High-power IGBT flexible power supply control system

Abstract

The present invention relates to the field of electronic devices, and relates to a high-power IGBT flexible power supply control system. In the present invention, for the problems of a large scale, a load sudden change working condition and a complex industrial site environment of high-power IGBT flexible power supply devices, targeted system design is performed, so that the devices can be applied to various industrial production scenarios. In the present invention, for the problem of a large scale of high-power power electronic devices, a clock synchronization strategy is formulated, and modular design of the devices is performed, so that the system can easily expand a power scale, and the control effect can be guaranteed. All controllers form a ring communication redundancy structure, thereby greatly improving the system security. For the problems of the load sudden change working conditions and the complex industrial environment, a system fault self-recovery function is added, thereby improving the automation level of the devices. Moreover, a Sigma-Delta sampling module is used, thereby ensuring the accuracy and rapidity of current sampling, and improving the performance of the devices.

Description

High-power IGBT flexible power supply control system Technical Field

[0001] The invention belongs to the field of electronic devices and relates to a high-power IGBT flexible power supply control system. Background Art

[0002] Industrial production has a strong demand for flexible power supply devices. Due to the limitations of the voltage and current resistance of power electronic devices, high-power industrial applications often use multi-stage series and parallel connections of IGBT power unit modules. As the power increases, the scale of the equipment increases accordingly, which requires more IGBTs and controllers to participate in the control. Therefore, the problem of synchronous control between multiple IGBT power units and multiple controllers is very important.

[0003] The operation of industrial production is complex and there are sudden load changes. This places high demands on the real-time performance of the device control system, requiring a fast control cycle and fault self-healing functions to ensure control effects and equipment safety.

[0004] Industrial sites often have complex on-site environments, where dust and electromagnetic environments can interfere with devices. This requires the equipment to have good anti-interference capabilities and redundancy functions.

[0005] Summary of the Invention

[0006] In light of this, the present invention aims to provide a high-power IGBT flexible power supply control system featuring easy scalability, diverse external communication methods, and high real-time control. This system employs a synchronous control strategy for the controller within the system and a novel sampling method to ensure fast and stable current sampling. Furthermore, the system incorporates targeted designs for sudden load changes and complex industrial environments, ensuring stable, efficient, and safe operation.

[0007] In order to achieve the above object, the present invention provides the following technical solutions:

[0008] High-power IGBT flexible power supply control system, the system includes a master controller and several slave controllers;

[0009] The plurality of slave controllers are all connected to the master controller via a network cable;

[0010] The main controller is connected to the digital input signal DI, digital output signal DO, analog input AI, analog output AO and communication module through the network cable;

[0011] The plurality of slave controllers are all connected to the digital input signal DI, the digital output signal DO and the sampling signal through optical fibers;

[0012] The plurality of slave controllers are further connected to a plurality of power units via optical fibers;

[0013] The plurality of adjacent slave controllers are connected via network cables;

[0014] The plurality of power units are interconnected;

[0015] The main controller is connected to the human-machine interface and the industrial field controller respectively via Ethernet;

[0016] The master controller is connected to all slave controllers via real-time industrial Ethernet, and the links form a ring topology, enabling communication to be transmitted in both directions, providing communication redundancy for the system.

[0017] Optionally, the main controller is equipped with a Linux-RT real-time operating system, the system has an IEC 61131-3 programming language environment, and the task cycle reaches 100us.

[0018] Optionally, the master controller is responsible for all control calculations in the system program, and uses distributed clock technology to synchronize the clocks of the master controller and all slave controllers. The control system can complete the pulse download and sampling upload of all slave controllers within 100ns, ensuring the pulse control consistency of all IGBT power units.

[0019] Optionally, the sampling signal is composed of analog and digital parts, and provides a data stream output based on oversampling and noise shaping.

[0020] Optionally, the sampling signal is sampled by a high-speed analog signal sampler, and the sampled signal is compared with the digital signal to obtain an error signal; the error signal is passed through an integrator and a proportional amplifier to obtain a feedback signal, and the feedback signal is digitally filtered and digitally denoised through a digital signal processor to obtain a digital output.

