Power Semiconductor Preheating for Loss Reduction
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Solution Overview
Problem
Power semiconductors in converters, particularly in electric and hybrid vehicles, face significant electrical losses due to prolonged switch-off processes and reduced blockability at lower temperatures, leading to costly overdimensioning and restricted operating conditions.
Innovation Solution
A method involving temperature sensing and pre-heating phases to adjust the switch-off speed of power semiconductors, where a pre-heating current is impressed into an electrical load based on temperature comparisons with reference values, allowing operation beyond manufacturer-restricted temperatures without exceeding maximum blocking collector-emitter voltage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the switch-off speed of power semiconductors is increased to reduce electrical losses, then the duration of switch-off process is reduced, but the collector-emitter switch-off overvoltage increases beyond the maximum blocking voltage
Solution Approach 1:
The patent applies preliminary action by pre-heating the power semiconductor before the main switching operation. A pre-heating phase is introduced where a pre-heating current is applied to raise the semiconductor's temperature to a reference temperature before normal operation begins. This preliminary thermal preparation enables the semiconductor to withstand higher switch-off overvoltages without exceeding its maximum blocking voltage, thus allowing faster switch-off speeds and reduced electrical losses while maintaining reliability.
2Reliability
If power semiconductors are operated at lower temperatures to prevent overheating, then thermal reliability is improved, but the maximum blocking collector-emitter voltage decreases requiring overdimensioning
Solution Approach 1:
The patent applies dynamics by making the operating temperature of the power semiconductor variable rather than fixed. A temperature management system dynamically adjusts the semiconductor's temperature using a pre-heating phase that raises the temperature from low ambient conditions to an optimal reference temperature before normal operation. During operation, the temperature is maintained within an optimal range through controlled pre-heating cycles, allowing the semiconductor to operate at higher temperatures that provide better blocking voltage characteristics without risking thermal damage, thus eliminating the need for overdimensioning.
3Reliability
If the maximum blocking collector-emitter voltage is used as the design basis for switch-off speed, then device safety is ensured, but the switch-off process duration increases causing higher electrical losses
Solution Approach 1:
The patent applies parameter changes by modifying the temperature parameter of the power semiconductor. By introducing a pre-heating phase that raises the semiconductor's temperature to a reference temperature before normal operation, the electrical characteristics of the device change. Specifically, the maximum blocking collector-emitter voltage increases at higher temperatures, allowing for faster switch-off speeds that reduce the duration of switch-off processes and thereby reduce electrical losses, while still ensuring device safety through controlled temperature management.
4Adaptability or versatility
If power semiconductors are designed for the entire temperature range including low temperatures, then adaptability is improved, but the maximum blocking collector-emitter voltage must be reduced to account for low-temperature conditions
Solution Approach 1:
The patent applies preliminary action by implementing a pre-heating phase that prepares the power semiconductor for optimal operation before the main switching tasks begin. When the semiconductor starts from low temperatures, the pre-heating phase raises its temperature to a reference temperature where the maximum blocking collector-emitter voltage is optimized. This preliminary thermal preparation allows the system to achieve fast switch-off speeds and low electrical losses during normal operation, while still maintaining adaptability to operate across the entire temperature range by dynamically applying pre-heating when needed.
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 method reduces electrical losses and extends the operational temperature range of power semiconductors, preventing overheating and ensuring reliable operation while maintaining efficiency, thus addressing the limitations of existing designs.
Implementation Method 1
measuring with a temperature sensor a temperature of at least one of the power semiconductors
Implementation Method 2
impressing the pre-heating current into an electrical load
Data Source
AI summary
A method for operating power semiconductors arranged in converters, includes measuring with a temperature sensor a temperature of at least one of the power semiconductors, performing a comparison of the temperature of the at least one power semiconductor with a reference temperature and providing a result of the comparison; activating a pre-heating phase for preheating the power semiconductors as a function of the result; during the pre-heating phase, defining a pre-heating current; and impressing the pre-heating current into an electrical load.


