The disclosure of Japanese Patent Application No. 2019-116803 filed on Jun. 24, 2019 including the specification, drawings and abstract is incorporated herein by reference in its entirety.
The present invention relates to an inrush current preventing technique of semiconductor device that performs power conversion.
As a power supply device for converting AC power into DC power, a switching power supply device for converting the AC input voltage to the DC output voltage by controlling on and off of the switching elements is widely known.
Further, in the switching power supply device, it is common to use a PFC (Power Factor Correction) circuit in order to suppress a deterioration of the power factor due to a phase difference between the input voltage and the input current and a generation of harmonics.
The switching power supply device is required to be highly reliable because the generated power is directly related to an operation quality of circuit to which it is supplied. An inrush current countermeasure is known as a method for enhancing reliability. Non-patent Document 1 describes a circuit for limiting inrush current by connecting a resistor and PTC (Positive Temperature Coefficient) in series with a line (
However, adding the switch, relay, thyristor, and capacitor to prevent inrush current in the power converter device leads to high costs. In particular, for the switch and relay, there is a disadvantage that the power converter device is degraded because opening and closing numbers of the switch and relay throughout their lifetime is extremely small.
Other objects and novel features will become apparent from the description of the specification and drawings.
A semiconductor device according to one embodiment includes a rectifier circuit that rectifies an AC input voltage, a zero-cross detection circuit that detects a zero-cross of the AC input voltage, a control circuit that turns on the rectifier circuit at a timing determined by the zero-cross detected by the zero-cross detection circuit and a predetermined phase angle, and the phase angle is set so that an output voltage of the rectifier circuit is gradually increased.
A semiconductor device according to one embodiment allows power conversion with an inrush current countermeasure.
Hereinafter, a semiconductor device according to an embodiment will be described in detail by referring to the drawings. In the specification and the drawings, the same or corresponding form elements are denoted by the same reference numerals, and a repetitive description thereof is omitted. In the drawings, for convenience of description, the configuration may be omitted or simplified. Also, at least some of the embodiments may be arbitrarily combined with each other.
As shown in
Switching element S1 is disposed between the first output terminal 51 and the node N2 which is coupled to the first input terminal 41 via the coil L1 and the Filter. Switching element S2 is disposed between the node N2 and the second output terminal 52. Switching elements S1, S2 are power transistors, for example IGBT (Insulated Gate Bipolar Transistor) and power MOS. The thyristor SCR 1 is disposed between the first output terminal 51 and the node N1 which is coupled to the second input terminal 42 via the Filter. The thyristor SCR 2 is disposed between the node N1 and the second output terminal 52.
Switching element drive circuit 12 turns on or off the switching element S1, S2 based on an instruction of the control circuit 11. Similarly, the thyristor drive circuit 13 turns on or off the thyristors SCR 1, SCR 2 based on the instruction of the control circuit 11.
Zero-cross detection circuit 14 monitors the AC input voltage and detects the timing at which the amplitude becomes zero cross. The detection result is notified to the control circuit 11.
Control circuit 11 has two functions. The first function is a function during normal operation and is a control function equivalent to the conventional bridgeless totem pole type power factor correction circuit. However, the control of the thyristors SCR 1, SCR 2 differs from the conventional one because the conventional bridgeless totem pole type power factor correction circuit does not have thyristors SCR 1, SCR 2. More particularly, the control circuit 11, by controlling the switching elements S1, S2 based on a predetermined control method, performs power factor correction using the coil L1. At this time, the thyristors SCR 1, SCR 2 are alternately turned on based on the timings of the zero crossings of the AC input voltages detected by the zero-cross detection circuit 14. Specifically, when a voltage of the connecting point of the switching elements S1 and S2 (hereinafter, referred to as node N2) changes from a positive voltage to a negative voltage and a voltage of the connection point of the thyristors SCR 1 and SCR 2 (hereinafter, referred to as node N1) changes from a negative voltage to a positive voltage, the thyristor SCR 1 is turned on, the thyristor SCR 2 is turned off. When the voltage at the node N2 changes from a negative voltage to a positive voltage, and the voltage at the node N1 changes from a positive voltage to a negative voltage, the thyristor SCR 1 turns off and the thyristor SCR 2 turns on. As a result, semiconductor device 10 is equivalent to a conventional bridgeless totem-pole type power factor correction circuit.
The second function of the control circuit 11 is a control function after the AC input voltage is turned on. In the second function, the switching elements S1, S2 are always off. Further, the thyristors SCR 1, SCR 2, based on the timing of the zero-cross detected by the zero-cross detection circuit 14, is turned on alternately at a predetermined timing (phase angle). The control circuit 11 performs the second function until the above-described normal operation is performed.