[0021] Optionally, the main controller has a fault self-healing function, and the specific steps are as follows:

[0022] S1: The system determines that a short circuit, open circuit or power unit failure occurs based on detection;

[0023] S2: The main controller immediately blocks the power unit pulses;

[0024] S3: After the pulse is blocked, the system determines whether a fault exists;

[0025] S4: The system determines that the fault is repaired and the main controller regenerates pulse control;

[0026] S5: The system determines that a fault exists and automatically shields the faulty components and power units.

[0027] S6: After shielding the faulty part, the system determines whether there is a fault in the remaining parts;

[0028] S7: After the fault is shielded, the system still has a fault and the device stops.

[0029] The beneficial effects of the present invention are as follows: the present invention carries out targeted system design for the problems of large-scale, sudden load changes and complex industrial field environments of high-power IGBT flexible power supply devices, so that the equipment can be applied to various industrial production scenarios. In order to solve the problem of large-scale high-power power electronic devices, the present invention has formulated a clock synchronization strategy and carried out modular design of the device, so that the system can easily expand the power scale and the control effect can be guaranteed. All controllers form a ring communication redundancy, which greatly improves the safety of the system. In order to solve the problems of sudden load changes and complex industrial environments, a system fault self-healing function is added to improve the automation level of the equipment, and a Sigma-Delta sampling module is used to ensure the accuracy and speed of current sampling, thereby improving the performance of the equipment.

[0030] Other advantages, objects, and features of the present invention will be described in part in the following description and, in part, will be apparent to those skilled in the art upon examination of the following description or may be learned from practice of the present invention. The objects and other advantages of the present invention may be realized and obtained through the following description. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] In order to make the purpose, technical solutions and advantages of the present invention more clear, the present invention will be described in detail below with reference to the accompanying drawings, in which:

[0032] Figure 1 is a schematic diagram of the structure of a high-power IGBT flexible power supply control system;

[0033] FIG2 is a diagram showing the principle of multi-controller synchronous control in an embodiment of the present invention;

[0034] FIG3 is a flow chart of a system fault self-healing function according to an embodiment of the present invention. DETAILED DESCRIPTION

[0035] The following describes the embodiments of the present invention by means of specific examples, and those skilled in the art can easily understand other advantages and effects of the present invention from the contents disclosed in this specification. The present invention can also be implemented or applied through other different specific embodiments, and the details in this specification can also be modified or changed in various ways based on different viewpoints and applications without departing from the spirit of the present invention. It should be noted that the illustrations provided in the following embodiments are only schematic illustrations of the basic concept of the present invention, and the following embodiments and features in the embodiments can be combined with each other without conflict.

[0036] Among them, the accompanying drawings are only for illustrative purposes and represent only schematic diagrams rather than actual pictures, and should not be understood as limiting the present invention. In order to better illustrate the embodiments of the present invention, some parts of the accompanying drawings may be omitted, enlarged or reduced, and do not represent the dimensions of actual products. For those skilled in the art, it is understandable that some well-known structures and their descriptions may be omitted in the accompanying drawings.

[0037] The same or similar numbers in the drawings of the embodiments of the present invention correspond to the same or similar parts; in the description of the present invention, it should be understood that if there are terms such as "upper", "lower", "left", "right", "front", "back", etc. indicating directions or positional relationships, they are based on the directions or positional relationships shown in the drawings. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific direction, be constructed and operate in a specific direction. Therefore, the terms describing the positional relationship in the drawings are only used for illustrative purposes and cannot be understood as limiting the present invention. For ordinary technicians in this field, the specific meanings of the above terms can be understood according to specific circumstances.

[0038] As shown in Figure 1, the present invention provides a high-power IGBT flexible power supply control system, which includes a network cable connection part and an optical fiber connection part; the network cable connection part is composed of a human-machine interface, an industrial field controller, a main controller, peripheral equipment DO, DI and communication modules, and a slave controller; the network cable connection part is the functional part of the device for realizing control communication; the optical fiber connection part is composed of internal DI, DO, sampling module, and power unit; the optical fiber connection part is the functional part of the device for realizing power output; the operator operates the industrial field controller through the human-machine interface to send instructions to the main controller, and the main controller indirectly controls the IGBT power unit through the slave controller, thereby generating power output.

