TWI598608B - Intelligent diagnosis system for power module and method thereof - Google Patents
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本發明係關於一種功率模組檢測機制,特別是,係關於一種智能型功率模組診斷系統及其方法。 The present invention relates to a power module detection mechanism, and more particularly to an intelligent power module diagnostic system and method thereof.
整合式功率模組(Intelligent Power Module,IPM)大量應用於馬達驅動控制系統當中,如升降機具、電動載具等,其架構主要是以外露的直接覆銅(Direct Bond Copper,DBC)的裸銅結構,透過導線結合模封形式,再加上一組驅動控制電路成為功率模組。 Integrated Power Modules (IPMs) are widely used in motor drive control systems, such as lifts and electric vehicles. The structure is mainly exposed bare copper of Direct Bond Copper (DBC). The structure is connected to the form of the mold through the wire, and a set of drive control circuits is used as the power module.
由於功率模組的操作環境相當嚴苛,且擔負著整套驅動控制系統關鍵的角色,但常因外在因素異常操作,例如熱失控、過電流、過電壓等,而在不可預期的狀況下燒毀,造成突發性整套系統的失效,發生不可預期的損失。具體來說,整合式功率模組實際運用在如智慧化工廠或風力發電機場域時,如果能預估內部元件將損壞的或然率,藉此評估並進行預先更換,此將比突然故障再來更換維修來得更有效益,因為故障可能導致元件不可預期的受損,更可能導致機器運作停擺,影響層面將難以估計。 Because the operating environment of the power module is quite demanding and bears the key role of the whole set of drive control system, it often burns under unpredictable conditions due to abnormal operation of external factors, such as thermal runaway, over current, over voltage, etc. , causing the failure of the sudden complete system and unpredictable losses. Specifically, if the integrated power module is actually used in a smart plant or wind turbine field, if it can estimate the probability of damage to the internal components, it can be evaluated and pre-replaced, which will be replaced later than the sudden failure. Maintenance is more efficient because failures can cause unpredictable damage to components and are more likely to cause machine operation to stall, and the impact level will be difficult to estimate.
本發明之目的係提出一種功率模組檢測機制,提供智能化功率模組危險指數診斷與預測,以智能化的檢測機智預測功率模組的危險指數,透過累計的危險指數,在功率模組失效前達到有效的預警及檢修。 The object of the present invention is to provide a power module detection mechanism, which provides intelligent power module risk index diagnosis and prediction, intelligently detects the dangerous index of the power module, and passes the accumulated danger index in the power module failure. Achieve effective early warning and maintenance.
本發明係提出一種智能型功率模組診斷系統,包括:功率模組,其設有溫度感測元件,用於量測該功率模組之起始最低溫度以及當前溫度以得到溫差;硬體檢測迴路模組,其設置於該功率模組一側並設有電流感測元件、電壓感測元件以及磁耦合閉迴路檢測元件,其中,該電流感測元件用於感測該功率模組內之電流,該電壓感測元件用於量測該功率模組之輸出電壓與輸入電壓,該磁耦合閉迴路檢測元件用於自我檢測當下硬體迴路狀態以得到硬體迴路檢測狀態;以及診斷模組,其連接該功率模組與該硬體檢測迴路模組,係依據該當前溫度以及該電流感測元件所測得之電流計算出該功率模組之已操作之循環次數,透過該輸出電壓、該輸入電壓及該電流計算出量測阻抗,俾由該量測阻抗、該輸出電壓及該電流計算出即時功率,其中,該診斷模組依據該已操作之循環次數、該溫差、該量測阻抗、該即時功率及該硬體迴路檢測狀態以計算出危險指數。 The invention provides an intelligent power module diagnostic system, comprising: a power module, which is provided with a temperature sensing component for measuring the initial minimum temperature and the current temperature of the power module to obtain a temperature difference; hardware detection a loop module disposed on one side of the power module and provided with a current sensing component, a voltage sensing component, and a magnetically coupled closed loop detecting component, wherein the current sensing component is configured to sense the power module Current, the voltage sensing component is configured to measure an output voltage and an input voltage of the power module, the magnetic coupling closed loop detecting component is configured to self-detect a current hardware loop state to obtain a hardware loop detection state; and a diagnostic module Connecting the power module and the hardware detection loop module, calculating the number of cycles of operation of the power module according to the current temperature and the current measured by the current sensing component, and transmitting the output voltage, The input voltage and the current calculate a measured impedance, and the instantaneous power is calculated from the measured impedance, the output voltage, and the current, wherein the diagnostic module is based on the The number of cycles, the temperature difference, the impedance measurement, and the instantaneous power of the hardware state detection circuit to calculate risk index.
本發明另提出一種智能型功率模組診斷方法,包括:量測功率模組之溫度、電流、輸入電壓及輸出電壓;自我檢測硬體迴路狀態;依據該溫度及該電流計算出該功率模 組已操作之循環次數;透過該輸出電壓、該輸入電壓及該電流計算出量測阻抗;由該量測阻抗、該輸出電壓及該電流計算出即時功率;以及依據該已操作之循環次數、該溫度、該量測阻抗、該即時功率及該硬體迴路檢測狀態計算出危險指數。 The invention further provides an intelligent power module diagnosis method, comprising: measuring a temperature, a current, an input voltage and an output voltage of the power module; self-detecting a hardware circuit state; calculating the power mode according to the temperature and the current The number of cycles that the group has operated; the measured impedance is calculated from the output voltage, the input voltage, and the current; the instantaneous power is calculated from the measured impedance, the output voltage, and the current; and according to the number of cycles of the operation, The temperature, the measured impedance, the instantaneous power, and the hardware loop detection state calculate a risk index.
本發明還提出一種電流感測元件,其透過貼片方式設置於功率模組之導線上,其中,於電流通過該導線而於該導線周邊產生磁場下,令該電流感測元件感測該磁場,藉以計算通過該導線之電流值。 The present invention also provides a current sensing component that is disposed on a wire of a power module through a patch, wherein the current sensing element senses the magnetic field when a current is passed through the wire to generate a magnetic field around the wire. In order to calculate the current value through the wire.
本發明更提出一種磁耦合閉迴路檢測元件,其設置於功率模組之三相橋接驅動器內各絕緣閘雙極電晶體處,用於檢測該些絕緣閘雙極電晶體的硬體迴路當前狀態。 The invention further provides a magnetically coupled closed loop detecting component, which is disposed at each insulating gate bipolar transistor in the three-phase bridge driver of the power module, and is used for detecting the current state of the hardware loop of the insulating gate bipolar transistors .
