THERMAL REGULATION & PROTECTION FOR POWER ELECTRONIC COMPONENTS
20230195189 · 2023-06-22
Inventors
Cpc classification
G06F1/28
PHYSICS
International classification
Abstract
One embodiment relates to a system that includes a power electronic system and a cooling system. The power electronic system includes a semiconductor switch, which has a rated maximum temperature. The power electronic system itself has a rated maximum power. The system further includes a temperature sensor that is configured to sense a temperature of the (at least one) semiconductor switch. The cooling system is thermally coupled to the power electronic system and configured to carry heat away from the power electronic system using a cooling agent. A system controller is configured to receive information concerning the sensed temperature of the semiconductor switch and a temperature of the cooling agent (coolant). The system controller is further configured to adjust a power of the power electronic system by controlling the switching operation of the semiconductor switch. When the temperature of the coolant is below a threshold temperature, then the controller adjusts the power of the power electronic system to a target value greater than the rated maximum power based on the sensed temperature of the semiconductor switch and the temperature of the cooling agent.
Claims
1. A system comprising: a power electronic system including a semiconductor switch, which has a rated maximum temperature, the power electronic system having a rated maximum power; a temperature sensor configured to sense a temperature of the semiconductor switch; a cooling system thermally coupled to the power electronic system and configured to carry heat away from the power electronic system using a cooling agent; a controller configured to: receive information concerning the sensed temperature of the semiconductor switch and a temperature of the cooling agent, and adjust a power of the power electronic system by controlling the switching operation of the semiconductor switch; wherein in response to the temperature of the cooling agent being below a threshold temperature the controller is configured to adjusts the power of the power electronic system to a target value greater than the rated maximum power based on the sensed temperature of the semiconductor switch and the temperature of the cooling agent.
2. The system of claim 1, wherein, to adjust the power of the power electronic system, the controller is configured to increases the power of the power electronic system as long as the sensed temperature of the semiconductor switch is below a temperature threshold which depends on the temperature of the cooling agent.
3. The system of claim 1, wherein the controller includes a memory for storing a characteristic curve representing the temperature threshold over the temperature the cooling agent.
4. The system of claim 3, wherein the characteristic curve is represented by digital values stored in the memory and forming a lookup-table.
5. The system of claim 1, wherein in response to the temperature of the cooling agent being above the threshold temperature the controller is configured to reduces the power of the power electronic system to a target value lower than the rated maximum power based on the sensed temperature of the semiconductor switch.
6. The system of claim 1, wherein the power electronic system includes a plurality of semiconductor switches, and wherein the temperature sensor is configured to sense the temperature representing at least one of the plurality semiconductor switches.
7. The system of claim 1, further comprising: a sensor configured to sense a coolant temperature, or a communication link via which the controller can receive information concerning the coolant temperature from an external device.
8. A method for controlling a power electronic system, the method comprising: sensing a temperature of a semiconductor switch included in the power electronic system; adjusting a power of the power electronic system by controlling the switching operation of the semiconductor switch, wherein in response to the temperature of a cooling agent, which is used to cool the power electronic system, being below a threshold temperature the power of the power electronic system is adjusted to a target value greater than the rated maximum power based on the sensed temperature of the semiconductor switch and a temperature of a cooling agent.
9. The method of claim 8, further comprising: derating the power of the power electronic system to a value lower than the rated maximum power based on the sensed temperature of the semiconductor switch in response to the temperature of cooling agent being above a critical temperature.
10. The method of claim 8, further comprising: derating the power of the power electronic system to a value lower than the rated maximum power based on the sensed temperature of the semiconductor switch in response to the sensed temperature of the semiconductor switch exceeding a threshold value.
11. The method of claim 8, further comprising: operating the power electronic system at the rated maximum power in response to the temperature of cooling agent is being above the threshold temperature and not exceeding a critical temperature.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The embodiments described below can be better understood with reference to the following drawings and descriptions. The components in the figures are not necessarily to scale; instead emphasis is placed upon illustrating the principles underlying the embodiments. Moreover, in the figures, like reference numerals designate corresponding parts. In the drawings:
[0010]
[0011]
[0012]
[0013]
[0014]
DETAILED DESCRIPTION
[0015] According to known design approaches, power electronic (PE) components and systems have the same maximum power (also referred to as “rated power”) throughout the whole operating temperature range (e.g. −40° C. to 80° C.) regardless of the actual operating temperature and the actual power at different operating temperatures. A known safety concept is so-called “power derating” at high operating temperatures. That is, when the ambient temperature (e.g. measured on a circuit board or a at a housing wall of a power electronic component) exceeds a specified limit, the power of the PE component or system is gradually reduced (derated) to avoid the junction temperature T.sub.J of the PE component exceeding the maximum value T.sub.J,max. As a consequence, PE systems, which are designed in accordance with the “traditional” approach, cannot exhaust their full potential at low operating temperatures.
[0016] As currently known thermal regulation and protection concepts are implemented by sensing the housing temperature or circuit board temperature close to the switching device, the sensed temperature may not only have a high deviation from the actual junction T.sub.J but may also have a time delay, which also requires an extra safety margin in the system design. Accordingly, the known current thermal regulation and protection concepts lead to an overdesign of the system.
