A high voltage direct current module

Abstract

The utility model relates to a kind of high-voltage direct current module, comprising: inverter circuit, sampling circuit and voltage doubler circuit;Inverter circuit includes: double-tube forward circuit, drive circuit and high-frequency transformer;Double-tube forward circuit includes two switching tubes, and drive circuit drives two switching tubes alternate conduction / shut down, and double-tube forward circuit converts input direct-current voltage into high-frequency alternating current signal and then inputs high-frequency transformer to be boosted and then inputs voltage doubler circuit;Voltage doubler circuit outputs after the voltage of high-frequency alternating current signal is multiplied;Sampling circuit obtains the output voltage of high-voltage direct current module by collecting the voltage output by voltage doubler circuit;Realize the isolation sampling of high-voltage and low-voltage system, improve the anti-electromagnetic interference capability of power supply.

Description

Technical Field

[0001] This utility model relates to the field of power modules, specifically to a high-voltage DC module. Background Technology

[0002] A high-voltage DC module is a complex power electronic device used to convert alternating current into high voltage. It has a wide range of applications, such as power transmission, transportation, and power systems.

[0003] Existing high-voltage DC power supply products generally use microcontroller or PLC control technology. Although the output voltage sampling signal of the high-voltage DC power supply is relatively low, its signal is obtained directly through a high-voltage divider resistor. Therefore, the sampling signal obtained in this way is easily penetrated by surge current and harmonic voltage, especially when spark flashover occurs. If this signal is directly connected to the microcontroller or PLC control circuit, it is easy to damage the microelectronic circuit when surge current and harmonic voltage occur. Utility Model Content

[0004] This invention addresses the technical problems existing in the prior art by providing a high-voltage DC module. Based on the high-voltage DC module and its fiber-optic isolated voltage-frequency conversion sampling technology, it achieves isolated sampling between high-voltage and low-voltage systems, thereby improving the sampling accuracy and anti-electromagnetic interference capability of the power supply.

[0005] The technical solution of this utility model to solve the above-mentioned technical problems is as follows: a high-voltage DC module, comprising: an inverter circuit, a sampling circuit and a voltage multiplier circuit;

[0006] The inverter circuit includes: a two-transistor forward converter, a drive circuit, and a high-frequency transformer;

[0007] The dual-transistor forward converter includes two switching transistors. The driving circuit drives the two switching transistors to alternately turn on and off. The dual-transistor forward converter converts the input DC voltage into a high-frequency AC signal, which is then input to the high-frequency transformer for boosting and then input to the voltage multiplier circuit.

[0008] The voltage multiplier circuit amplifies the voltage of the high-frequency AC signal before outputting it.

[0009] The sampling circuit acquires the voltage output by the voltage multiplier circuit to obtain the output voltage of the high voltage DC module.

[0010] Based on the above technical solution, the present invention can be further improved as follows.

[0011] Furthermore, the dual-transistor forward converter circuit includes two identical switching transistor modules;

[0012] The switching module includes: NMOS transistor M1, NMOS transistor M2, diode D0, diode D1, inductor L1, resistor R1, and transformer;

[0013] One end of the input DC voltage is connected to the drain (D) of the NMOS transistor M1 and the cathode of the diode D1, and the other end of the DC voltage is connected to the anode of the diode D0, the source (S) of the NMOS transistor M1, and ground.

[0014] The source (S) of the NMOS transistor M0 is connected to the negative terminal of the diode D0 and then connected to one end of the input terminal of the transformer; the drain (D) of the NMOS transistor M1 is connected to the positive terminal of the diode D1 and then connected to the other end of the input terminal of the transformer through the inductor L1.

[0015] One end of the transformer's output terminal is grounded, and the other end is connected to another switching transistor module via resistor R1.

[0016] Furthermore, the voltage multiplier circuit includes at least two boost units; each boost unit includes: diode D2, diode D3, capacitor C1, and capacitor C2;

[0017] One end of capacitor C1 is connected to one end of the input of the boost unit, and the other end is connected to the negative terminal of diode D2 and the positive terminal of diode D3. Capacitor C2 is also connected between the positive terminal of diode D2 and the negative terminal of diode D3. The positive terminal of diode D2 is also connected to the other end of the input of the boost unit.

[0018] The two ends of the diode D3 are connected to the output terminal of the boost unit and the input terminal of the next boost unit.

[0019] Furthermore, the high-voltage DC module also includes an input filter circuit; the input filter circuit includes a surge protection circuit, an EMC circuit, and a soft-start circuit connected in sequence; the input DC voltage enters the inverter circuit after being processed by the input filter circuit.

[0020] Furthermore, the surge protection circuit includes: a fuse, a varistor R1, a varistor R2, a varistor R3, and a ceramic gas discharge tube;

[0021] One end of the input power supply is connected to one end of the varistor R2 and varistor R3 after passing through the fuse. One end of the varistor R1 and varistor R3 are connected in series and the connection point is connected to the ceramic gas discharge tube. The other end of the varistor R1 and varistor R2 is connected to one end of the input power supply.

[0022] Furthermore, the EMC circuit includes multiple EMC circuit units, which are connected in series via a common-film inductor.