本發明所提出之智能型功率模組診斷系統及其方法,在既有的功率模組上結合電氣檢測規則(Electrical rule check)及診斷等模組電路,透過硬體迴路的檢測機制回傳功率模組之運作狀態,再由微控制器內診斷模組進行即時分析,並依照危險指數判斷是否有即刻性的危險,若判斷結果為達到預設危險指標,則診斷模組開始累計異常指數,並儲存在可複寫記憶體中,以提供使用者監控功率模組的狀態。另外,當發生即刻性的危險,如熱失控、過電壓、短路等狀態時,透過診斷模組所在之控制板,立刻中斷驅動電路之輸出,並且記錄重大失效於操作履歷當中。透過上述機制,使用者可透過異常指數累計情況得到功率模組狀態,藉此判斷硬體狀態是否已產生不正常情況,亦即危 險指數的累積將利於使用者判斷是否進行硬體修復或更新。 The intelligent power module diagnosis system and method thereof provided by the invention combines electrical circuit detection (Electrical rule check) and diagnostic module circuits on an existing power module, and returns power through a hardware loop detection mechanism The operating state of the module is then analyzed by the diagnostic module in the microcontroller, and the risk index is used to determine whether there is an immediate danger. If the judgment result is that the preset risk indicator is reached, the diagnostic module starts to accumulate the abnormal index. And stored in rewritable memory to provide the user to monitor the status of the power module. In addition, when there is a danger of immediate danger, such as thermal runaway, overvoltage, short circuit, etc., the output of the drive circuit is interrupted immediately through the control panel where the diagnostic module is located, and the major failure is recorded in the operation history. Through the above mechanism, the user can obtain the status of the power module through the accumulation of the abnormality index, thereby judging whether the hardware state has generated an abnormal condition, that is, dangerous. The accumulation of the risk index will help the user to determine whether to perform a hardware repair or update.
1‧‧‧智能型功率模組診斷系統 1‧‧‧Intelligent Power Module Diagnostic System
11、21‧‧‧功率模組 11, 21‧‧‧ Power Module
111、511‧‧‧溫度感測元件 111, 511‧‧‧ Temperature sensing components
12‧‧‧硬體檢測迴路模組 12‧‧‧ hardware detection loop module
121、621‧‧‧電流感測元件 121, 621‧‧‧ current sensing components
122、722‧‧‧電壓感測元件 122, 722‧‧‧ voltage sensing components
123、823‧‧‧磁耦合閉迴路檢測元件 123, 823‧‧‧ Magnetically coupled closed loop detection components
13‧‧‧診斷模組 13‧‧‧Diagnostic Module
22‧‧‧硬體檢測迴路電路板 22‧‧‧ hardware detection loop circuit board
23‧‧‧控制板 23‧‧‧Control panel
24‧‧‧上蓋板 24‧‧‧Upper cover
25‧‧‧下蓋板 25‧‧‧Under cover
311‧‧‧溫度感測器 311‧‧‧temperature sensor
322‧‧‧電壓感測器 322‧‧‧Voltage sensor
323‧‧‧磁耦閉迴路檢測 323‧‧‧Magnetic coupling closed loop detection
1201‧‧‧導線 1201‧‧‧Wire
1221‧‧‧電流感測元件 1221‧‧‧ Current sensing components
S101~S106‧‧‧步驟 S101~S106‧‧‧Steps
第1圖係為本發明之智能型功率模組診斷系統的系統架構圖;第2圖係為本發明一具體實施例之智能型功率模組診斷系統的外觀示意圖;第3圖係為本發明一具體實施例之智能型功率模組診斷系統的內部關係示意圖;第4A和4B圖係為本發明之智能型功率模組診斷系統中危險指數和反應時間的關係示意圖;第5A和5B圖係為本發明之智能型功率模組診斷系統中溫度感測元件設置位置的示意圖;第6A和6B圖係為本發明之智能型功率模組診斷系統中電流感測元件設置位置的示意圖;第7A和7B圖係為本發明之智能型功率模組診斷系統中電壓感測元件設置位置的示意圖;第8A和8B圖係為本發明之智能型功率模組診斷系統中磁耦合閉迴路檢測元件設置位置的示意圖;第9圖係為本發明判斷風險指數的流程圖;第10圖係為本發明之智能型功率模組診斷方法的步驟圖;第11圖係為本發明之磁耦合閉迴路檢測機制的示意圖;以及 第12圖係為本發明之電流感測元件的示意圖。 1 is a system architecture diagram of an intelligent power module diagnostic system of the present invention; FIG. 2 is a schematic diagram of an appearance of an intelligent power module diagnostic system according to an embodiment of the present invention; A schematic diagram of the internal relationship of an intelligent power module diagnostic system according to a specific embodiment; FIGS. 4A and 4B are diagrams showing the relationship between the risk index and the reaction time in the intelligent power module diagnostic system of the present invention; FIGS. 5A and 5B are diagrams The schematic diagram of the position of the temperature sensing component in the intelligent power module diagnostic system of the present invention; FIGS. 6A and 6B are schematic diagrams showing the position of the current sensing component in the intelligent power module diagnostic system of the present invention; And the 7B diagram is a schematic diagram of the position of the voltage sensing component in the intelligent power module diagnostic system of the present invention; the 8A and 8B diagrams are the magnetic coupling closed loop detection component set in the intelligent power module diagnostic system of the present invention. FIG. 9 is a flow chart of the judgment risk index of the present invention; FIG. 10 is a step diagram of the intelligent power module diagnosis method of the present invention; Schematic diagram of the magnetic coupling closed loop detection mechanism of the invention; Figure 12 is a schematic illustration of the current sensing element of the present invention.
以下藉由特定的具體實施形態說明本發明之技術內容,熟悉此技藝之人士可由本說明書所揭示之內容輕易地瞭解本發明之優點與功效。然本發明亦可藉由其他不同的具體實施形態加以施行或應用。 The technical contents of the present invention are described below by way of specific embodiments, and those skilled in the art can easily understand the advantages and effects of the present invention from the contents disclosed in the present specification. The invention may be embodied or applied by other different embodiments.
請參照第1圖,係為本發明之智能型功率模組診斷系統的系統架構圖。本發明係提出智能化功率模組的危險指數診斷與預測,藉此達到降低功率模組在驅動器當中的不可預期失效,有別於現有在功率模組上設單一溫度感測機制或過電流保護機制,本發明提出在功率模組設置硬體檢測迴路機制以及相關驅動電路。 Please refer to FIG. 1 , which is a system architecture diagram of the intelligent power module diagnostic system of the present invention. The invention proposes the risk index diagnosis and prediction of the intelligent power module, thereby achieving the unpredictable failure of the power module in the driver, which is different from the existing single temperature sensing mechanism or overcurrent protection on the power module. Mechanism, the present invention proposes to set up a hardware detection loop mechanism and associated drive circuit in the power module.
如第1圖所示,本發明之智能型功率模組診斷系統1包括功率模組11、硬體檢測迴路模組12以及診斷模組13。 As shown in FIG. 1 , the intelligent power module diagnostic system 1 of the present invention includes a power module 11 , a hardware detection loop module 12 , and a diagnostic module 13 .
功率模組11上設有溫度感測元件111,用於量測功率模組11之起始最低溫度以及當前溫度並得到兩者溫差。功率模組11的溫度狀態表現可反應出功率模組11現況,故功率模組11設有可用於量測起始最低溫度以及當前溫度之溫差之溫度感測元件111。 The power module 11 is provided with a temperature sensing component 111 for measuring the initial minimum temperature and the current temperature of the power module 11 and obtaining the temperature difference between the two. The temperature state of the power module 11 can reflect the current state of the power module 11, so the power module 11 is provided with a temperature sensing element 111 that can be used to measure the temperature difference between the initial minimum temperature and the current temperature.
