CN112787485A - High-frequency DC-DC converter module and auxiliary converter system - Google Patents
High-frequency DC-DC converter module and auxiliary converter system Download PDFInfo
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- CN112787485A CN112787485A CN201911096767.8A CN201911096767A CN112787485A CN 112787485 A CN112787485 A CN 112787485A CN 201911096767 A CN201911096767 A CN 201911096767A CN 112787485 A CN112787485 A CN 112787485A
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
- H02M1/00—Details of apparatus for conversion
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L23/00—Details of semiconductor or other solid state devices
- H01L23/34—Arrangements for cooling, heating, ventilating or temperature compensation ; Temperature sensing arrangements
- H01L23/46—Arrangements for cooling, heating, ventilating or temperature compensation ; Temperature sensing arrangements involving the transfer of heat by flowing fluids
- H01L23/473—Arrangements for cooling, heating, ventilating or temperature compensation ; Temperature sensing arrangements involving the transfer of heat by flowing fluids by flowing liquids
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
- H02M3/00—Conversion of dc power input into dc power output
- H02M3/22—Conversion of dc power input into dc power output with intermediate conversion into ac
- H02M3/24—Conversion of dc power input into dc power output with intermediate conversion into ac by static converters
- H02M3/28—Conversion of dc power input into dc power output with intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode to produce the intermediate ac
- H02M3/325—Conversion of dc power input into dc power output with intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode to produce the intermediate ac using devices of a triode or a transistor type requiring continuous application of a control signal
- H02M3/335—Conversion of dc power input into dc power output with intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode to produce the intermediate ac using devices of a triode or a transistor type requiring continuous application of a control signal using semiconductor devices only
- H02M3/33507—Conversion of dc power input into dc power output with intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode to produce the intermediate ac using devices of a triode or a transistor type requiring continuous application of a control signal using semiconductor devices only with automatic control of the output voltage or current, e.g. flyback converters
- H02M3/33523—Conversion of dc power input into dc power output with intermediate conversion into ac by static converters using discharge tubes with control electrode or semiconductor devices with control electrode to produce the intermediate ac using devices of a triode or a transistor type requiring continuous application of a control signal using semiconductor devices only with automatic control of the output voltage or current, e.g. flyback converters with galvanic isolation between input and output of both the power stage and the feedback loop
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K7/00—Constructional details common to different types of electric apparatus
- H05K7/20—Modifications to facilitate cooling, ventilating, or heating
- H05K7/2089—Modifications to facilitate cooling, ventilating, or heating for power electronics, e.g. for inverters for controlling motor
- H05K7/20927—Liquid coolant without phase change
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- Dc-Dc Converters (AREA)
- Inverter Devices (AREA)
Abstract
The invention provides a high frequency DC-DC converter module and an auxiliary converter system, the high frequency DC-DC converter module comprises: frame subassembly, reinforcing insulating type water-cooling radiator, TLBuck side IGBT component, the compound female row of TLBuck side low-inductance, TLBuck side drive assembly, LLC side IGBT component, the compound female row of LLC side low-inductance, LLC side drive assembly, LLC side support capacitance assembly, pulse control subassembly, control power supply subassembly and the integrative connector of water and electricity, TLBuck side IGBT component and LLC side IGBT component are arranged respectively to reinforcing insulating type water-cooling radiator's both sides. The invention adopts the low-voltage IGBT device to improve the switching frequency, solves the problems of insulation and pressure resistance and the like of the low-voltage device applied under the high-voltage working condition, reduces the size of the reinforced insulation type water-cooling radiator by arranging the IGBT devices on two sides, thereby improving the power density of the converter module, reduces the size and the weight of the magnetic element of the auxiliary converter system by improving the switching frequency of the device, and realizes the aim of reducing the size and the weight of the auxiliary converter system.
Description
Technical Field
The invention belongs to the technical field of direct current conversion, and particularly relates to a high-frequency DC-DC converter module and an auxiliary converter system.
Background
In recent years, as power electronic technology is rapidly developed, the defects of low performance, low efficiency, low reliability, large volume and heavy weight of a converter device are more obvious, and in order to pursue high performance, high efficiency, high reliability, small volume and light weight of the converter device, the realization of high frequency of the converter is the most important design idea. The high frequency converter not only can reduce the volume and weight of the converter, thereby increasing the power density and cost performance ratio of the converter, but also can greatly improve the instantaneous response speed, so the high frequency of the converter becomes a new development trend.
