Variable frequency motor driver power module and controller

Abstract

The utility model relates to a kind of frequency conversion motor driver power module and controller, belong to power electronics field;Including printed circuit board, independent full-bridge circuit is integrated on the printed circuit board, the full-bridge circuit includes at least one upper bridge arm and one lower bridge arm, each upper bridge arm and lower bridge arm include controllable switch tube and diode reverse-parallel with it in parallel;The full-bridge circuit is also connected with accessory component;The full-bridge circuit and its accessory component, high-voltage terminal, low-voltage row pin / flat cable are integrated on a piece of printed circuit board.By splitting traditional power board into independent full-bridge module, to reduce maintenance cost, improve product reliability and expansibility.

Description

Technical Field

[0001] This utility model relates to a variable frequency motor driver power module and controller, belonging to the field of power electronic equipment technology. Background Technology

[0002] With the development of motor drive technology, low-voltage variable frequency motor drivers widely use MOSFETs as power devices. Traditional structures typically integrate all power components (such as MOSFETs and diodes) and drive circuitry onto a single aluminum-based printed circuit board, forming a monolithic power board. While this structure offers high integration and ease of mass production, it suffers from the following drawbacks: High maintenance costs: If the power board is partially damaged (such as a single bridge arm failure), the entire power board needs to be replaced, which significantly increases maintenance costs. Poor internal resistance consistency: In traditional solutions, the three full-bridge circuits are integrated on the same power board. Due to the dispersion of MOSFET parameters and welding process, it is difficult to ensure that the internal resistance of the three-phase bridge arms is consistent, resulting in uneven output current and uneven module heating, which affects the life of the controller. Limited scalability: If the controller output power needs to be increased, the entire power board needs to be redesigned, which results in a long development cycle and high costs. Utility Model Content

[0003] The present invention aims to provide a variable frequency motor driver power module and controller, which reduces maintenance costs, improves product reliability and scalability, and solves the defects of the prior art by splitting the traditional power board into an independent full-bridge module.

[0004] The variable frequency motor driver power module of this utility model includes a printed circuit board, on which an independent full-bridge circuit is integrated. The full-bridge circuit includes at least one upper bridge arm and one lower bridge arm. Each upper bridge arm and lower bridge arm includes a controllable switching transistor connected in parallel and a diode connected in reverse parallel with it. The full-bridge circuit is also connected to auxiliary components, high-voltage terminals and low-voltage pin headers / wires. The full-bridge circuit and its auxiliary components, high-voltage terminals and low-voltage pin headers / wires are integrated and packaged on a single printed circuit board.

[0005] Preferably, the controllable switch is a surface-mount MOSFET, and the auxiliary components include a gate drive element, a thermistor, and an interface for transmitting control signals.

[0006] Preferably, the thermistor is mounted on the heat-generating area of ​​the printed circuit board to measure the temperature of the power module during operation, and its output terminal is electrically connected to the control signal interface.

[0007] Preferably, one side of the printed circuit board is provided with a fixing part for connecting a heat dissipation structure, and the other side is provided with an internal resistance grouping mark.

[0008] Preferably, the heat dissipation surface of the printed circuit board is coated with thermally conductive silicone grease, and the fixing part is a screw hole that penetrates the printed circuit board.

[0009] The variable frequency motor driver controller of this utility model includes a controller base plate and a DC bus input module, at least one variable frequency motor driver power module, a phase line output module and a control circuit board mounted on the controller base plate; the control signal and temperature information of the variable frequency motor driver power module are connected to the control circuit board through low voltage pin headers / wires.

[0010] Preferably, the number of variable frequency motor driver power modules is three, and each variable frequency motor driver power module is arranged at intervals along the length direction of the controller substrate, and the internal resistance group identification number of the three variable frequency motor driver power modules is the same.

[0011] Preferably, the controller base plate is provided with a structural retainer, which is an insulating frame. The frame is provided with a positioning groove corresponding to the variable frequency motor driver power module. The variable frequency motor driver power module is limited by the positioning groove and fixed to the controller base plate by screws.

[0012] Preferably, it also includes a current detection module, which is connected between the output terminal of the variable frequency motor driver power module and the phase line output module, and is used to collect the three-phase output current signal in real time and feed it back to the control circuit board.

[0013] Compared with existing technologies, the variable frequency motor driver power module and controller of this utility model have the following advantages: 1. The power circuit of the motor controller is split into a full-bridge module, and the full-bridge module is made into a separate SMT power module.

[0014] 2. Before use, power modules that have completed SMT surface mount soldering are screened and grouped by testing equipment, and the group number is etched onto the full-bridge module. All three full-bridge modules on the same controller must be products from the same group. Ensure that the internal resistance of the three bridge arms is consistent.

[0015] 3. When repairing the product, only the damaged full-bridge module needs to be replaced. The replacement should be strictly in accordance with the internal resistance group to ensure that the internal resistance of the three bridge arms is consistent, control the heat generation of each bridge arm to be consistent, and improve the quality of product repair.