硬體檢測迴路模組12設置於功率模組11一側,其設有電流感測元件121、電壓感測元件122以及磁耦合閉迴路檢測元件123,其中,電流感測元件121用於感測功率模組11內的電流,電壓感測元件122用於量測功率模組11之輸出電壓與輸入電壓,磁耦合閉迴路檢測元件123用 於檢測硬體迴路狀態。簡單來說,本發明於智能型功率模組診斷系統1設置硬體檢測迴路模組12,藉此量測功率模組11的狀態,包括電流、電壓以及閉迴路是否閉合,所量測到之電流、輸出電壓與輸入電壓可用於計算阻抗或功率,是用於診斷功率模組11狀態。 The hardware detection circuit module 12 is disposed on the side of the power module 11 and is provided with a current sensing component 121, a voltage sensing component 122, and a magnetic coupling closed loop detecting component 123. The current sensing component 121 is used for sensing. The current in the power module 11 and the voltage sensing component 122 are used to measure the output voltage and the input voltage of the power module 11, and the magnetic coupling closed loop detecting component 123 For detecting the status of the hardware loop. Briefly, the present invention provides a hardware detection loop module 12 in the intelligent power module diagnostic system 1 to measure the state of the power module 11, including current, voltage, and whether the closed loop is closed. The current, output voltage, and input voltage can be used to calculate impedance or power and are used to diagnose the state of the power module 11.
診斷模組13其連接功率模組11與硬體檢測迴路模組12,係依據功率模組11之溫度感測元件111所感測之當前溫度以及硬體檢測迴路模組12內電流感測元件121所測得之電流計算出功率模組11之已操作之循環次數。功率模組11為包括數個絕緣閘雙極電晶體且具有三相六臂設計之功率模組,也就是說,功率模組11內三相六臂於功率模組運作時,透過持續運行時間與瞬間最大電流之積分結果可得到循環次數,因而這裡所指之已操作之循環次數是指功率模組11各臂的閘體運行時間積分。 The diagnostic module 13 is connected to the power module 11 and the hardware detection circuit module 12 according to the current temperature sensed by the temperature sensing component 111 of the power module 11 and the current sensing component 121 in the hardware detection loop module 12 . The measured current calculates the number of cycles of operation of the power module 11. The power module 11 is a power module including a plurality of insulated gate bipolar transistors and having a three-phase six-arm design, that is, the three-phase six-arm in the power module 11 is operated through the continuous operation time of the power module. The number of cycles can be obtained from the integration result of the instantaneous maximum current, and thus the number of cycles of operation referred to herein refers to the integral of the gate running time of each arm of the power module 11.
診斷模組13尚透過電壓感測元件122所量測之輸出電壓及輸入電壓以及電流感測元件121所測得之電流,以計算出功率模組11運作時之量測阻抗,另外,也依據該量測阻抗、該輸出電壓及該電流計算出功率模組11之即時功率。 The diagnostic module 13 further passes the output voltage and the input voltage measured by the voltage sensing component 122 and the current measured by the current sensing component 121 to calculate the measured impedance of the power module 11 during operation, and is also based on The measured impedance, the output voltage, and the current calculate the instantaneous power of the power module 11.
診斷模組13更依據上述所得到之已操作之循環次數、溫差、量測阻抗、即時功率及硬體迴路檢測狀態以計算出危險指數,本發明包括上述五個量測資訊(數據),用於判斷器具是否瀕臨危險或損壞,本發明利用五個量測資訊產生一危險指數,此危險指數用於判斷器具危險或損壞程 度等級。簡單來說,當危險指數大於一預設值時,則判斷功率模組11有瀕臨危險或損壞的可能,因而將異常指數紀錄進行累積,假若危險等級越高,則異常指數紀錄累計速度越快,舉例來說,普通危險可在每半秒累積一次異常指數紀錄,若為高度危險可在每0.1秒累積一次異常指數紀錄。 The diagnostic module 13 further calculates the risk index according to the obtained cycle number, temperature difference, measurement impedance, instantaneous power and hardware loop detection state, and the present invention includes the above five measurement information (data). In order to determine whether the appliance is at risk or damaged, the present invention uses five measurement information to generate a risk index, which is used to determine the danger or damage of the appliance. Degree level. Briefly speaking, when the risk index is greater than a preset value, it is judged that the power module 11 is likely to be dangerous or damaged, and thus the abnormal index record is accumulated. If the risk level is higher, the abnormal speed of the abnormal index record is faster. For example, the general risk can accumulate an abnormal index record every half second. If it is a high risk, the abnormal index record can be accumulated every 0.1 seconds.
另外,可於上述異常指數紀錄累積大於預設之警告值時,診斷模組13可產生警告訊息,並透過儀器螢幕顯示或訊息傳遞,通知相關人員設備內之功率模組11將有極可能將要損壞。 In addition, when the abnormality index record is accumulated more than the preset warning value, the diagnostic module 13 can generate a warning message and notify the relevant personnel that the power module 11 in the device will be likely to pass through the instrument screen display or message transmission. damage.
上述是針對持續檢測以得到功率模組11的運作狀態,並透過異常指數紀錄的累積,協助使用者判斷是否需要檢修功率模組11,上述情況是透過判斷器具狀態的結果,然有些情況是會立即損壞功率模組11,此時若還是以異常指數紀錄累積的方式預警,恐無法避免功率模組11損壞所帶來的傷害。 The above is for continuous detection to obtain the operating state of the power module 11, and accumulates through the abnormality index record, and assists the user in judging whether the power module 11 needs to be inspected. The above situation is the result of judging the state of the appliance, but in some cases, The power module 11 is immediately damaged. At this time, if the warning is still accumulated by the abnormal index record, the damage caused by the damage of the power module 11 cannot be avoided.
為了避免上述情況產生,當磁耦合閉迴路檢測元件123於檢測出當下硬體迴路狀態有異常情況時,診斷模組13會直接產生中止指令以令功率模組11停止運作。另外,當溫差、量測阻抗、即時功率各別超過對應之臨界值時,則表示有立即損壞功率模組11的可能性,故診斷模組13也會產生中止指令,以令功率模組11立即停止運作。上述立即中止情況當然也會被記錄下來,提供使用者後續參考。 In order to avoid the above situation, when the magnetic coupling closed loop detecting component 123 detects an abnormal condition of the current hardware loop state, the diagnostic module 13 directly generates a suspension command to stop the power module 11 from operating. In addition, when the temperature difference, the measured impedance, and the instantaneous power respectively exceed the corresponding threshold value, it indicates that there is a possibility of damaging the power module 11 immediately, so the diagnostic module 13 also generates a suspension command to make the power module 11 Stop working immediately. The above-mentioned immediate suspension will of course be recorded and provide the user with a follow-up reference.
本發明利用上述機制以提供智能型功率模組診斷系統1的危險指數診斷與預測,如此不僅可智能化的檢測機智預測功率模組11的危險指數,透過累計的危險指數,使用者可觀察功率模組11的運作狀態,故可在功率模組11失效前達到有效的預警及檢修。 The present invention utilizes the above mechanism to provide risk index diagnosis and prediction of the intelligent power module diagnostic system 1, so that not only the intelligent detection of the risk index of the power module 11 can be predicted, but also the user can observe the power through the accumulated risk index. The operating state of the module 11 can achieve effective early warning and maintenance before the power module 11 fails.
