A string pump controller

Abstract

The utility model relates to a kind of string pump controllers, solve the problem that abnormal LED display and false alarm overcurrent failure caused by bus capacitor reverse charging due to induced electromotive force of existing technology existing unpowered water pump, the technical scheme used: including main control module, with the main control module electricity, signal connection's inverter circuit, with the main control module and inverter circuit electricity connection's power module, with the main control module electricity, signal connection's sampling module, the main control module with the inverter circuit electricity, signal connection, it is characterized in that the inverter circuit includes IPM inverter module, with the input end cooperation of the IPM inverter module's anti-backflow module.Its effect: by adding anti-backflow module, the current flow direction bus capacitor of unpowered water pump's motor due to induced electromotive force when single pump operation can be effectively blocked, completely eliminate bus capacitor reverse charging phenomenon, avoid LED lamp display abnormality, false alarm overcurrent and other faults appear, improve the running stability of string pump system.

Description

Technical Field

[0001] This utility model relates to the field of circuitry for series pump systems, and more particularly to a series pump controller for preventing reverse charging of the bus capacitor in a series pump system. Background Technology

[0002] To address insufficient head during pump operation, a common practice is to operate two pumps in series. In a series pump system, the flow rate remains constant after the two pumps are connected in series, and the head is the sum of the two pumps' heads. This system is suitable for scenarios where the pumping station head is high, the water delivery distance is long, or the head of a single pump is insufficient and no suitable high-head pump is available. In practical applications, the series pump system can be flexibly switched to single-pump operation or dual-pump combined operation mode.

[0003] However, in single-pump operation mode, when pump A is powered on and pump B is not powered on or running, pump A drives the water flow, which in turn drives the impeller of pump B to rotate (the higher the flow rate of pump A, the greater the probability of this phenomenon). This, in turn, drives the motor of pump B to rotate and generate an induced electromotive force (EMF). This induced EMF charges the bus capacitor of pump B through the freewheeling diode built into the IPM module in the inverter circuit of pump B (the actual measured bus voltage can reach up to 80V, while the bus voltage is about 310V under normal power-on). The bus capacitor then supplies power to the display circuit and motor drive module on the controller. Because the bus voltage generated by the induced EMF is unstable, it can cause abnormal LED display of pump B (such as flashing) and may falsely trigger the hardware overcurrent protection (hardware overcurrent is often used to indicate a large current at a certain point on the control board), causing the system to falsely report an overcurrent fault (such as displaying the E01 fault code), affecting the reliability and stability of the series pump system. Summary of the Invention

[0004] The purpose of this utility model is to solve the above-mentioned problems existing in the prior art by providing a series pump controller. By adding an anti-reverse current diode D1, it can effectively prevent the current generated by the induced electromotive force of the motor of the unpowered pump from flowing to the bus capacitor when the single pump is running, completely eliminating the reverse charging phenomenon of the bus capacitor, avoiding abnormal LED display or false overcurrent alarms, and improving the operational stability of the series pump system.

[0005] The above-mentioned technical objective of this utility model is mainly achieved through the following technical solution: a series pump controller, comprising a main control module, an inverter circuit electrically and signal-connected to the main control module, a power supply module electrically connected to the main control module and the inverter circuit, and a sampling module electrically and signal-connected to the main control module. The main control module is electrically and signal-connected to the inverter circuit. The inverter circuit comprises an IPM inverter module and an anti-backflow module that cooperates with the input terminal of the IPM inverter module. The sampling module is used to collect water pump motor operating data, the IPM inverter module is used to output power to the water pump motor, and the anti-backflow module is used to prevent false fault reports from the series pumps.

[0006] As a further improvement and supplement to the above technical solution, the present invention adopts the following technical measures: Preferably, the anti-reverse current module includes an anti-reverse current diode D1, which is connected in series between the DC high voltage power output from the power module and the IPM inverter module.

