GB2564700A - A power electronics module and a method of detecting a fault in a power electronics module - Google Patents

A power electronics module and a method of detecting a fault in a power electronics module Download PDF

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Publication number
GB2564700A
GB2564700A GB1711740.9A GB201711740A GB2564700A GB 2564700 A GB2564700 A GB 2564700A GB 201711740 A GB201711740 A GB 201711740A GB 2564700 A GB2564700 A GB 2564700A
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GB
United Kingdom
Prior art keywords
fault
switching device
power electronics
capacitor
electronics module
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
GB1711740.9A
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GB201711740D0 (en
Inventor
Jayampathi Gajanayake Chandana
Sathik Mohamed
Kumar Gupta Amit
Dharmasiri Gamini Jayasinghe Shantha
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Rolls Royce PLC
Original Assignee
Rolls Royce PLC
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Rolls Royce PLC filed Critical Rolls Royce PLC
Priority to GB1711740.9A priority Critical patent/GB2564700A/en
Publication of GB201711740D0 publication Critical patent/GB201711740D0/en
Publication of GB2564700A publication Critical patent/GB2564700A/en
Withdrawn legal-status Critical Current

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Classifications

    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02MAPPARATUS 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
    • H02M1/00Details of apparatus for conversion
    • H02M1/32Means for protecting converters other than automatic disconnection
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02HEMERGENCY PROTECTIVE CIRCUIT ARRANGEMENTS
    • H02H7/00Emergency protective circuit arrangements specially adapted for specific types of electric machines or apparatus or for sectionalised protection of cable or line systems, and effecting automatic switching in the event of an undesired change from normal working conditions
    • H02H7/10Emergency protective circuit arrangements specially adapted for specific types of electric machines or apparatus or for sectionalised protection of cable or line systems, and effecting automatic switching in the event of an undesired change from normal working conditions for converters; for rectifiers
    • H02H7/12Emergency protective circuit arrangements specially adapted for specific types of electric machines or apparatus or for sectionalised protection of cable or line systems, and effecting automatic switching in the event of an undesired change from normal working conditions for converters; for rectifiers for static converters or rectifiers
    • H02H7/122Emergency protective circuit arrangements specially adapted for specific types of electric machines or apparatus or for sectionalised protection of cable or line systems, and effecting automatic switching in the event of an undesired change from normal working conditions for converters; for rectifiers for static converters or rectifiers for inverters, i.e. dc/ac converters
    • H02H7/1227Emergency protective circuit arrangements specially adapted for specific types of electric machines or apparatus or for sectionalised protection of cable or line systems, and effecting automatic switching in the event of an undesired change from normal working conditions for converters; for rectifiers for static converters or rectifiers for inverters, i.e. dc/ac converters responsive to abnormalities in the output circuit, e.g. short circuit
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02MAPPARATUS 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
    • H02M1/00Details of apparatus for conversion
    • H02M1/08Circuits specially adapted for the generation of control voltages for semiconductor devices incorporated in static converters
    • HELECTRICITY
    • H03ELECTRONIC CIRCUITRY
    • H03KPULSE TECHNIQUE
    • H03K17/00Electronic switching or gating, i.e. not by contact-making and –breaking
    • H03K17/08Modifications for protecting switching circuit against overcurrent or overvoltage
    • HELECTRICITY
    • H03ELECTRONIC CIRCUITRY
    • H03KPULSE TECHNIQUE
    • H03K17/00Electronic switching or gating, i.e. not by contact-making and –breaking
    • H03K17/08Modifications for protecting switching circuit against overcurrent or overvoltage
    • H03K17/082Modifications for protecting switching circuit against overcurrent or overvoltage by feedback from the output to the control circuit
    • H03K17/0822Modifications for protecting switching circuit against overcurrent or overvoltage by feedback from the output to the control circuit in field-effect transistor switches
    • HELECTRICITY
    • H03ELECTRONIC CIRCUITRY
    • H03KPULSE TECHNIQUE
    • H03K17/00Electronic switching or gating, i.e. not by contact-making and –breaking
    • H03K17/18Modifications for indicating state of switch
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02HEMERGENCY PROTECTIVE CIRCUIT ARRANGEMENTS
    • H02H7/00Emergency protective circuit arrangements specially adapted for specific types of electric machines or apparatus or for sectionalised protection of cable or line systems, and effecting automatic switching in the event of an undesired change from normal working conditions
    • H02H7/20Emergency protective circuit arrangements specially adapted for specific types of electric machines or apparatus or for sectionalised protection of cable or line systems, and effecting automatic switching in the event of an undesired change from normal working conditions for electronic equipment
    • H02H7/205Emergency protective circuit arrangements specially adapted for specific types of electric machines or apparatus or for sectionalised protection of cable or line systems, and effecting automatic switching in the event of an undesired change from normal working conditions for electronic equipment for controlled semi-conductors which are not included in a specific circuit arrangement

