CN110763946A - Method for real-time online diagnosis and life prediction of electrolytic capacitor life - Google Patents
Method for real-time online diagnosis and life prediction of electrolytic capacitor life Download PDFInfo
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Abstract
The invention discloses a real-time online diagnosis and life prediction method for the service life of an electrolytic capacitor, which is characterized in that a voltage-sharing resistor in an electrolytic capacitor system is multiplexed, the midpoint voltage of the voltage-sharing resistor is compared with a reference voltage, the real-time online diagnosis of the service life of each electrolytic capacitor is realized, early warning and alarming are sent out in advance when the service life expires, a user is helped to accurately position the electrolytic capacitor with expired service life and replace the electrolytic capacitor, and a large amount of loss caused by system shutdown is avoided; the midpoint voltage of the voltage-sharing resistor of the electrolytic capacitor is sampled, the service life of the electrolytic capacitor is calculated through a mathematical model, real-time online prediction of the service life of each electrolytic capacitor is realized, and visual pre-maintenance reference information is provided for a user. The invention realizes the real-time online diagnosis and prediction of the service life of each electrolytic capacitor in the power electronic system, and has low implementation cost.
Description
Technical Field
The invention relates to a method for diagnosing and predicting the service life of an electrolytic capacitor, in particular to a method for diagnosing and predicting the service life of the electrolytic capacitor on line in real time.
Background
The electrolytic capacitor is used as a core part in the power electronic converter and plays important roles of supporting, energy storage, filtering and the like, however, the electrolytic capacitor belongs to a vulnerable part, and the service life of the electrolytic capacitor is the service life bottleneck of the power electronic converter. If the service life of the electrolytic capacitor expires, the power electronic converter is abnormally operated, production line stop loss is caused, and even mechanical equipment and a workpiece in processing are damaged. Therefore, there are many related studies domestically and internationally in terms of life-time expiration prevention of electrolytic capacitors.
In the prior art, the early method is to mark the service life of the electrolytic capacitor under the specified working conditions, such as working temperature, working voltage and working load, in a user manual, provide a service life conversion formula under other working conditions, and provide an approximate standard for component replacement, so that a user can conveniently and programmatically replace the electrolytic capacitor before the service life of the capacitor in the power electronic converter expires, thereby avoiding huge loss caused by unexpected shutdown. However, this is only a manual precaution, which can only be done by the user according to the manual, and the lifetime of the electrolytic capacitor is not necessarily exactly what the user can do. FIG. 1 is a screenshot of the Anchuan Sigma7 servo driver handbook for capacitance replacement.
Later, the development of intelligent real-time online service life diagnosis and service life prediction methods for electrolytic capacitors appeared. These methods can be broadly divided into two broad categories: a method based on a life model and a method based on parameter online identification.
The method based on the life model generally selects one or more parameters which are linearly and strongly related to the life of the electrolytic capacitor, establishes an equation of the life of the electrolytic capacitor and the parameters through theory and experiment, and realizes real-time prediction and diagnosis of the life of the electrolytic capacitor by monitoring the parameters in real time on line. Part of Japanese servo driver products, such as an Anchuan Sigma7 driver, have integrated the function of capacitor life prediction, can gather the temperature around the capacitor through the temperature sensor, and substitute the capacitor life equation and calculate the percentage of remaining life in real time and show to the user, if the life-span is less than certain threshold value still can produce the warning (do not shut down), remind the user to arrange the batch replacement of electrolytic capacitor in time. The method has the advantages that the online prediction and diagnosis of the service life of the electrolytic capacitor can be realized by adding less hardware cost, but the disadvantages of the method are also obvious: a large amount of manpower and physical investment is needed to obtain a life model in the early stage; the method belongs to an indirect prediction method based on a model, and the prediction deviation caused by individual capacitance difference and working condition difference is large; the service life of the electrolytic capacitor cannot be accurately positioned to be due, even if the service lives of different electrolytic capacitors in the same power electronic converter are different, the service lives of the different electrolytic capacitors are uniformly judged to be due and are completely replaced, and certain waste is caused.