請參照第2圖,係為本發明一具體實施例之智能型功率模組診斷系統的外觀示意圖。如圖所示,智能型功率模組診斷系統包括功率模組21、上蓋板24及下蓋板25外,本發明提出用於檢測數據的硬體檢測迴路模組以及診斷模組,硬體檢測迴路模組可設置於硬體檢測迴路電路板22中,診斷模組可設置於控制板23內。 Please refer to FIG. 2 , which is a schematic diagram of the appearance of an intelligent power module diagnostic system according to an embodiment of the present invention. As shown in the figure, the intelligent power module diagnostic system includes a power module 21, an upper cover 24 and a lower cover 25. The present invention provides a hardware detection loop module and a diagnostic module for detecting data, and a hardware The detection circuit module can be disposed in the hardware detection circuit board 22, and the diagnosis module can be disposed in the control board 23.
在一實施例中,硬體檢測迴路電路板22和控制板23都以電路板等方式實現,硬體檢測迴路電路板22設置於功率模組21一側,控制板23與功率模組21和硬體檢測迴路電路板22電性連接,位於功率模組21和硬體檢測迴路電路板22中各感測元件,可感測出功率模組21之溫度、電流、電壓或得到硬體迴路當前檢測狀態等數據或結果,之後傳送至控制板23來進行運算與分析,進而得到危險指數。也就是說,硬體檢測迴路模組即包含硬體檢測迴路電路板22內電子元件、韌體等組件,而診斷模組即包含控制板23內電子元件、韌體等組件。更具體設置方式,將於後續進一步說明。 In an embodiment, the hardware detection circuit board 22 and the control board 23 are implemented by a circuit board or the like. The hardware detection circuit board 22 is disposed on the power module 21 side, and the control board 23 and the power module 21 are The hardware detection circuit board 22 is electrically connected, and is located in each of the sensing components of the power module 21 and the hardware detection circuit board 22, and can sense the temperature, current, voltage of the power module 21 or obtain the current hardware circuit. Data or results such as status are detected, and then transmitted to the control board 23 for calculation and analysis to obtain a risk index. That is to say, the hardware detection circuit module includes components such as electronic components and firmware in the hardware detection circuit board 22, and the diagnostic module includes components such as electronic components and firmware in the control board 23. More specific settings will be further explained later.
請參照第3圖,係為本發明一具體實施例之智能型功率模組診斷系統的內部關係示意圖。如圖所示,馬達透過 三相橋接驅動器(即三相六臂驅動迴路)控制其運作,三相橋接驅動器包括六個臂,依據各臂開合與否決定電路如何流通,進而控制馬達運作,其中,溫度感測器311、電壓感測器322、磁耦閉迴路檢測323分別設置於整個智能型功率模組內,用於自我檢測當下硬體迴路狀態。 Please refer to FIG. 3, which is a schematic diagram of the internal relationship of the intelligent power module diagnostic system according to an embodiment of the present invention. As shown, the motor passes through The three-phase bridge driver (ie, the three-phase six-arm drive circuit) controls its operation, and the three-phase bridge driver includes six arms, and determines whether the circuit circulates according to whether the arms are opened or closed, thereby controlling the motor operation, wherein the temperature sensor 311 The voltage sensor 322 and the magnetic coupling closed loop detection 323 are respectively disposed in the entire intelligent power module for self-detecting the current hardware loop state.
請參照第4A和4B圖,係為本發明之智能型功率模組診斷系統中危險指數和反應時間的關係示意圖。如前所述,藉由各個感測元件來量測感測模組的溫度、電流、電壓等,接著可被運算成已操作之循環次數和量測阻抗,透過這些檢測數值或換算後得到數據,將被整合出一個危險指數。 Please refer to FIGS. 4A and 4B for the relationship between the danger index and the reaction time in the intelligent power module diagnostic system of the present invention. As described above, the temperature, current, voltage, and the like of the sensing module are measured by the respective sensing elements, and then can be calculated into the number of cycles of operation and the measured impedance, and the data is obtained through the detected values or converted. Will be integrated into a dangerous index.
如第4A圖所示,本發明將危險指數分成五個等級,分別為L1到L5,一般來說,可設計L3以上才算有危險存在。在一實施例中,感測到的各項數值或數據經計算後會產生一個1以下的數值,例如危險指數為1的話,即位在L5處,此表示極度危險,另外,若危險指數為0.3的話,即位在L2和L3間,則表示並非火急的危險,而此危險指數將影響異常指數紀錄的累積速度。 As shown in Fig. 4A, the present invention divides the risk index into five levels, respectively L1 to L5. In general, it is considered dangerous to design L3 or higher. In an embodiment, the sensed values or data are calculated to produce a value of 1 or less. For example, if the risk index is 1, the position is at L5, which indicates extreme danger. In addition, if the risk index is 0.3. If it is between L2 and L3, it means that it is not a danger of fire, and this risk index will affect the cumulative speed of the abnormal index record.
如第4B圖所示,橫向表示危險指數的數值,縱向表示反應時間,舉例來說,若危險指數為0.8,且危險等級為L4,則表示每600ms要紀錄一次,亦即異常指數紀錄加上一次(例如加1),換言之,若越緊急則反應時間越短,表示異常指數紀錄要在很短時間內被加上一次,反之,若不緊急則反應時間可較長,表示間隔較久時間才被紀錄一次,隨著異常指數紀錄增加速度越快或數值越大,則表示 功率模組狀態可能不佳。 As shown in Figure 4B, the horizontal value represents the value of the hazard index, and the vertical direction represents the reaction time. For example, if the hazard index is 0.8 and the hazard level is L4, it means that it is recorded every 600 ms, that is, the abnormal index record plus Once (for example, plus 1), in other words, the more emergency, the shorter the reaction time, indicating that the abnormal index record should be added once in a short time. Conversely, if it is not urgent, the reaction time can be longer, indicating that the interval is longer. Only once recorded, as the anomaly index increases faster or the value increases, it means The power module status may be poor.
因此,透過硬體檢測迴路模組的檢測機制回傳功率模組的運作狀態,由控制板內診斷模組進行即時分析,將會產生五種風險指數,接著依照該些風險指數判斷是否有立刻性的危險。若判斷結果為達到危險指標,診斷模組會開始累計異常指數並儲存,當然若發生立刻性的危險時,如熱失控、過電壓或短路等,則控制板將即刻中斷驅動電路之輸出並且紀錄重大失效。 Therefore, through the detection mechanism of the hardware detection loop module, the operation status of the power module is returned, and the real-time analysis by the diagnostic module in the control panel will generate five risk indexes, and then according to the risk indexes, it is judged whether there is an immediate Sexual danger. If the judgment result is that the dangerous index is reached, the diagnostic module will start accumulating the abnormal index and store it. Of course, if there is an immediate danger, such as thermal runaway, overvoltage or short circuit, the control panel will immediately interrupt the output of the drive circuit and record. Major failure.