The auxiliary converter system is an important component of a motor train auxiliary system, and the performance of the auxiliary converter system is directly related to whether the motor train unit can normally run or not. At present, a power frequency auxiliary transformer is commonly used for a bullet train auxiliary system, namely, electricity is taken from a direct current end of a traction converter to be directly inverted by an auxiliary transformer system, and then voltage is reduced through a power frequency transformer, and the bullet train auxiliary system mainly comprises an inverter and the power frequency transformer. The scheme has a simple structure, but the whole auxiliary converter system has larger volume and heavier weight.
Disclosure of Invention
In view of the above, the present invention is directed to a high frequency DC-DC converter module and an auxiliary converter system, in which a DC voltage is converted to a reasonable level by the high frequency DC/DC converter module and then supplied to an inverter for inversion, and compared with power frequency auxiliary transformation, the present invention omits a power frequency transformer by using the high frequency DC/DC converter module, thereby greatly saving the volume and weight of the converter. Meanwhile, the invention solves the problems of insulation and voltage resistance of low-voltage devices applied under high-voltage working conditions, enables the low-voltage devices to be applied to a high-voltage system, and enables the converter module to be applied to higher switching frequency, thereby reducing the size of a high-frequency DC/DC loop magnetic component and further reducing the volume and the weight of an auxiliary converter system.
The embodiment of the invention provides a high-frequency DC-DC converter module, which comprises: the device comprises a frame assembly, an enhanced insulating type water-cooled radiator, a TLBuck side IGBT element, a TLBuck side low-inductance composite busbar, a TLBuck side driving assembly, an LLC side IGBT element, an LLC side low-inductance composite busbar, an LLC side driving assembly, an LLC side supporting capacitor assembly, a pulse control assembly, a control power assembly and a water-electricity integrated connector, wherein the TLBuck side IGBT element, the TLBuck side low-inductance composite busbar and the TLBuck side driving assembly are sequentially arranged on one side of the enhanced insulating type water-cooled radiator, the LLC side IGBT element, the LLC side low-inductance composite busbar and the LLC side driving assembly are sequentially arranged on the opposite side of the enhanced insulating type water-cooled radiator, the LLC side supporting capacitor assembly is positioned at the front end of the enhanced insulating type water-cooled radiator and is connected with the LLC side IGBT element through the LLC side low-inductance composite busbar, the pulse control assembly and the control power assembly are mounted on the LLC side supporting capacitor assembly, the water-electricity integrated connector is positioned at the rear end of the reinforced insulation type water-cooling radiator and is connected with a water inlet and a water outlet of the reinforced insulation type water-cooling radiator and the input and the output of a main circuit; the TLBuck side IGBT element and the LLC side IGBT element are both low-voltage IGBT elements, and the low-voltage IGBT elements refer to IGBT elements with the insulation voltage lower than the required voltage of a system.
Furthermore, an insulating heat conduction material is embedded in the reinforced insulating water-cooled radiator, and an insulating heat conduction gasket is arranged on the surface of the reinforced insulating water-cooled radiator.
Further, the frame subassembly is including setting up last frame subassembly and the underframe subassembly of both sides about the insulating type water-cooling radiator of reinforcing, LLC side support capacitor subassembly is installed go up the frame subassembly, underframe subassembly front end, LLC side support capacitor subassembly includes LLC side support capacitor and the panel beating of LLC side support capacitor both sides is bent the part, then LLC side support capacitor can be installed at the frame subassembly inboard of converter module through the panel beating that is located its both sides is bent the part.
Furthermore, the converter module comprises a module mounting and fixing component arranged on the frame component, and the module mounting and fixing component comprises long screw components positioned on the upper side and the lower side of the converter module and a guide pin positioned at the rear end of the converter module.
Further, integrative connector of water and electricity includes two water connectors and eight electric connection joint, two water connectors respectively with business turn over water swivel on the inlet outlet of insulating type water-cooling radiator of reinforcing is connected respectively, eight electric connection joint with insulating type water-cooling radiator's of reinforcing main circuit output connection, then the converter module passes through integrative connector of water and electricity is connected with the quick plug of external interface.
Furthermore, the TLBuck side IGBT component adopts two double-tube IGBT components which are uniformly arranged to form a TLBuck circuit at a position far away from the water inlet and the water outlet, and two TLBuck side equalizing resistors which are uniformly arranged are arranged at a position close to the water inlet and the water outlet; the LLC side IGBT component adopts four double-tube IGBT components which are uniformly arranged to form a two-way H-bridge circuit near the water inlet and outlet, and two LLC side equalizing resistors which are uniformly arranged are arranged far away from the water inlet and outlet.