[0023] The EMC circuit unit includes an X capacitor CX1, a Y capacitor CY1, and a Y capacitor CY2;

[0024] Y capacitors CY1 and CY2 are connected in series and then in parallel with X capacitor CX1. The input power supply is filtered by common mode by X capacitor CX1, then by differential mode by Y capacitors CY1 and CY4, and finally by low-frequency common mode interference filtered out by the common film inductor before being sent to the next EMC circuit unit.

[0025] Furthermore, the soft-start circuit includes: switch S1, switch S2, and a rectifier bridge circuit, wherein the rectifier bridge circuit consists of four diodes;

[0026] Switch S1 is connected in series with a resistor and then in parallel with switch S2. One end of the input power supply is connected to one input terminal of the rectifier bridge circuit after passing through switches S1 and S2, and the other end of the input power supply is connected to the other input terminal of the rectifier bridge circuit. The output terminal of the rectifier bridge circuit is connected to an inductor and a capacitor connected in series.

[0027] Furthermore, the high-voltage DC module also includes a control circuit connected to the sampling circuit; the control circuit receives the output voltage collected by the sampling circuit and sends a drive signal to the drive circuit.

[0028] Furthermore, the control circuit includes: a voltage / frequency conversion chip, an electro-optical conversion circuit, a photoelectric conversion circuit, and an FPGA;

[0029] The voltage / frequency conversion chip converts analog voltage signals into digital frequency signals through voltage-to-frequency conversion. The electro-optical conversion circuit converts the electrical signal of the digital frequency signal into an optical signal, and then the photoelectric conversion circuit converts it back into an electrical signal before inputting it into an FPGA. The FPGA outputs a drive signal to the drive circuit.

[0030] Furthermore, the high-voltage DC module also includes an auxiliary power supply module that provides power.

[0031] The beneficial effects of adopting the above-mentioned further solutions are: improving the sampling accuracy and anti-electromagnetic interference capability of the module; achieving complete isolation between high-voltage and low-voltage systems to ensure signal stability; optimizing the electromagnetic compatibility of the system and reducing the impact of electromagnetic interference on the power supply system; and improving the overall reliability and stability of the module. Attached Figure Description

[0032] Figure 1 This is an overall block diagram of the high-voltage DC module and the host computer system;

[0033] Figure 2 A structural block diagram of an embodiment of a high-voltage DC module provided by this utility model;

[0034] Figure 3 A block diagram illustrating the components of an embodiment of a high-voltage DC module provided by this utility model;

[0035] Figure 4 The main circuit topology diagram of an embodiment of a high-voltage DC module provided by this utility model;

[0036] Figure 5 A circuit topology diagram of an embodiment of the input filtering section provided by this utility model;

[0037] Figure 6 A circuit diagram of an embodiment of a lightning protection circuit provided by this utility model;

[0038] Figure 7 A circuit diagram of an embodiment of an EMC circuit provided by this utility model;

[0039] Figure 8 A circuit diagram of an embodiment of a soft-start circuit provided by this utility model;

[0040] Figure 9 A circuit diagram of an embodiment of a two-transistor forward converter circuit provided by this utility model;

[0041] Figure 10 A circuit diagram of a high-frequency transformer according to a first embodiment of the present invention;

[0042] Figure 11 A circuit diagram of a second embodiment of a high-frequency transformer provided by this utility model;

[0043] Figure 12 A circuit diagram of a third embodiment of a high-frequency transformer provided by this utility model;

[0044] Figure 13 A circuit diagram of an embodiment of a voltage multiplier circuit provided by this utility model;

[0045] Figure 14 A schematic diagram of an embodiment of a sampling circuit provided by this utility model;

[0046] Figure 15 A circuit diagram of an embodiment of a power chip circuit provided by this utility model;

[0047] Figure 16 A schematic diagram showing the structural dimensions of an embodiment of a high-voltage DC module housing provided by this utility model;

[0048] Figure 17 This is a schematic diagram of the overall three-dimensional structure of an embodiment of a high-voltage DC module housing provided by this utility model. Detailed Implementation

[0049] The principles and features of this utility model are described below with reference to the accompanying drawings. The examples given are only for explaining this utility model and are not intended to limit the scope of this utility model.

[0050] Figure 1 This diagram shows the overall block diagram of the high-voltage DC module and the host computer system. The high-voltage DC module and the host computer are connected via optical fiber to achieve high-speed and stable data transmission. The optical fiber has excellent electrical insulation properties, greatly enhancing the anti-interference capability of the communication line. The high-voltage DC module provides power to the load, and its chassis is grounded, providing a reliable current discharge path for the equipment. It is also equipped with insulating posts to ensure safe power supply to the load.

[0051] like Figure 2 and Figure 3 The diagram shown is a structural block diagram and a block diagram of each component of an embodiment of a high-voltage DC module provided by this utility model. Figure 2 and Figure 3 It can be seen that the high-voltage DC module includes: an inverter circuit, a sampling circuit, and a voltage multiplier circuit.

[0052] The inverter circuit includes: a two-transistor forward converter, a drive circuit, and a high-frequency transformer.

[0053] A two-transistor forward converter includes two switching transistors. A driving circuit drives the two switching transistors to alternately turn on and off. The two-transistor forward converter converts the input DC voltage into a high-frequency AC signal, which is then input to a high-frequency transformer for boosting and then input to a voltage multiplier circuit.