The last point is particularly obvious on some large-scale mechanical equipment, because the large-scale mechanical equipment needs more electrolytic capacitors to finish energy storage, if the electrolytic capacitors of the whole capacitor energy storage system are replaced due to certain life warning or alarm, great loss is caused to users. The accurate positioning to the lifetime of each electrolytic capacitor is an urgent requirement from the user end.
The method based on parameter online identification usually selects parameters capable of directly representing the expiration of the service life of the electrolytic capacitor for real-time online measurement, generates early warning to remind a user to replace the electrolytic capacitor once the parameters are close to the limit range specified by a manual, and generates alarm to stop the machine once the parameters exceed the limit range specified by the manual. Meanwhile, the service life calculation based on parameter online identification can be carried out according to the mathematical model between the parameters and the service life of the electrolytic capacitor, and the residual service life is displayed. Common parameters that can directly characterize the lifetime expiration of electrolytic capacitors are shown in the first column of fig. 3, as leakage current, capacitance, loss tangent angle, etc., and the criteria for lifetime expiration of electrolytic capacitors are shown in table 1. The method has the advantages that the method can directly represent the parameters of the service life of the electrolytic capacitor based on real-time online monitoring, can most directly early warn and alarm the expiration of the service life of the capacitor, is more accurate compared with the former method, can predict the service life more accurately compared with the former method, can respectively monitor the service life of each capacitor by increasing the hardware cost, and prompts a user to pertinently replace the electrolytic capacitor with the expired service life in the system, but the method also has certain defects: the method needs to monitor 2 or more than 2 variables in the power electronic equipment in real time with certain precision, calculate and obtain the parameters directly representing the service life of the electrolytic capacitor, and need to increase certain hardware cost. Especially, when the accurate positioning is required to predict the service life of each electrolytic capacitor, the cost is multiplied, and the user is difficult to accept.
TABLE 1 criterion for the end of life of electrolytic capacitors
| Parameter variable | Criterion for end of life |
| Leakage current | Less than 0.01CV |
| Capacitance capacity | The reduction is not more than 10 percent compared with the factory value |
| Loss tangent angle | Compared with the factory value, the increase is not more than 200 percent |
Disclosure of Invention
Aiming at the defects of the existing electrolytic capacitor intelligent online service life diagnosis and service life prediction method, the invention provides an electrolytic capacitor service life real-time online diagnosis and service life prediction method, which reuses a voltage equalizing resistor in an electrolytic capacitor system, compares the midpoint voltage of the voltage equalizing resistor with a reference voltage, realizes the real-time online diagnosis of the service life of each electrolytic capacitor, sends out early warning and alarm in advance when the service life expires, helps a user accurately position the electrolytic capacitor with expired service life, and replaces the electrolytic capacitor, thereby avoiding the loss caused by the shutdown of the system; the midpoint voltage of the voltage-sharing resistor of the electrolytic capacitor is sampled, the service life of the electrolytic capacitor is calculated through a mathematical model, real-time online prediction of the service life of each electrolytic capacitor is realized, and visual pre-maintenance reference information is provided for a user.
The invention provides a real-time online diagnosis and life prediction method for the service life of an electrolytic capacitor, which aims to realize the purpose of the invention and comprises the following steps:
real-time online diagnosis of the service life of the electrolytic capacitor:
And 2, carrying out logic judgment according to the comparison result: if the voltage of each intermediate node of the series capacitor bridge arm is not higher than the upper alarm threshold value and is not lower than the lower alarm threshold value, the service lives of all electrolytic capacitors of the series capacitor bridge arm are not expired, and no alarm of the expired service life is generated; if any node and all the node voltages below the node are higher than the upper alarm threshold value and all the node voltages above the node are lower than the lower alarm threshold value, the service life of the electrolytic capacitor with the node as the lower node is expired, an alarm is generated, a client is informed that the service life of the electrolytic capacitor is expired, and shutdown maintenance is needed.