Further, TLBuck side low-inductance composite busbar adopts two-layer tripolar structure, and positive and negative copper plate is located same one deck and intermediate level copper lamination, and the copper is middle and the lateral surface all separates with the insulating layer, TLBuck side low-inductance composite busbar one end is connected with TLBuck side component, and the other end extends to reinforcing insulation type water-cooling radiator front end to with place the support capacitance connection in the reinforcing insulation type water-cooling radiator outside.
Further, the LLC side low-inductance composite busbar adopts a two-layer tripolar structure, positive and negative copper plates are located in the same layer and laminated with an interlayer copper plate, the middle and outer side surfaces of the copper plates are separated by insulating layers, one end of the LLC side low-inductance composite busbar is connected with an LLC side element, the other end of the LLC side low-inductance composite busbar is connected with an LLC side supporting capacitor, and the LLC side low-inductance composite busbar is used for realizing the LLC side element and the high-frequency low-inductance connection of the LLC side supporting capacitor.
Further, the converter module comprises an LLC side absorption capacitor, the LLC side absorption capacitor is installed on a direct current terminal of the LLC side IGBT element through the LLC side low-inductance composite busbar, and the LLC side absorption capacitor is used for absorbing a high-frequency overvoltage spike of a direct current loop.
The embodiment of the invention also provides an auxiliary converter system which comprises a high-frequency auxiliary transformation module, wherein the high-frequency auxiliary transformation module comprises the high-frequency DC-DC converter module.
According to the high-frequency DC-DC converter module and the auxiliary converter system provided by the embodiment of the invention, the switching frequency is improved by adopting the low-voltage IGBT device, and the low-voltage IGBT device is arranged on the two sides of the reinforced insulation type water-cooling radiator, so that the problems of insulation and voltage resistance of the low-voltage device under a high-voltage working condition and the like are solved, the size of the reinforced insulation type water-cooling radiator is reduced, and the purposes of reducing the volume and the weight of the auxiliary converter system are realized.
In order to make the aforementioned and other objects, features and advantages of the invention comprehensible, preferred embodiments accompanied with figures are described in detail below.
Drawings
Fig. 1 is a schematic circuit diagram according to an embodiment of the present invention.
Fig. 2 is an exploded view of an embodiment of the present invention 1.
Fig. 3 is an exploded view of fig. 2 according to an embodiment of the present invention.
Wherein 1: enhancing the insulation type water-cooling radiator; 2: TLBuck side IGBT element; 3: TLBuck side low-inductance composite busbar; 4: a TLBuck side drive assembly; 5: an LLC side IGBT element; 6: an LLC side low inductance composite bus; 7: an LLC side drive component; 8: the LLC side supports a capacitor component; 9: a pulse control component; 10: a hydro-electric integrated connector; 11: an insulating heat-conducting gasket; 12: an upper frame assembly; 13: a lower frame assembly; 14: a long screw assembly; 15: a guide pin; 16: a water joint; 17: TLBuck side voltage-sharing resistor; 18: LLC side voltage-sharing resistor; 19: an LLC side absorption capacitance; 20: a TLBuck side power module; 21: the TLBuck side outputs a copper bar assembly; 22: LLC side output copper bar assembly
Detailed Description
To further illustrate the technical means and effects of the present invention for achieving the intended purpose, the following detailed description is given for the specific embodiments, methods, steps, structures, features and effects of the high frequency DC-DC converter module and the auxiliary converter system according to the present invention with reference to the accompanying drawings and preferred embodiments.
The foregoing and other aspects, features and advantages of the invention will be apparent from the following more particular description of preferred embodiments, as illustrated in the accompanying drawings. While the invention has been described in connection with specific embodiments thereof, it is to be understood that the invention is not limited to the disclosed embodiments, but is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the invention.
