TWI598608B - Intelligent diagnosis system for power module and method thereof - Google Patents

Description

Intelligent power module diagnosis system and method thereof

The present invention relates to a power module detection mechanism, and more particularly to an intelligent power module diagnostic system and method thereof.

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.

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.

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.

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.

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.

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.

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 .

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‧‧‧Intelligent Power Module Diagnostic System

11, 21‧‧‧ Power Module

111, 511‧‧‧ Temperature sensing components

12‧‧‧ hardware detection loop module

121, 621‧‧‧ current sensing components

122, 722‧‧‧ voltage sensing components

123, 823‧‧‧ Magnetically coupled closed loop detection components

13‧‧‧Diagnostic Module

22‧‧‧ hardware detection loop circuit board

23‧‧‧Control panel

24‧‧‧Upper cover

25‧‧‧Under cover

311‧‧‧temperature sensor

322‧‧‧Voltage sensor

323‧‧‧Magnetic coupling closed loop detection

1201‧‧‧Wire

1221‧‧‧ Current sensing components

S101~S106‧‧‧Steps

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.

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.

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.

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 .

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

The setting and application of each sensing element will be separately described later.

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.

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.

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.

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.

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. .

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.

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.

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).

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.

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.

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.

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.

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.

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)

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).

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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. .

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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. .

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.

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‧‧‧Intelligent Power Module Diagnostic System

11‧‧‧Power Module

111‧‧‧Temperature sensing components

12‧‧‧ hardware detection loop module

121‧‧‧ Current sensing components

122‧‧‧Voltage sensing components

123‧‧‧Magnetic coupled closed loop detection components

13‧‧‧Diagnostic Module

Claims (16)

An intelligent power module diagnostic system includes: a power module, which is provided with a temperature sensing component for measuring a minimum temperature and a current temperature of the power module to obtain a temperature difference; a hardware detection loop module, The utility model is disposed on a side of the power module and is provided with a current sensing component, a voltage sensing component and a magnetic coupling closed loop detecting component, wherein the current sensing component is configured to sense a current in the power module, the voltage The 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 connected to the The power module and the hardware detection loop module calculate the number of cycles of operation of the power module based on the current temperature and the current measured by the current sensing component, and the output voltage, the input voltage, and The current calculates 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 number of cycles of the operation The temperature difference, the impedance measurement, and the instantaneous power of the hardware state detection circuit to calculate risk index. The intelligent power module diagnostic system of claim 1, wherein the diagnostic module accumulates an abnormality index record when the risk index is greater than a predetermined value. The intelligent power module diagnostic system of claim 2, wherein the warning message is generated when the abnormality index record is greater than the warning value. The intelligent power module diagnostic system of claim 1, wherein the diagnostic module generates a suspension command when the hardware loop detection state is abnormal to stop the power module from operating. The intelligent power module diagnostic system of claim 1, wherein the diagnostic module generates a suspension command when the temperature difference, the measured impedance, and the instantaneous power respectively exceed a corresponding threshold value The power module stops working. The intelligent power module diagnostic system of claim 1, wherein the temperature sensing component is disposed at a three-phase circuit of the three-phase bridge driver in the power module. The intelligent power module diagnostic system of claim 1, wherein the current sensing component is disposed on the U-phase, V-phase, and W-phase coils of the three-phase bridge driver in the power module. The intelligent power module diagnostic system of claim 1, wherein the voltage sensing component is disposed at a voltage output of the three-phase bridge driver and a voltage input of the power module. The intelligent power module diagnostic system of claim 1, wherein the magnetically coupled closed loop detecting component is disposed at each of the insulated gate bipolar transistors in the three-phase bridge driver of the power module. An intelligent power module diagnostic method includes: Measuring the temperature, current, input voltage and output voltage of the power module; self-detecting the hardware loop state; calculating the number of cycles that the power module has been operated according to the temperature and the current; and transmitting the output voltage, the input voltage, and Calculating the impedance from the current; calculating the instantaneous power from the measured impedance, the output voltage, and the current; and determining the impedance according to the operated cycle number, the temperature, the measured impedance, the instantaneous power, and the hardware circuit The detection status calculates the risk index. For example, the intelligent power module diagnosis method described in claim 10 of the patent application includes the cumulative abnormality index record when the risk index is greater than a preset value. The intelligent power module diagnosis method described in claim 11 further includes generating a warning message when the abnormality index record is greater than the warning value. The intelligent power module diagnostic method according to claim 10, wherein when the hardware circuit state is abnormal, a suspension command is generated to stop the power module from operating. The smart power module diagnostic method according to claim 10, wherein when the temperature, the measured impedance, and the instantaneous power respectively exceed a corresponding threshold, a suspension command is generated to cause the The power module stops working. A current sensing component is disposed on a wire of a power module through a patch, wherein a current is generated by a current passing through the wire to generate a magnetic field around the wire, so that the current sensing component senses the magnetic field, thereby calculating The current value of the wire. A magnetically coupled closed loop detecting component is 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 loop of the insulated gate bipolar transistors.