The present invention relates to a power conversion device including a power semiconductor device.
A power conversion device represented by a general-purpose inverter has been widely used as a motor driving unit in a manufacturing device, an elevating device, a transporting device, or the like in industry. In such various applications, the general-purpose inverter is required to be stably operated. In a case where the general-purpose inverter is stopped, production halt of a factory or operation halt of a facility occurs, which is an enormous impact.
The general-purpose inverter controls the flow or the interruption of a current in the power semiconductor device such as an IGBT or a diode, and performs desired power conversion. The power semiconductor device is joined by wire bonding or soldering to a copper foil pattern or the like formed on an insulating substrate, and thus, is electrically connected to a circuit outside the power semiconductor device. The insulating substrate is mounted on a metal base, and the power semiconductor device is cooled through the metal base. As described above, a component in which a power semiconductor device is built in a housing having an electrical connection structure with an external circuit or a cooling structure is referred to as a power module.
When a current flows through the power semiconductor device or interrupted, the power semiconductor device produces heat, and a temperature difference (hereinafter, referred to as ΔT) occurs between a junction and a fin (a metal base having a cooling structure). When the inverter is stopped, heat is not produced, and ΔT decreases. Since a material having a different thermal expansion coefficient is generally used in the junction (the wire bonding or the junction to the copper foil pattern) of the power semiconductor device, a thermal stress is exerted to the junction, in accordance with the fluctuation of ΔT. In a case where the fluctuation of ΔT is repeated, peeling or crack occurs in the junction, which causes a failure. A time to cause such a failure is different in accordance with the degree or the frequency of ΔT. The degree or the frequency of ΔT varies in accordance with the usage of the power conversion device and a device to be driven by the power conversion device. In addition, a load ratio on the IGBT and the diode is different in accordance with a usage condition of the device. Therefore, in order to prevent such a failure, it is necessary to grasp the degree of load on the IGBT and the diode, in accordance with the usage condition of the power conversion device.
As the related art in this technical field, there is Patent Document 1. In Patent Document 1, an electric motor control device is proposed in which a temperature change estimation unit estimates a temperature change of a semiconductor element of a switching circuit, on the basis of an output current signal, an operation frequency signal, and a carrier frequency signal calculated from a current flowing through the semiconductor element, and calculates a temperature change amplitude, a thermal stress calculation unit converts power cycle curve data stored in a power cycle curve data storage unit into a power cycle number corresponding to the temperature change amplitude, and calculates a thermal stress signal, and a life estimation unit estimates the life of the semiconductor element, on the basis of the thermal stress signal, and outputs a life estimation result signal to a display unit.
In Patent Document 1, the calculation of the temperature change estimation unit, the calculation of the thermal stress calculation unit, and the calculation of the life estimation unit are simultaneously performed. In such a configuration, there is a problem that a great load on the calculation device performing the calculation described above, and the calculation is not performed with high accuracy. In addition, in the specification, a method for calculating the amount of heat production of the semiconductor element as a function of an output current I in Expression (1) is exemplified, but there is a problem that an effective current flowing through a power transistor and a diode is different in accordance with a powering state or a regenerating state, and thus, it is not possible to calculate each loss with high accuracy.
As an example of the present invention, there is a power conversion device that controls a flow or an interruption of a current with an inverter including a power semiconductor device and performs desired power conversion, the device including: a motor control unit calculating a gate signal on the basis of a current value detected by a current sensor, a speed command, and a carrier frequency and controlling the inverter; a temperature history calculator estimating a loss of the power semiconductor device and calculating a temperature history; a temperature history storage device storing a calculation result of the temperature history; and a damage calculator calculating damage to the power semiconductor device from the temperature history read from the temperature history storage device.
According to the present invention, the life of the power semiconductor device can be calculated with high accuracy.
Hereinafter, examples of the present invention will be described by using the drawings.
First, the main circuit 200 will be described. The main circuit 200 includes a diode rectifier 201 rectifying alternating-current power that is transmitted from an alternating-current source 101, a smoothing capacitor 202, and an inverter 205 including an IGBT 203 that is a power semiconductor switching element and a diode 204 connected to the IGBT 203 in inverse-parallel. In this example, the inverter 205 will be described as a three-phase two-level inverter illustrated in
The inverter 205 is controlled by a motor control unit 206. Specifically, the motor control unit 206 calculates a gate signal with a current value detected by current sensors 207a and 207b, a speed command, and a carrier frequency fc that is set. The calculated gate signal is amplified by a gate driver 208, and is input to the IGBT 203 (a, b, c, d, e, and f) as a gate voltage. A ratio of a gate-on period to a carrier cycle will be referred to as an on-duty D. Accordingly, a voltage is output such that the motor 102 is at the speed according to the command. In both of the IGBT 203 and the diode 204, a junction temperature increases due to a joule loss in an on state, and a switching loss and a recovery loss when switching between a flow and an interruption, and the junction temperature decreases in an off state.
In
In
Since the power semiconductor element 222 is joined with a material having a different thermal expansion coefficient, a stress is exerted to the junction when the temperature of the power semiconductor element increases and decreases. A resistance to the stress will be referred to as a power cycle resistance, and is indicated by the number of repetitions available for a predetermined temperature amplitude that is referred to as a life cycle. Therefore, in a case where a temperature history of the semiconductor element is known, it is possible to estimate the life.
Next, the life estimation device 300 will be described. In
First, for example, as illustrated in
Here, rq and vq are the slope and the intercept of a linear approximation curve 332 of collector-emitter voltage-collector current characteristics 331 of the IGBT illustrated in
In addition, when a current is in the positive direction, a loss Pd of a diode of a lower arm, for example, is calculated by Expression (3) described below when powering, and is calculated by Expression (4) described below when regenerating.
