Resonant Inverter Junction Temperature Estimation at High Switching Frequency
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods struggle to accurately estimate the junction temperature of switching elements in high-power inverters due to high switching frequencies exceeding the bandwidth of current sensors, leading to potential failure from excessive heat in devices like full-bridge resonant inverters used in plasma generation systems.
Innovation Solution
A plasma generating system that estimates junction temperature in real time by using device output voltage and current values to calculate an inverted current estimate, which is then used to determine the junction temperature, employing a controller and junction temperature estimator to manage power supply devices with full-bridge resonant inverters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If direct current measurement methods are used to estimate junction temperature, then measurement simplicity is maintained, but measurement precision deteriorates due to switching frequency exceeding sensor bandwidth
Solution Approach 1:
The patent introduces an intermediary calculation approach by using easily measurable voltage and power values as mediators to indirectly obtain the inverted current information. Instead of directly measuring the high-frequency switching current, the system uses voltage sensors and power measurements as intermediaries to derive the necessary current data through calculations involving impedance and power relationships, thereby avoiding the bandwidth limitations of direct current sensors.
Solution Approach 2:
The patent replaces the mechanical/electrical measurement system (direct current sensing) with a computational system. Instead of using physical current sensors that cannot handle high switching frequencies, the system substitutes direct measurement with mathematical calculations based on measurable voltage and power parameters, effectively replacing the physical measurement constraint with a computational solution that has no bandwidth limitations.
2Speed
If high switching frequency is used to achieve fast switching function, then operation speed is improved, but heat generation increases causing potential failure
Solution Approach 1:
The patent implements preliminary thermal management by continuously estimating the junction temperature before it reaches dangerous levels. By using the derived current information from voltage and power measurements, the system can predict thermal conditions in advance and take preventive actions such as adjusting switching parameters or activating cooling mechanisms, thereby preventing thermal runaway while maintaining high switching speeds.
Solution Approach 2:
The patent establishes a feedback mechanism where the estimated junction temperature and current information are continuously monitored and fed back to the control system. This feedback loop allows the system to dynamically adjust operating parameters to maintain optimal thermal conditions, enabling sustained high-speed switching operations without exceeding temperature limits that would cause failure.
Data Source
AI summary
Provided is a plasma generating system including: a resonant inverter including a switching circuit and configured to generate a device output current and a device output voltage, and to have a switching frequency based on an input DC current and an input DC voltage; a plasma source configured to generate a plasma based on the device output current and the device output voltage; a controller configured to control the switching frequency of the resonant inverter based on a value of the input DC current, a value of the input DC voltage, a value of the device output current, and a value of the device output voltage; and a junction temperature estimator configured to: estimate a current output from the switching circuit based on the value of the input DC voltage, the value of the device output current, and the value of the device output voltage, generate an inverted current estimate value, and estimate a junction temperature of the switching circuit based on the inverted current estimate value.