[0007] Preferably, the IPM inverter module further includes a bus capacitor E1, which is connected in parallel with the anti-reverse current diode D1. One end of the bus capacitor E1 is connected to the DC power output of the power module, and the other end is grounded.

[0008] Preferably, the IPM inverter module includes an IPM power module and an IPM control module, both connected to the power supply module. The IPM power module converts the DC high-voltage electricity output from the power supply module into AC high-voltage electricity (i.e., the AC high-voltage electricity converted from DC high-voltage electricity powers the water pump motor). The IPM control module is also connected to the main control module and receives the DC low-voltage electricity output from the power supply module and the control signals from the main control module. The power supply module outputs DC high-voltage electricity to the IPM power module and low-voltage DC electricity to both the IPM control module and the main control module.

[0009] Preferably, the IPM power module includes a high-voltage integrated circuit HVIC and three IGBT switching elements Q1, Q2, and Q3 connected to the high-voltage integrated circuit HVIC. The three IGBT switching elements Q1, Q2, and Q3 are connected in parallel with corresponding bootstrap capacitors C1, C2, and C3, respectively. The IPM control module includes a low-voltage integrated circuit HVIC and three other IGBT switching elements connected to the low-voltage integrated circuit HVIC.

[0010] Preferably, the sampling module includes sampling resistors R1 and R2; the main control module is connected to the resistors R1 and R2, and the sampling resistors R1 and R2 are connected to the circuit on the water pump motor. The main control module collects the current on the sampling resistors R1 and R2 to form three complementary drive signals with dead time, which are used to control the switching state of the six IGBTs in the IPM inverter module, so that the IPM inverter module inverts the DC bus voltage into U / V / W three-phase high-voltage AC power to the water pump motor.

[0011] Preferably, the IPM control module has a voltage sampling pin CSC that is connected to the main control module. The sampling module includes a sampling resistor R3. The voltage sampling pin CSC collects the voltage across the sampling resistor R3 to determine whether the main control module has a short circuit.

[0012] Preferably, the IPM control module has an overcurrent protection pin VFO connected to the main control module signal, and the overcurrent protection pin VFO cooperates with the voltage sampling pin CSC. When the main control module experiences a short circuit, the voltage sampling pin CSC receives the short-circuit signal from the sampling resistor R3 and transmits a low-level signal to the main control module through the overcurrent protection pin VFO. The main control module receives the low-level signal and generates a control command for overcurrent protection.

[0013] Preferably, the IPM control module has a temperature detection pin VOT that is connected to the main control module. The temperature detection pin VOT is used to detect the internal temperature of the IPM inverter module and transmit the temperature signal to the main control module.

[0014] Preferably, the series pump controller further includes at least eight sets of RC filter modules. Six sets of the RC filter modules are provided between the main control module and the IPM inverter module to ensure stable transmission of the six drive signals output by the main control module to the IPM inverter module. One of the RC filter modules is connected to the overcurrent protection pin VFO and the temperature detection pin VOT on the IPM control module, respectively.

[0015] The beneficial effects of this utility model are as follows: 1. The addition of an anti-reverse current diode D1 effectively prevents the current generated by the induced electromotive force of the motor of an unpowered pump from flowing to the bus capacitor during single-pump operation, completely eliminating the reverse charging phenomenon of the bus capacitor, avoiding faults such as abnormal LED display and false overcurrent alarms, and improving the operational stability of the series pump system. 2. The anti-reverse current diode D1 only blocks the reverse current generated by the induced electromotive force. When two pumps in the series pump system are powered on and running simultaneously, it does not affect the normal inverter function of the IPM inverter module and the motor drive, realizing flexible adaptation of the working mode. 3. The circuit structure is simple. The existing technical problems can be solved by simply adding an anti-reverse current diode, resulting in low modification costs and easy industrial application. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of a series pump controller involved in this utility model.

[0017] Figure 2 This is a schematic diagram of an LED indicator on a serial pump, which is part of this utility model, showing the normal operation of the serial pump.

[0018] Figure 3 and Figure 4 These are two schematic diagrams showing the LED lights on the series pump of this utility model indicating abnormal operation of the series pump.