[0054] A voltage multiplier circuit amplifies the voltage of a high-frequency AC signal before outputting it.

[0055] The sampling circuit collects the voltage output from the voltage multiplier circuit to obtain the output voltage of the high-voltage DC module.

[0056] This invention provides a high-voltage DC module with a dual-transistor forward converter circuit that prevents shoot-through, improves efficiency, reduces voltage stress on the switching transistors, and enhances reliability. By having the two switching transistors operate alternately, high-efficiency energy conversion and reduced device temperature are achieved. Based on the high-voltage DC module and its fiber-optic isolated voltage-to-frequency conversion sampling technology, isolated sampling between high-voltage and low-voltage systems is achieved, improving the power supply's sampling accuracy and electromagnetic interference resistance.

[0057] Example 1

[0058] Embodiment 1 provided by this utility model is an embodiment of a high-voltage DC module provided by this utility model, such as... Figure 4 The diagram shown is a structural block diagram of an embodiment of the modular hardware circuit design of a high-voltage DC module provided by this utility model.

[0059] Depend on Figure 4 It can be seen that it includes: inverter circuit, sampling circuit and voltage multiplier circuit.

[0060] The inverter circuit includes: a two-transistor forward converter, a drive circuit, and a high-frequency transformer.

[0061] The two-transistor forward converter includes two switching transistors. A driver circuit alternately turns these transistors on and off. The two-transistor forward converter converts the input DC voltage into a high-frequency AC signal, which is then boosted by a high-frequency transformer and fed into a voltage multiplier circuit. The driver circuit amplifies the signal from the control circuit to drive the power switching devices on and off, providing sufficient drive current and voltage to ensure their normal operation. The high-frequency transformer safely and efficiently converts the input voltage of 220V to 5.5kV, providing electrical isolation. A magnetic core grounding shield divides the capacitance generated by the mutual influence between the primary and secondary windings into two small capacitors. The grounding shield provides a low-impedance loop, allowing fault current to flow to ground through the shield, thus reducing the impact on the equipment.

[0062] A voltage multiplier circuit amplifies the voltage of a high-frequency AC signal before outputting it.

[0063] Voltage multiplier circuits are used to multiply voltage by charging and discharging capacitors, raising a lower DC voltage to a higher DC voltage to meet the needs of high-voltage applications.

[0064] The sampling circuit collects the voltage output from the voltage multiplier circuit to obtain the output voltage of the high-voltage DC module.

[0065] The sampling circuit monitors the module's output voltage and current, providing feedback signals to the control circuit. It utilizes voltage-to-frequency conversion technology to convert the voltage signal into a frequency signal and enhances the signal transmission rate and system response speed through voltage boosting. Optical fiber communication technology is employed, achieving fiber optic isolation.

[0066] like Figure 4 The diagram shown is a main circuit topology diagram of an embodiment of a high-voltage DC module provided by this utility model. Figure 4 It can be seen that the main circuit topology of the high voltage DC module adopts a design scheme that combines a dual-transistor forward converter circuit and a voltage multiplier circuit. This scheme takes into account high reliability, high efficiency conversion and high voltage output stability.

[0067] The two switching transistors in the inverter section alternately turn on and off, converting the rectified DC voltage (approximately 300V DC) of the input 220V AC into a high-frequency AC signal (operating frequency 40kHz), which is then boosted to 5.5kV AC by a high-frequency transformer.

[0068] The voltage multiplier section adopts a 12-stage 24-voltage multiplier circuit topology, consisting of alternating series connection of high-voltage capacitors and high-voltage diodes. The 5.5kV AC output from the high-frequency transformer is charged by multiple stages of capacitors and rectified by diodes, gradually multiplying it to 100kV DC.

[0069] In one possible embodiment, such as Figure 9 The diagram shown is a circuit diagram of an embodiment of a two-transistor forward converter circuit provided by this utility model. Figure 9 As can be seen, the two-transistor forward converter uses two two-transistor forward converters as the main circuit topology for the high-voltage capacitor charging power supply. It consists of transistors, diodes, energy storage inductors, energy storage capacitors, and a transformer. The two-transistor forward converter is a power electronic topology that uses two switching transistors working together to control the power output, improving efficiency, reducing voltage stress, and enhancing system reliability. Specifically, this two-transistor forward converter includes two identical switching transistor modules.

[0070] The switching module includes: NMOS transistor M1, NMOS transistor M2, diode D0, diode D1, inductor L1, resistor R1, and transformer.

[0071] One end of the input DC voltage is connected to the drain (D) of NMOS transistor M1 and the cathode of diode D1, while the other end of the DC voltage is connected to the anode of diode D0, the source (S) of NMOS transistor M1, and ground.

[0072] The source (S) of NMOS transistor M0 is connected to the negative terminal of diode D0 and then connected to one end of the transformer input terminal; the drain (D) of NMOS transistor M1 is connected to the positive terminal of diode D1 and then connected to the other end of the transformer input terminal through inductor L1.

[0073] One end of the transformer's output is grounded, and the other end is connected to another switching transistor module via resistor R1. The advantages of using a two-transistor forward converter circuit include:

[0074] Voltage clamping effect of diodes: When the switching transistor is turned off, the leakage inductance energy of the transformer in the two-transistor forward converter is freewheeled and released through the diode connected in parallel with the switching transistor, so that the voltage spike across the switching transistor is clamped near the bus voltage.

