A testing device for IGBT modules of wind farm converters

Abstract

This utility model relates to the field of IGBT module testing technology, and provides a testing device for IGBT modules in wind farm converters. It includes a pre-charge rectifier module for converting acquired AC power to DC power, an IGBT module for inverting the DC power output from the pre-charge rectifier module back to AC power, a wave generator for real-time control of the IGBT module's high-frequency switching on and off, a detection module for acquiring the AC power output of the IGBT module and displaying current and temperature on the wave generator, and an inductive reactor L for providing the AC load output current. This utility model overcomes the shortcomings of existing technologies. The testing device uses a single-phase system, its principle is simple and easy to understand, and the construction and assembly process is easy to operate, reducing construction difficulty and labor costs. Furthermore, due to the small number of components, smaller inverter inductors can be selected, reducing the investment in large equipment and improving safety while reducing costs.

Description

Technical Field

[0001] This utility model relates to the field of IGBT module testing technology, specifically to a testing device for IGBT modules in wind farm converters. Background Technology

[0002] During the operation of wind farm converters, IGBT modules and drive circuits face severe environmental challenges. They must withstand electrical stress, thermal stress, and environmental corrosion over long periods, leading to severe load phenomena in the IGBT modules and drive circuits. These load issues can trigger a chain reaction of failures, often resulting in the destruction of multiple IGBT modules. Given the high procurement cost of a single IGBT module, frequent replacements would significantly increase the operating costs of wind farms. To effectively reduce the procurement cost of converter modules and improve the reuse rate of spare parts, there is an urgent need to develop an IGBT module testing device for pre-installation inspection of IGBT modules after maintenance, ensuring the good performance of IGBT modules in use and reducing the probability of failure.

[0003] In response to the aforementioned problems, we propose a testing device for IGBT modules in wind farm converters. Utility Model Content

[0004] To address the shortcomings of existing technologies, this invention provides a testing device for IGBT modules in wind farm converters, thereby resolving the aforementioned problems in the prior art.

[0005] To achieve the above objectives, this utility model provides the following technical solution:

[0006] A testing device for IGBT modules of a wind farm converter includes: a pre-charge rectifier module for converting acquired AC power into DC power; an IGBT module for inverting the DC power output from the pre-charge rectifier module into AC power; a wave generator for real-time control of the high-frequency switching on and off of the IGBT module; a detection module for acquiring the AC power output of the IGBT module and displaying the current and temperature on the wave generator; and an inductive reactor L for providing the AC load output current.

[0007] The waveform tester includes a 15V power supply module, an IGBT drive module that acquires power and controls the on / off state of the insulated gate bipolar transistor, an IGBT drive module that adjusts the PWM duty cycle to control the output current, a detection module that monitors the current signal in real time and feeds the information back to the waveform tester for numerical display, and an IGBT drive module that is electrically connected to the base terminal of the insulated gate bipolar transistor in the IGBT module.

[0008] Furthermore, the pre-charge rectifier module includes a circuit breaker S1, a switch K1, a current-limiting resistor R1, and a single-phase rectifier bridge; the single-phase rectifier is composed of diodes D1, D2, D3, and D4. One end of the circuit breaker S1 is electrically connected to one end of the AC power supply, and the other end of the circuit breaker S1 is electrically connected to one end of the switch K1 and the current-limiting resistor R1. The other end of the current-limiting resistor R1 is electrically connected to the other end of the switch K1, the positive terminal of diode D1, and the negative terminal of diode D2. The negative terminal of diode D1 is electrically connected to the negative terminal of diode D3, the positive terminal of diode D3 is electrically connected to the negative terminal of diode D4 and the other end of the AC power supply, and the positive terminal of diode D4 is electrically connected to the positive terminal of diode D2.