後面將各別說明每一個感測元件的設置與應用。 The setting and application of each sensing element will be separately described later.
請參照第5A和5B圖,係為本發明之智能型功率模組診斷系統中溫度感測元件設置位置的示意圖。如第5A圖所示,其顯示溫度感測元件511設置於功率模組的位置,亦即,於三相六臂驅動迴路(右側方塊)和整流迴路(左側方塊)中設置溫度感測元件511,即可設置於功率模組內三相橋接驅動器的三相位電路處。溫度感測元件511將透過硬體檢測迴路電路板22(第2圖)內硬體檢測迴路模組進行一階濾波放大,並送至控制板23(第2圖)進行讀取並由其內診斷模組進行分析。 Please refer to FIGS. 5A and 5B, which are schematic diagrams showing the positions of temperature sensing elements in the intelligent power module diagnostic system of the present invention. As shown in FIG. 5A, the temperature sensing element 511 is disposed at a position of the power module, that is, the temperature sensing element 511 is disposed in the three-phase six-arm driving circuit (right square) and the rectifying circuit (left square). , can be set in the three-phase circuit of the three-phase bridge driver in the power module. The temperature sensing element 511 is first-stage filtered and amplified by the hardware detection loop module in the hardware detection loop circuit board 22 (Fig. 2), and sent to the control board 23 (Fig. 2) for reading and being used therein. The diagnostic module is analyzed.
另外,第5B圖則為第5A圖的等效電路。左邊為整流模組,可稱之為橋式整理器,右邊為三相六臂驅動迴路,溫度感測元件511則設置於三個橋接處,用於感測橋接處之絕緣閘雙極電晶體的溫度。 In addition, Fig. 5B is an equivalent circuit of Fig. 5A. The left side is a rectifier module, which can be called a bridge finisher, the right side is a three-phase six-arm drive circuit, and the temperature sensing element 511 is placed at three bridges for sensing the insulated gate bipolar transistor at the bridge. temperature.
請參照第6A和6B圖,係為本發明之智能型功率模組診斷系統中電流感測元件設置位置的示意圖。如第6A圖 所示,其顯示電流感測元件621設置於功率模組的位置,亦即於三相橋接驅動器的U-V-W相位置設置電流感測元件621,電流感測元件621可為Hall感測器,也就是說,電流感測元件621設置於功率模組內三相橋接驅動器的U相、V相和W相線圈上。電流感測元件621將透過硬體檢測迴路電路板22(第2圖)內硬體檢測迴路模組進行一階濾波放大,並送至控制板23(第2圖)進行讀取並由其內診斷模組進行分析。 Please refer to FIGS. 6A and 6B for a schematic diagram of the position of the current sensing component in the intelligent power module diagnostic system of the present invention. As shown in Figure 6A As shown, the display current sensing component 621 is disposed at the position of the power module, that is, the current sensing component 621 is disposed at the UVW phase position of the three-phase bridge driver, and the current sensing component 621 can be a Hall sensor, that is, The current sensing component 621 is disposed on the U-phase, V-phase, and W-phase coils of the three-phase bridge driver in the power module. The current sensing element 621 is first-stage filtered and amplified by the hardware detection loop module in the hardware detection loop circuit board 22 (Fig. 2), and sent to the control board 23 (Fig. 2) for reading and being used therein. The diagnostic module is analyzed.
另外,第6B圖表示電流感測元件621於硬體檢測迴路電路板22的位置,硬體檢測迴路電路板22是位在功率模組一側。本發明之電流感測元件621是直接設置於功率模組內電線所在位置處,透過電磁感應機制,感測磁場進而推算出電流,並非如一般現有的電流感測,另外拉線至功率模組外進行感測,故有利於整體體積微小化。 In addition, FIG. 6B shows the position of the current sensing element 621 on the hardware detection circuit board 22, and the hardware detection circuit board 22 is located on the power module side. The current sensing component 621 of the present invention is directly disposed at the position of the electric wire in the power module, and the electromagnetic field is sensed to sense the magnetic field and then calculate the current, which is not the current current sensing, and the cable is pulled to the power module. Sensing outside makes it easy to miniaturize the overall volume.
請參照第7A和7B圖,係為本發明之智能型功率模組診斷系統中電壓感測元件設置位置的示意圖。如第7A圖所示,其顯示電壓感測元件722設置於硬體檢測迴路電路板22(第2圖)的位置,亦即位在總壓輸入處和一相輸出處,即功率模組的輸出電壓與輸入電壓,也就是說,電壓感測元件設置於功率模組內三相橋接驅動器的電壓輸出處以及電壓輸入處。電壓感測元件722將透過硬體檢測迴路電路板22內硬體檢測迴路模組進行一階濾波放大,並送至控制板23(第2圖)進行讀取並由其內診斷模組進行分析。 Please refer to FIGS. 7A and 7B, which are schematic diagrams showing the positions of voltage sensing elements in the intelligent power module diagnostic system of the present invention. As shown in FIG. 7A, the display voltage sensing component 722 is disposed at the position of the hardware detection circuit board 22 (Fig. 2), that is, at the total voltage input and the phase output, that is, the output of the power module. The voltage and the input voltage, that is, the voltage sensing element are disposed at the voltage output of the three-phase bridge driver in the power module and at the voltage input. The voltage sensing component 722 is first-stage filtered and amplified by the hardware detection loop module in the hardware detection loop circuit board 22, and sent to the control board 23 (Fig. 2) for reading and analysis by the internal diagnostic module. .
另外,第7B圖即顯示第7A圖的等效電路,其顯示三 相六臂驅動迴路,電壓感測元件722則設置於三相六臂驅動迴路的總壓輸入處和一相輸出處,故可量測出當前輸出電壓與當前輸入電壓。 In addition, Figure 7B shows the equivalent circuit of Figure 7A, which shows three The phase six-arm drive circuit, the voltage sensing component 722 is disposed at the total voltage input of the three-phase six-arm drive circuit and the one-phase output, so the current output voltage and the current input voltage can be measured.
請參照第8A和8B圖,係為本發明之智能型功率模組診斷系統中磁耦合閉迴路檢測元件設置位置的示意圖。如第8A圖所示,其顯示磁耦合閉迴路檢測元件823設置於硬體檢測迴路電路板22(第2圖)的位置,磁耦合閉迴路檢測元件823共有七個,分別設置於功率模組中。功率模組透過磁耦合閉迴路方式隔離高低壓側,並將三相橋接驅動器的訊號回傳至控制板以進行開閉合狀態確認。磁耦合閉迴路檢測元件823將透過硬體檢測迴路電路板22內硬體檢測迴路模組進行一階濾波放大,並送至控制板23(第2圖)進行讀取並由其內診斷模組進行分析。 Please refer to FIGS. 8A and 8B, which are schematic diagrams showing the positions of the magnetic coupling closed loop detecting elements in the intelligent power module diagnostic system of the present invention. As shown in FIG. 8A, the magnetic coupling closed loop detecting element 823 is disposed at the position of the hardware detecting loop circuit board 22 (Fig. 2), and the magnetic coupling closed loop detecting element 823 is provided in the power module. in. The power module isolates the high and low voltage sides through a magnetically coupled closed loop, and transmits the signals of the three-phase bridge driver back to the control board for confirmation of the open and closed states. The magnetically coupled closed loop detecting component 823 performs first-order filtering amplification through the hardware detecting loop module in the hardware detecting loop circuit board 22, and sends it to the control board 23 (Fig. 2) for reading and the internal diagnostic module. Analyze.