[0019] Figure 5 This is a schematic diagram of the structure of an IPM inverter module involved in this utility model.

[0020] Figure 6 This is a schematic diagram of a circuit structure of an IPM power module involved in this utility model.

[0021] Figure 7 This is a schematic diagram of a series pump involved in this utility model.

[0022] Figure 8 This is a schematic diagram of a circuit structure on a series pump involved in this utility model. Detailed Implementation

[0023] The technical solution of this utility model will be further described in detail below through embodiments and with reference to the accompanying drawings. In this document, "high voltage" refers to a voltage higher than 3.3V, 15V, or 220V, such as 310V, while "low voltage" refers to a voltage lower than 310V, such as 3.3V, 15V, or 220V.

[0024] Example: Figures 1-8As shown, a series pump controller includes a main control module, an inverter circuit electrically and signal-connected to the main control module, a power supply module electrically connected to the main control module and the inverter circuit, and a sampling module electrically and signal-connected to the main control module. The main control module is electrically and signal-connected to the inverter circuit.

[0025] The difference between this technical solution and the prior art is that the inverter circuit includes an IPM inverter module and an anti-backflow module that cooperates with the input terminal of the IPM inverter module. The sampling module is used to collect the operating data of the water pump motor, the IPM inverter module is used to output power to the water pump motor, and the anti-backflow module is used to prevent false fault reports from the series water pumps.

[0026] For tandem pumps, there are generally two or more sets of water pumps (usually two or three sets) connected to the same pipeline, and each set of water pumps is equipped with a tandem pump controller.

[0027] The difference between this technical solution and the existing technology is that an anti-backflow module is added to the IPM inverter module.

[0028] In a series pump system, pump A is powered on and running, while pump B is not powered on or running (the control boards of pumps A and B are not directly connected except for the 220V AC power; the voltage and current generated by pump B do not flow directly from pump A to pump B after pump A is powered on. Instead, pump A's motor rotates after being powered on, converting electrical energy into mechanical energy. Since pumps A and B are in the same pipeline, mechanical energy does work on pump B, and pump B acts as a generator to convert mechanical energy into electrical energy. Thus, pumps A and B are only structurally connected through the same water pipe, not electrically connected). The powered pump A drives the water flow, which in turn drives the impeller in pump B to rotate. The rotation of the impeller causes the motor of pump B to rotate, and the rotation of the motor generates an induced electromotive force.

[0029] If a conventional IPM inverter module is used, the induced voltage will charge the bus capacitor E1 in the series pump controller of water pump B through the freewheeling diodes (Q3, Q4, Q5) of the three IGBTs (Q1, Q2, Q3) in the upper bridge of the series pump controller. This will cause the LED in the series pump controller of the unpowered water pump B to flicker abnormally (e.g., Figure 2 For LED indicator lights to show that the pump is working properly, Figure 3 and Figure 4 The LED lights indicate the abnormal (or fault) status of the series pump, indicating that the series pump is in a faulty state, or that false alarms such as hardware overcurrent have occurred.

[0030] When using the series pump controller of this technical solution, if one pump is running while the other is not, the added anti-backflow module (such as anti-backflow diode D1) dissipates most of the induced electrical energy flowing from the freewheeling diodes (Q3, Q4, Q5) as heat energy. The induced voltage cannot flow into the bus capacitor E1, and the bus capacitor E1 cannot supply power to other modules on the series pump controller, thus preventing false fault alarms from the series pumps. When both pumps are running simultaneously, both pumps can operate normally without induced current.

[0031] The above technical solution will then be explained in more detail: In practical applications, the anti-reverse current module includes an anti-reverse current diode D1, which is connected in series between the DC high voltage power output from the power module and the IPM inverter module.

[0032] In practical applications, the IPM inverter module also includes a bus capacitor E1, which is connected in parallel with the anti-reverse current diode D1. One end of the bus capacitor E1 is connected to the DC power output of the power module, and the other end is grounded.