[0075] The presence of two diodes effectively limits the amplitude of voltage spikes, preventing damage to switching transistors or other circuit components due to excessively high voltage spikes. In contrast to voltage spikes that may occur in other topologies, which are much higher than the bus voltage, the stability and safety of the circuit are further improved.

[0076] Shoot-through problem without bridge arm: In a two-transistor forward converter, the two switches are turned on and off alternately, and a dead time is set in the control logic. That is, after one switch is turned off, a certain period of time must be waited before the other switch is allowed to turn on, thus avoiding the shoot-through phenomenon caused by the two switches being turned on at the same time.

[0077] Compared with a single-transistor forward converter, there is no risk of shoot-through caused by a single switch mis-turning or abnormal drive signal, thus improving the reliability and stability of the circuit and reducing the potential damage to the switch and circuit failure caused by shoot-through.

[0078] Controllable current: The two-transistor forward converter usually uses a large energy storage inductor. During normal operation, the large inductor can make the current change relatively slowly, which makes it easy to control the current precisely by controlling the duty cycle of the switching transistor, thereby achieving a stable output voltage and current.

[0079] When a short circuit fault occurs in a circuit, due to the presence of inductance, and based on the characteristic that the current of an inductor cannot change abruptly, the inductor will impede the rapid rise of the current, thus limiting the rate of rise of the short circuit current and preventing an excessively large short circuit current from appearing instantaneously.

[0080] A smaller short-circuit current can reduce the impact and damage to circuit components during a short circuit, reduce the scope of the fault, and also provide a certain time margin for the short-circuit protection circuit to operate, enabling the protection circuit to detect the fault more promptly and take corresponding protective measures.

[0081] Demagnetizing path: The diode provides a demagnetizing path for the transformer. When the switching transistor is turned off, the magnetic flux of the transformer is released through the diode, which helps to reduce the magnetic saturation and iron loss of the transformer.

[0082] Simple control: The control strategy of the two-transistor forward converter is relatively simple. Pulse width modulation (PWM) can be used to control the output voltage and achieve stable output.

[0083] Suitable for a variety of loads: This converter can adapt to different load conditions and maintain good performance from light load to heavy load.

[0084] High reliability: Due to the advantages mentioned above, the two-transistor forward converter has high reliability. Reduced stress on the switching transistors and effective control of the transformer's magnetic flux contribute to improved overall system stability and lifespan.

[0085] In one possible embodiment, Figures 10-12 The circuit diagrams of Embodiment 1, Embodiment 2, and Embodiment 3 of the high-frequency transformer provided by this utility model are combined with... Figure 10-12 It can be seen that the general power equivalent circuit of a high-frequency transformer is as follows: Figure 10As shown in the figure. In this figure, Rp and Rs represent the winding resistances of the primary and secondary windings, Lp and Ls represent the leakage inductances of the primary and secondary windings, Lm represents the magnetizing inductance, Cdp and Cds represent the distributed capacitances of the primary and secondary windings, and Rc is equivalent to the core loss, which includes hysteresis loss and eddy current loss.

[0086] A high-frequency transformer is used to safely and effectively boost the input voltage from 300V to 5kV. The secondary and primary windings interact to generate parasitic capacitance, as shown in Figure 11, model 2 of the high-frequency transformer.

[0087] To reduce the impact of the secondary winding on the primary winding of the high-frequency transformer, a magnetic core grounding shielding method is used to divide the capacitance generated by the mutual influence between the primary and secondary windings into two small capacitors, such as... Figure 12 As shown. When equipment fails, the grounding shield can provide a low-impedance loop, allowing the fault current to flow to the ground through the shield, thereby reducing the impact on the equipment.

[0088] Electromagnetic Interference (EMI) Suppression: Core grounding can serve as an outer shield for the transformer, effectively suppressing electromagnetic interference. This shielding method reduces common-mode interference current caused by MOSFETs and heat sinks, thereby improving electromagnetic compatibility (EMI).

[0089] Reducing the voltage division effect of capacitors: Dividing the capacitance generated by the mutual influence between the primary and secondary windings into two smaller capacitors can reduce the influence of the secondary winding on the primary winding, reduce the voltage division effect of capacitors, and thus improve the insulation performance and stability of the transformer.

[0090] Reduce leakage inductance and parasitic oscillations: By increasing the effective coupling area of ​​the transformer primary and secondary windings, the leakage inductance of the transformer is greatly reduced, the voltage spikes caused by leakage inductance are reduced, the voltage stress of the MOSFET is reduced, the common-mode interference current is reduced, and the EMI performance is improved.

[0091] Improved safety: Grounding the magnetic core eliminates the possibility of forming a floating potential in the magnetic core, reduces the risk of intermittent breakdown discharge between the magnetic core and ground, and improves the safety of transformer operation.

[0092] Improving transformer efficiency: Reducing leakage inductance and parasitic oscillations can reduce transformer losses and improve transformer efficiency.

[0093] Improving transformer thermal management: By optimizing the winding structure and reducing copper losses, the thermal management of transformers can be improved, thus extending their service life.

