Inverter PWM Edge Phase Control Near Zero Cross

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Solution Overview

Problem

Existing inverter control devices face challenges in accurately controlling the timing of zero cross and pulse edges in the near-zero cross region, leading to voltage errors, increased direct-current components, and current ripples in the output current.

Innovation Solution

An inverter control device with a PWM control unit and a pulse edge control unit that adjusts the phase difference between the zero cross point of the modulation wave and the pulse edge of the PWM pulse within a predetermined range, using trapezoidal wave modulation to reduce voltage errors and current ripples.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If trapezoidal wave modulation is used in overmodulation region, then output voltage is increased, but voltage error occurs in near-zero cross region and current ripple increases

Engineering Contradiction:
Improveoutput voltageVSAvoidvoltage control precision
Core Design Contradiction:
PowerVSManufacturing precision

Solution Approach 1:

The patent applies preliminary action by pre-calculating and storing the relationship between modulation wave zero-cross points and PWM pulse edges in a lookup table before operation. During real-time control, the system simply retrieves the appropriate phase difference correction value from the table based on the current operating region, avoiding complex real-time calculations and ensuring accurate pulse timing even in the near-zero cross region where voltage errors would otherwise occur.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The patent changes the parameter of PWM pulse phase positioning by introducing a region-dependent phase difference between the modulation wave zero-cross point and the PWM pulse edge. Instead of using a fixed phase relationship, the system adjusts this phase difference based on the operating region (overmodulation vs. one-pulse region), thereby optimizing voltage control precision across different operating conditions while maintaining high output voltage capability.

Inventive Principle:
Principle #35Parameter changes

2Ease of operation

If PWM pulse timing is not accurately controlled in near-zero cross region, then control simplicity is maintained, but direct-current component and current ripple increase

Engineering Contradiction:
Improvecontrol simplicityVSAvoidcurrent ripple
Core Design Contradiction:
Ease of operationVSObject-generated harmful factors

Solution Approach 1:

The patent uses preliminary action by pre-computing the optimal phase difference values for different operating regions and storing them in a lookup table. This allows the control system to maintain simplicity during real-time operation by simply retrieving pre-calculated values rather than performing complex real-time calculations, while still achieving accurate PWM pulse timing control that minimizes current ripple and direct-current component.

Inventive Principle:
Principle #10Preliminary action

3Device complexity

If phase difference between zero cross point and PWM pulse edge is not controlled, then device complexity is reduced, but output torque fluctuation and noise/vibration occur

Engineering Contradiction:
Improvecontrol logic complexityVSAvoidoutput torque stability
Core Design Contradiction:
Device complexityVSStability of the object's composition

Solution Approach 1:

The patent applies parameter changes by introducing a controlled phase difference parameter between the modulation wave zero-cross point and the PWM pulse edge. This parameter is adjusted based on the operating region (overmodulation vs. one-pulse region) to maintain stable output torque and minimize noise/vibration. The phase difference is determined from pre-calculated lookup tables, which keeps the control logic relatively simple while achieving the desired torque stability.

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The patent uses preliminary action by pre-calculating the optimal phase difference values for different operating regions and storing them in lookup tables. This approach maintains relatively simple control logic during real-time operation while ensuring stable output torque by retrieving pre-determined phase difference values that have been optimized to minimize torque fluctuation and noise/vibration.

Inventive Principle:
Principle #10Preliminary action

Data Source

PatentUS12170497B2Inverter control device and electric vehicle system
Publication Date: 2024.12.17 ASTEMO LTD
  • US12170497B2 patent drawing
  • US12170497B2 patent drawing
  • US12170497B2 patent drawing

AI summary

An inverter control device 200 includes a PWM control unit 220 that generates a PWM pulse for controlling an inverter 100, and a pulse edge control unit 250 that performs pulse edge control for correcting (shifting) a phase of a pulse edge of the PWM pulse generated by the PWM control unit 220. The PWM control unit 220 generates a PWM pulse by using a modulation rate based on a voltage command (Vd*, Vq*). The pulse edge control unit 250 corrects the PWM pulse so that a phase difference between a zero cross point where the modulation wave changes across 0 and a pulse edge of the PWM pulse falls within a predetermined range.