[0016] 4. The controller has a simple overall structure, clear assembly logic, and high space utilization. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the structure in which the power module is placed in this utility model; Figure 2 This is a schematic diagram of the overall assembly structure of this utility model; Figure 3 This is a circuit connection diagram of the variable frequency motor driver power module and controller in this utility model; Figure 4 This is a circuit diagram of the power module of the variable frequency motor driver in this utility model; In the diagram: 1. Printed circuit board; 2. Variable frequency motor driver power module; 3. Controller baseboard; 4. DC bus input module; 5. Phase line output module; 6. Control circuit board. Detailed Implementation

[0018] The technical solutions in the embodiments of this utility model will be clearly and completely described below. Obviously, the described embodiments are only some embodiments of this utility model, and not all embodiments.

[0019] Example 1: like Figure 1 As shown, this embodiment discloses a variable frequency motor driver power module, including a printed circuit board 1. An independent full-bridge circuit is integrated on the printed circuit board 1. The full-bridge circuit includes at least one upper bridge arm and one lower bridge arm. Each upper bridge arm and lower bridge arm includes a controllable switching transistor connected in parallel and a diode connected in reverse parallel with it. The full-bridge circuit is also connected to auxiliary components. The full-bridge circuit and its auxiliary components, high-voltage terminals, and low-voltage pin headers / wires are integrated on a single printed circuit board 1.

[0020] The controllable switching transistor is a surface-mount MOSFET, and the auxiliary components include a gate drive element, a thermistor, and an interface for transmitting control signals.

[0021] The thermistor is mounted on the heat-generating area of ​​the printed circuit board 1 to measure the temperature of the power module during operation, and its output terminal is electrically connected to the control signal interface.

[0022] One side of the printed circuit board 1 is provided with a fixing part for connecting with the heat dissipation structure, and the other side is provided with internal resistance grouping marks.

[0023] The heat dissipation surface of the printed circuit board 1 is coated with thermal grease, and the fixing part is a screw hole that passes through the printed circuit board 1.

[0024] The motor controller power module described in this embodiment consists of surface-mount MOSFETs, gate resistors, capacitors, and a thermistor soldered onto a printed circuit board 1 to form a full-bridge circuit. The thermistor is used to measure the temperature during module operation. Control signals and temperature information are connected to the control board via pin headers. The consistency of the power module is ensured through circuit board design and soldering processes. The internal resistance of the power module is measured using a testing device, and the modules are grouped and labeled.

[0025] like Figure 4As shown, the core of the circuit is a full-bridge topology, consisting of an upper arm and a lower arm. Each arm is composed of three N-channel MOSFETs (model NCEP028N12LL) connected in parallel. In the upper arm, the drains (D) of the three MOSFETs (Q1, Q2, Q3) are all connected to the positive terminal of the 12V power supply, and their sources (S) are connected to the upper arm output node (marked as the "upper arm midpoint"). In the lower arm, the sources (S) of the three MOSFETs (Q4, Q5, Q6) are all connected to GND, and their drains (D) are connected to the lower arm output node (marked as the "lower arm midpoint"). The upper and lower arm midpoints are connected by a wire to form the AC output terminal of the full-bridge circuit.

[0026] The gate (G) of each MOSFET is connected to the drive signal input terminal through a gate resistor. In the upper bridge arm drive, the gates of Q1, Q2, and Q3 are connected to the current-limiting resistor R10 (10Ω), and the other end of R10 is connected to the upper bridge arm drive signal input terminal HOA1. In the lower bridge arm drive, the gates of Q4, Q5, and Q6 are connected to the current-limiting resistor R13 (10Ω), and the other end of R13 is connected to the lower bridge arm drive signal input terminal LOA1. A diode D10 (1N4148W) is connected in parallel between HOA1 and GND, and a diode D7 (1N4148W) is connected in parallel between LOA1 and 12V to protect the gate drive circuit from reverse voltage surges.

[0027] Signal interface and external connection: The right side of the circuit has a 4P stand-up pin (H1) with a 2.54mm pitch, a total of 8 pins, which serve as the connection interface between the control signal and the external circuit.

[0028] Example 2: Based on Example 1, such as Figures 2-3 As shown, the variable frequency motor driver controller of this utility model includes a controller base plate 3 and a DC bus input module 4, a variable frequency motor driver power module 2, a phase line output module 5 and a control circuit board 6 mounted on the controller base plate 3; the control signal and temperature information of the variable frequency motor driver power module are connected to the control circuit board 6 through low voltage pin headers / wires.

[0029] There are three variable frequency motor driver power modules 2, and each variable frequency motor driver power module 2 is arranged at intervals along the length of the controller base plate 3. The internal resistance group identification group number of the three variable frequency motor driver power modules 2 is the same.