Abstract

A power electronics module (e.g. inverter) includes at least one solid state switching device M1 (e.g. MOSFET, IGBT), a gate driver, a controller and a fault detector. The gate driver connects to, and provides a drive input to, a gate terminal of the switching device to activate the switching device. The controller provides a gate signal to the gate driver. The fault detector includes a capacitor (e.g. external Miller capacitor, CM) connected to a collector terminal of the switching device and a comparator connected to the capacitor. The comparator compares a voltage received from the capacitor against a threshold voltage. If the voltage exceeds the threshold, a control signal indicates a short circuit fault. The control signal may activate a fault protection circuit which reduces the current and/or voltage received by the switching device. The capacitor may be further connected to the controller via an isolation circuit. The controller may assess the severity of the fault, based on the signal received from the capacitor via the isolation circuit and, if the fault exceeds a shut-down threshold, the gate driver and, thus, the switching device is disabled.

Description

A POWER ELECTRONICS MODULE AND A METHOD OF DETECTING A FAULT IN A POWER ELECTRONICS MODULE
The disclosure relates to a power electronics module and a method of detecting a fault in a power electronics module.
Power electronics modules are playing an increasingly important role in industrial power conversion systems. Such modules utilise solid-state switching devices, such as IGBT and MOSFET, to convert electric energy from one form to another, such as converting between AC and DC (e.g. a rectifier or an inverter) or changing the frequency or voltage of the electric energy (AC-AC or DC-DC converters).
Failure of these power modules is the most common fault associated with industrial drives, such as variable speed drives used for controlling pumps, rolling mills, etc. Consequently, software and hardware protection systems are used to detect faults in power modules and provide protection against over current or short circuit current.
During a short circuit fault the time between the fault initiation and the device failure is very short. Typically, the switching devices can withstand abnormal current (generally twice the rated current) for up to around 10ps. However, this may reduce due to ageing and overstress, and so detection should preferably happen well within this period. This is particularly important for mission-critical applications, such as those found in the aerospace industry.
Common techniques for detecting short circuit faults in solid-state switching devices include desaturation detection and gate voltage monitoring.
With the desaturation detection technique, a diode is used to continuously monitor the collector-emitter voltage. Although desaturation detection is a simple method, the response time is not suitable for high speed switching. Further, a blanking time is usually required to reject noise generated by switching transients. Such blanking time is typically around 1 to 5ps and so is significant when compared with the withstand time of the device.
Gate voltage monitoring methods are more sophisticated, but require significant additional components.
It is therefore desired to provide a fault detector which is able to quickly detect a fault with minimal additional passive components.
In accordance with an aspect of the disclosure, there is provided a power electronics module comprising: at least one solid state switching device; a gate driver connected to a gate terminal of the switching device and configured to provide a drive input to the gate terminal to activate the switching device; a controller connected to the gate driver and configured to provide a gate signal to the gate driver; and a fault detector, the fault detector comprising a capacitor connected to a collector terminal of the switching device and a comparator connected to the capacitor, wherein the comparator is configured to compare a voltage received from the capacitor against a threshold voltage and if the voltage exceeds the threshold voltage provide a control signal indicating a short circuit fault.
The capacitor may be further connected to the controller via an isolation circuit.
The controller may be configured to assess the severity of the fault based on the signal received from the capacitor via the isolation circuit and if the fault exceeds a shut-down threshold to disable the gate driver and thus the switching device.
The power electronics module may further comprise a latch circuit which receives and stores the output from the comparator until it is reset.
The controller may be configured to provide a reset signal to the latch circuit if the fault does not exceed the shut-down threshold.
The power electronics module may further comprise a fault protection circuit. The control signal may activate the fault protection circuit in the event of a short circuit fault.
The fault protection circuit may reduce the current and/or voltage received by the switching device.
The control signal and the gate signal may form inputs to an AND gate, and the output of the AND gate may trigger the fault protection circuit if both of the inputs are high.
The power electronics module may be an inverter.
In accordance with another aspect of the disclosure, there is provided a method of detecting a fault in a power electronics module comprising at least one solid state switching device, the method comprising: receiving a voltage from a capacitor connected to a collector terminal of the switching device; comparing the voltage received from the capacitor against a threshold voltage; and if the voltage exceeds the threshold voltage, provide a control signal indicating a short circuit fault.