[0009] Furthermore, the IGBT module includes two sets, and the two sets of IGBT modules share the DC power output by the pre-charge rectifier module; the two sets of IGBT modules independently invert the DC power into AC power through the pulse signal of the waveform tester, and are connected in series with each other;

[0010] Each IGBT module consists of two insulated-gate bipolar transistors and a capacitor C1. The two insulated-gate bipolar transistors are composed of a first insulated-gate bipolar transistor Q1 and a second insulated-gate bipolar transistor Q2, respectively. The two diodes are composed of a first diode D5 and a second diode D6.

[0011] Furthermore, each insulated gate bipolar transistor (IGBT) is provided with a diode, the positive terminal of which is electrically connected to the emitter of the IGBT, and the negative terminal of which is electrically connected to the collector of the IGBT.

[0012] Furthermore, the collector of the first insulated gate bipolar transistor Q1 is electrically connected to one end of capacitor C1 and the negative terminal of diode D1, the emitter of the first insulated gate bipolar transistor Q1 is electrically connected to the collector of the second insulated gate bipolar transistor Q2, and the emitter of the second insulated gate bipolar transistor Q2 is electrically connected to the other end of capacitor C1 and the positive terminal of diode D4.

[0013] Furthermore, when the IGBT drive module performs power testing on the IGBT module, a detection module is retained. This detection module includes a temperature sensor, a reactor L, and a Hall current sensor H. The temperature sensor monitors the temperature of the IGBT module substrate and sends the detected temperature signal to a waveform tester for numerical display. The two sets of IGBT modules control the switching on and off of the insulated gate bipolar transistors in the IGBT modules via pulse signals from the waveform tester. The IGBT module inverts DC voltage into AC current, which is then connected in series across the two ends of the reactor L. The reactor L is connected in series between the two sets of IGBT modules and serves as the load output current value. The Hall current sensor H is fitted onto either end of the reactor L and sends the detected current signal to the waveform tester for numerical display.

[0014] This invention provides a testing device for IGBT modules in wind farm converters. It offers the following advantages: the testing device uses a single-phase system, its principle is simple and easy to understand, and the construction and assembly process is easy to operate, reducing construction difficulty and labor costs; furthermore, due to the small number of components, smaller inverter inductors can be selected, reducing the investment in large equipment, thus lowering costs while improving safety.

[0015] By reducing the occurrence of IGBT module failures, the reliability and stability of the equipment have been significantly improved, ensuring the normal operation of the wind farm converter and reducing downtime and production losses caused by equipment failures.

[0016] This testing device can meet more testing needs and facilitate comprehensive testing of equipment. If multiple modules need to be tested, a multi-level parallel connection can be used. At the same time, the device flexibly supports testing of various modules, which can meet the diverse needs of different customers and expand its application scope. Attached Figure Description

[0017] Figure 1 This is the module circuit diagram of this utility model;

[0018] Figure 2 This is a schematic diagram of the power test of this utility model; Detailed Implementation

[0019] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model.

[0020] refer to Figures 1-2 As shown, a wind farm converter IGBT module testing device includes: a pre-charge rectifier module for converting acquired AC power into DC power; an IGBT module for inverting the DC power output from the pre-charge rectifier module into AC power; a wave generator for real-time control of the high-frequency switching on and off of the IGBT module; a detection module for acquiring the AC power output of the IGBT module and displaying the current and temperature on the wave generator; and an inductive reactor L for providing the AC load output current.

[0021] The waveform tester includes a 15V power supply module, an IGBT drive module that acquires power and controls the on / off state of the insulated gate bipolar transistor, an IGBT drive module that adjusts the PWM duty cycle to control the output current, a detection module that monitors the current signal in real time and feeds the information back to the waveform tester for numerical display, and an IGBT drive module that is electrically connected to the base terminal of the insulated gate bipolar transistor in the IGBT module.

[0022] The pre-charge rectifier module includes a circuit breaker S1, a switch K1, a current-limiting resistor R1, and a single-phase rectifier bridge. The single-phase rectifier is composed of diodes D1, D2, D3, and D4. One end of the circuit breaker S1 is electrically connected to one end of the AC power supply. The other end of the circuit breaker S1 is electrically connected to one end of the switch K1 and the current-limiting resistor R1. The other end of the current-limiting resistor R1 is electrically connected to the other end of the switch K1, the positive terminal of diode D1, and the negative terminal of diode D2. The negative terminal of diode D1 is electrically connected to the negative terminal of diode D3. The positive terminal of diode D3 is electrically connected to the negative terminal of diode D4 and the other end of the AC power supply. The positive terminal of diode D4 is electrically connected to the positive terminal of diode D2.

