Inverter Control System Soft Turn-Off IGBT Protection

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Solution Overview

Problem

Inverters in electric vehicles can experience short circuits due to collisions, poor maintenance, or assembly errors, leading to overcurrents in IGBTs, which can result in excessive voltage and potential damage if not managed properly.

Innovation Solution

An inverter control system with a gate operating portion, a current buffer, and a filter that delays the forcible turn-off control current to ensure a soft turn-off of the IGBT, preventing excessive voltage and protecting the IGBT, while allowing high DC link voltage usage without changing the rated voltage of the IGBT.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If forcible turn-off control is applied to stop IGBT switching during overcurrent, then IGBT damage is prevented, but excessive voltage (voltage over shoot) is generated at both ends of the IGBT

Engineering Contradiction:
ImproveIGBT protectionVSAvoidexcessive voltage
Core Design Contradiction:
ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent applies beforehand cushioning by introducing a filter circuit that delays the forcible turn-off control current signal. This delay allows the IGBT to remain conducting for a brief period longer, cushioning against the sudden voltage spike that would otherwise occur during immediate forcible turn-off. The filter acts as a protective buffer that softens the turn-off process, preventing excessive voltage generation while still protecting the IGBT from damage.

Inventive Principle:
Principle #11Beforehand cushioning (Prior cushioning)

2Reliability

If soft turn-off is applied to prevent excessive voltage, then IGBT is protected, but turn-off response time is delayed

Engineering Contradiction:
ImproveIGBT protectionVSAvoidturn-off response speed
Core Design Contradiction:
ReliabilityVSSpeed

Solution Approach 1:

The patent applies partial action by implementing a filter that provides only a partial delay to the turn-off control current, rather than a complete or excessive delay. The filter is designed to delay the signal just enough to prevent excessive voltage spikes during turn-off, but not so much that it significantly impacts the overall response time. This partial delay achieves the necessary protection while minimizing the impact on switching speed.

Inventive Principle:
Principle #16Partial or excessive action

3Power

If high DC link voltage is used to increase power output, then inverter power capability is improved, but IGBT voltage stress increases beyond rated voltage

Engineering Contradiction:
Improveinverter power outputVSAvoidIGBT voltage tolerance
Core Design Contradiction:
PowerVSStrength

Solution Approach 1:

The patent applies beforehand cushioning by using the filter to delay the turn-off control signal, which prevents excessive voltage spikes during IGBT switching. This cushioning effect allows the system to operate with high DC link voltage without subjecting the IGBT to voltage stresses beyond its rated capability. The filter protects the IGBT from voltage over-shoot, enabling the use of higher DC link voltages to increase inverter power output while maintaining IGBT safety within its voltage ratings.

Inventive Principle:
Principle #11Beforehand cushioning (Prior cushioning)

Data Source

PatentUS8451045B2Inverter control system
Publication Date: 2013.05.28 HYUNDAI MOTOR CO LTD
  • US8451045B2 patent drawing
  • US8451045B2 patent drawing
  • US8451045B2 patent drawing

AI summary

An inverter control apparatus is provided that offers a ‘soft turn off’ to a gate operation of the inverter so as to securely protect the IGBT. In particular, an inverter control system according to the present invention may include a gate operating portion that controls turn on/off of an IGBT and forcibly turns off the IGBT if a short circuit or an over current is detected from the IGBT, a current buffer that amplifies a control current for the turn on/off of the IGBT that is outputted from the gate operating portion, and a filter that delays the forcible turn off control current that is outputted from the gate operating portion.