Fig. 1 is a schematic circuit diagram according to an embodiment of the present invention. As shown in fig. 1, a circuit of a high-frequency DC-DC (direct current/direct current conversion) converter module according to an embodiment of the present invention includes a TLBuck (three-level buck chopper conversion) circuit and a high-frequency LLC (full-bridge resonant conversion circuit) circuit. The TLBuck circuit comprises two TLBuck side IGBT elements 2 (namely V1 and V2) and two diodes (namely D1 and D2), the high-frequency LLC circuit comprises two H bridges connected in series, a resonant circuit and a rectifying circuit, the resonant circuit and the rectifying circuit are arranged outside a converter module, the first H bridge circuit comprises 4 LLC side IGBT (insulated gate bipolar transistor) elements 5 (namely V3, V4, V5 and V6), the second H bridge circuit comprises 4 LLC side IGBT elements 5 (namely V7, V8, V9 and V10), and the front end and the rear end of the TLBuck circuit are provided with voltage-sharing resistors and supporting capacitors. The capacitors, inductors, resonant tank and rectifying tank within the dashed box shown in fig. 1 are located outside the converter module. The working mode is as follows: the converter module inputs high voltage (such as DC3600V), and after the voltage is reduced through the TLBuck circuit, secondary voltage reduction is realized through the high-frequency LLC circuit, and output voltage (such as DC700V) is obtained. The TLBuck-side IGBT element 2 and the LLC-side IGBT element 5 are both low-voltage IGBT elements, and the low-voltage IGBT elements are IGBT elements having an insulation voltage lower than a system required voltage.
The circuit of the high-frequency DC-DC converter module of the embodiment comprises a TLBuck circuit and a high-frequency LLC circuit, and the switching frequency of a device can be improved through low-voltage IGBT elements in two H-bridge circuits in the high-frequency LLC circuit, so that the size of a magnetic component of a high-frequency DC/DC loop is reduced, and compared with a traditional power frequency auxiliary converter system, the volume and the weight of the whole auxiliary converter system can be reduced by about 40%.
Fig. 2 is an exploded view 1 of an embodiment of the present invention, and fig. 3 is an exploded view 2 of an embodiment of the present invention. The structure and implementation of the high-frequency DC-DC converter module of the present embodiment are specifically described below with reference to fig. 2 and 3.
The high frequency DC-DC converter module of the present embodiment includes: the device comprises a frame component, an enhanced insulation type water-cooling radiator 1, a TLBuck side IGBT component 2, a TLBuck side low-inductance composite busbar 3, a TLBuck side driving component 4, an LLC side IGBT component 5, an LLC side low-inductance composite busbar 6, an LLC side driving component 7, an LLC side supporting capacitor component 8, a pulse control component 9, a control power component and a water-electricity integrated connector 10, wherein the TLBuck side IGBT component 2, the TLBuck side low-inductance composite busbar 3 and the TLBuck side driving component 4 are sequentially arranged on one side of the enhanced insulation type water-cooling radiator 1, the LLC side IGBT component 5, the LLC side low-inductance composite busbar 6 and the LLC side driving component 7 are sequentially arranged on the opposite side of the enhanced insulation type water-cooling radiator 1, the LLC side supporting capacitor component 8 is positioned at the front end of the enhanced insulation type water-cooling radiator 1 and is connected with the LLC side IGBT component 5 through the LLC side low-inductance composite busbar 6, the pulse control component 9 and the control component are installed on the LLC side supporting capacitor, the water and electricity integrated connector 10 is positioned at the rear end of the reinforced insulation type water-cooling radiator 1 and is connected with a water inlet and a water outlet of the reinforced insulation type water-cooling radiator 1 and the input and the output of a main circuit; both the TLBuck-side IGBT element 2 and the LLC-side IGBT element 5 are low-voltage IGBT elements.
Specifically, the enhanced insulation type water-cooling radiator 1 is positioned in the middle of the converter module, one side of the enhanced insulation type water-cooling radiator 1 is sequentially provided with a TLBuck side IGBT element 2, a TLBuck side low-inductance composite bus bar 3 and a TLBuck side driving assembly 4, the other opposite side of the enhanced insulation type water-cooling radiator 1 is sequentially provided with an LLC side IGBT element 5, an LLC side low-inductance composite bus bar 6 and an LLC side driving assembly 7, the enhanced insulation type water-cooled radiator 1 is respectively provided with the TLBuck side IGBT component 2 and the LLC side IGBT component 5 on both sides, the insulation voltage level of the IGBT component to the ground can be enhanced, the IGBT devices are arranged on the two sides of the enhanced insulating type water-cooling radiator 1 for heat dissipation, so that the size of the enhanced insulating type water-cooling radiator 1 can be reduced, the volume of the converter module is further reduced, the power density of the converter module is improved, meanwhile, high-efficiency heat dissipation can be realized by enhancing the flow channel design of the insulating water-cooled radiator 1.