[0094] Improving transformer reliability: Core grounding shielding and optimized winding structure can improve the reliability of transformers under high-frequency operation and reduce failures caused by electromagnetic interference and thermal problems.

[0095] In summary, using a high-frequency transformer combined with magnetic core grounding shielding and an optimized winding structure can not only safely and effectively achieve voltage boosting, but also bring many benefits such as electromagnetic interference suppression, improved safety, and reduced capacitive voltage division effect, thereby enhancing the reliability of the equipment.

[0096] In one possible embodiment, such as Figure 13 The diagram shown is a circuit diagram of an embodiment of a voltage multiplier circuit provided by this utility model. The voltage multiplier circuit consists of capacitors and diodes, connected in a specific manner to achieve the effect of voltage multiplication. A 12-stage 24-voltage multiplier circuit topology is adopted, and current limiting is performed using series resistors to protect the circuit and improve its reliability. Specifically, the voltage multiplier circuit includes at least two boost units; each boost unit includes: diode D2, diode D3, capacitor C1, and capacitor C2.

[0097] One end of capacitor C1 is connected to one end of the input of the boost unit, and the other end is connected to the negative terminal of diode D2 and the positive terminal of diode D3. Capacitor C2 is also connected between the positive terminal of diode D2 and the negative terminal of diode D3. The positive terminal of diode D2 is also connected to the other end of the input of the boost unit.

[0098] The two ends of diode D3 are connected to the output of the boost unit and the input of the next boost unit.

[0099] In one possible embodiment, the high-voltage DC module further includes: an input filter circuit; Figure 5 A circuit topology diagram of an embodiment of the input filtering section provided by this utility model, combined with Figure 5 As can be seen, the input filtering circuit includes a surge protection circuit, an EMC circuit, and a soft-start circuit connected in sequence, forming a complete anti-interference and overvoltage protection system. The input DC voltage enters the inverter circuit after being processed by the input filtering circuit, preventing voltage spikes, filtering out interference from strong pulse signals, and preventing power supply surges. The surge protection circuit handles surges, the EMC circuit filters out high-frequency noise (cutoff frequency 10MHz), and the soft-start circuit suppresses inrush current (peak current reduced by 80%). These three levels of circuitry provide layered protection, ensuring stable input power and reliable operation of the high-voltage DC module in complex power grid environments.

[0100] The function of a surge protection circuit is to protect the module from damage caused by lightning surges and transient overvoltages in the power grid. Its function is to limit overvoltages to a level that the equipment can withstand by absorbing and shunting high-energy transients.

[0101] The EMC circuit ensures that the module meets electromagnetic compatibility requirements, reduces electromagnetic interference (EMI) emissions and susceptibility, and uses filters, shielding, and grounding techniques to reduce noise and interference, thereby improving the stability and reliability of the module.

[0102] The function of a soft-start circuit is to reduce current surges during device startup, protect the power supply and load, and gradually increase the output voltage and current to avoid transient overload during startup.

[0103] In one possible embodiment, Figure 6 A circuit diagram illustrating an embodiment of a lightning protection circuit provided by this utility model, combined with... Figure 6 It can be seen that the surge protection circuit adopts a single-phase parallel surge protection circuit, which consists of a varistor and a ceramic gas discharge tube. A power frequency fuse is connected in series before the surge protection circuit to prevent the varistor from short-circuiting and causing a fire. Specifically, the surge protection circuit includes: a fuse, varistor R1, varistor R2, varistor R3, and ceramic gas discharge tube.

[0104] One end of the input power supply is connected to one end of varistor R2 and varistor R3 after passing through a fuse. One end of varistor R1 and varistor R3 are connected in series and the connection point is connected to the ceramic gas discharge tube. The other end of varistor R1 and varistor R2 is connected to one end of the input power supply.

[0105] The primary purpose of lightning protection circuits is to protect electronic equipment from the high voltage and large current surges generated by lightning. They utilize physical properties such as conductivity, discharge capability, and shielding to guide, release, and isolate lightning strikes, thus achieving lightning protection. Using a varistor—a non-linear element with variable resistance—the circuit automatically adjusts its resistance parameters when the applied voltage reaches a certain range, dispersing the overvoltage signal to ground. Furthermore, under overvoltage conditions, a gas discharge tube conducts, providing a low-impedance discharge path to discharge the excessive voltage to ground, protecting equipment and systems from lightning strikes and other unforeseen events.

[0106] To effectively prevent dangerous situations such as fires caused by short circuits in varistors, a power frequency fuse is connected in series at the front end of the surge protection circuit. When the circuit encounters a lightning strike or abnormal overvoltage, the varistor can quickly respond to the excessively high voltage, clamping the voltage within a relatively safe range and playing a crucial role in protecting downstream circuits. However, if the varistor itself malfunctions and causes a short circuit, the current in the circuit will increase sharply, easily leading to serious safety accidents such as fires. The series-connected power frequency fuse can melt and disconnect the circuit in time when the current increases instantaneously to a certain level, avoiding the potential fire hazard caused by a short circuit in the varistor, greatly improving the safety and stability of the entire circuit system, and providing more reliable surge protection and safety measures for the equipment.