The method may further comprise assessing a severity of the fault based on a signal received from the capacitor at a controller of a gate driver of the switching device, and if the fault exceeds a shut-down threshold, disabling the gate driver and thus the switching device.
The method may further comprise activating a fault protection circuit in the event of a short circuit fault.
The fault protection circuit may reduce the current and/or voltage received by the switching device.
For a better understanding of the disclosure, and to show more clearly how it may be carried into effect, reference will now be made, by way of example, to the accompanying drawings, in which:Figure 1 is a block diagram of a motor drive comprising a gate driver module with a fault detector;
Figure 2 is a schematic diagram showing elements of the gate driver module;
Figure 3 is a schematic diagram showing the circuits of the gate driver module in further detail;
Figure 4 is a flow chart of a short circuit detection and protection method employed using the gate driver module; and
Figure 5 shows graphs of variables during a short circuit fault.
Figure 1 shows a motor drive circuit comprising a power module with a fault detector. The circuit comprises a three-phase motor drive M which is powered by a DC power source, VDC. The DC power source VDC is connected to the motor M via a split DC-link formed by a pair of serially connected capacitors which are grounded therebetween and a three-phase inverter. The inverter is formed by three half-bridge inverters each comprising a pair of transistors (switches), such as IGBTs or MOSFETs. Specifically, a first phase leg is formed by transistors Mt and M2 having an output terminal A formed therebetween, a second phase leg is formed by transistors M3 and M4 having an output terminal B formed therebetween, and a third phase leg is formed by transistors M5 and M6 having an output terminal C formed therebetween. Each of the transistors MrM6 is provided with a flyback diode DrD6 connected between its collector and emitter.
The gates of the upper transistors M3 and M5 are connected to a first gate driver module GDt and the gates of the lower transistors M2, M4 and M6 are connected to a second gate driver module GD2.
The first and second gate driver modules GDt and GD2 are configured to control the transistors MrM6 to provide outputs at terminals A, B, C which are offset by 120°. The gate driver modules GD^ GD2 are controlled by a digital signal processor (or other controller) which receives feedback from the motor M. In particular, the position of the motor may be relayed to the digital signal processor, as well as the input currents or voltages on terminals A, B, C via suitable sensors. As shown, these inputs are provided to the digital signal processor via an isolated Analog-to-Digital Converter (ADC).
Each of the transistors MrM6 are connected to an external miller capacitor CM (although only shown for transistors Mt and M2) via its collector terminal which provides an input to the respective gate driver module GD^ GD2.
As shown in Figure 2, the gate driver modules GD^ GD2 each comprise a fault evaluation circuit, an analog isolation circuit and a gate driver/fault protection circuit.
As shown in Figure 3, the fault evaluation circuit comprises a comparator circuit formed by an operational amplifier which compares the voltage received from the external miller capacitor CM via a shunt resistor Rs with a reference voltage, Vref.
The output signal from the comparator circuit is fed to a delay circuit and also to a D flip flop. In the delay circuit, the output signal is divided to form two input channels into an AND gate, with one of the input channels passing through an odd number (three shown here) of inverter (NOT) gates. The inverter gates delay the signal such that it is offset from that of the other input channel, as well as being inverted. There is therefore a short period where the signals are both high (when the input signal first changes from low to high) which causes a short pulse of a high output from the AND gate. The output from the AND gate is passed via a buffer to a regulated DC supply which is supplied to the gate driver circuit.
The output signal from the comparator circuit is fed to the S input of the D flip flop. The D flip flop also has its reset input R connected to the digital signal processor. The output Q from the D flip flop is combined with the gate pulse VG in an AND gate and the output from the AND gate is used to control a fault protection circuit.
The output from the external Miller Capacitor CM is also passed to the digital signal processor via the analog isolation circuit. As shown, the analog isolation circuit comprises an optocoupler OCi formed by an LED and a phototransistor which are galvanically isolated from one another to form two isolated circuits, but which communicate via light waves.
The operation of the circuit will now be described with reference to Figure 4.
Under normal operating conditions (i.e. where no fault is present), the voltage across the collector and emitter of the transistor Mt is less than the reference voltage Vref (typically 7V) and so the comparator output stays low. Consequently, no short circuit condition is detected and the output from the AND gate remains low such that the fault protection circuit is not activated.
When a short circuit fault occurs, the voltage across the collector and emitter spikes above the normal on-state voltage and the external miller capacitor CM will act as a path for this voltage spike to the comparator. This voltage is compared with the reference voltage Vref of the comparator and if the voltage exceeds this threshold, then the output of the comparator will become high. The output from the comparator is stored by the D flip flop and is then supplied to the AND gate where it is combined with the gate pulse of the transistor. If both inputs to the AND gate are high, the output of AND gate will cause the fault protection circuit to be enabled. The fault protection circuit clamps the gate voltage to a lower gate voltage to limit the fault current received by the transistor Mr