另外,第8B圖即顯示第8A圖的等效電路,其顯示三相六臂驅動迴路,七個磁耦合閉迴路檢測元件823設置於三相六臂驅動迴路的六個絕緣閘雙極電晶體處,也就是說,磁耦合閉迴路檢測元件823設置於功率模組內三相六臂驅動迴路內各絕緣閘雙極電晶體處,另一個磁耦合閉迴路檢測元件823則設於功率模組的煞車臂處(圖中最左側)。 In addition, FIG. 8B shows an equivalent circuit of FIG. 8A, which shows a three-phase six-arm drive circuit, and seven magnetically coupled closed-loop detecting elements 823 are provided in six insulated gate bipolar transistors of a three-phase six-arm drive circuit. That is, the magnetic coupling closed loop detecting component 823 is disposed at each of the insulating gate bipolar transistors in the three-phase six-arm driving circuit in the power module, and the other magnetic coupling closed loop detecting component 823 is disposed in the power module. At the brake arm (leftmost in the picture).
如前所述,本發明提出透過已操作之循環次數、溫差、量測阻抗、即時功率及硬體迴路自我檢測機制計算出危險指數,下面將說明危險指數如何得到。 As described above, the present invention proposes to calculate a hazard index by the number of cycles of operation, temperature difference, measured impedance, instantaneous power, and hardware loop self-detection mechanism. The following describes how the hazard index is obtained.
在紀錄風險指數之前,是先透過各個感測元件,將可得到溫度、電流、電壓等數據得到危險指數,藉此危險指 數的累積情況,進而得到風險高低。有關風險指數計算是透過以下方式。 Before the risk index is recorded, the temperature, current, voltage and other data can be obtained through various sensing components to obtain a hazard index. The accumulation of the number, in turn, the risk level. The risk index is calculated in the following manner.
已操作之循環次數(Cycle Count)是透過下列方程式(1)得到,其中,ton為功率模組內三相六臂驅動迴路中單一臂開啟次數,0.1s<ton<60s,Ncyc則表示單位時間的開啟次數。 The cycle count (Cycle Count) is obtained by the following equation (1), where t on is the number of single arm opening in the three-phase six-arm drive circuit in the power module, 0.1s<t on <60s, N cyc Indicates the number of times the unit time is turned on.
當前最低溫度與當前溫度的差異(Delta T),即溫差,可透過下列方程式(2),其中,Max T為當前溫度,Min T為最低溫度,簡單來說,當溫度開始產生變化時,取功率模組內三相六臂驅動迴路處的最高溫者和最低溫者,可算出溫差。 The difference between the current minimum temperature and the current temperature (Delta T), that is, the temperature difference, can be obtained by the following equation (2), where Max T is the current temperature and Min T is the lowest temperature, simply speaking, when the temperature begins to change, The temperature difference can be calculated from the highest temperature and the lowest temperature in the three-phase six-arm drive circuit in the power module.
利用當前輸入電壓與輸出電壓推算電阻,並可利用下列方程式(3)得到量測阻抗(△Vce),其中,Vout為輸出電壓,Vin為輸入電壓,IRate為輸入電流。 Using the currently input voltage and the output voltage estimating resistance, and the use of the following equation (3) to give the measured impedance (△ Vce), wherein, V out is the output voltage, V in is the input voltage, I Rate input current.
透過上述量測阻抗(△Vce)、輸出電壓Vout以及輸入電流IRate可計算出即時功率累積PRate,如下列方程式(4)所示。 Transmitted through the measuring impedance (△ Vce), output voltage V out and the input current I Rate calculate the accumulated instantaneous power P Rate, as shown in the following equation (4).
P Rate =△Vce[%]×(Vout×IRate) (4) P Rate = △ Vce [%] × ( Vout × IRate ) (4)
另外再搭配磁耦合閉迴路的檢測結果,可透過下列方程式(5)計算出一組危險指數(GPR)。 In addition, with the detection result of the magnetic coupling closed loop, a set of risk index (GPR) can be calculated by the following equation (5).
透過預先建立表格,危險指數(GPR)可對應出反應時間,如第3圖所示,每一個危險指數在不同等級下,會對應出一個反應時間,即為多久要於異常指數紀錄(RIP)上記一次。因而當危險指數已達一預定值(設定閥值)時,即會開始進行開始累計異常指數紀錄。 By pre-establishing the form, the risk index (GPR) can correspond to the reaction time. As shown in Figure 3, each risk index will correspond to a reaction time at different levels, ie how long is the abnormality index record (RIP) Write it once. Therefore, when the risk index has reached a predetermined value (set threshold), the start of the cumulative abnormality index record is started.
請參照第9圖,係為本發明判斷風險指數的流程圖。配合前述危險指數的計算,功率循環能力、量測阻抗△Vce、溫差△Delta T、即時功率P Rate 、以及磁耦合與否將會判斷功率模組的風險。 Please refer to Fig. 9, which is a flow chart for judging the risk index of the present invention. In conjunction with the calculation of the aforementioned risk index, the power cycle capability, the measured impedance ΔVce , the temperature difference Δ Delta T , the instantaneous power P Rate , and the magnetic coupling will determine the risk of the power module.
量測功率循環能力時,當其健康狀態(SOH)大於預定X%時,則表示功率循環能力有問題,並要求複合加法器(SUM)開始記錄。 When measuring the power cycle capability, when its health state (SOH) is greater than the predetermined X%, it indicates that there is a problem with the power cycle capability, and the composite adder (SUM) is required to start recording.
量測阻抗時,先判斷是否有過電壓保護(OVP)情況,若有,即執行過電壓中斷,即傳送至全域中斷處,要求控制板令功率模組立即停止。若沒有過電壓保護(OVP)的情況,則判斷是否大於預定Y%時,若有,則表示量測阻抗有問題,並要求複合加法器開始記錄,若無,則持續監控。 When measuring the impedance, first determine whether there is overvoltage protection (OVP). If there is, the overvoltage interrupt is executed, that is, it is transmitted to the global interrupt, and the control panel is required to stop the power module immediately. If there is no overvoltage protection (OVP), if it is judged whether it is greater than the predetermined Y%, if it is, it means that the measurement impedance has a problem, and the composite adder is required to start recording. If not, the monitoring is continued.
量測溫差時,先判斷是否有過溫保護(OTP)的情況,若有,即執行過溫中斷,即傳送至全域中斷處,要求控制板令功率模組立即停止。若沒有過溫保護(OTP)情況,則判斷是否大於預定Z%時,若有,則表示溫度有問題, 並要求複合加法器開始記錄,若無,則持續監控。 When measuring the temperature difference, first determine whether there is over-temperature protection (OTP). If there is, the over-temperature interrupt is executed, that is, it is transmitted to the global interrupt, and the control board is required to stop the power module immediately. If there is no over-temperature protection (OTP) condition, if it is judged whether it is greater than the predetermined Z%, if it is, it means that there is a problem with the temperature. The composite adder is required to start recording, and if not, it is continuously monitored.