In an embodiment, insulating heat conduction materials are embedded in the enhanced insulating water-cooled radiator 1, an insulating heat conduction gasket 11 is installed on the surface of the enhanced insulating water-cooled radiator 1, the TLBuck side IGBT element 2, the LLC side IGBT element 5 and the radiator are isolated, and accordingly the insulating voltage level of the IGBT element to the ground is enhanced, so that the low-voltage packaged TLBuck side IGBT element 2 and LLC side IGBT element 5 can be applied to a higher voltage system, and the implementation mode can also be applied to the problem that multiple elements such as a three-level type element, a cascade type element and the like are insufficient in ground voltage.
In one embodiment, the TLBuck-side drive assembly 4 includes a TLBuck-side element drive board and a drive power supply.
In an embodiment, the TLBuck-side driving assembly 4 and the TLBuck-side power module 20 are installed above the TLBuck-side IGBT element 2 and fixed on the reinforced insulation type water-cooled radiator 1 by installing an aluminum plate and a plurality of (for example, 4) supporting columns, and a gate wiring harness on the TLBuck-side IGBT element 2 is bound to the TLBuck-side driving assembly 4 through the supporting columns, so that the driving wiring harness is guaranteed to be driven from the IGBT element to the TLBuck-side element driving plate in the shortest path. TLBuck side power module 20 mainly is the power supply of TLBuck side drive assembly 4, installs on aluminum plate, and installation aluminum plate both had been used for the installation of TLBuck side power module 20, also was used for the heat dissipation of TLBuck side power module 20.
In one embodiment, the LLC-side drive assembly 7 is soldered directly on top of the LLC-side IGBT device.
In an embodiment, the TLBuck-side power module 20 is mounted above the TLBuck-side IGBT elements 2.
In one embodiment, the pulse control assembly 9 may include a control shielding aluminum case, a pulse control circuit board, a control adapter plug, and a main circuit adapter support. The pulse control circuit board can be arranged in the control shielding aluminum box, the control adapter plug and the main circuit adapter support seat are arranged on the front side face of the control shielding aluminum box, and the front side face of the control shielding aluminum box is provided with a hole for connecting the pulse control circuit board, the control adapter plug and the main circuit adapter support seat with an external circuit. And the rear side face of the control shielding aluminum box is provided with a hole for being connected with the LLC side driving component 7, the TLBuck side driving component 4 and the line of the TLBuck side power module 20.
In one embodiment, the ac output terminal of the TLBuck-side IGBT element 2 is connected to the hydro-electric integrated connector 10 through the TLBuck-side output copper bar assembly 21, and the ac output terminal of the TLBuck-side IGBT element 2 is also connected to the negative terminal of the LLC-side low-inductance composite busbar 6 through the TLBuck-side output copper bar assembly 21.
In one embodiment, the ac output terminals of the LLC side IGBT elements 5 are connected to the hydro-electric integral connector 10 through the LLC side output copper bar assembly 22, and in order to prevent the "skin effect" of the LLC side high-frequency current, the LLC side output copper bars may be laminated by 3 layers of thin copper plates. The skin effect means that when alternating current or an alternating electromagnetic field exists in a conductor, the current distribution in the conductor is uneven, and the current is concentrated on the skin part of the conductor, namely the current is concentrated on a thin layer on the outer surface of the conductor, and the closer to the surface of the conductor, the higher the current density is, and the smaller the current is actually in the conductor. As a result, the resistance of the conductor increases, and the power loss also increases.
In an embodiment, the frame assembly may include an upper frame assembly 12 and a lower frame assembly 13 disposed on upper and lower sides of the reinforced insulation type water-cooled heat sink 1, the LLC side supporting capacitor assembly 8 is mounted at the front end of the upper frame assembly 12 and the lower frame assembly 13, the LLC side supporting capacitor assembly 8 includes the LLC side supporting capacitor and metal plate bending parts on both sides of the LLC side supporting capacitor, and the LLC side supporting capacitor may be mounted inside the frame assembly of the converter module through the metal plate bending parts on both sides thereof.
In one embodiment, the converter module includes a module mounting fixture assembly mounted to the frame assembly, the module mounting fixture assembly including a long screw assembly 14 on both upper and lower sides of the converter module and a guide pin 15 at the rear end of the converter module. When the converter module is installed in the cabinet body, the converter module can be guided and positioned by a guide pin 15 positioned at the rear end of the converter module, and then is installed and fixed by long screw assemblies 14 positioned at the upper side and the lower side of the converter module.