[0023] Specifically, the pre-charge rectifier module converts the 220VAC AC mains power into a 310VDC DC source for the bus capacitor. A 22Ω current-limiting resistor is used to achieve a smooth rise in the bus voltage, and the contactor closure controls the bus voltage to remain constant.

[0024] The IGBT module converts the DC bus voltage into AC power, and the IGBT module output is connected to a reactor load (with a reactance value of 0.4mH) to simulate the characteristics of a reactive load.

[0025] The waveform tester drives the IGBT module to run under a 200A current load for 2 hours, allowing real-time observation of the temperature and current operation of the two-phase IGBT modules; it includes single pulse signal input and continuous load input functions, injecting PWM signals to control the IGBT's on / off state in real time and adjust the duty cycle.

[0026] The IGBT module includes two sets, which share the DC power output from the pre-charge rectifier module. The two sets of IGBT modules independently convert DC power into AC power through the pulse signal of the waveform tester and are connected in series with each other.

[0027] Specifically, two sets of IGBT modules (representing two bridge arms or half-bridges) are connected in parallel on the DC bus (i.e., both are connected to the two ends of the pre-charge rectifier module output); the two sets of IGBT modules share the same DC power supply (the output of the pre-charge rectifier module); each set of modules can be tested independently or operate simultaneously, allowing the device to test one IGBT module individually or test two IGBT modules simultaneously.

[0028] Each IGBT module consists of two insulated-gate bipolar transistors (IGBTs), two diodes (upper diode Q1 and lower diode Q2), and a capacitor C1. The two IGBTs are composed of the first IGBT Q1 and the second IGBT Q2, respectively; the two diodes are composed of the first diode D5 and the second diode D6.

[0029] Each insulated-gate bipolar transistor (IGBT) is provided with a diode, the positive terminal of which is electrically connected to the emitter of the IGBT, and the negative terminal of which is electrically connected to the collector of the IGBT.

[0030] Specifically, the insulated-gate bipolar transistors (Q1, Q2) in the two IGBT modules serve as switching transistors; Q1 is the upper transistor, and Q2 is the lower transistor. Two anti-parallel diodes (D5, D6) are connected in anti-parallel across Q1 and Q2, respectively, to prevent excessively high reverse electromotive force from the inductor, protecting the upper and lower IGBT transistors from reverse breakdown and improving circuit stability and reliability. A bus capacitor C1 is connected between the first insulated-gate bipolar transistor Q1 and the second insulated-gate bipolar transistor Q2, filtering out DC bus ripple, providing low-inductive local energy storage for IGBT switching operations, absorbing energy surges during switching, and stabilizing the bus voltage.

[0031] The collector of the first insulated gate bipolar transistor Q1 is electrically connected to one end of capacitor C1 and the negative terminal of diode D1. The emitter of the first insulated gate bipolar transistor Q1 is electrically connected to the collector of the second insulated gate bipolar transistor Q2. The emitter of the second insulated gate bipolar transistor Q2 is electrically connected to the other end of capacitor C1 and the positive terminal of diode D4.

[0032] When the IGBT drive module performs power testing on the IGBT module, the detection module is retained. The detection module includes a temperature sensor, a reactor L, and a Hall current sensor H. The temperature sensor is used to monitor the temperature of the IGBT module substrate and sends the detected temperature signal to the waveform tester for numerical display. The two sets of IGBT modules control the on / off state of the insulated gate bipolar transistors in the IGBT modules through the pulse signal of the waveform tester. The IGBT module inverts the DC voltage into AC current and connects the AC current output from the two sets of IGBT modules in series through the two ends of the reactor L. The reactor L is connected in series between the two sets of IGBT modules as the load output current value. The Hall current sensor H is fitted onto either end of the reactor L and sends the detected current signal to the waveform tester for numerical display.