[0107] In one possible embodiment, Figure 7 A circuit diagram illustrating an embodiment of an EMC circuit provided by this utility model, in conjunction with... Figure 7As can be seen, the main function of EMC circuit is to ensure that electrical and electronic equipment can work normally in its electromagnetic environment and not cause unbearable electromagnetic interference to anything in that environment. It is composed of three-level EMC circuits connected in series, with X capacitors and Y capacitors selected as filter capacitors for use together. Specifically, the EMC circuit includes multiple EMC circuit units, and each EMC circuit unit is connected in series through a common film inductor.

[0108] The EMC circuit unit includes X capacitor CX1, Y capacitor CY1, and Y capacitor CY2;

[0109] Y capacitors CY1 and CY2 are connected in series and then in parallel with X capacitor CX1. The input power supply is filtered by common mode by X capacitor CX1, then by differential mode by Y capacitors CY1 and CY4, and finally by low-frequency common mode interference filtered by common film inductor before being sent to the next EMC circuit unit.

[0110] The function of the EMC circuit is:

[0111] Suppressing electromagnetic interference emissions: Electronic devices generate various electromagnetic interferences during operation, such as conducted interference and radiated interference. Filters and shielding in EMC circuits can effectively suppress the emission of these interferences, preventing them from interfering with other electronic devices and ensuring that all devices can operate normally in the same electromagnetic environment.

[0112] Enhancing equipment's anti-interference capabilities: In complex electromagnetic environments, equipment may be subject to various external electromagnetic interferences, such as lightning, radio signals, and industrial electromagnetic noise. EMC circuits, through filtering, grounding, and shielding techniques, enable equipment to have a certain degree of immunity to these interferences, allowing it to operate stably and reliably in interference environments and reducing equipment failures and malfunctions caused by interference.

[0113] Achieving electromagnetic compatibility (EMC) means ensuring that equipment can operate normally in an electromagnetic environment without causing unacceptable electromagnetic interference to other equipment. This is crucial for guaranteeing the stability and reliability of the entire electronic system.

[0114] A soft-start circuit is a circuit used to control the gradual increase of voltage, current, or power in electronic devices or electrical systems during startup, thereby achieving a smooth start-up. In one possible embodiment, Figure 8 A circuit diagram illustrating an embodiment of the soft-start circuit provided by this utility model, in conjunction with... Figure 8 It can be seen that the soft-start circuit includes: switch S1, switch S2 and rectifier bridge circuit, which consists of four diodes.

[0115] Switch S1 is connected in series with a resistor and then in parallel with switch S2. One end of the input power supply is connected to one input terminal of the rectifier bridge circuit after passing through switches S1 and S2, and the other end of the input power supply is connected to the other input terminal of the rectifier bridge circuit. The output terminal of the rectifier bridge circuit is connected to an inductor and a capacitor connected in series.

[0116] Soft-start circuits gradually increase the voltage, thus preventing a sudden surge of current during equipment startup. Applying full rated voltage and current immediately upon startup can generate a large instantaneous current, potentially damaging the equipment's power supply system and electrical components. Soft-start circuits effectively mitigate the impact on the power grid and help protect equipment, extending its service life.

[0117] In one possible embodiment, the high-voltage DC module further includes a control circuit connected to the sampling circuit; the control circuit receives the output voltage acquired by the sampling circuit and sends a drive signal to the drive circuit.

[0118] The control circuit is used to control and regulate the operation of the inverter circuit to achieve precise output voltage and current.

[0119] In practice, the inverter circuit can be precisely controlled by manually setting specific parameters through data collected by the sampling circuit. Alternatively, parameters such as switching frequency and duty cycle can be adjusted through a microcontroller or dedicated control chip.

[0120] In one possible embodiment, Figure 14 This is a schematic diagram of an embodiment of a sampling circuit provided by this utility model, combined with... Figure 14 It can be seen that the control circuit includes: a voltage / frequency conversion chip, an electro-optical conversion circuit, a photoelectric conversion circuit, and an FPGA.

[0121] The voltage / frequency conversion chip converts analog voltage signals into digital frequency signals through voltage-to-frequency conversion. The digital frequency signals are then converted into optical signals through an electro-optical conversion circuit. Finally, the digital frequency signals are converted back into electrical signals through a photoelectric conversion circuit and input into the FPGA. The FPGA then outputs drive signals to the drive circuit.

[0122] The control sampling section adopts a positive and negative bipolar DC high-voltage isolation sampling circuit. It uses voltage / frequency and frequency / voltage conversion methods and measures such as fiber optic and transformer isolation to achieve simultaneous isolation sampling of positive and negative bipolar DC high voltage. This solves the problems of positive and negative voltage imbalance and incomplete isolation between control signals and high-power system ground in bipolar DC high-voltage power supplies, and improves the power supply's anti-electromagnetic interference capability.

[0123] A voltage / frequency conversion chip is used to convert analog voltage signals into digital frequency signals through voltage-frequency conversion, realizing simultaneous isolated sampling of positive and negative bipolar DC high voltage.

[0124] Solving voltage imbalance problems: By converting voltage to frequency, the problem of positive and negative voltage imbalance in bipolar DC high-voltage power supplies is solved, thereby improving the stability and reliability of the power supply system.