In an embodiment, the water and electricity integrated connector 10 includes two water connectors 16 and eight electrical connectors, the two water connectors 16 are respectively connected to water inlets and water outlets on the water inlet and the water outlet of the reinforced insulation type water-cooled radiator 1, the eight electrical connectors are connected to the main circuit output of the reinforced insulation type water-cooled radiator 1, and then the converter module is connected to the external interface through the water and electricity integrated connector 10 in a quick plug-pull manner.
In an embodiment, the TLBuck side IGBT elements 2 and the LLC side IGBT elements 5 disposed on both sides of the reinforced insulating water-cooled heat sink 1 may be arranged in a staggered manner, and by arranging the IGBT elements with large loss in a staggered manner on both sides of the reinforced insulating water-cooled heat sink 1 and arranging the heat sink runners reasonably, the reasonable distribution of the surface temperature of the reinforced insulating water-cooled heat sink 1 can be realized, and the problem of converter module failure due to too high local temperature is avoided.
In one embodiment, the TLBuck-side IGBT element 2 may adopt two double-tube IGBT elements which are uniformly arranged to form a TLBuck circuit at a position far away from the water inlet and outlet, and two TLBuck-side equalizing resistors 17 which are uniformly arranged are arranged at a position close to the water inlet and outlet; the LLC side IGBT component 5 can adopt four double-tube IGBT components which are uniformly arranged to form a two-way H-bridge circuit near the water inlet and outlet, and two LLC side equalizing resistors 18 which are uniformly arranged are arranged far away from the water inlet and outlet, so that the reasonable radiator flow channel arrangement design can be realized by the implementation mode. The number of IGBTs is not limited in this embodiment, and those skilled in the art can determine the corresponding number of IGBTs according to design requirements.
In an embodiment, the TLBuck-side low-inductance composite busbar 3 adopts a two-layer three-pole structure, the positive copper plate and the negative copper plate are positioned on the same layer and laminated with the middle layer of copper plate, the middle and the outer side surfaces of the copper plates are separated by an insulating layer, one end of the TLBuck-side low-inductance composite busbar 3 is connected with a TLBuck-side element, and the other end of the TLBuck-side low-inductance composite busbar extends to the front end of a converter module and is connected with a support capacitor placed on the outer. The low-inductance design can be realized by using the TLBuck-side low-inductance composite busbar 3 in the embodiment.
In an embodiment, the LLC side low-inductance composite busbar 6 adopts a two-layer three-pole structure, the positive and negative copper plates are located in the same layer and laminated with the intermediate copper plate, the middle and outer side surfaces of the copper plates are separated by an insulating layer, one end of the LLC side low-inductance composite busbar 6 is connected with the LLC side element, the other end is connected with the LLC side supporting capacitor, and the LLC side low-inductance composite busbar 6 is used for realizing the high-frequency low-inductance connection of the LLC side element and the LLC side supporting capacitor. In the present embodiment, the low inductance design can be realized by using the LLC side low inductance composite busbar 6.
In an embodiment, the converter module includes an LLC-side absorption capacitor 19, the LLC-side absorption capacitor 19 is mounted on the dc terminals of the LLC-side IGBT element 5 through the LLC-side low-inductance composite busbar 6, and the LLC-side absorption capacitor 19 can be used to absorb high-frequency overvoltage spikes of the dc circuit.
The high-frequency DC-DC converter module of the embodiment can be applied to a high-frequency auxiliary transformer module of a motor car auxiliary converter system, mainly solves the application problem of a low-voltage device in a high-voltage system, solves the insulation and voltage resistance problem of the low-voltage device under the high-voltage working condition, solves the low-inductance design problem of the module under the high-frequency application, solves the problems of outgoing line, high-efficiency heat dissipation, installation and maintenance and the like of a complex main circuit of the high-frequency auxiliary transformer system, and has the following specific beneficial effects:
1) the invention can improve the switching frequency of the IGBT element 5 at the LLC side, thereby reducing the size of the high-frequency DC/DC loop magnetic element and reducing the volume and weight of the LLC loop magnetic element. Compared with the traditional power frequency auxiliary transformer system, the volume and the weight of the whole auxiliary transformer system can be reduced by about 40%.