The real-time online prediction step of the electrolytic capacitor life:
Where x represents the xth capacitor in the series arm, x being an integer from 1 to m. Rnx is the parallel voltage-sharing resistor of the x capacitor of the n series bridge arm.
Compared with the existing method for intelligently diagnosing and predicting the service life of the electrolytic capacitor on line, the method has the following advantages:
1. the service life of each electrolytic capacitor in the power electronic system can be diagnosed and predicted on line in real time.
2. The capacitor voltage-sharing resistor in the power electronic system is reused, and the real-time online diagnosis of the service life of the electrolytic capacitor can be realized only by adding a simple comparison circuit, so that early warning and alarming are generated, and the cost is very low; similarly, the life prediction of each electrolytic capacitor in the system only needs to sample the midpoint voltage of the equalizing resistor, and does not need to sample 2 or more than 2 parameters, so the cost is low. The advantages of the invention are more evident especially when it is desired to diagnose and predict the lifetime of each capacitor in a multi-capacitor system.
3. The method is a method for realizing the real-time online diagnosis and prediction of the service life of the electrolytic capacitor by detecting the direct characterization parameter of the service life expiration of the electrolytic capacitor, namely the leakage current, and is more accurate and reliable compared with a service life model-based method.
A typical topology for a dc bus to which the present invention is applicable is shown in fig. 4. The invention is suitable for any electrolytic capacitor series-parallel connection to realize the bus supporting topology, and any topology and method which are slightly modified on the topology and method of the invention are all within the protection claim scope of the invention.
Drawings
FIG. 1 is a screenshot of an Anthra Sigma7 servo drive manual capacitance replacement.
FIG. 2 is a screenshot of the Anthrachian Sigma7 servo drive handbook life prediction.
FIG. 3 is data of life test of electrolytic capacitor.
Fig. 4 is a diagram of a typical dc bus topology.
FIG. 5 is a bathtub plot of electrolytic capacitor life.
FIG. 6 is an example of the real-time online diagnosis of the lifetime of the electrolytic capacitor according to the present invention.
FIG. 7 is a graph of electrolytic capacitor life and leakage current.
FIG. 8 is an example of the real-time online prediction of the lifetime of the electrolytic capacitor according to the present invention.
Fig. 9 is a flowchart of a first series branch electrolytic capacitor life prediction algorithm.
Detailed Description
The method of the present invention will be described in further detail with reference to the accompanying drawings and examples.
Due to the limitations of cost and devices, a typical direct current bus topology is usually realized by connecting N low-voltage low-capacity electrolytic capacitors in series and in parallel, and because the low-voltage electrolytic capacitors are connected in series to withstand high bus voltage, certain voltage-sharing measures must be added, the most common measures are voltage sharing by adopting resistors, and the theoretical calculation of the resistors is based on the following:
R＝UC/(5×IL)＝UC/(5×0.003CUC)＝1/(0.015×C)
wherein U isCIs the capacitor voltage, ILIs the leakage current of the capacitor, and C is the capacitance value of the capacitor. However, practice proves that the voltage-sharing resistance value can be calculated according to the R being 1/(0.0015C) in consideration of the actual leakage current of the electrolytic capacitor and the power consumption of the voltage-sharing resistance. As the lifetime of the electrolytic capacitor is reduced, the leakage current tends to increase, and when the lifetime of a certain electrolytic capacitor expires, the leakage current increases sharply, which corresponds to the stage C in fig. 5: wear out and expiration date. Setting the leakage current of the expired electrolytic capacitor as I according to the failure criterion of the electrolytic capacitor in Table 1DThe parameter is based on data provided by electrolytic capacitor manufacturers, such as the criterion of the failure leakage current of the electrolytic capacitors in south China, river and sea, CD29C series is 0.01CUC. The normal state electrolytic capacitor is in stage B-life in FIG. 7, the leakage current is very small, usually equal to IDDifference is tens of times, and current actually flowing through the equalizing resistor is equal to IDThe ratio is much smaller.