量測即時功率時,先判斷是否有過電流保護(OCP)的情況,其中也包含短路部分,若有,即執行功率錯誤中斷,即傳送至全域中斷處,要求控制板令功率模組立即停止。若沒有過電流保護(OCP)情況,則要求複合加法器持續紀錄即時功率。 When measuring the instantaneous power, first determine whether there is overcurrent protection (OCP), which also includes the short-circuit part. If there is, the power error interrupt is executed, that is, it is transmitted to the global interrupt, and the control board is required to stop the power module immediately. . If there is no overcurrent protection (OCP) condition, the composite adder is required to continuously record the instantaneous power.
量測磁耦合時,先判斷是否符合電路規則,若無,即表示硬體迴路檢測異常,因而將此訊息傳送至全域中斷處,要求控制板令功率模組立即停止。若有過符合電路規則,則要求複合加法器持續紀錄硬體迴路檢測狀態。上述電路規則即指三相六臂驅動迴路運作時,不同運行狀態的各臂開閉情況,例如那些臂要開或那些臂要閉,若開閉不正常時,會導致馬達運作出問題。 When measuring the magnetic coupling, first determine whether the circuit rules are met. If not, it means that the hardware loop detection is abnormal, so the message is transmitted to the global interrupt, and the control board is required to stop the power module immediately. If there is a compliance with the circuit rules, the composite adder is required to continuously record the hardware loop detection status. The above circuit rules refer to the opening and closing of the arms in different operating states when the three-phase six-arm drive circuit is operated, for example, those arms are to be opened or those arms are to be closed, and if the opening and closing is not normal, the motor operation may be problematic.
複合加法器用於紀錄前述各項數據,經過運算後可算出危險指數,並送至危險指數區,危險指數區若發現資訊有誤,可要求複合加法器再提供資料,若無問題,則產生對應的反應時間,例如超過一定危險時,於風險指數紀錄區中紀錄異常狀態。另外,風險指數紀錄區發現要紀錄的資料有問題時,也會向危險指數區要求重送資料。 The compound adder is used to record the above data. After the calculation, the danger index can be calculated and sent to the danger index area. If the information is found to be incorrect in the danger index area, the composite adder can be requested to provide the data. If there is no problem, the corresponding data is generated. The reaction time, for example, when the risk is exceeded, the abnormal state is recorded in the risk index record area. In addition, when the risk index record area finds that there is a problem with the information to be recorded, it will also request the re-delivery of information to the risk index area.
全域中斷係表示十分危急情況,將立即停止功率模組的運作,若發生此情況將會記錄在致命異常錯誤區,然而此類也屬於功率模組即將損壞或已損毀的可能,故也會將資料通知危險指數區,進而記錄於風險指數紀錄區。 The global interrupt system indicates a very critical situation and will immediately stop the operation of the power module. If this happens, it will be recorded in the fatal abnormal error area. However, this type of power module is also likely to be damaged or damaged, so it will also The information is notified to the risk index area and recorded in the risk index record area.
請參照第10圖,係為本發明之智能型功率模組診斷方 法的步驟圖。於步驟S101中,量測功率模組之溫度、電流、輸入電壓及輸出電壓。本步驟即透過各種感測元件,量測功率模組運作時的溫度、電流和電壓。 Please refer to Figure 10 for the diagnosis of the intelligent power module of the present invention. Step diagram of the law. In step S101, the temperature, current, input voltage, and output voltage of the power module are measured. In this step, the temperature, current and voltage of the power module are measured through various sensing components.
於步驟S102中,檢測硬體迴路自我檢測機制。本步驟除了上述運作數據檢測外,還會進一步全時自我檢測硬體迴路當前狀態,若檢測迴路出現異常時,即表示功率模組運作異常,則連接功率模組的馬達會有運作錯誤的情況。 In step S102, a hardware loop self-detection mechanism is detected. In addition to the above-mentioned operational data detection, this step further self-detects the current state of the hardware loop. If the detection loop is abnormal, it indicates that the power module is operating abnormally, and the motor connected to the power module may have an operational error. .
於步驟S103中,依據該溫度及該電流計算出已操作之循環次數。本步驟是計算功率模組的已操作之循環次數,可由溫度和電流,此處的循環次數是指功率模組三相六臂驅動迴路內各臂的閘體運行時間積分。 In step S103, the number of cycles of operation has been calculated based on the temperature and the current. This step is to calculate the number of cycles of the power module that has been operated. It can be the temperature and current. The number of cycles here refers to the integral of the running time of the arm of each arm in the three-phase six-arm drive circuit of the power module.
於步驟S104中,透過該輸出電壓、該輸入電壓及該電流計算出量測阻抗。本步驟是計算量測阻抗,可由電壓和電流等計算得到。 In step S104, the measured impedance is calculated from the output voltage, the input voltage, and the current. This step is to calculate the measured impedance, which can be calculated from voltage and current.
於步驟S105中,由該量測阻抗、該輸出電壓及該電流計算出即時功率。於本步驟中,即利用量測阻抗、電壓、電流計算即時功率。 In step S105, the instantaneous power is calculated from the measured impedance, the output voltage, and the current. In this step, the instantaneous power is calculated by measuring impedance, voltage, and current.
於步驟S106中,依據該已操作之循環次數、該溫度、該量測阻抗、該即時功率及該硬體迴路狀態計算出危險指數,以於該危險指數大於一預設值時,累計異常指數紀錄。 於本步驟中,即前述各數值計算出一個危險指數,此危險指數表示器具瀕臨危險的指數高低。另外,於危險指數大於預設值時,可開始異常指數紀錄的累積,若越危急則紀錄頻率越高,使用者可透過異常指數紀錄得到功率模組的 狀態。 In step S106, a risk index is calculated according to the number of cycles of operation, the temperature, the measured impedance, the instantaneous power, and the hardware loop state, so that the cumulative index is accumulated when the risk index is greater than a predetermined value. Record. In this step, the aforementioned values calculate a hazard index, which indicates the level of the index at which the appliance is at risk. In addition, when the risk index is greater than the preset value, the accumulation of the abnormal index record can be started. If the more dangerous the record frequency is, the user can obtain the power module through the abnormal index record. status.
於本步驟中,還可包括於該異常指數紀錄大於警告值時,產生警告訊息。簡單來說,異常指數紀錄的累積是利於使用者提早發現問題,但若異常指數紀錄的累積大於一警告值時,亦可透過產生警告訊息來進行告警。 In this step, the warning message may be generated when the abnormality index record is greater than the warning value. In short, the accumulation of the abnormal index record is beneficial for the user to find the problem early, but if the accumulation of the abnormal index record is greater than a warning value, the alarm can also be generated by generating a warning message.