Operations of zero-cross detection circuit 14, zero-cross prediction circuit 16 and phase angle calculation circuit 17 will be described in more detail with reference to
Zero-cross prediction circuit 16, from the measurement points Zn−3, Zn−2, Zn−1, predicts a timing of next zero-cross of the AC input voltage. For example, since a half cycle of the AC input voltage can be measured from an interval of Zn−3 and Zn−2, it is possible to predict Zn which is a next zero-cross timing from Zn−1. Alternatively, by taking a mean value of the interval between Zn−3 and Zn−2 and the interval between Zn−2 and Zn−1, the half cycle of the AC input voltage may be determined. Zn+1, which is a prediction point of the timing of zero crossing, is also obtained in the same manner.
Next, an operation of the phase angle calculation circuit 17 will be described. The phase angle calculation circuit 17, based on the prediction point predicted by the zero-cross prediction circuit 16, determines timings of turning on the thyristors SCR 1 and SCR 2. Specifically, as shown in
Next, the operation of semiconductor device 10 will be described.
First, in the initial state before the AC input voltage is input, each of the elements (switching elements S1, S2, the thyristors SCR 1, SCR 2) is off state. Control circuit 11, by controlling the switching element drive circuit 12 and the thyristor drive circuit 13, outputs gate signals and control signals to turn off each element (step S0). In present embodiment, each element turns off when the gate signals and the control signals are a ground voltage (0V), and each element turns on when the gate signals and the control signals are a positive high voltage, but not limited thereto.
When the AC input voltage is supplied (step S10), the zero-cross detection circuit 14 detects the zero-cross timing of the AC input voltage, and notifies the control circuit 11 of the detection result (step S11).
Zero-cross prediction circuit 16, as described in
The phase angle calculation circuit 17 calculates phase angles A0 to A5 with respect to Z0 to Z5 which are the predicted zero-cross timings (step S13). As explained in
The thyristor control circuit 19 generates control signals for turning on the thyristors SCR 1 and SCR 2 using Z0 to Z5 predicted by the zero-cross prediction circuit 16 and A0 to A5 calculated by the phase angle calculation circuit 17 (step S14). In the case of Z0, a control signal for turning on the thyristor SCR 1 at a timing t0 preceding from Z0 by A0 (15 degrees) is generated. For Z1, a control signal for turning on SCR 2 at a timing t1 preceding from Z1 by A1 (30 degrees) is generated. Similarly, control signals for turning on the thyristor SCR 1 at t2, t4, and control signals for turning on the thyristor SCR 2 at t3, t5 are generated.
The thyristor drive circuit 13 turns on the thyristors SCR 1, SCR 2 based on the control signals generated by the thyristor control circuit 19. As shown in
We now focus on the voltage at node N1. When the voltage at t0 is V0 and the voltage at t2 is V2, V2>V0. This is because, as described above, since the phase angle is gradually increased, t2 is a timing farther from the zero-cross timing than t1. In the range of 0 to 90 degrees of the AC input voltage, the voltage becomes higher as it moves away from the zero-cross. The same applies to the voltage of node N2. Therefore, from t0 to t5, the voltage applied to the capacitor C1 gradually increases (
At timing t5 (phase angle 90 degrees) (step S15), the control circuit 11 ends the control for a turn-on of the AC input voltage (the second function), and proceeds to the normal control (the first function) (step S16). In the normal control, the control circuit 11, at the zero-cross timing of the AC input voltage, controls so that the thyristors SCR 1, SCR 2 are turned on alternately (t6, t7 in
As described above, in present embodiment, a power conversion with a measure against inrush current can be performed without any additional switching element, relay, capacitor, and the like.
In the embodiment, the circuit is based on a bridgeless totem-pole type power factor correction circuit, whereas the first modified example combines a rectifier circuit (diode-bridge) with a boost-type PFC circuit, and is particularly based on a single-type circuit. As shown in
Thyristor drive circuit 22 and the switching element drive circuit 23 perform on/off of the thyristors SCR 3, SCR 4, and the switching element S3 as a third switching element based on an instruction of the control circuit 21.
Zero-cross detection circuit 24 detects a timing of the AC input voltage becomes zero-cross, and notifies the detection result to the control circuit 21. Zero-cross detection circuit 24 is equivalent to the zero-cross detection circuit 14 of the embodiment.