[0033] Specifically, the circuit breaker S1 is model iC65N-C-20A; the current-limiting resistor R1 is model RXG14-400W-22Ω; the rectifier diodes D1-D4 are model GBPC3506W; the capacitor C1 is model C3B1M407JBOH834-1100V-400uF; the Hall current sensor H is model HAT 1500-S; the temperature sensor is model PT100; the reactor L is model DCL-0250 / 0.4mH; and the 15V power supply module is model LRS-350-15.

[0034] Working principle: First, one end of circuit breaker S1 is electrically connected to one end of the AC power supply, and the other end is electrically connected to one end of switch K1 and current-limiting resistor R1. The current-limiting resistor R1 (22Ω) is used to control the smooth rise of the bus voltage and prevent sudden current changes. The single-phase rectifier bridge consists of four diodes D1, D2, D3, and D4, which convert the AC power into pulsating DC power. The bus capacitor C1 is used for filtering to make the output voltage more stable. After switch K1 is closed, the bus voltage is kept constant. Finally, a 310VDC DC power source is output to power the IGBT module inverter.

[0035] The IGBT module obtains 310VDC direct current from the pre-charge rectifier module; the IGBT module inverts the direct current into alternating current through switching transistors (such as the first group of modules Q1 and Q2), and connects the output terminal to the inductor L load (0.4mH) to simulate the characteristics of a reactive load;

[0036] like Figure 2As shown, in power test mode, the waveform tester uses the IGBT drive module to achieve real-time control and monitoring of the IGBT modules. A reactor L is connected in series between two IGBT modules, and a Hall current sensor H is fitted onto the leads of reactor L. The IGBT drive module controls the IGBTs to turn on and off according to the PWM signal set by the waveform tester. When on, it drives the two IGBT modules to perform inverter operation. The Hall current sensor H detects the output AC current, and the temperature sensor monitors the IGBT module temperature. The waveform tester monitors and displays the temperature of each IGBT module in real time. After the test is completed, the waveform tester stops transmitting waveforms.

[0037] In the power test mode, the IGBT drive module in the waveform tester ensures that the switching action of the IGBT module meets the requirements. By adjusting the PWM duty cycle of the on / off state of the IGBT module under test (e.g., the upper transistor Q1 and the lower transistor Q2 of the first group of modules), the stability of the target current is maintained, ensuring that the switching action of the IGBT module meets the requirements.

[0038] The waveform tester starts running (load range initial test), and a low initial target current is set (e.g., 40A). Based on the set value and the actual current fed back by the Hall current sensor H, the PWM duty cycle of the first insulated gate bipolar transistor (e.g., the upper transistor Q1 and the lower transistor Q2 of the first module) is adjusted to perform closed-loop current control.

[0039] Measure the actual current. If the current cannot reach 40A or deviates too much from the set value: Possible causes include: faulty connection of reactor L; damage to the first insulated-gate bipolar transistor Q1, the second insulated-gate bipolar transistor Q2, the first diode D5, and the second diode D6 in the two IGBT modules; abnormal drive; or a faulty Hall current sensor H. End the process and report the fault.

[0040] If the current is approximately 40A and the initial test is passed, proceed to the high-current load test. During the high-current load test, slowly adjust the current setting value using the waveform tester (rotate the current knob) to gradually increase the output current to the target load value of 200A. The waveform tester continuously outputs pulses to control the AC side target current to be stably maintained at 200A.

[0041] Start the timing and run the IGBT module continuously at 200A current for 2 hours; monitor and display the load current (from Hall current sensor H), bus voltage, and temperature of the IGBT module under test in real time. The operator closely monitors whether the temperature is within the safe range. After 2 hours, the waveform tester stops the output of the IGBT drive module (turns off the drive signals of Q1 and Q2), and the current drops to 0A.