Here, rd and vd are the slope and the intercept of a linear approximation curve 342 of forward voltage-forward current characteristics 341 of the diode illustrated in
Next, the temperature history of the semiconductor element of each of the IGBT and the diode is calculated. Hereinafter, the details will be described.
First, a temperature difference ΔTq between a junction and a fin of the IGBT, for example, is calculated by Expression (5) described below.
Here, τthq and rthq are the variables of an approximation curve 352 of thermal impedance-time characteristics 351 of the IGBT illustrated in
The calculation of the loss Pq and the calculation of ΔTq are performed at a cycle of Δt that can be arbitrarily set, and i-th ΔTq is ΔTq[i]. In
ΔTq[0] can be set to an arbitrary value that is suitable for a timing when the calculation command A is issued. For example, in a case where it is determined that a stop time of the inverter is sufficiently greater than τthq, the calculation can be performed with higher accuracy by setting Tq[0] to 0. In addition, calculation accuracy of the temperature history can be improved by setting Δt to be small. In order to obtain constant accuracy, it is preferable that Δt is set to be less than 1/10 of a thermal time constant of the power module. On the other hand, in a case where Δt is set to be large, a data amount of the temperature history per unit time can be reduced, and thus, there is an advantage that it is possible to save storage capacity and to store the temperature history for a longer period of time.
Next, a temperature difference ΔTd between a junction and a fin of the diode, for example, is calculated by Expression (6).
Here, τthd and rthd are the variables of an approximation curve 357 of thermal impedance-time characteristics 356 of the diode illustrated in
An example of the calculation result of the temperature history of the IGBT of the upper arm and the diode in a powering and accelerating operation is illustrated in
Next, processing of estimating a deterioration degree (the damage) by using the temperature history will be described. Note that, hereinafter, discrimination between the IGBT and diode will be omitted. A damage calculator 305 illustrated in
Here, R[j] is j-th R, and n[j] indicates the number of times in which R[j] occurs. alx and blx are a coefficient of an approximation curve 362 of a life cycle-Tjc characteristics curve 361 illustrated in
In this example, a coefficient in the case of performing linear approximation with respect to a resistance characteristics curve will be described as an example, and approximation may be performed by other methods, or characteristics may be tabulated. Processing of extracting the reversal point may be performed by the temperature history calculator 301. In a case where this processing is performed by the temperature history calculator 301, it is not necessary to store information other than the reversal point, and thus, it is possible to reduce a storage amount.
This calculation result d[1] is transmitted to an accumulated damage calculator 307 illustrated in
[Expression 8]
d[0]=d[0]+d[1] (8)
d[0] is initially 0, increases as the damage is accumulated, and reaches 1, which is determined as the end of life.
This calculation result d[0] is transmitted to the accumulated damage storage device 308, and is stored. Then, d[0] is transmitted to a life estimator 309 from the accumulated damage storage device 308, and life L is calculated by Expression (9).
[Expression 9]
L=100(1−d[0]) (9)
L is initially 100, decreases as the damage is accumulated, and reaches 0, which is determined as the end of life.
According to the configuration described above, the life estimation device 300 is capable of calculating the life according to a power cycle of the IGBT 203 and the diode 204.
Note that, it is necessary to obtain processing of estimating the loss and processing of calculating the temperature history from an instant current and control information when operating the inverter. On the other hand, the temperature history is stored in the storage device, and thus, the calculation of the damage may be performed when there is available capacity in processing capacity of the inverter. For example, in order to smooth a calculation load, the processing may be performed during the waiting of an inverter in which PWM is not calculated and a load on a calculation device is small. Alternatively, the calculation of the damage may be performed once while processing of calculating a temperature is performed a plurality of times.
Next, the interface device 400 will be described. In
In addition, in the alarming period, as illustrated in
As described above, by clearly specifying the life and the alarming, for example, it is possible to replace the power module before reaching the end of life, to extend the life of the power module by degeneration such as an increase in an acceleration and deceleration time of the inverter, to consider the prevention of an unexpected failure, and to prevent the unexpected failure.
As described above, according to this example, it is possible to calculate the life of the IGBT and the diode with high accuracy. In addition, by clearly specifying the life and the alarming, it is possible to prevent the unexpected failure.
In
According to the configuration described above, it is possible to monitor the plurality of power conversion devices 100 with the monitoring device 503. Further, by mounting a display unit such as a detailed display or a high-performance calculation device on the monitoring device 503, comprehensive management and analysis such as the comparison between operation conditions of the plurality of power conversion devices 100, and the detection of an abnormal operation is available. For example, the daily operation condition can be managed even at a location such as an office that is separated from the power conversion device, and management work can be efficiently performed. Further, by accumulating the data, it is possible to sequentially update information required for preparing a maintenance schedule or an operation schedule. In addition, when an abnormity occurs, the objective operation condition can be shared in the interested department, and thus, a downtime can be reduced.
In this example, a power conversion device using a regenerating converter will be described.
In
Examples have been described, but the present invention is not limited to Examples described above, and includes various modification examples. For example, Examples described above have been described in detail in order to explain the present invention in an understandable manner, and are not necessarily limited to having all the configurations described. In addition, it is possible to add, delete, or replace a part of the configuration of each of Examples with another configuration. In addition, a part or all of the configurations and the functions described above may be attained by software in which a processor interprets and executes a program for attaining each of the functions, or may be attained by hardware, for example, by designing an integrated circuit.
Number | Date | Country | Kind |
---|---|---|---|
2020-128210 | Jul 2020 | JP | national |
Filing Document | Filing Date | Country | Kind |
---|---|---|---|
PCT/JP2021/027226 | 7/20/2021 | WO |