Electric-Power Conversion Controller Thermal Management
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Solution Overview
Problem
In electric-power conversion systems, high temperatures of switching devices and diodes lead to increased switching losses, performance deterioration, and shortened lifetimes, with existing solutions failing to provide effective countermeasures.
Innovation Solution
An electric-power conversion system controller that uses a temperature sensor to switch between voltage-boosting and direct-coupling control based on device temperature, preventing continuous current concentration and overheating by alternately controlling positive-polarity and negative-polarity switching devices, thereby maintaining device performance and extending their lifespan.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If direct-coupling control is used to improve system efficiency, then power loss is reduced, but switching devices and diodes overheat and their lifetime is shortened
Solution Approach 1:
The patent applies periodic action by switching between direct-coupling control and voltage-boosting control in alternating cycles. The controller periodically transitions between these two control modes based on temperature feedback, causing the current path to alternate between the positive-polarity-side device and the negative-polarity-side device. This periodic switching prevents continuous current concentration in a single device, thereby reducing thermal accumulation while maintaining overall system efficiency.
Solution Approach 2:
The patent implements dynamics by making the control mode adaptable and changeable based on real-time temperature conditions. The controller dynamically switches between direct-coupling control (when temperature is low) and voltage-boosting control (when temperature is high), allowing the system to optimize between efficiency and device protection according to actual operating conditions rather than using a fixed control mode.
2Reliability
If voltage-boosting control is used to reduce device temperature, then device lifetime is extended, but switching loss increases
Solution Approach 1:
The patent applies partial action by using voltage-boosting control only partially and only when necessary. Instead of continuously applying voltage-boosting control, the system uses it intermittently based on temperature thresholds, combining it with direct-coupling control during cooler periods. This partial application minimizes the additional switching losses while still achieving the goal of preventing device overheating.
3Productivity
If direct-coupling control is continuously applied, then system efficiency is maximized, but device temperature rises and performance deteriorates
Solution Approach 1:
The patent implements feedback control by continuously monitoring the temperature of switching devices and diodes through temperature sensors, and using this temperature information to adjust the control mode. When the temperature exceeds a predetermined threshold, the controller automatically switches from direct-coupling control to voltage-boosting control, and when the temperature decreases, it returns to direct-coupling control. This closed-loop feedback mechanism ensures the system maintains high efficiency while preventing excessive temperature rise.
Data Source
AI summary
There is provided an electric-power conversion system controller in which even when the temperatures of a switching device and a diode included in the driving circuit for a converter become high, the performances of the devices are prevented from being deteriorated and the lifetimes thereof are prevented from being shortened. In the case where even when determining that direct-coupling control is to be performed, a positive-polarity-side device temperature is higher than a determination temperature, the electric-power conversion system controller performs voltage-boosting control in which the positive-polarity-side switching device and the negative-polarity-side switching device are on/off-controlled in an on/off period; in the case where the positive-polarity-side device temperature is the same as or lower than the determination temperature, the electric-power conversion system controller performs direct-coupling control in which the positive-polarity-side switching device is turned on and the negative-polarity-side switching device is turned off.