[0033] In practical applications, the IPM inverter module includes an IPM power module and an IPM control module, both connected to the power supply module. The IPM power module converts the DC high-voltage electricity output from the power supply module into AC high-voltage electricity (i.e., the AC high-voltage electricity converted from DC high-voltage electricity powers the water pump motor). The IPM control module is also connected to the main control module and receives the DC low-voltage electricity output from the power supply module and the control signals from the main control module. The power supply module outputs DC high-voltage electricity to the IPM power module and low-voltage DC electricity to both the IPM control module and the main control module.

[0034] In practical applications, a display module is often set up on the series pump controller. During use, the power module on the series pump controller is connected to 220V AC power. The power module outputs 310V, 15V and 3.3V DC power. The 15V DC power supplies the IPM control module, the 310V DC power is input to the IPM power module, and the 3.3V DC power supplies the display module and the main control chip.

[0035] In practical applications, the IPM power module includes a high-voltage integrated circuit (HVIC) and three IGBT switching elements Q1, Q2, and Q3 connected to the HVIC. Each of the three IGBT switching elements Q1, Q2, and Q3 is connected in parallel with a corresponding bootstrap capacitor C1, C2, and C3. The IPM control module includes a low-voltage integrated circuit (HVIC) and three additional IGBT switching elements connected to the HVIC. The bootstrap capacitors C1, C2, and C3 are used to ensure the IGBT switching elements Q1, Q2, and Q3 are properly turned on and output a stable current.

[0036] In practical applications, the sampling module includes sampling resistors R1 and R2; the main control module is connected to the resistors R1 and R2, and the sampling resistors R1 and R2 are connected to the circuit on the water pump motor. The main control module collects the current on the sampling resistors R1 and R2 to form three complementary drive signals with dead time, which are used to control the switching state of the six IGBTs in the IPM inverter module, so that the IPM inverter module inverts the DC bus voltage into U / V / W three-phase high-voltage AC power to the water pump motor.

[0037] In this technical solution, the three complementary drive signals with dead time are UH-UL, VH-VL, and WH-WL, respectively. The inverter U / V / W three-phase high-voltage AC power supplies the water pump motor.

[0038] In practical applications, the IPM control module has a voltage sampling pin CSC that is connected to the main control module signal. The sampling module includes a sampling resistor R3. The voltage sampling pin CSC collects the voltage across the sampling resistor R3 to determine whether the main control module has a short circuit. Generally, the sampling resistor R3 detects the large current generated by a short circuit in the three phases (UVW) of the motor. If a large current is detected, a short circuit exists; if no large current is detected, no short circuit exists.

[0039] In practical applications, the IPM control module has an overcurrent protection pin VFO that is connected to the main control module signal, and the overcurrent protection pin VFO works in conjunction with the voltage sampling pin CSC.

[0040] When a short circuit occurs in the main control module, the voltage sampling pin CSC receives the short circuit signal from the sampling resistor R3 and transmits a low-level signal to the main control module through the overcurrent protection pin VFO. The main control module receives the low-level signal and generates a control command for overcurrent protection.

[0041] In other words, the voltage sampling pin CSC samples the voltage on R3 to determine whether a short circuit has occurred in the circuit. If a short circuit occurs, the overcurrent pin VFO will transmit a low-level signal to the main control module. The main control module will then pause the output of the drive signal and lock the main control chip in the main control module to the overcurrent protection state, thus achieving the purpose of overcurrent protection.

[0042] In practical applications, the IPM control module has a temperature detection pin VOT that is connected to the main control module. The temperature detection pin VOT is used to detect the internal temperature of the IPM inverter module and transmit the temperature signal to the main control module.

[0043] In other words, the temperature detection pin VOT can detect the internal temperature of the IPM inverter module and output the corresponding voltage value to the main control chip proportionally. If the corresponding voltage exceeds the set value, the over-temperature protection will be triggered.