2) According to the invention, the module can be quickly positioned through the guide pin 15 positioned at the rear end of the module and the long screw rods positioned at two sides of the module frame after being pushed out of the cabinet body through the guide rail, and the connector can be quickly installed in place through the guiding action of the guide pin 15 positioned at the rear end of the module.
3) The invention innovatively provides a scheme for improving the insulation and voltage resistance of the IGBT to the ground (radiator), so that the low-voltage packaged IGBT element can be applied to a higher-voltage system. The scheme can be applied to the problem that the voltage to ground of various elements such as a three-level element, a cascade element and the like is not enough.
4) The invention provides a low-inductance interconnection and high-frequency absorption scheme for an LLC side loop aiming at high switching frequency application, solves the high-frequency low-inductance problem of the LLC loop by adopting a low-inductance composite bus and a high-frequency absorption capacitor through devices and capacitors, and improves the high-frequency skin effect problem in a multi-layer thin copper plate lamination mode.
5) The invention provides a high-efficiency heat dissipation method, which realizes reasonable distribution of surface temperature of a radiator and avoids module faults caused by overhigh local temperature by arranging IGBT elements with large loss in a staggered way on two sides and reasonably arranging a radiator flow channel.
The embodiment of the invention is also based on the same inventive concept, and provides an auxiliary converter system which comprises a high-frequency auxiliary transformer module, wherein the high-frequency auxiliary transformer module comprises the high-frequency DC-DC converter module of the embodiment. For a specific implementation of this embodiment, reference may be made to the implementation of the high-frequency DC-DC converter module, which is not described herein again.
In the auxiliary converter system of the embodiment, the high-frequency DC/DC converter module converts the direct-current voltage to a reasonable level and then provides the reasonable level for the inverter for inversion, and compared with power frequency auxiliary transformation, the auxiliary converter system of the invention saves a power frequency transformer by using the high-frequency DC/DC converter module, thereby greatly saving the volume and the weight of the converter. Meanwhile, the switching frequency is improved by adopting a low-voltage IGBT device, the low-voltage IGBT device is arranged on the two sides of the reinforced insulation type water-cooling radiator, the problems of insulation and voltage resistance and the like of the low-voltage device applied under a high-voltage working condition are solved, the size of the reinforced insulation type water-cooling radiator is reduced by arranging the IGBT device on the two sides, the power density of a converter module is improved, the size and the weight of a magnetic element of an auxiliary converter system are reduced by improving the switching frequency of the device, and the purpose of reducing the size and the weight of the auxiliary converter system is achieved.
Although the present invention has been described with reference to the preferred embodiments, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims.
Claims (10)
1. A high frequency DC-DC converter module, comprising: the high-voltage power supply comprises a frame assembly, an enhanced insulating type water-cooled radiator (1), a TLBuck side IGBT element (2), a TLBuck side low-inductance composite busbar (3), a TLBuck side driving assembly (4), an LLC side IGBT element (5), an LLC side low-inductance composite busbar (6), an LLC side driving assembly (7), an LLC side supporting capacitor assembly (8), a pulse control assembly (9), a control power supply assembly and a water-electricity integrated connector (10), wherein the TLBuck side IGBT element (2), the TLBuck side low-inductance composite busbar (3) and the TLBuck side driving assembly (4) are sequentially arranged on one side of the enhanced insulating type water-cooled radiator (1), the LLC side IGBT element (5), the LLC side low-inductance composite busbar (6) and the LLC side driving assembly (7) are sequentially arranged on the opposite side of the enhanced insulating type water-cooled radiator (1), and the LLC side supporting capacitor assembly (8) is located at the front end of the enhanced insulating type water-cooled radiator (1), the LLC side low-inductance composite busbar (6) is connected with the LLC side IGBT element (5), the pulse control assembly (9) and the control power supply assembly are mounted on the LLC side support capacitor assembly (8), and the water-electricity integrated connector (10) is positioned at the rear end of the enhanced insulation type water-cooling radiator (1) and is connected with a water inlet and a water outlet of the enhanced insulation type water-cooling radiator (1) and the input and the output of a main circuit;
the TLBuck side IGBT element (2) and the LLC side IGBT element (5) are both low-voltage IGBT elements, and the low-voltage IGBT elements refer to IGBT elements with the insulation voltage lower than the required voltage of a system.
2. The high frequency DC-DC converter module according to claim 1, wherein the reinforced insulation type water-cooling heat sink (1) is embedded with insulation heat conduction material, and an insulation heat conduction gasket (11) is installed on the surface of the reinforced insulation type water-cooling heat sink (1).