Fig. 6 shows an example of an implementation of the lifetime diagnosis of the electrolytic capacitor, and the basic principle is as follows: the electrolytic capacitors of the same series arm only have one entering loss and failure period at the same time, and other electrolytic capacitors are still in the service life period, namely, the electrolytic capacitors failThe equivalent series resistance of the capacitor circuit can be obviously reduced, and the equivalent series impedance of other circuits is basically unchanged, so that the voltage of all nodes below the capacitor is raised, the voltage of all nodes above the capacitor is reduced, and by utilizing the characteristic, the real-time online diagnosis of the service life of the electrolytic capacitor can be realized by using a simple hardware comparison circuit, and the alarm and the early warning can be generated in time. The specific description takes the first column of capacitor series branches in fig. 6 as an example: suppose a capacitance C12The leakage current is increased suddenly when the service life is expired and the loss and failure period is entered, which results in the equivalent series impedance of the capacitor branch circuit being reduced obviously and the node O below the capacitor branch circuit12-O1(m-1)The voltage of the voltage signal is obviously increased and the upper limit reaches a signal P after passing through an alarm comparison circuit12-P1(m-1)Above it a node O11The voltage is obviously reduced, and the lower limit reaches a signal N after passing through an alarm comparison circuit11Integrating P according to the judgment principle of the voltage rise of the lower node and the voltage drop of the upper node of the degraded capacitor12-P1(m-1)And N11Logic judgment, accurate positioning to the electrolytic capacitor C12The life is expired and an alarm signal is generated, and the detection delay is very small. The method has the advantages that the method is the same as the alarm principle, the early warning of the service life degradation of the electrolytic capacitor can be realized by adjusting the threshold value of the comparator, the early warning signal is generated, the detection delay is very small, and a user is reminded to arrange a maintenance plan in advance. The diagnostic mechanism of other serial branches is the same and will not be described herein. Similarly, based on the principle, the service life of the electrolytic capacitor can be diagnosed on line in real time by sampling the node voltage and carrying out logic judgment in the MCU, but the cost is slightly higher. The electrolytic capacitor service life real-time online diagnosis method of the invention reuses the voltage-sharing resistor of the electrolytic capacitor, the cost of the system additional hardware is very low, the service life early warning and alarming of each electrolytic capacitor positioned in the system are realized, the economic performance and the competitive power are excellent, and the cost advantage is more obvious along with the increase of the number of the electrolytic capacitors of the system. FIG. 6 is an example of the real-time online diagnosis of the lifetime of the electrolytic capacitor according to the present invention. FIG. 7 is a data curve of life test of a manufacturer for 8 electrolytic capacitors of 400V560uF, which is labeled 1# -8 #. As can be seen, the leakage of the electrolytic capacitor after the leakage current repair regionThe current increases linearly with time and the leakage current of the electrolytic capacitor is a parameter that can directly characterize its lifetime. If the electrolytic capacitor is stored for a long time, the leakage current index can be degraded and can be repaired by adding voltage, the electrolytic capacitor is positioned in a leakage current repairing area in the first half period of time of fig. 7, and the leakage current linearly decreases along with the time.
Fig. 8 shows an implementation of the lifetime prediction of the electrolytic capacitor provided by the present invention, which is described by taking the first capacitor series branch as an example, and sampling the node voltage U11-U1(m-1)And the current I of the series branch of the electrolytic capacitor1Multiplexing the variable bus voltage U required for the control of the power electronic system itself0Each electrolytic capacitor C in the series branch can be solved by the formula (1)1xLeakage current I ofdx。
FIG. 9 shows a flowchart of an algorithm for predicting the lifetime of each electrolytic capacitor in the first series branch, in which a parameter U is periodically sampled11-U1(m-1)、I1、U0Calculating the leakage current I of each electrolytic capacitor in the capacitor series branchdxSequentially processing each electrolytic capacitor, comparing the leakage current of the capacitor in the current period with the previous period, judging whether the electrolytic capacitor is in a leakage current repairing area, and if so, judging the service life percentage L1xIs 100%; if the residual life percentage L of the electrolytic capacitor is in the leakage current repair area, looking up a table to obtain the residual life percentage L of the electrolytic capacitor according to the established life model1x. The algorithm flows of other parallel capacitor branches are the same, and are not described herein. The method for predicting the service life of the electrolytic capacitors on line in real time can display the service life condition of each electrolytic capacitor in a system in real time for a user, so that the user can prepare for maintenance in advance and prevent unexpected shutdown, and particularly, the system has more electrolytic capacitors in large-scale machinery, such as a servo press, and the requirement of the user on the aspect is very urgent. And the real-time online service life prediction method of the electrolytic capacitor provided by the invention aims at N capacitors of each series branch,only N parametric quantities need to be sampled, and compared with the traditional method, 2N parametric quantities need to be sampled, and the complexity and the cost of the system are greatly reduced.
