The present invention relates to a method for activating a rectifier having active switching elements in the event of a load dump, an activating circuit for activating a rectifier having active switching elements in the event of a load dump, a rectifier having active switching elements, and an electric generator.
Rectifiers are generally used for supplying direct current systems from three-phase current systems, such as in the public three-phase system. These rectifiers are mostly designed as a bridge circuit, diodes being used as rectifier elements. The diodes do not need any additional activating circuit, since they transition automatically at the correct point in time into the conducting or blocking state.
Bridge rectifiers are also used as rectifiers in three-phase generators for motor vehicles. The power loss implemented in the diode rectifiers results from the diode design and the current to be rectified. These losses may be reduced only insignificantly by circuitry-related measures, such as parallel switching of diodes. However, if the diodes are replaced by active switches, e.g., MOSFETs, these losses may be considerably reduced. The use of active switches, however, requires a controller which switches the switches on and off at the correct point in time.
A critical operating state of an active rectifier is the load dump. A load dump is present if the load cable drops or consumers are abruptly turned off in the case of an excited machine having output current. The generator usually continues to deliver energy, which must be converted in the rectifier, for 300 ms to 500 ms in order to protect the vehicle electrical system against damage due to overvoltage.
In conventional diode rectifiers, this energy loss may be converted into heat. Here, the diodes offer an adequate integrated circuit packaging having low thermal impedances. Furthermore, the Zener diodes offer the advantage that the Zener voltage rises with rising temperature. In this way, almost even distribution of the current load of the branches is achieved among the individual branches. In the thermally balanced state, the Zener voltages are initially not identical due to manufacturing deviations. Switching branches having a lower Zener voltage are subjected to more current. A self-inhibiting effect occurs, which results in an almost even distribution of the current, due to the fact that the Zener voltage rises with rising temperature.
In the case of active rectifiers, MOSFETs are usually used as power switches. In known circuits for voltage clamping, the clamp voltage is a function of the threshold voltage of the MOSFETs, which is why the decrease in the threshold voltage results in a decrease in the clamp voltage. Since the threshold voltages of MOSFETs have negative temperature coefficients, the clamp voltage of such active rectifiers decreases when the temperature increases. This results in an uneven distribution of the current resulting in an uneven distribution of the temperature, which reinforces the uneven distribution of the current and is demonstrated as a positive feedback effect.
In known circuits for voltage clamping, the clamp voltage is composed of the breakdown voltage of a Zener diode, or a chain of Zener diodes, and the threshold voltage of the MOSFET. Since the Zener diodes are thermally not coupled or coupled only insufficiently to the MOSFET, their positive temperature coefficient cannot compensate for the negative temperature coefficient of the threshold voltage of the MOSFET.
An output stage having an even distribution of the Zener voltage and a method for operating this output stage are known from the publication WO 2006/114362 A2. The above-described output stage is used for switching inductive loads and includes at least two parallel-switched individual output stages. In parallel-switched output stages, problems may occur during switch-off due to tolerances, thus resulting in the output stage being strictly limited in its range of application. To avoid this from happening, it is proposed to carry out a thermal coupling between a Zener diode and a switching transistor which are components of an individual output stage, thus causing the output stage extinction voltage to be evenly distributed.
Against this background, a method for activating a rectifier having the features of Claim 1, an activating circuit according to Claim 9, a rectifier according to Claim 11, and an electric generator according to Claim 12 are presented. Embodiments result from the dependent claims and the description.
The presented method is used to distribute the power converted during the voltage clamping during a load dump as evenly as possible to the power transistors of all switching branches in order to achieve the most homogeneous heating possible of the involved power transistors. A method is thus represented for evenly distributing the power loss when the voltage is delimited in rectifiers.
Further advantages and embodiments of the present invention result from the appended drawings and the description.
It is understood that the above-mentioned features and the features to be elucidated below are usable not only in the given combination, but also in other combinations or alone without departing from the scope of the present invention.
The present invention is illustrated schematically in the drawings on the basis of specific embodiments and is described in detail in the following with reference to the drawings. The method of the present invention is described in the following with reference to a 3-phase system, but it is easily transferrable to multi-phase systems.