3. The high frequency DC-DC converter module according to claim 1, wherein the frame assembly includes an upper frame assembly (12) and a lower frame assembly (13) disposed at upper and lower sides of the reinforced insulation type water-cooled heat sink (1), the LLC-side support capacitor assembly (8) is mounted at a front end of the upper frame assembly (12) and the lower frame assembly (13), the LLC-side support capacitor assembly (8) includes an LLC-side support capacitor and a sheet metal bent part at both sides of the LLC-side support capacitor, and the LLC-side support capacitor can be mounted inside the frame assembly of the converter module by the sheet metal bent part at both sides thereof.
4. The high frequency DC-DC converter module according to claim 1, wherein the converter module comprises a module mounting fixture assembly mounted on the frame assembly, the module mounting fixture assembly comprising long screw assemblies (14) on both upper and lower sides of the converter module and guide pins (15) at the rear end of the converter module.
5. The high-frequency DC-DC converter module according to claim 1, wherein the integrated water-electricity connector (10) comprises two water connectors (16) and eight electrical connectors, the two water connectors (16) are respectively connected with water inlets and water outlets on the water inlet and the water outlet of the reinforced insulation type water-cooling radiator (1), the eight electrical connectors are connected with the main circuit output of the reinforced insulation type water-cooling radiator (1), and then the converter module is connected with an external interface through the integrated water-electricity connector (10) in a quick plug-in and pull-out manner.
6. The high-frequency DC-DC converter module according to claim 1, characterized in that the TLBuck side IGBT component (2) adopts two double-tube IGBT components which are uniformly arranged at the position far away from the water inlet and outlet to form a TLBuck circuit, and two TLBuck side equalizing resistors (17) which are uniformly arranged are arranged at the position close to the water inlet and outlet; the LLC side IGBT component (5) adopts four double-tube IGBT components which are uniformly arranged to form a two-way H-bridge circuit near the water inlet and outlet, and two LLC side equalizing resistors (18) which are uniformly arranged are arranged far away from the water inlet and outlet.
7. The high-frequency DC-DC converter module according to claim 1, wherein the TLBuck-side low-inductance composite busbar (3) adopts a two-layer three-pole structure, the positive copper plate and the negative copper plate are positioned in the same layer and are laminated with the middle copper plate, the middle and the outer side surfaces of the copper plates are separated by an insulating layer, one end of the TLBuck-side low-inductance composite busbar (3) is connected with a TLBuck-side element, and the other end of the TLBuck-side low-inductance composite busbar extends to the front end of the reinforced insulating water-cooling radiator (1) and is connected with a supporting capacitor placed on the outer side of the reinforced insulating water-cooling radiator (.
8. The high-frequency DC-DC converter module according to claim 1, wherein the LLC side low-inductance composite busbar (6) adopts a two-layer three-pole structure, the positive and negative copper plates are positioned in the same layer and laminated with the middle copper plate, the middle and outer side surfaces of the copper plates are separated by an insulating layer, one end of the LLC side low-inductance composite busbar (6) is connected with an LLC side element, the other end of the LLC side low-inductance composite busbar is connected with the LLC side support capacitor, and the LLC side low-inductance composite busbar (6) is used for realizing high-frequency low-inductance connection of the LLC side element and the LLC side support capacitor.
9. The high frequency DC-DC converter module according to claim 1, characterized in that the converter module comprises an LLC-side absorption capacitor (19), said LLC-side absorption capacitor (19) being mounted on the DC terminals of said LLC-side IGBT elements (5) through said LLC-side low-inductance composite busbar (6), said LLC-side absorption capacitor (19) being adapted to absorb high frequency overvoltage spikes of a DC circuit.
10. An auxiliary converter system, characterized in that it comprises a high frequency auxiliary converter module comprising a high frequency DC-DC converter module according to any of claims 1-9.
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| CN201911096767.8A CN112787485A (en) | 2019-11-11 | 2019-11-11 | High-frequency DC-DC converter module and auxiliary converter system |
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| CN201911096767.8A CN112787485A (en) | 2019-11-11 | 2019-11-11 | High-frequency DC-DC converter module and auxiliary converter system |
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| CN201911096767.8A Pending CN112787485A (en) | 2019-11-11 | 2019-11-11 | High-frequency DC-DC converter module and auxiliary converter system |
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Application publication date: 20210511 |