於另一實施態樣中,上述是針對持續觀察並紀錄來協助判斷功率模組是否可能損壞或需要更新,但若偵測到危急情況下,當然要立即提供功率模組的運作。因此,於硬體迴路狀態異常時,或者於溫差、量測阻抗、即時功率各別超過對應之臨界值時,則可產生中止指令以令功率模組停止運作。 In another embodiment, the above is for continuous observation and recording to help determine whether the power module is likely to be damaged or needs to be updated, but if a critical situation is detected, the operation of the power module is of course provided immediately. Therefore, when the hardware circuit state is abnormal, or when the temperature difference, the measured impedance, and the instantaneous power respectively exceed the corresponding threshold, an abort command may be generated to stop the power module from operating.
請參照第11圖,係為本發明之磁耦合閉迴路檢測機制的示意圖。本發明之磁耦合閉迴路檢測元件可設置於功率模組內三相橋接驅動器內各絕緣閘雙極電晶體處,用於檢測該些絕緣閘雙極電晶體的硬體迴路當前狀態,下面將透過第11圖來說明磁耦合閉迴路檢測機制。 Please refer to FIG. 11 , which is a schematic diagram of the magnetic coupling closed loop detection mechanism of the present invention. The magnetically coupled closed loop detecting component of the present invention can be disposed at each of the insulated gate bipolar transistors in the three-phase bridge driver of the power module for detecting the current state of the hardware loops of the insulated gate bipolar transistors. The magnetic coupling closed loop detection mechanism is explained through Fig. 11.
三相橋接驅動器可將功率模組分隔為高壓端和低壓端。超低靜態電流LDO電壓調節器可由外部提供電源,經過電源電壓監控器後,送至三相橋接驅動器,此時經過微控制器後,轉送至電源電壓調節器,以控制三相橋接驅動器,三相橋接驅動器控制閘極驅動器以驅動絕緣閘雙極電晶體(IGBT)的驅動,此時,會回傳閘極驅動器輸出和閘極驅動器輸入,藉此得到功率模組中各臂的硬體迴路狀態。 A three-phase bridge driver separates the power module into a high voltage end and a low voltage end. The ultra-low quiescent current LDO voltage regulator can be supplied from the external power supply, and then sent to the three-phase bridge driver after passing through the power supply voltage monitor. After passing through the microcontroller, it is transferred to the power supply voltage regulator to control the three-phase bridge driver. The phase bridge driver controls the gate driver to drive the insulation gate bipolar transistor (IGBT). At this time, the gate driver output and the gate driver input are returned, thereby obtaining the hardware loop of each arm in the power module. status.
本發明透過磁耦合閉迴路檢測機制,除了電壓、電流和溫度等監控外,更進一步硬體迴路自我檢測,此檢測是針對三相橋接驅動器中各臂是否是正常運作,若有異常產生,則儘速進行修復或更新。 The invention passes through the magnetic coupling closed loop detection mechanism, in addition to the monitoring of voltage, current and temperature, and further self-detection of the hardware loop, the detection is for whether the arms of the three-phase bridge driver are normally operated, and if an abnormality occurs, Fix or update as soon as possible.
請參照第12圖,係為本發明之電流感測元件的示意圖本發明之電流感測元件1221,其透過貼片方式設置於功率模組之導線1201上,其中,於電流通過該導線1201而於該導線1201周邊產生磁場下,令該電流感測元件1221感測該磁場,藉以計算通過該導線之電流值。 Referring to FIG. 12, it is a schematic diagram of a current sensing component of the present invention. The current sensing component 1221 of the present invention is disposed on a wire 1201 of a power module through a patch, wherein a current passes through the wire 1201. Under the magnetic field generated around the wire 1201, the current sensing component 1221 senses the magnetic field, thereby calculating the current value through the wire.
一般功率模組的電流感測,都是另外將感測線連接至導線,並在功率模組外設置電流感測器,進而得到流經該導線之電流。本發明則提出貼片方式設置於功率模組之導線1201上,當電流通過導線時,會在導線周邊產生磁場,此時貼片式的電流感測元件1221可用來感測磁場,如此可藉由磁場換算成通過該導線之電流值。 In the current sensing of the power module, the sensing line is additionally connected to the wire, and a current sensor is disposed outside the power module to obtain a current flowing through the wire. The present invention proposes that the patch mode is disposed on the wire 1201 of the power module. When a current passes through the wire, a magnetic field is generated around the wire. At this time, the chip type current sensing component 1221 can be used to sense the magnetic field, so The value of the current passing through the wire is converted by the magnetic field.
透過貼片式的電流感測元件,讓電流測量更方便,即可直接透過磁感應而得到電流。有別於一般電流感測,即便是採用磁場感應,感測元件也是需要包圍導線線路來感測磁場,但本發明為貼片式,可直接貼附於線路上,亦不同於一般磁場量測。 Through the chip-type current sensing component, the current measurement is more convenient, and the current can be obtained directly through the magnetic induction. Different from general current sensing, even if magnetic field sensing is used, the sensing element needs to surround the wire line to sense the magnetic field, but the invention is a patch type, which can be directly attached to the line, and is different from the general magnetic field measurement. .
綜上所述,本發明之智能型功率模組診斷系統及其方法,在功率模組上結合硬體檢測迴路(Electrical rule check)模組及診斷等模組電路,藉此得到危險指數,並依照危險指數判斷是否有立刻性的危險,若判斷結果達到危險指標 預定值時,則開始累計異常指數,並儲存在可複寫記憶體中,如此可提供使用者監控功率模組的狀態。透過上述機制,使用者可透過異常指數累計情況得到功率模組的狀態,判斷硬體是否需要進行硬體修復或更新,故可達到事前監控的目的。 In summary, the intelligent power module diagnostic system and method of the present invention combines a hardware rule check module and a diagnostic module circuit on the power module to obtain a danger index, and According to the risk index, it is judged whether there is an immediate danger, and if the judgment result reaches the danger index When the value is predetermined, the cumulative abnormality index is started and stored in the rewritable memory, so that the user can monitor the state of the power module. Through the above mechanism, the user can obtain the status of the power module through the accumulation of the abnormal index, and determine whether the hardware needs to be repaired or updated by hardware, so that the purpose of the pre-monitoring can be achieved.
上述實施形態僅例示性說明本發明之原理及其功效,而非用於限制本發明。任何熟習此項技藝之人士均可在不違背本發明之精神及範疇下,對上述實施形態進行修飾與改變。因此,本發明之權利保護範圍,應如後述之申請專利範圍所列。 The above embodiments are merely illustrative of the principles and effects of the invention and are not intended to limit the invention. Modifications and variations of the above-described embodiments can be made by those skilled in the art without departing from the spirit and scope of the invention. Therefore, the scope of protection of the present invention should be as set forth in the scope of the claims described below.
1‧‧‧智能型功率模組診斷系統 1‧‧‧Intelligent Power Module Diagnostic System
11‧‧‧功率模組 11‧‧‧Power Module
111‧‧‧溫度感測元件 111‧‧‧Temperature sensing components
12‧‧‧硬體檢測迴路模組 12‧‧‧ hardware detection loop module
121‧‧‧電流感測元件 121‧‧‧ Current sensing components
122‧‧‧電壓感測元件 122‧‧‧Voltage sensing components
123‧‧‧磁耦合閉迴路檢測元件 123‧‧‧Magnetic coupled closed loop detection components
13‧‧‧診斷模組 13‧‧‧Diagnostic Module
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