[0125] Isolation measures: Through measures such as fiber optic and transformer isolation, simultaneous isolated sampling of positive and negative bipolar DC high voltage is achieved, avoiding interference between control signals and high-power system ground, and enhancing the system's anti-interference capability.

[0126] Improved control precision: This method uses closed-loop control to detect and adjust the output DC high voltage in real time, ensuring the stability and reliability of the output DC voltage and improving the control precision of the power supply.

[0127] Electromagnetic compatibility optimization: By employing voltage / frequency conversion methods and combining them with isolation measures, the electromagnetic compatibility of the system was optimized, reducing the impact of electromagnetic interference on the power supply system.

[0128] Fiber optic isolation: This involves converting electrical signals into optical signals, transmitting them through optical fibers, and then converting the optical signals back into electrical signals. Fiber optic isolation transmission meets high-voltage insulation requirements and has strong resistance to electromagnetic interference.

[0129] Voltage boosting: After sampling the voltage signal, the circuit provides an external voltage value through voltage boosting. After passing through a voltage-to-frequency conversion chip, the output frequency signal is significantly boosted compared to the original signal. Since digital circuits typically process frequency signals faster than analog voltage signals, they can process more data in a shorter time, thereby improving the system's response speed and processing capacity.

[0130] Power chip driver: After the signal is transmitted to the FPGA chip, the chip converts the electrical signal into a voltage signal and obtains the output voltage value by comparing it with the given boost voltage.

[0131] Sampling current isolation: The voltage is converted from 220V to 20V by a transformer with a shielding layer in a half-bridge circuit, and then rectified by an uncontrolled rectifier to power the sampling circuit. Figure 15 A circuit diagram of an embodiment of a power chip circuit provided by this utility model.

[0132] In one possible embodiment, the high-voltage DC module further includes an auxiliary power supply module that provides power.

[0133] In specific implementation, such as Figure 16 This is a schematic diagram showing the structural dimensions of an embodiment of a high-voltage DC module housing provided by this utility model. Figure 17This is a schematic diagram of the overall three-dimensional structure of an embodiment of a high-voltage DC module housing provided by this utility model. Figure 16 shows a schematic diagram of the overall structure of a single positive high-voltage DC module, and Figure 17 shows a schematic diagram of its three-dimensional structure. The main body dimensions of the device are 500mm (length) × 430mm (width) × 133mm (height). The width of the 19-inch chassis panel is 483mm, therefore the actual installation dimensions of the device are 500mm (length) × 483mm (width) × 133mm (height).

[0134] This invention provides a high-voltage DC module, aiming to address the shortcomings of existing technologies and improve the module's sampling accuracy and electromagnetic interference resistance. The following are some specific application scenarios:

[0135] Microelectronics and Semiconductor Fabrication: In semiconductor chip manufacturing and microfabrication technology, high-voltage DC modules are used to drive processes such as electron beam etching and ion implantation, providing high-stability and low-ripple high-voltage output to ensure the quality of precision machining.

[0136] Medical Devices and Life Sciences: In nuclear medicine imaging and radioisotope research, high-voltage DC modules are used to drive scintillation detectors to achieve high-sensitivity capture of weak radiation signals, ensuring image quality and diagnostic accuracy.

[0137] Industrial manufacturing and materials handling: In processes such as electrostatic printing, thin film deposition, and electrostatic spraying, high-voltage DC modules are used to control the electrostatic field to ensure high quality and consistency of the process.

[0138] Pulse power technology: In complex electromagnetic interference environments, fiber-optic isolated voltage-frequency conversion sampling technology is used in highly robust bipolar high-voltage isolation sampling circuits to ensure the power supply's electromagnetic interference resistance and stability.

[0139] Military and Defense: In military energy storage power supplies and electronic security systems, high-voltage DC modules and their fiber optic isolated sampling technology are used for high-voltage feedback control to ensure the reliability and safety of the system.

[0140] These application scenarios demonstrate the wide application of high-voltage DC modules and their fiber optic isolated sampling technology in fields requiring high precision and high stability.

[0141] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the application.

[0142] It is understood that spatial relation terms such as "below," "under," "below," "below," "above," "above," etc., can be used here to describe the relationship between one element or feature shown in the figure and other elements or features. It should be understood that, in addition to the orientation shown in the figure, spatial relation terms also include different orientations of the device in use and operation. For example, if the device in the figure is flipped, the element or feature described as "below" or "below" of the other element or feature will be oriented "above" the other element or feature. Therefore, the exemplary terms "below" and "below" can include both upper and lower orientations. Furthermore, the device may also include other orientations (e.g., rotated 90 degrees or other orientations), and the spatial descriptive terms used herein will be interpreted accordingly.

[0143] It should be noted that when one element is considered to be "connected" to another element, it can be directly connected to the other element or connected to the other element through an intermediary element. In the following embodiments, "connection" should be understood as "electrical connection," "communication connection," etc., if the connected circuits, modules, units, etc., have the transmission of electrical signals or data between them.

[0144] When used here, the singular forms of “a,” “an,” and “ / the” may also include the plural forms unless the context clearly indicates otherwise. It should also be understood that the terms “including / contains” or “having” specify the presence of the stated feature, whole, step, operation, component, part, or combination thereof, but do not preclude the possibility of the presence or addition of one or more other features, wholes, steps, operations, components, parts, or combinations thereof.

