This application claims priority to German Patent Application No. 102023118441.5 filed on 12 Jul. 2023, which is hereby incorporated by reference.
The present disclosure relates to a method for monitoring a semiconductor switch and an inverter circuit for carrying out the method.
Thermomechanical stresses due to load and temperature changes in semiconductor switches (e.g. MOSFETs or IGBTs) are the main causes of failures in the switches. The thermomechanical stresses can cause various failures, such as Heel cracks in the wire bonds due to cyclic displacement of the wires, fatigue of the solder at the die attachment (the resistance of the die attachment solder layer increases as the solder layer deteriorates) or lift-off of the bond wire (temperature fluctuation leads to a change in the length of the wire; since both wire ends are mechanically fixed, micro-movements occur, which lead to stresses at the bonding interface of the bond wires and finally to lift-off of the bond wire).
Such faults can be detected by monitoring the drain-source voltage VDSon across the switch or by measuring the switch-on resistance RDS (or RDson) of the switch and comparing it with previously measured values. Any significant change in the drain-source voltage or its on-resistance may indicate degradation or premature failure of the bond wires or solder layer. However, the measurements are strongly influenced by parasitic elements in the components (bond wires, etc.). Random calibration is also required to compensate for the influence of intermediate connections. Thus, the determination of VDSon or RDS is not very accurate and also requires complicated circuits to measure VDSon, especially for high-voltage (HV) switches. In the latter case, it is also necessary to separate or isolate the high-voltage area from the evaluation electronics, which makes the transmission of the measured signal from the power electronics to the evaluation electronics very complex due to the isolation and also the interference immunity. In turn, the measurement of RDS is heavily dependent on the load current. Other methods for fault detection are, for example, measuring the gate peak current or the Miller plateau length when the gate driver is switched off.
According to the disclosure, a method for monitoring a semiconductor switch and an inverter circuit for carrying out the method are proposed with the features of the independent patent claims. Advantageous embodiments are the subject of the dependent claims and the following description.
In order to monitor the semiconductor switch, which has a control terminal, a current input terminal and a current output terminal, in particular to monitor the electrical connections, the disclosure proposes monitoring the voltage between the current input terminal and the current output terminal (drain-source voltage or collector-emitter voltage) without having to measure it directly. In particular, a simple circuit (which is also referred to below as a DeSat circuit) is used between the current input terminal and a potential terminal instead, whereby the current input terminal is connected to the potential terminal via a reverse-biased diode, a connection point of a capacitor whose other connection point is connected to ground, a resistor component and a current source. The drain-source voltage can be determined from the voltage dropping across the capacitor.
This is particularly advantageous because the concept of desaturation (DeSat) protection, which is known per se for semiconductor switches, can be used for the circuit configuration described with a minimum of additional components, so that the effort and costs are considerably reduced. Commercially available gate driver ICs (hereinafter referred to as gate drivers) can have a DeSat connection to which the drain connection of the semiconductor switch is connected via a DeSat circuit as described above. The gate driver can thus monitor the semiconductor switch for overcurrent or short circuit and switch it off in the event of a fault. In the context of the disclosure, a deteriorating or even failed electrical connection of the semiconductor switch is now detected by a special evaluation of voltages in the DeSat circuit.
Specifically, the DeSat voltage dropping across the capacitor is determined at a first point in time and at a second point in time, and a drain-source voltage dropping between the current input terminal and the current output terminal of the semiconductor switch at the first point in time is determined from the DeSat voltage determined at the first point in time and the DeSat voltage determined at the second point in time. These steps are repeated for several different first points in time in order to obtain a plurality of drain-source voltages for the several different first points in time. A functionality or operability of the semiconductor switch is then determined from the plurality of drain-source voltages for the plurality of different first points in time.
The disclosure overcomes the disadvantages of the prior art and in particular leads to a number of advantages. Neither VDSon nor RDS need to be measured in order to measure the voltage of the switch or the switch-on resistance of the switch in the on-state; instead, these can be derived very simply from the DeSat voltage.
A data interface can be used to transmit the measurement signals to the evaluation electronics (control unit) with appropriately equipped gate drivers, so that no additional signal transmission is required. The isolation of the measured signal is then also provided by the isolation of the gate driver.
The proposed concept can be used for online monitoring of the state of the semiconductor switch and online fault detection.
No additional space is required as no precise high-bandwidth current sensor needs to be added to each switch. This is particularly advantageous for Transistor Outline (TO) housings connected to the busbars or PCB (printed circuit board), where space is usually limited. Furthermore, the disclosure can be advantageously used for power modules that contain several parallel chips.
