolar transistor is placed on a dedicated protection board. One end of the control cable is connected to the gate drive board, and the other end of the control cable is connected to the power module control board and the power supply board respectively. The connection point between the control cable and the gate drive board is positioned to avoid the DC busbar.
2. The ABB frequency converter optimization and upgrade device for wind turbine units as described in claim 1, characterized in that, Also includes: Fan control circuit; For the ABB frequency converter of the wind turbine, the original system's fan power board and frequency converter board were removed, and a fan control circuit was added. The fan control circuit sets the power frequency of the fan control system to 380V.
3. The ABB frequency converter optimization and upgrade device for wind turbine units as described in claim 1, characterized in that, Also includes: Control chip; The control chip is connected to the gate driver board, and the operating temperature range of the control chip is upgraded to 125°C.
4. The ABB frequency converter optimization and upgrade device for wind turbine units as described in claim 1, characterized in that: The control cable is fixed in a position away from the DC busbar via a cable tray.
5. The ABB frequency converter optimization and upgrade device for wind turbine units as described in claim 2, characterized in that: The fan control circuit includes a frequency converter, a contactor, and a power supply, with the contactor connected between the frequency converter and the power supply.
6. The ABB frequency converter optimization and upgrade device for wind turbine units as described in claim 5, characterized in that: The contactor is an AC contactor.
7. The ABB frequency converter optimization and upgrade device for wind turbine units as described in claim 5, characterized in that: The power supply is a 380V AC power supply.
8. The ABB frequency converter optimization and upgrade device for wind turbine units as described in claim 1, characterized in that: The gate drive board, insulated gate bipolar transistor, dedicated protection board, cooling fan, control cable, control chip and fan control circuit are all installed inside the ABB inverter.