Generator 10 generates three phase signals, namely phase U 20, phase V 22, and phase W 24. These three phases 20, 22, and 24 are fed into rectifier 12 in which switching elements are situated between a plus pole 26 and a minus pole 28 in a first branch 30, a second branch 32, and a third branch 34.
Here, first branch 30 includes a first switching element 40 and a second switching element 42, second branch 32 includes a third switching element 50 and a fourth switching element 52, and third branch 34 includes a fifth switching element 60 and a sixth switching element 62. Switching elements 40, 42, 50, 52, 60, 62 each include a switch having a parallel-switched diode and may be designed as MOSFETs, each having a source, drain, and gate connection.
The three phases U 20, V 22, and W 24 are converted by rectifier 12 into DC values.
Circuit 14 for generating the activating signals evaluates the three phases 20, 22, and 24 and generates control signals using which activation 16 takes place for the switches of switching elements 40, 42, 50, 52, 60, and 62.
The switch-on conditions of the active switches occur via an evaluation of the voltage at the diodes or inverse diodes of the MOSFETs. In the case of a forward voltage of typically 0.7 V, a reliable detection of the switch-on condition is possible at a limiting value of 0.35 V, for example. As soon as the activation has taken place, this signal breaks down, since the diode forward voltage through the RDS_ON of the MOSFET is bridged. Therefore, a voltage measurement to ascertain the switch-off point in time is problematic.
It is to be noted that a significantly higher signal may be achieved as a result of a loss-free current measurement. It is important that the voltage measurement is loss-free, since the efficiency gain would be eliminated as a result of the introduction of a shunt.
An activation on the basis of a voltage measurement is advantageous compared to an activation on the basis of a current measurement, since the efficiency may be optimally used in this way.
Furthermore, the illustration shows a controller 78, a first control unit 80, a second control unit 82, and a third control unit 84.
In the case of a load dump, current paths according to
Both current paths start at phase connection V and end at phase connection W. This also applies to paths III and IV having phases U and W. Thus, the paths are equivalent to the outside and the current will take the path having the lower counter-voltage. Now, since the clamp voltages marked with shaded arrows 90 are higher than the forward breakdown voltages marked with the other arrows 92 by one order of magnitude, the occurring counter-voltages are dominated by the Zener voltages and the current will select the path having the lower clamp voltage.
Combined with the negative temperature coefficient (TC) described in the following, this effect results in an uneven load of the output stages, the unevenness worsening in the course of the load drop due to an occurring positive feedback effect.
In order to generate an even energy distribution of a load dump among the six switches involved in the present example, in the active rectifier, the negative temperature coefficient of the threshold voltage of the MOSFETs must be compensated for by a suitable countermeasure.
It includes a MOSFET 102, a diode 104, a Zener diode 106, and a resistor 108.
For the configuration shown in
U
—
DS=U
—
Z+U
—
GS
Since MOSFET 102 is operated at a working point at a very steep characteristic curve, small changes in the threshold voltage significantly influence the drain current of the MOSFET.
In rectifier diodes of passive rectifiers, the avalanche effect dominates in the blocking operation, which is why these diodes have positive temperature coefficients of the breakdown voltage. In passive rectifiers, the power loss converted during voltage clamping therefore is distributed almost evenly among the involved branches.
It is to be noted that in generators for motor vehicles, time periods of approximately 200 ms to 500 ms are necessary to reduce the excitation current during a load dump event. Corresponding time periods therefore apply for the clamping operation of the rectifiers during a load dump event.
In the presented method, it is now provided in one embodiment to run the effect of the increasing clamp voltage in a considerably lower time scale in a time-controlled manner. Here, it is exploited that a load dump consists of chronologically returning events similar to sinusoidal half-waves. The frequency of the sinusoidal half-waves is in this case a function of the pole pair number of the instantaneous rotational speed of the used electric machine. Now, the clamp voltage within every single sinusoidal half-wave is supposed to start at an established level and increase within a millisecond by 2 V, for example.
It is to be noted that the increase in the clamp voltage is selected to be high enough to be able to compensate for the drop in the threshold voltage above the temperature.