The proposed method is hardly dependent on the load current and the temperature of the DeSat circuit.
Existing temperature sensors for the switch and also the phase current measurement can be used for detection purposes without the need for additional sensors.
The disclosure has particular advantages for semiconductor switches which are used in an inverter circuit to control an electric machine, in particular in vehicles, for example as a drive or traction drive, since large currents flow here and evaluation is therefore simplified. As is known, an inverter circuit or a power converter circuit is used to connect AC voltage terminals of the electric machine to DC voltage terminals of a network, such as a vehicle network, and to convert the voltages accordingly. The inverter circuit has a number of semiconductor switches for this purpose, each of which can be opened (non-conductive) and closed (conductive) in accordance with a control signal. The semiconductor switches can comprise MOSFETs and IGBTs, for example gallium nitride (GaN) or silicon carbide (SiC) FETs. The vehicle network can be a low-voltage network or a high-voltage network, whereby in the latter case a low-voltage network is also present to supply the components of the inverter circuit with electricity. The high-voltage network and low-voltage network can be coupled in the vehicle via a suitable DC/DC converter. The nominal voltage level of the high-voltage network (hereinafter also referred to as the high-voltage level) can, for example, be significantly higher than a permissible touch voltage, in particular 60 V, e.g. up to several hundred volts. For example, high-voltage levels of 400 V or 800 V are often used in current electric vehicles. The nominal voltage level of the low-voltage network can, for example, correspond to standard vehicle low voltages of 12 V or 24 V, for example.
In one embodiment, the inverter circuit can have a number of high-side semiconductor switches and a number of low-side semiconductor switches and at least one gate driver for one or more of the semiconductor switches in each case. The gate driver is used to apply a control signal to a control terminal of a semiconductor switch (e.g. gate terminal of MOSFET). In particular, the gate driver has a DeSat connection.
Further advantages and embodiments of the disclosure are shown in the description and the accompanying drawing.
The disclosure is illustrated schematically in the drawing by means of embodiment examples and is described below with reference to the drawing.
The semiconductor switch 10 has a current input terminal 10-1, a control terminal 10-2 and a current output terminal 10-3. In the present case, the semiconductor switch 10 is illustrated as a MOSFET or SIC MOSFET, so that the terminals are usually and hereinafter referred to as drain, gate and source. However, it can also be an IGBT, in which case the connections are usually referred to as collector, gate and emitter.
The gate driver 20 comprises a terminal or pin DESAT, which can be used to monitor the semiconductor switch 10 if it is correctly connected. Internal components of the gate driver 20 are only partially indicated, but the DESAT connection is usually connected via a current source (here IC) to a voltage supply (here VCC2) via a terminal VCC2 and to a comparator (here operational amplifier), which compares the voltage VDSAT dropping between the DESAT pin and ground with an internal threshold voltage (here VDSAT_th) and initiates protective measures depending on the comparison result.
A DeSat circuit 30 is arranged between the current input terminal or drain terminal 10-1 of the semiconductor switch 10 and the DeSat terminal DESAT of the gate driver 20, which has a resistor component (hereinafter also simply a resistor) RDSAT, a blanking capacitor CDSAT and a diode DDSAT. The diode is connected to the drain terminal 10-1 of the semiconductor switch 10 to be monitored. It should be noted at this point that the diode can also be connected to the drain terminals of several semiconductor switches to be monitored. In series with the diode DDSAT and the resistor component RDSAT is the connection point of the capacitor CDSAT, the other connection point of which is connected to ground.
When the circuit arrangement 100 is switched on, the current source IC charges the blanking capacitor CDSAT and the diode DDSAT is conductive. The current strength of IC can be adjustable, but is also fixed in some gate drivers. In normal operation, the voltage of the capacitor is clamped to the forward voltage of the diode. In the event of a short circuit or generally a very high load current through the semiconductor switch, the diode becomes non-conductive and the DeSat voltage VDSAT dropping between the DESAT terminal and ground (or across the capacitor) is then quickly charged to the threshold voltage (by the current source), which triggers the DeSat protection function on the gate driver side and leads to the semiconductor switch being switched off. The switch-off process can be carried out as a soft turn-off to prevent damage to the switch due to the overvoltage that occurs during switch-off.
In such a circuit arrangement, the drain-source voltage VDSon can also be derived from available measured values in accordance with embodiments of the disclosure. In principle, VDSon is obtained using the following equations (1) and (2):
with VF,DSAT: forward voltage of the diode
However, the forward voltage VF,DSAT of the diode and the resistance (value) of the component RDSAT are strongly temperature-dependent, which negatively influences the accuracy of the calculated value RDSon.