As shown in Figure 4, the voltage from the capacitor, which is isolated by the analog isolation circuit, is sent to the digital signal processor where the severity of the fault is evaluated. If the fault level is above a threshold limit, the digital signal processor stops the PWM pulses to the gate driver, which stops the switching of the transistors MrM6 within the inverter. If the fault level is below the threshold limit, then the digital signal processor resets the D flip flop and sends a control signal to the fault protection circuit which disables the fault protection circuit, such that the inverter resumes switching operations.
Figure 5 shows a simulation of the certain variables during a short circuit fault. Specifically, the graphs show the collector current, the collector-emitter voltage, the miller capacitor output, the fault detection output (i.e. the output of the AND gate providing the control signal to the fault protection circuit) and the gate-emitter voltage. The graphs show the outputs initially under normal operating conditions, with the transistor being switched on at 300ps and operating properly until just after 330ps when a short circuit fault takes place. During the initial period prior to the fault, the output voltage of the miller capacitor is zero and so the fault detection output remains at zero. However, when the short circuit fault occurs, the voltage of the miller capacitor rises quickly causing the fault detection output to become high. The gate voltage is immediately clamped at a lower voltage to limit the current, and the severity of the fault is assessed (within the fault assessment window period) prior to taking action to protect the power module. At the end of the fault assessment period, the gate voltage is reduced smoothly to zero to protect the power module from the fault current and potential stress.
The fault detector formed by the external miller capacitor and comparator provides a simple arrangement for detecting a short circuit fault. The fault detector can be used to prevent failure of solid state switching devices under short circuit fault conditions which generate a current surge and potential overshoot that could exceed the safe operating window of the device. Although the fault detector has been described with reference to a specific power converter, it will be appreciated that it may be used with any other form of power converter which comprises a solid state switching device.
The fault detector is able to detect both hard switch faults and faults under load. The arrangement provides faster fault detection compared to other techniques, such as desaturation and gate voltage sensing methods, making it particularly suitable for high switching frequency devices such Sic MOSFET. The arrangement also uses less passive components and differential amplifier circuits, and so has a better noise rejection ratio compared to a gate voltage sensing method and provides faster dynamic feedback control to the system to improve the overall reliability.
The arrangement described can be implemented as an integral part of the power module within the gate driver circuit. Alternatively, the fault detector may be offered as an auxiliary component.
The fault detector may be used with a suitable fault protection circuit which is configured to shut down the module in a safe manner to reduce the potential and thermal stress imposed during fault conditions and to avoid the device exceeding its operating specification. Alternatively, this function may be provided through direct control of the gate driver in a conventional manner.
The fault detector may have a control profile which is configured for a specific type of power module (e.g. MOSFET or IGBT). For example, the control profile may dictate a specific voltage threshold, etc. suitable for the power module. Where the detector is provided as an auxiliary component, it may be suitable for use with a plurality of different types of power module by selecting one of a plurality of preinstalled control profiles.
The short circuit detection and protection can be adjusted to provide optimum usage and protection specific to the power module’s specification, application, mission, environment, system lifecycle and system loads.
The detector can be extended to detect the permanent short circuit fault occurring in fault tolerant (multi-level) converters or hot swap converters and use that for reconfiguration. It may also be applied in detecting the short circuit conditions in protection devices such as Solid State power controllers.
The detector can be applied across a number of applications that use power electronics devices such as IGBT, MOSFET, etc. and across devices manufactured from different materials such as Si, SiC, GaN etc. For example, one application could be in Grid connected inverters often used in solar, fuel cell, and wind energy generation. It may also be used with industrial drives, such as variable speed drives used for controlling pumps, rolling mills, etc., as well as in DC-DC converters used in various switch mode power supplies.
The arrangement described may also be particularly useful in safety critical applications, such as power converters used in the starter generator, e-oil, e-fuel or electrical actuation systems in aero applications. Electrical/hybrid electric propulsion systems used on land and sea are also potential applications.