[0030] The controller base plate 3 is provided with a structural retainer, which is an insulating frame. The insulating frame is provided with a positioning groove corresponding to the variable frequency motor driver power module 2. The variable frequency motor driver power module 2 is limited by the positioning groove and fixed to the controller base plate 3 by screws.

[0031] It also includes a current detection module, which is connected between the output terminal of the variable frequency motor driver power module 2 and the phase line output module 5, and is used to collect the three-phase output current signal in real time and feed it back to the control circuit board 6.

[0032] A three-phase AC motor controller requires three functionally identical "full-bridge" circuits. Each "full-bridge" consists of an "upper bridge arm" and a "lower bridge arm." Each bridge arm is composed of a controllable switching transistor and a diode connected in parallel. By alternating the conduction of the switching devices, the DC to AC inversion conversion can be achieved. The output power density of the "full-bridge" circuit is twice that of the "half-bridge" circuit, and it has the ability to precisely control the forward and reverse rotation and braking of the motor.

[0033] The existing technical solution involves soldering three "full-bridge" circuits and their associated components onto an aluminum-based circuit board to form a power board. Signals are transmitted to the low-voltage control board of the controller via pin headers or ribbon cables, enabling the control board to control the power board and complete the motor drive function.

[0034] The solution described in this embodiment encapsulates the three "full-bridge" circuits of the controller separately. Specifically, one "upper bridge arm" and one "lower bridge arm," along with their associated components, high-voltage terminals, and low-voltage pin headers or cables, are integrated onto a single printed circuit board 1. Each variable frequency motor driver controller uses three identical variable frequency motor driver power modules 2. The three variable frequency motor driver power modules 2 are connected to the corresponding interfaces of the control circuit board 6 via low-voltage pin headers or cables. This enables the control circuit board 6 to control the power boards and complete the motor drive function.

[0035] The above description is only a preferred embodiment of the present utility model, but the protection scope of the present utility model is not limited thereto. Any equivalent substitutions or changes made by those skilled in the art within the technical scope disclosed in the present utility model, based on the technical solution and the inventive concept of the present utility model, should be included within the protection scope of the present utility model.

Claims

1. A variable frequency motor driver power module, characterized in that, The circuit includes a printed circuit board (1), on which an independent full-bridge circuit is integrated. The full-bridge circuit includes at least one upper bridge arm and one lower bridge arm. Each upper bridge arm and lower bridge arm contains a controllable switching transistor connected in parallel and a diode connected in reverse parallel with it. The full-bridge circuit is also connected to auxiliary components, high-voltage terminals and low-voltage pin headers / wires. The full-bridge circuit and its auxiliary components, high-voltage terminals and low-voltage pin headers / wires are integrated and packaged on a printed circuit board (1).

2. The variable frequency motor driver power module according to claim 1, characterized in that, The controllable switch is a surface-mount MOSFET, and the auxiliary components include a gate drive element, a thermistor, and an interface for transmitting control signals.

3. The variable frequency motor driver power module according to claim 2, characterized in that, The thermistor is mounted on the heating area of ​​the printed circuit board (1) to measure the temperature of the power module during operation, and its output terminal is electrically connected to the interface of the control signal.

4. The variable frequency motor driver power module according to claim 1, characterized in that, The printed circuit board (1) has a fixing part on one side, which is used to connect the heat dissipation structure, and an internal resistance grouping mark on the other side.

5. The variable frequency motor driver power module according to claim 4, characterized in that, The heat dissipation surface of the printed circuit board (1) is coated with thermally conductive silicone grease, and the fixing part is a screw hole that penetrates the printed circuit board (1).

6. A variable frequency motor driver controller, characterized in that, It includes a controller base plate (3) and a DC bus input module (4) mounted on the controller base plate (3), at least one variable frequency motor driver power module (2) as described in any one of claims 1-5, a phase line output module (5) and a control circuit board (6); the control signal and temperature information of the variable frequency motor driver power module (2) are connected to the control circuit board (6) through a low voltage pin header / wire.

7. The variable frequency motor driver controller according to claim 6, characterized in that, The number of variable frequency motor driver power modules (2) is three, and each variable frequency motor driver power module (2) is arranged at intervals along the length direction of the controller base plate (3). The internal resistance group identification group number of the three variable frequency motor driver power modules (2) is the same.

8. The variable frequency motor driver controller according to claim 6, characterized in that, The controller base plate (3) is provided with a structural retainer, which is an insulating frame. The insulating frame is provided with a positioning groove corresponding to the variable frequency motor driver power module (2). The variable frequency motor driver power module (2) is limited by the positioning groove and fixed to the controller base plate (3) by screws.

9. The variable frequency motor driver controller according to claim 6, characterized in that, It also includes a current detection module, which is connected between the output end of the variable frequency motor driver power module (2) and the phase line output module (5) to collect the three-phase output current signal in real time and feed it back to the control circuit board (6).

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