Typical inverter circuits normally already have a load or phase current measurement, so that no additional current sensor is required. This sensor is used in embodiments of the disclosure and is arranged on the load side. If this is a high-voltage network, for example, the output of the sensor must be isolated and then sent to the evaluating control unit, which is usually located in a low-voltage network.
VDSAT can be measured in the gate driver (see also
A first measurement takes place at a first point in time tn, whereby a first load current IL(tn) flows through the semiconductor switch 10 as a drain current (ID). The following then applies:
with a voltage drop Vdrop(tn) across the DeSat resistor component and the DeSat diode of
If the first measurement is carried out at the apex of the current wave, or at a sufficiently high value, this is advantageous for the signal/noise ratio.
In the next step, the measurement takes place at a different point in time tn+1 of the load current cycle (see
If, in one embodiment, the second measurement is carried out at a time when the current is as low as possible, but the semiconductor switch is still conducting, for example at or near the zero crossing (see
In particular, it must be ensured that the semiconductor switch 10 is conductive at the first point in time tn and at the second point in time tn+1. Advantageously, a situation arises in which the DeSat voltage determined at the first point in time tn is greater, in particular significantly greater, e.g. by a factor of 2 or more, than the DeSat voltage determined at the second point in time tn+1.
The following applies:
If the two measurements are very close to each other in terms of duration (e.g. a few 10 to 100 ms), it can be assumed that the temperature of the semiconductor switch, the DeSat diode and the DeSat resistor component has not changed significantly. Therefore, no change in Vdrop is expected for two consecutive measurements tn, tn+1 within one electrical cycle, or in other words, if the semiconductor switch 10 is non-conductive between the first time tn and the second time tn+1. Then the following applies:
The effect of Vdrop on the measurement can therefore be neglected, so that the following applies:
Thus, the drain-source voltage VDSon(IL(tn),Tj) for a specific load current IL(tn) and a specific junction temperature Tj results from two successive measurements of VDSAT (i.e. VDSAT(tn) for a first point in time and VDSAT(tn+1) for a second point in time) in the event that the load current IL(tn+1) is (essentially) zero at the second measurement or at the second point in time.
From the drain-source voltage VDSon(IL(tn),Tj) and the load current IL(tn), it is possible to determine the switch-on resistance RDSon(IL(tn),Tj), but is not necessary for the invention. After determining the drain-source voltage VDSon(IL(tn),Tj) using equation (9), the value is conveniently stored in a storage device, such as a local non-volatile memory or a remote memory (such as a cloud), as a table for given temperatures and load currents.
By comparing a current drain-source voltage (and/or a current turn-on resistance) with an earlier value, or in other words by comparing a drain-source voltage at a current first point in time with a drain-source voltage at an earlier first point in time, a operability of the semiconductor switch can be monitored or checked. In particular, the operability can be determined from the comparison result, whereby a malfunction can be inferred in the event of a significant deviation (i.e. if a difference between the drain-source voltage at the current first point in time and the drain-source voltage at the earlier first point in time exceeds a threshold value). Such a malfunction may include, for example, a poor electrical connection.
If the operability of the semiconductor switch is determined to be insufficient, a measure can be carried out, e.g. a repair request, a fault memory entry, etc. can be triggered or carried out.
To enable a meaningful comparison of the calculated VDSon and/or RDson with previously measured values, the comparison should be carried out with the same load current IL. (drain current ID) (within permissible tolerances) and the same junction temperature Tj (within permissible tolerances). The load current is usually measured in inverters for control and protection purposes anyway. Therefore, if a high-resolution and accurate load current is available, this value can be used for the analysis. The junction temperature is also usually determined, e.g. estimated, in inverters for protection and de-rating purposes.
It can be seen that initially no significant change in the value can be seen in a period 301, and then the value gradually increases in a period 302 before rising sharply in a period 303. This means that the electrical connection of the semiconductor switch in period 301 is little to undamaged; this indicates a normal wear or degradation. Increasing degradation or deterioration occurs in period 302, which can include detachment of bonding wires and/or solder defects. In period 303, failure is imminent or has already occurred.
In particular, in embodiments of the disclosure, if it is determined that the semiconductor switch is in the r period 302, this can be determined as an insufficient operability of the semiconductor switch, and an action such as a repair request, a fault memory entry, etc. can be triggered or performed. Detection can take place, for example, by comparison with previous values. For example, a fault can be detected if the current value deviates from a reference value by more than a permissible tolerance threshold. For example, a moving average can be determined as a reference value.