Claims (2)
1. A real-time online diagnosis method for the service life of an electrolytic capacitor comprises the following steps:
step 1, comparing the voltage of the middle node of the electrolytic capacitor series bridge arm with an upper alarm threshold and a lower alarm threshold from top to bottom in sequence to obtain a comparison result of each node;
and 2, carrying out logic judgment according to the comparison result:
if the voltage of each intermediate node of the series capacitor bridge arm is not higher than the upper alarm threshold value and is not lower than the lower alarm threshold value, the service lives of all electrolytic capacitors of the series capacitor bridge arm are not expired, and no alarm of the expired service life is generated;
if any node and all the node voltages below the node are higher than the upper alarm threshold value and all the node voltages above the node are lower than the lower alarm threshold value, the service life of the electrolytic capacitor taking the node as the lower node is expired, an alarm is generated, and the expiration of the service life of the electrolytic capacitor is judged.
2. A real-time online life prediction method for the service life of an electrolytic capacitor comprises the following steps:
step 1, sequentially sampling voltages of electrolytic capacitors in series connection with intermediate nodes of bridge arms from top to bottom to obtain intermediate node voltage value Un1-Un(m-1)Wherein n represents the nth electrolytic capacitor series bridge arm, and m is the capacitance number of the nth electrolytic capacitor series bridge arm. Sampling the current flowing through the n-th electrolytic capacitor series bridge arm to obtain a current value In；
Step 2, multiplexing necessary parameter bus voltage U controlled by the system0Sequentially calculating and obtaining the leakage current I of each electrolytic capacitor in the series bridge arm according to the following mathematical formuladnx
Whereinx represents the x-th capacitance in the series arm, x being an integer from 1 to m. RnxThe voltage-sharing resistor is connected in parallel with the xth capacitor of the nth series bridge arm;
step 3, the leakage current I of each electrolytic capacitor is measureddnxComparing with the leakage current of the last sampling period, if the leakage current is reduced, judging that the capacitor is still in a self-healing repair interval, wherein the residual life of the capacitor is 100%; if the leakage current is increased, the capacitor is judged to be in the life loss interval, and a mathematical model L between the leakage current and the life is used for judgingnx＝f(Idnx) And calculating the residual life percentage of the capacitor.
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| PCT/CN2020/110293 WO2021103678A1 (en) | 2019-11-27 | 2020-08-20 | Real-time online lifetime diagnosis and prediction method for electrolytic capacitors |
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| CN112505454B (en) * | 2020-11-25 | 2022-09-23 | 上海儒竞智控技术有限公司 | Capacitance life calculation method, system, medium, terminal, voltage detection circuit and driver |
| CN115034131B (en) * | 2022-05-23 | 2024-04-19 | 中车永济电机有限公司 | Online identification method based on actual measurement charging data and simulated data capacitor full life state construction |
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| CN112364499A (en) * | 2020-11-09 | 2021-02-12 | 广西电网有限责任公司电力科学研究院 | Method and terminal for predicting service life of electrolytic capacitor under broadband disturbance test |
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| Publication number | Publication date |
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| CN111474437A (en) | 2020-07-31 |
| CN111474437B (en) | 2022-01-28 |
| WO2021103678A1 (en) | 2021-06-03 |
| CN110763946B (en) | 2020-07-28 |
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