The control circuit 21 has the first function and the second function in the same manner as the control circuit 11 of the embodiment. In the first function (normal operation), similarly to the conventional boost type PFC, the power factor correction of semiconductor device 20 is performed by controlling the switching element S3. However, since a conventional rectifier circuit (diode bridges) does not have thyristors SCR 3, SCR 4, the control of the thyristors SCR 3, SCR 4 differs from the conventional. Specifically, when the voltage of the node N3 changes from a negative voltage to a positive voltage, and the voltage of the node N4 changes from a positive voltage to a negative voltage, the thyristor SCR 3 is turned on, and the thyristor SCR 4 is turned off. Further, when the voltage of node N3 changes from a positive voltage to a negative voltage, and the voltage of node N4 changes from a negative voltage to a positive voltage, the thyristor SCR 3 is turned off, and the thyristor SCR 4 is turned on. As a result, semiconductor device 20 has the same functionality as a conventional rectifier circuit and a boost-type PFC.
The second function of the control circuit 21 is a control function after the AC input voltage is turned on. In this function, the switching element S3 is always off. Thyristors SCR 3, SCR 4 is turned on alternately at a predetermined timing (phase angle) based on the zero-cross timing detected by the zero-cross detection circuit 24. Control circuit 21 performs the second function until a transition to the normal operation. The control circuit 21, like the control circuit 11 of the embodiment, has a zero-cross prediction circuit, a phase angle calculation circuit, a switching element control circuit, a thyristor control circuit.
Next, the operation of semiconductor device 20 according to the first modified example will be described.
The operation of semiconductor device 20 is similar to that of the embodiment. The thyristor SCR 1 of
As in the description of
At the timing t5 (phase angle 90-degree), control circuit ends the control (the second function) for the AC input voltage and proceeds to the normal control (the first function). In the normal control, the control circuit 21 controls so that the thyristors SCR 3, SCR 4 are turned on alternately at the zero-cross timing of the AC input-voltage. Further, the control circuit 21 performs power factor correction by controlling the switching element S3. The control method of the switching element S3 for power factor correction will be omitted because it is the same as the conventional.
As described above, the rectifier circuit and the booster-type PFC circuit of the present first modified example can obtain the same effect as that of the embodiment.
A difference between this second modified example and the first modified example is points where rectifier diodes D1, D2, and thyristors SCR 3, SCR 4 are coupled. That is, the thyristor SCR 3 is disposed between a node N4 coupled to the first input terminal 41 via a Filter and the first output terminal 51 via a coil L2 and the boost diode D3 connected in series. The thyristor SCR 4 is disposed between a node N3 coupled to the second input terminal 42 via the Filter and the first output terminal 51 via the coil L2 and the boost diode D3 connected in series. Rectifying diode D1 is disposed between the node N4 and the second output terminal 52. Rectifying diode D2 is disposed between the node N3 and the second output terminal 52. Since the operation of semiconductor device 30 is the same as that of semiconductor device 20, the detail is omitted.
The present second modified example can obtain the same effects as those of first modified example.
This third modified example is based on a rectifier circuit and a boost-type interleaved PFC circuit. In the interleaved PFC circuit, a coil L3 as a third coil, a boost diode D4 as a fourth diode, and a switching element S4 as a fourth switching element are added to a single-type PFC circuit (first modified example). The coil L3 and the boost diode D4 are arranged in series between the rectifying diodes D1, D2 and the first output terminal 51, the switching element S4 is disposed between the connection point (node N6) between the coil L3 and the boost diode D4 and the second output terminal 52. Like first modified example, the rectifier circuits composed of rectifier diodes D1, D2, and thyristors SCR 3, SCR 4 differs from the conventional.
The operation of semiconductor device 40 is the same as that of first modified example except for the interleave operation. Like the embodiment and first modified example, the control circuit 31 has the first function and the second function. In the first function (normal operation), similarly to the conventional interleaved PFC circuit, the power factor of semiconductor device 40 is improved by controlling the switching elements S3, S4. However, since conventional rectifier circuit does not have the thyristors SCR 3, SCR 4, the control of the thyristors SCR 3, SCR 4 differs from the conventional one. The control of thyristors SCR 3, SCR 4 is similar to first modified example. As a result, semiconductor device 40 is equivalent to the conventional rectifier circuit and the boost-type interleaved PFC circuit.
The second function of the control circuit 31 is a control function after the AC input voltage is turned on. The operation of this function is the same as that of first modified example, and therefore detailed description thereof is omitted.
In the semiconductor device 40 according to present third modified example, in the rectifier circuit and the boost type interleaved PFC circuit, it is possible to obtain the same effects as the embodiment.
The difference between this fourth modified example and third modified example is that the rectifier diodes D1, D2, and thyristors SCR 3, SCR 4 are coupled similar to the second modified example. Since the operation of semiconductor device 50 is the same as that of semiconductor device 40, the detail is omitted.
The present fourth modified example can obtain the same effects as those of third modified example.
It should be noted that the present invention is not limited to the above-mentioned embodiments, and various modifications can be made without departing from the gist thereof.
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