The advantages over the related art are:
In the representation of a circuit for voltage clamping from a MOSFET and Zener diodes according to
If the algorithm explained above is now implemented in the ASIC, the MOSFETs are subjected to load relatively symmetrically, viewed on average. The temperature difference of the individual MOSFETs is significantly smaller. The hottest MOSFET is subjected to a heating by 90K and the coolest to a heating by 50K according to the simulation. Consequently, an extreme overload of individual switching branches, as in
In
The presented algorithm is apparent by a negative voltage curve at the gate of the MOSFET, as illustrated in
Due to the negative voltage progression, it is achieved that every MOSFET takes on the greatest energy at the beginning of a half-wave as a result of the high activating voltage and tightens its channel further in the course of the pulse by reducing the activating voltage, and consequently causes less and less energy to be taken in due to the greater resistance.
This effect may alternatively also be measured at the closed control unit between an arbitrary phase and Bat+ or Bat−. During the clamping operation at a constant clamping current, the increase in the clamp voltage, which is a function of time, may be measured. The measurement should preferably take place at low currents, i.e., without noteworthy power input, to ensure that the measured clamp voltage is not influenced by temperature effects. The measurement may take place at a stationary generator in the laboratory by inputting an external clamping current into an arbitrary switching branch.
The result to be expected is shown in
Alternatively or additionally to the method presented above, the problem of the even power loss distribution during a load dump event may be improved by monolithically integrating the Zener diode according to
If the Zener diode is integrated into the activating circuit in such a way that it is spatially separated from the MOSFET, the temperature flow from the MOSFET, which heats up considerably during the load dump event, to the Zener diode takes place in a time-delayed manner. This delay is within a range of approximately 100 ms for the DBC structure shown in
In the presented method, it is provided in one embodiment to obtain a symmetrization of the currents to the individual MOSFETs with the aid of a positive (viewed overall) temperature coefficient. This is implemented by the fact that a Zener diode is implemented in the MOSFETs in which the cathode is connected to the drain of the MOSFET, as illustrated in
The negative temperature coefficient of the threshold voltage of the MOSFET is overcompensated for by the positive temperature coefficient of the Zener diode of −14 mV/K, for example. In this way, an effect of the counter-coupling takes place, which results in the approximately even distribution of the power loss during the voltage clamping during the load dump event. The maximum temperature of the MOSFETs is thus reduced to 200° C. after simulation, as illustrated in
Basically, the even distribution of the power loss is thus caused by the thermal coupling of a power semiconductor and a Zener diode.
In comparison to
The advantages over passive diode rectifiers are based on the fact that the clamp voltage does not drift upward over the entire load dump period, that the clamp voltage is tolerable in a closer range than in passive rectifiers, since hardly any current flows in the involved Zener diode, and that a smaller power loss occurs during the rectifier operation.
The advantages over the related art are:
In the illustration of a circuit for voltage clamping from a MOSFET and a Zener diode according to
In another specific embodiment, the anode of the Zener diode may be connected directly, as an integral part of the integration, to the gate of the MOSFET during the monolithic integration of the MOSFET and the Zener diode.
Two methods have been described above using which it is possible to achieve an approximately even distribution in the rectifying elements during the power losses converted during the voltage clamping. Subsequently, another method is shown which may be used as an alternative or in combination.
Subsequently, an improved method for controlling the clamp voltage is described which noticeably suppresses the influence of the negative temperature coefficient of the threshold voltage of the MOSFET.
In this case, predefined voltage U_setpoint 474 may either be constant or increase over time, i.e., have a ramp-shaped characteristic. By using a ramp-shaped characteristic of U_setpoint, it is possible to combine this specific embodiment of the method with the first-mentioned specific embodiment of the method. The implementation of this improved method for controlling the clamp voltage and also the provision of ramp-shaped reference variables for the clamp voltage may, for example, take place as discrete circuits or by integrating the components into an ASIC or also largely digitally, e.g., by using microcontrollers or FPGAs.
The advantages over the related art are:
The efficiency of the described measure may be proven based on simulations.
It is clearly apparent in
Number | Date | Country | Kind |
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10 2011 006 316.1 | Mar 2011 | DE | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/EP2012/050010 | 1/2/2012 | WO | 00 | 12/4/2013 |