[0145] The above are merely preferred embodiments of the present utility model and are not intended to limit the present utility model. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present utility model shall be included within the protection scope of the present utility model.

Claims

1. A high-voltage DC module, characterized in that, The high-voltage DC module includes: an inverter circuit, a sampling circuit, and a voltage multiplier circuit; The inverter circuit includes: a two-transistor forward converter, a drive circuit, and a high-frequency transformer; The dual-transistor forward converter includes two switching transistors. The driving circuit drives the two switching transistors to alternately turn on and off. The dual-transistor forward converter converts the input DC voltage into a high-frequency AC signal, which is then input to the high-frequency transformer for boosting and then input to the voltage multiplier circuit. The voltage multiplier circuit amplifies the voltage of the high-frequency AC signal before outputting it. The sampling circuit acquires the voltage output by the voltage multiplier circuit to obtain the output voltage of the high voltage DC module.

2. The high-voltage DC module according to claim 1, characterized in that, The dual-transistor forward converter circuit includes: two identical switching transistor modules; The switching module includes: NMOS transistor M1, NMOS transistor M2, diode D0, diode D1, inductor L1, resistor R1, and transformer; One end of the input DC voltage is connected to the drain (D) of the NMOS transistor M1 and the cathode of the diode D1, and the other end of the DC voltage is connected to the anode of the diode D0, the source (S) of the NMOS transistor M1, and ground. The source (S) of the NMOS transistor M0 is connected to the negative terminal of the diode D0 and then connected to one end of the input terminal of the transformer; the drain (D) of the NMOS transistor M1 is connected to the positive terminal of the diode D1 and then connected to the other end of the input terminal of the transformer through the inductor L1. One end of the transformer's output terminal is grounded, and the other end is connected to another switching transistor module via resistor R1.

3. The high-voltage DC module according to claim 1, characterized in that, The voltage multiplier circuit includes at least two boost units; each boost unit includes: diode D2, diode D3, capacitor C1, and capacitor C2; One end of capacitor C1 is connected to one end of the input of the boost unit, and the other end is connected to the negative terminal of diode D2 and the positive terminal of diode D3. Capacitor C2 is also connected between the positive terminal of diode D2 and the negative terminal of diode D3. The positive terminal of diode D2 is also connected to the other end of the input of the boost unit. The two ends of the diode D3 are connected to the output terminal of the boost unit and the input terminal of the next boost unit.

4. The high-voltage DC module according to claim 1, characterized in that, The high-voltage DC module further includes an input filter circuit; the input filter circuit includes a lightning protection circuit, an EMC circuit, and a soft-start circuit connected in sequence; the input DC voltage enters the inverter circuit after being processed by the input filter circuit.

5. The high-voltage DC module according to claim 4, characterized in that, The lightning protection circuit includes: a fuse, a varistor R1, a varistor R2, a varistor R3, and a ceramic gas discharge tube; One end of the input power supply is connected to one end of the varistor R2 and varistor R3 after passing through the fuse. One end of the varistor R1 and varistor R3 are connected in series and the connection point is connected to the ceramic gas discharge tube. The other end of the varistor R1 and varistor R2 is connected to one end of the input power supply.

6. The high-voltage DC module according to claim 4, characterized in that, The EMC circuit includes multiple EMC circuit units, which are connected in series through a common film inductor. The EMC circuit unit includes an X capacitor CX1, a Y capacitor CY1, and a Y capacitor CY2; Y capacitors CY1 and CY2 are connected in series and then in parallel with X capacitor CX1. The input power supply is filtered by common mode by X capacitor CX1, then by differential mode by Y capacitors CY1 and CY4, and finally by low-frequency common mode interference filtered out by the common film inductor before being sent to the next EMC circuit unit.

7. The high-voltage DC module according to claim 4, characterized in that, The soft-start circuit includes: switch S1, switch S2 and rectifier bridge circuit, wherein the rectifier bridge circuit consists of four diodes; Switch S1 is connected in series with a resistor and then in parallel with switch S2. One end of the input power supply is connected to one input terminal of the rectifier bridge circuit after passing through switches S1 and S2, and the other end of the input power supply is connected to the other input terminal of the rectifier bridge circuit. The output terminal of the rectifier bridge circuit is connected to an inductor and a capacitor connected in series.

8. The high-voltage DC module according to claim 1, characterized in that, The high-voltage DC module also includes a control circuit connected to the sampling circuit; the control circuit receives the output voltage collected by the sampling circuit and sends a drive signal to the drive circuit.

9. The high-voltage DC module according to claim 8, characterized in that, The control circuit includes: a voltage / frequency conversion chip, an electro-optical conversion circuit, a photoelectric conversion circuit, and an FPGA; The voltage / frequency conversion chip converts analog voltage signals into digital frequency signals through voltage-to-frequency conversion. The electro-optical conversion circuit converts the electrical signal of the digital frequency signal into an optical signal, and then the photoelectric conversion circuit converts it back into an electrical signal before inputting it into an FPGA. The FPGA outputs a drive signal to the drive circuit.

10. The high-voltage DC module according to claim 1, characterized in that, The high-voltage DC module also includes an auxiliary power supply module that provides power.

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