In
The inverter circuit 400 has a gate driver 20, a DeSat circuit 30 and a control unit 410. The control unit 410 can be a local control unit of the inverter circuit, for example an electric motor control unit (MCU), or all data can be transmitted to a remote control unit or a cloud and then analyzed remotely. In this example, the use of a local control unit is shown.
The half-bridge arrangement is connected to a terminal B+on the supply side and to a terminal B-on the ground side, which can be supplied, for example, from a DC link and/or a high-voltage network of a vehicle. The center tap of the half-bridge arrangement is connected as load terminal VOUT to a stator or phase winding of the electric machine, for example.
A desired load current IL. can be generated in the stator winding by selectively controlling the semiconductor switches 10 and 11. In the example shown, a load current measurement is realized by means of a current measuring circuit 420, which can be connected, for example, to a corresponding current sensor 421 in the phase winding or its supply line.
A temperature measurement is realized by means of a temperature sensor 431, for example a PTC or NTC, which is connected to an analog input Al of the gate driver 20 in the present case. The temperature sensor 431 can be installed on the power module or on the housing of the semiconductor switch 10 and detect a temperature TS of the semiconductor switch 10.
The control unit 410 contains a logic unit 411, which implements the functionality of the control unit 410 in terms of programming.
The modules used to implement one embodiment of the invention are shown separately and, in particular, independently of the logic unit 411. As explained, they can also be implemented elsewhere or in other control units. However, implementation in an MCU is advantageous, since much of the required information or data is available there anyway.
In particular, the logic unit 411 determines PWM signals PWM_1 and PWM_2 for controlling the semiconductor switches 10 and 11, which are routed to inputs IN− and IN+ of the gate driver 20 and to an ADC unit 412. The gate driver 20 outputs the control signals (in this case separate signals for ON and OFF) for the semiconductor switch 10 at outputs OUTH or OUTL, which are connected to the gate 10-2 via current limiting resistors RON and ROFF. One or more separate gate driver(s) (not shown) must be provided for the semiconductor switch 11, which can be constructed and connected in the same way as the gate driver 20, or corresponding additional terminals (not shown) must be provided in the gate driver 20.
The ADC unit 412 is used to acquire and digitize various input signals, as shown, which originate, for example, from the gate driver 20 and the current measurement circuit 420 or within the control unit 410. The PWM signals PWM_1 and PWM_2 are used to determine suitable first and second points in time for the measurement, for example apex and zero crossing. The PWM_1 and PWM_2 signals can also be used to derive when the semiconductor switches 10 and 11 are conducting or non-conducting. The variables used in equation (9) may only be determined on a conductive semiconductor switch 10.
Data required for the further process, such as the load current or drain current IL(=ID), are transferred to a calculation module 414 and/or a memory module 416.
By means of a digital data interface 413, e.g. an SPI interface, data can be exchanged digitally between the gate driver 20 and the control unit 410, whereby in the present example the temperature TS of the semiconductor switch 10 and the DeSat voltage VDSAT are included. The DeSat voltage VDSAT is transferred to the calculation module 414, which uses it to calculate the drain-source voltage VDSon, as described above, and transfers it to the memory module 416.
The ADC unit 412 (or the data interface 413) can also be used to receive an error signal from the gate driver 20 (“Fault” terminal). For further analysis, an error status of the gate driver can then also be read out by means of the data interface 413. In the event of a fault or the receipt of a fault signal, the DeSat values should not be used to monitor the status of the switch.
A current junction temperature Tj_est of the semiconductor switch 10 is determined by means of a program unit for a thermal model 415. For this purpose, in addition to the temperature measured at the semiconductor switch 10, a coolant temperature TCool and/or an ambient temperature TAmb (e.g. depending on whether air-cooled or water-cooled) can also be fed to the control unit. For example, the junction temperature Tj_est can be calculated based on the coolant temperature from a “junction-to-cooling” thermal resistance and the current power consumption, which in turn can be determined, for example, from the load current and the drain-source voltage. Alternatively, a temperature characteristic of the semiconductor switch 10 can also be measured and stored as a function of RDS at different load currents. The junction temperature can be easily estimated from RDS at a given ID (or IL.).
In the memory module 416, the recorded values are stored as described above and shown, for example, in
In a fault detection module 417, fault detection is based on the stored values, as explained above.
In
As explained, the half-bridge arrangement can be arranged in a high-voltage network, 5 whereas the control unit 410 and other modules in both
Number | Date | Country | Kind |
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102023118441.5 | Jul 2023 | DE | national |