[0039] Figure 2 illustrates the synchronous control principle between the master and slave controllers in the system. The master controller issues a command data frame carrying its clock information, which then passes through each slave controller in sequence, simultaneously delivering pulse control instructions. After the pulse instructions are issued, a feedback data frame is sent from the last slave controller, which then passes through each slave controller in reverse order, simultaneously uploading sampled data. Finally, each controller performs clock calibration using the master controller's clock, local clocks, and delay compensation to achieve clock synchronization. The entire process is completed within 100ns. The IGBT power unit adopts a modular design, with modules connected in parallel. The number of modules can be freely adjusted based on production capacity requirements.

[0040] Figure 3 shows the system fault self-healing function flow chart, which is divided into the following seven steps:

[0041] S1: The system determines based on detection that a short circuit, open circuit or power unit failure has occurred.

[0042] S2: The main controller immediately blocks the power unit pulses.

[0043] S3: After the pulse is blocked, the system determines whether a fault exists.

[0044] S4: The system determines that the fault is repaired and the main controller regenerates pulse control.

[0045] S5: The system determines that a fault exists and automatically shields the faulty components and power units.

[0046] S6: After shielding the faulty part, the system determines whether there is a fault in the remaining parts.

[0047] S7: After the fault is shielded, the system still has a fault and the device stops.

[0048] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not limiting. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solutions of the present invention can be modified or replaced by equivalents without departing from the purpose and scope of the technical solutions, which should all be included in the scope of the claims of the present invention.

Claims

1. High-power IGBT flexible power supply control system, characterized in that: The system includes a main controller and several slave controllers; The several slave controllers are all connected to the main controller via network cables; The main controller accesses digital input signals DI, digital output signals DO, analog input AI, analog output AO, and a communication module via network cables; The several slave controllers all access digital input signals DI, digital output signals DO, and sampling signals via optical fibers; The several slave controllers also access several power units via optical fibers; The adjacent ones of the several slave controllers are connected via network cables; The several power units are interconnected; The main controller is connected to a human-machine interface and an industrial field controller respectively via Ethernet; The main controller is connected to all slave controllers via a real-time industrial Ethernet, and the link forms a ring topology, enabling communication to be transmitted bidirectionally, providing communication redundancy for the system.

2. The high-power IGBT flexible power supply control system according to claim 1, wherein: The main controller is equipped with a Linux-RT real-time operating system, the system has an IEC 61131-3 programming language environment, and the task cycle reaches 100 us.

3. The high-power IGBT flexible power supply control system according to claim 2, characterized in that: The main controller is responsible for all control calculation work in the system program. Using distributed clock technology, the main controller keeps the clock synchronized with all slave controllers. The control system can complete the pulse distribution to all slave controllers and the sampling upload within 100 ns, ensuring the consistency of pulse control for all IGBT power units.

4. The high-power IGBT flexible power supply control system according to claim 3, wherein: The sampling signal is jointly composed of analog and digital parts, and provides a data stream output based on oversampling and noise shaping.

5. The high-power IGBT flexible power supply control system according to claim 4, wherein: The sampling signal is sampled by a high-speed analog signal sampler, the sampled signal is compared with the digital signal to obtain an error signal; the error signal passes through an integrator and a proportional amplifier to obtain a feedback signal, and the feedback signal is digitally filtered and digitally denoised by a digital signal processor to obtain a digital output.

6. The high-power IGBT flexible power supply control system according to claim 5, wherein: The main controller has a self-healing function for faults, and the specific steps are as follows: S1: The system determines that there are short circuits, open circuits, or power unit faults according to detection; S2: The main controller immediately blocks the power unit pulses; S3: After the pulse blocking, the system determines whether the fault exists; S4: The system determines that the fault is repaired, and the main controller regenerates pulse control; S5: The system determines that the fault exists, and automatically shields the devices and power units with faults; S6: After shielding the faulty part, the system determines whether there are faults in the remaining parts; S7: After the fault is shielded and there are still faults in the system, the device stops.

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