Hybrid Vehicle High Side DC/DC Converter Thermal Balance Control
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Solution Overview
Problem
High side DC/DC converters in hybrid vehicles face inefficiencies due to unbalanced temperatures between inductors and IGBT switching elements, leading to increased switching losses and heat generation, which necessitate a method to adjust switching frequency based on temperature variations to maintain balance and reduce unit costs.
Innovation Solution
A device and method that includes temperature sensors for the inductor and IGBT switching elements, with a controller adjusting the switching frequency to maintain temperature balance by decreasing the frequency when IGBT elements are hotter and increasing it when the inductor is hotter, within predetermined critical frequency ranges to minimize heat and switching losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the switching frequency of the HDC is increased, then the voltage conversion efficiency is improved, but the switching loss in the IGBT switching element increases and temperature rises
Solution Approach 1:
The patent implements dynamic adjustment of the switching frequency based on real-time temperature feedback from both the inductor and IGBT switching element. The controller varies the switching frequency within a predetermined range according to temperature conditions, transforming the static switching frequency into a dynamic parameter that adapts to thermal states, thereby resolving the contradiction between conversion efficiency and switching loss.
Solution Approach 2:
The patent changes the physical parameter of switching frequency based on temperature conditions. By adjusting the switching frequency parameter within a specific range according to the thermal states of the inductor and IGBT, the system optimizes the balance between voltage conversion efficiency and switching loss, preventing excessive temperature rise while maintaining effective operation.
2Loss of energy
If the switching frequency of the HDC is decreased, then the switching loss in the IGBT switching element is reduced, but the ripple current of the inductor increases and heat generation occurs
Solution Approach 1:
The patent employs dual temperature feedback mechanisms, with temperature sensors monitoring both the inductor and IGBT switching element. The controller receives temperature information from both components and adjusts the switching frequency accordingly, creating a closed-loop feedback system that balances the contradictory thermal effects and prevents either component from overheating.
Solution Approach 2:
The patent adjusts the switching frequency parameter based on the thermal states of both the inductor and IGBT. By varying this parameter within a predetermined range according to temperature conditions, the system resolves the contradiction between reducing switching loss and preventing inductor overheating from increased ripple current.
3Reliability
If the number of IGBT switching elements is increased, then the temperature management is improved, but the unit cost increases
Solution Approach 1:
The patent enables the existing IGBT switching elements to serve multiple functions through intelligent control. By dynamically adjusting the switching frequency based on temperature feedback, the system allows the same components to operate efficiently under varying thermal conditions, eliminating the need for additional IGBT elements and thereby reducing unit cost while maintaining reliable temperature management.
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
This approach effectively maintains proper use temperatures for both inductors and IGBT switching elements, improving the utilization rate of IGBT switching elements, reducing heat generation, and minimizing switching losses, thereby enhancing the efficiency and longevity of the high side DC/DC converter.
Implementation Method 1
an element temperature sensing unit having a first temperature sensor configured to sense a temperature of the inductor, a second temperature sensor configured to sense a temperature of the lower IGBT switching element, and a third sensor configured to sense a temperature of the upper IGBT switching element
Implementation Method 2
a controller configured to receive temperature sensing values of the first to third temperature sensors, and in response to detecting a variation in temperature between the inductor and each IGBT switching element, adjust a switching frequency of the IGBT switching element to be increased or decreased to maintain a balance between the temperatures of the inductor and each IGBT switching element
Implementation Method 3
an upper IGBT switching element and a lower IGBT switching element, which switch current flowing through the inductor
Implementation Method 4
The HDC is configured with several types of semiconductor elements such as an inductor and an IGBT to increase the operating voltage of a drive motor
Data Source
AI summary
A device and a method for controlling a high side DC/DC converter (HDC) of a hybrid vehicle are provided. The switching frequency of the HDC is variably adjusted based on situations of temperatures of an inductor and an IGBT switching element, which constitute the HDC, to maintain a balance between the temperatures of the inductor and the IGBT switching element. Accordingly, temperatures of the inductor and the IGBT switching element are detected, and the switching frequency of the HDC is variably adjusted based on a situation for each temperature of each element to maintain a balance between the temperatures of the inductor and the IGBT switching element, thereby improving the utilization rate of the IGBT switching element.