[0044] In practical applications, the series pump controller also includes at least eight sets of RC filter modules. Six sets of the RC filter modules are provided between the main control module and the IPM inverter module to ensure stable transmission of the six drive signals output by the main control module to the IPM inverter module. One of the RC filter modules is connected to the overcurrent protection pin VFO and the temperature detection pin VOT on the IPM control module, respectively.

[0045] The above description is merely a preferred embodiment of the present utility model and is not intended to limit the present utility model. Various modifications and variations can be made to the above embodiments. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A series pump controller, comprising a main control module, an inverter circuit electrically and signal-connected to the main control module, a power supply module electrically connected to the main control module and the inverter circuit, and a sampling module electrically and signal-connected to the main control module, wherein the main control module is electrically and signal-connected to the inverter circuit, characterized in that... The inverter circuit includes an IPM inverter module and an anti-backflow module that works in conjunction with the input terminal of the IPM inverter module. The sampling module is used to collect the operating data of the water pump motor, the IPM inverter module is used to output power to the water pump motor, and the anti-backflow module is used to prevent false fault reports from the series-connected water pumps.

2. The string pump controller of claim 1, wherein The anti-reverse current module includes an anti-reverse current diode D1, which is connected in series between the DC power output from the power module and the IPM inverter module.

3. The string pump controller of claim 2, wherein The IPM inverter module also includes a bus capacitor E1, which is connected in parallel with the anti-reverse current diode D1. One end of the bus capacitor E1 is connected to the DC high voltage power output by the power module, and the other end is grounded.

4. The string pump controller of any one of claims 1-3, wherein The IPM inverter module includes an IPM power module and an IPM control module, both of which are connected to the power supply module. The IPM power module is used to convert the DC high-voltage electricity output by the power supply module into AC high-voltage electricity. The IPM control module is also connected to the main control module and is used to receive the DC low-voltage electricity output by the power supply module and the control signals from the main control module.

5. The string pump controller of claim 4, wherein The IPM power module includes a high-voltage integrated circuit HVIC and three IGBT switching elements Q1, Q2, and Q3 connected to the high-voltage integrated circuit HVIC. The three IGBT switching elements Q1, Q2, and Q3 are connected in parallel with corresponding bootstrap capacitors C1, C2, and C3, respectively. The IPM control module includes a low-voltage integrated circuit HVIC and three other IGBT switching elements connected to the low-voltage integrated circuit HVIC.

6. The string pump controller of claim 5, wherein The sampling module includes sampling resistors R1 and R2; the main control module is connected to the resistors R1 and R2, and the sampling resistors R1 and R2 are connected to the circuit on the water pump motor. The main control module collects the current on the sampling resistors R1 and R2 to form three complementary drive signals with dead time, which are used to control the switching state of the six IGBTs in the IPM inverter module, so that the IPM inverter module inverts the DC bus voltage into U / V / W three-phase high-voltage AC power to the water pump motor.

7. The string pump controller of claim 5, wherein The IPM control module has a voltage sampling pin CSC that is connected to the main control module. The sampling module includes a sampling resistor R3. The voltage sampling pin CSC collects the voltage across the sampling resistor R3 to determine whether the main control module has a short circuit.

8. The series pump controller according to claim 7, characterized in that... The IPM control module has an overcurrent protection pin VFO that is connected to the main control module signal. The overcurrent protection pin VFO works in conjunction with the voltage sampling pin CSC.

9. The string pump controller of claim 5, wherein The IPM control module has a temperature detection pin VOT that is connected to the main control module. The temperature detection pin VOT is used to detect the internal temperature of the IPM inverter module and transmit the temperature signal to the main control module.

10. The string pump controller of any one of claims 5-9, wherein It also includes at least eight sets of RC filter modules. Six sets of the RC filter modules are provided between the main control module and the IPM inverter module to ensure the stable transmission of the six drive signals output by the main control module to the IPM inverter module. One of the RC filter modules is connected to the overcurrent protection pin VFO and the temperature detection pin VOT on the IPM control module, respectively.

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