Electronic Control Apparatus Gate Drive Circuit Fault Detection

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Solution Overview

Problem

Conventional motor drive circuits fail to detect abnormalities in the ON-drive constant-current circuit, leading to potential thermal damage due to increased heat generation when the power transistor cannot be turned OFF correctly.

Innovation Solution

An electronic control apparatus that includes an ON-drive constant-current circuit with a current control transistor and a current detection resistor, where the control circuit monitors the voltage of the current detection resistor to detect abnormalities, such as short circuits or open faults, and controls the switching elements to prevent thermal damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the ON-drive constant-current circuit is used to supply constant current to the gate, then the power transistor can be turned ON reliably, but the circuit cannot detect abnormalities leading to potential thermal damage

Engineering Contradiction:
Improvereliability of power transistor turning OFFVSAvoiddifficulty of detecting abnormality in ON-drive circuit
Core Design Contradiction:
ReliabilityVSDifficulty of detecting and measuring

Solution Approach 1:

The patent introduces a feedback mechanism by monitoring the gate voltage through the gate resistor. The control circuit continuously checks the voltage across the gate resistor to detect abnormalities in the ON-drive constant-current circuit. When an abnormality is detected (such as failure to discharge gate charge properly), the control circuit can identify the fault condition and take appropriate action, thus resolving the contradiction between reliable switching and abnormality detection.

Inventive Principle:
Principle #23Feedback

Solution Approach 2:

The gate resistor serves as an intermediary element that enables abnormality detection. By monitoring the voltage across this resistor, the control circuit can indirectly detect abnormalities in the ON-drive circuit without directly interfacing with the gate drive transistors. This intermediary approach allows the system to detect faults while maintaining the reliability of the power transistor switching operation.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Object-affected harmful factors

If abnormality detection is added to the ON-drive circuit, then thermal damage can be prevented, but the device complexity increases

Engineering Contradiction:
Improvethermal damage to power transistorVSAvoidcomplexity of drive circuit
Core Design Contradiction:
Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The control circuit performs multiple functions: it controls the OFF-drive switching element to discharge gate charge, monitors the gate voltage through the gate resistor for abnormality detection, and can take protective actions when faults are detected. By making the control circuit multi-functional, the patent prevents thermal damage without adding separate dedicated detection hardware, thus resolving the contradiction between protection capability and circuit complexity.

Inventive Principle:
Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system uses its existing gate resistor and control circuitry to perform self-diagnosis. The control circuit monitors its own operation by checking the voltage across the gate resistor, which reflects the state of the ON-drive circuit. This self-service approach enables abnormality detection and thermal damage prevention without requiring additional external monitoring equipment, thereby avoiding increased device complexity.

Inventive Principle:
Principle #25Self-service

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Effectively detects abnormalities in the ON-drive constant-current circuit, preventing thermal damage by accurately determining and responding to faults, ensuring the switching element is turned OFF when necessary.

Implementation Method 1

a current detection resistor that detects the current flowing to the current control transistor

Methodology Applied
Scientific EffectOhm's Law: Ohm's Law

Implementation Method 2

supplying a constant current to the control terminal thereby charging the control terminal of the switching element with electrical charge

Methodology Applied
Scientific EffectCapacitance charging/discharging: Capacitance

Data Source

PatentUS9735767B2Electronic control apparatus having switching element and drive circuit
Publication Date: 2017.08.15 DENSO CORP
  • US9735767B2 patent drawing
  • US9735767B2 patent drawing
  • US9735767B2 patent drawing

AI summary

An electronic control apparatus includes a switching element; an ON-drive constant-current circuit supplying a constant current to the control terminal of the switching element thereby charging the control terminal of the switching element; an OFF-drive switching element discharging electrical charge from the control terminal of the switching element by being turned ON; and a control circuit adapted to control the ON-drive constant-current circuit and the OFF-drive switching element in response to a drive signal being inputted, thereby controlling the voltage of the control terminal of the switching element so as to drive the switching element. The control circuit controls the current control transistor based on the voltage of the current detection resistor and supplies the constant current to the control terminal of the switching element, and detects an abnormality in the ON-drive constant-current circuit based on the voltage of the current detection resistor.