[0042] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0043] The above embodiments are only used to illustrate the technical solutions of this utility model, and are not intended to limit it. Although this utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this utility model.

Claims

1. A wind farm converter IGBT module detection device, characterized in that, It includes a pre-charge rectifier module for converting the acquired AC power into DC power, an IGBT module for inverting the DC power output from the pre-charge rectifier module into AC power, a waveform tester for real-time control of the high-frequency switching on and off of the IGBT module, a detection module for acquiring the AC power output of the IGBT module and displaying the current and temperature on the waveform tester, and an inductive reactor L for providing the AC load output current. The waveform tester includes a 15V power supply module, an IGBT drive module that acquires power and controls the on / off state of the insulated gate bipolar transistor, an IGBT drive module that adjusts the PWM duty cycle to control the output current, a detection module that monitors the current signal in real time and feeds the information back to the waveform tester for numerical display, and an IGBT drive module that is electrically connected to the base terminal of the insulated gate bipolar transistor in the IGBT module.

2. The wind farm converter IGBT module detection device of claim 1, wherein: The pre-charge rectifier module includes a circuit breaker S1, a switch K1, a current-limiting resistor R1, and a single-phase rectifier bridge. The single-phase rectifier is composed of diodes D1, D2, D3, and D4. One end of the circuit breaker S1 is electrically connected to one end of the AC power supply. The other end of the circuit breaker S1 is electrically connected to one end of the switch K1 and the current-limiting resistor R1. The other end of the current-limiting resistor R1 is electrically connected to the other end of the switch K1, the positive terminal of diode D1, and the negative terminal of diode D2. The negative terminal of diode D1 is electrically connected to the negative terminal of diode D3. The positive terminal of diode D3 is electrically connected to the negative terminal of diode D4 and the other end of the AC power supply. The positive terminal of diode D4 is electrically connected to the positive terminal of diode D2.

3. The wind farm converter IGBT module testing device as described in claim 1, characterized in that: The IGBT module includes two sets, which share the DC power output from the pre-charge rectifier module. The two sets of IGBT modules independently convert DC power into AC power through the pulse signal of the waveform tester and are connected in series with each other. Each IGBT module consists of two insulated-gate bipolar transistors and a capacitor C1. The two insulated-gate bipolar transistors are composed of a first insulated-gate bipolar transistor Q1 and a second insulated-gate bipolar transistor Q2, respectively. The two diodes are composed of a first diode D5 and a second diode D6.

4. The wind farm converter IGBT module testing device as described in claim 3, characterized in that: Each insulated-gate bipolar transistor (IGBT) is provided with a diode, the positive terminal of which is electrically connected to the emitter of the IGBT, and the negative terminal of which is electrically connected to the collector of the IGBT.

5. The wind farm converter IGBT module testing device as described in claim 3, characterized in that: The collector of the first insulated gate bipolar transistor Q1 is electrically connected to one end of capacitor C1 and the negative terminal of diode D1. The emitter of the first insulated gate bipolar transistor Q1 is electrically connected to the collector of the second insulated gate bipolar transistor Q2. The emitter of the second insulated gate bipolar transistor Q2 is electrically connected to the other end of capacitor C1 and the positive terminal of diode D4.

6. The wind farm converter IGBT module testing device as described in claim 1, characterized in that: When the IGBT drive module performs power testing on the IGBT module, the detection module is retained. The detection module includes a temperature sensor, a reactor L, and a Hall current sensor H. The temperature sensor is used to monitor the temperature of the IGBT module substrate and sends the detected temperature signal to the waveform tester for numerical display. The two sets of IGBT modules control the on / off state of the insulated gate bipolar transistors in the IGBT modules through the pulse signal of the waveform tester. The IGBT module inverts the DC voltage into AC current and connects the AC current output from the two sets of IGBT modules in series through the two ends of the reactor L. The reactor L is connected in series between the two sets of IGBT modules as the load output current value. The Hall current sensor H is fitted onto either end of the reactor L and sends the detected current signal to the waveform tester for numerical display.

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