Claims (13)

1. A power electronics module comprising:
at least one solid state switching device;
a gate driver connected to a gate terminal of the switching device and configured to provide a drive input to the gate terminal to activate the switching device;
a controller connected to the gate driver and configured to provide a gate signal to the gate driver; and a fault detector, the fault detector comprising a capacitor connected to a collector terminal of the switching device and a comparator connected to the capacitor;
wherein the comparator is configured to compare a voltage received from the capacitor against a threshold voltage and if the voltage exceeds the threshold voltage provide a control signal indicating a short circuit fault.
2 A power electronics module as claimed in claim 1, wherein the capacitor is further connected to the controller via an isolation circuit.
3. A power electronics module as claimed in claim 2, wherein the controller is configured to assess the severity of the fault based on the signal received from the capacitor via the isolation circuit and if the fault exceeds a shut-down threshold to disable the gate driver and thus the switching device.
4. A power electronics module as claimed in any preceding claim, further comprising a latch circuit which receives and stores the output from the comparator until it is reset.
5. A power electronics module as claimed in claim 4 when dependent on claim 3, wherein the controller is configured to provide a reset signal to the latch circuit if the fault does not exceed the shut-down threshold.
6. A power electronics module as claimed in any preceding claim, further comprising a fault protection circuit, wherein the control signal activates the fault protection circuit in the event of a short circuit fault.
7. A power electronics module as claimed in claim 6, wherein the fault protection circuit reduces the current and/or voltage received by the switching device.
8. A power electronics module as claimed in claim 6 or 7, wherein the control signal and the gate signal form inputs to an AND gate, and the output of the AND gate triggers the fault protection circuit if both of the inputs are high.
9. A power electronics module as claimed in any preceding claim, wherein the power electronics module is an inverter.
10. A method of detecting a fault in a power electronics module comprising at least one solid state switching device, the method comprising:
receiving a voltage from a capacitor connected to a collector terminal of the switching device;
comparing the voltage received from the capacitor against a threshold voltage; and if the voltage exceeds the threshold voltage, provide a control signal indicating a short circuit fault.
11. A method as claimed in claim 10, further comprising assessing a severity of the fault based on a signal received from the capacitor at a controller of a gate driver of the switching device, and if the fault exceeds a shut-down threshold, disabling the gate driver and thus the switching device.
12. A method as claimed in claim 10 or 11, further comprising activating a fault protection circuit in the event of a short circuit fault.
13. A method as claimed in claim 12, wherein the fault protection circuit reduces the current and/or voltage received by the switching device.
GB1711740.9A 2017-07-21 2017-07-21 A power electronics module and a method of detecting a fault in a power electronics module Withdrawn GB2564700A (en)

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GB1711740.9A GB2564700A (en) 2017-07-21 2017-07-21 A power electronics module and a method of detecting a fault in a power electronics module

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Application Number Priority Date Filing Date Title
GB1711740.9A GB2564700A (en) 2017-07-21 2017-07-21 A power electronics module and a method of detecting a fault in a power electronics module

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GB2564700A true GB2564700A (en) 2019-01-23

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3787166A1 (en) * 2019-09-02 2021-03-03 ABB Schweiz AG Protection scheme for power converters utilizing cascaded bipolar and unipolar power semiconductor devices
EP4191645A3 (en) * 2021-12-03 2023-06-14 Delta Electronics, Inc. Power module

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0084245A1 (en) * 1981-12-22 1983-07-27 Hughes Aircraft Company Overcurrent limiter circuit for switching regulator power supplies
JP2002084173A (en) * 2000-09-11 2002-03-22 Mitsubishi Electric Corp Power semiconductor device and overcurrent protection circuit
JP2004222367A (en) * 2003-01-10 2004-08-05 Toshiba Corp Gate driver and power converter

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0084245A1 (en) * 1981-12-22 1983-07-27 Hughes Aircraft Company Overcurrent limiter circuit for switching regulator power supplies
JP2002084173A (en) * 2000-09-11 2002-03-22 Mitsubishi Electric Corp Power semiconductor device and overcurrent protection circuit
JP2004222367A (en) * 2003-01-10 2004-08-05 Toshiba Corp Gate driver and power converter

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3787166A1 (en) * 2019-09-02 2021-03-03 ABB Schweiz AG Protection scheme for power converters utilizing cascaded bipolar and unipolar power semiconductor devices
US11563370B2 (en) 2019-09-02 2023-01-24 Abb Schweiz Ag Protection scheme for power converters utilizing cascaded bipolar and unipolar power semiconductor devices
EP4191645A3 (en) * 2021-12-03 2023-06-14 Delta Electronics, Inc. Power module

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