[0017] The problem discussed above is further illustrated by the diagram of
[0018] It can be seen from
[0019] Furthermore, it can be seen from
[0020] In the light of the above discussion it can be concluded that the power electronic system remains well below its potential for lower coolant temperatures, in particular for coolant temperatures below, e.g., 0° C. However, with the concept and the thermal regulation approach illustrated in
[0021] The diagrams of
[0022] The available extra power ΔP.sub.boost decreases for increasing coolant temperature T.sub.COOL as long as the temperature T.sub.COOL is below the critical temperature T.sub.H. The available extra power ΔP.sub.boost becomes zero at the critical coolant temperature T.sub.H. Above the critical coolant temperature T.sub.H, the power of the power electronic system is reduced (derated) for further increasing coolant temperatures T.sub.COOL, wherein the power derating depends on the actually measured junction temperature T.sub.J in the same way as described above with reference to
[0023] In the top diagram the temperature T.sub.J,set may be regarded as a threshold temperature, which may be a function of the measured coolant temperature T.sub.COOL. For example, if the actually measured junction temperature T.sub.J does not exceed T.sub.J,set (i.e. if T.sub.J≤T.sub.J,set for a specific value T.sub.COOL), the system power P.sub.O may be set to P.sub.max,rated+ΔP.sub.boost, wherein the value of ΔP.sub.boost may also depend on the measured coolant temperature T.sub.COOL. When the actually measured junction temperature T.sub.J exceeds T.sub.J,set (i.e. if T.sub.J>T.sub.J,set for a specific value T.sub.COOL), the system power P.sub.O may be set to P.sub.max,rated (ΔP.sub.boost=0) in order to prevent thermal damage or thermally critical system states.
[0024]
[0025] It is understood that
[0026] The junction temperature T.sub.J may be measured in any conventional manner. For example, a temperature sensor 21 may be used to obtain information representing the junction temperature T.sub.J. The temperature sensor 21 may be integrated in the electronic switch T.sub.1 or mounted on a housing of the electronic switch T.sub.1 or mounted on a circuit board in close vicinity to the electronic switch T.sub.1. Regardless of the actual system design, the temperature sensor 21 needs to be thermally coupled to the power electronic device so that the measured temperature represents the actual junction temperature T.sub.J sufficiently well. It is understood that in practice there will always be a small deviation between the measured temperature and the actual junction temperature T.sub.J present in the interior of the power electronic device. Nevertheless, the measured temperature may be taken as an indication of the junction temperature T.sub.J.
[0027] A further sensor, which thermally coupled to the coolant recirculating in the cooling system, can be used to obtain the coolant temperature T.sub.COOL. The measured values representing the coolant temperatures may be transmitted to the controller 10 via a digital communication link (e.g. a serial bus such as an SPI bus, a CAN bus or the like). Alternatively, an analog sensor signal may be received any digitized by the controller 10 or the further sensor may be directly connected to the controller 10.
[0028] The controller 10 is configured to trigger a switch-on and a switch-off of the power electronic device(s) such as the electronic switch T.sub.1. In the present example, in which the electronic switch T.sub.1 is implemented using an IGBT, a gate driver circuit 20 (short gate driver) may be used. The gate driver 20 receives a logic signal ON generated by the controller 10 and generates a corresponding gate signal (gate voltage or gate current) for the IGBT T.sub.1. A transition of the logic signal to a high level (ON=1) may indicate a switch-on, whereas a transition to a low level (ON=0) may indicate a switch-off of the IGBT T.sub.1. In the present example, the gate driver 20 includes a galvanic isolation between its input and its output. Additionally, a galvanically isolating device 22 is arranged in the signal path between the temperature sensor 22 and the controller 10 to fully isolate the controller 10 (and peripheral circuitry) from the power electronics. It is understood that the controller 10 may driver the power electronic device(s) such as the IGBT T.sub.1 using any known modulation technique such was pulse-width modulation (PWM). That is, the logic signal ON may be, for example, a PWM signal. In many applications, the controller 10 will be configured to generates a plurality of logic signals to drive a plurality of power electronic devices.
[0029] The power electronic device (e.g. the semiconductor switch T.sub.1) of the system of
[0030] Based on the sensed junction temperature T.sub.J of the semiconductor switch T.sub.1 and the temperature T.sub.COOL of the cooling agent recirculating in the cooling system the controller 10 can adjust the power P.sub.O of the power electronic system to a target value P.sub.max,rated+ΔP.sub.boost greater than the rated maximum power P.sub.max,rated if the temperature T.sub.COOL of the cooling agent is below a threshold temperature (e.g. critical temperature T.sub.H, see
[0031] In the example shown in
[0032] In the boost mode the power electronic devices included in the system are operated at a power P.sub.O=P.sub.max,rated+ΔP.sub.boost above the rated maximum power P.sub.max,rated for low coolant temperatures (T.sub.COOL≤T.sub.R). The power P.sub.O can be increased beyond the maximum rated power P.sub.max,rated to such an extent that the actual junction temperature T.sub.J is closer to the maximum junction temperature T.sub.J,max than it would be if the power P.sub.O would be limited to P.sub.max,rated. As mentioned above with reference to
[0033] As in the previous example, the rated maximum power is reduced in power derating mode for coolant temperatures above the critical temperature T.sub.H. When the coolant temperature T.sub.COOL reaches the switch-off threshold temperature T.sub.OFF the system is shut down to avoid thermal damage. Also, when at any time the measured junction temperature exceeds the rated maximum junction temperature T.sub.J,max (e.g. 150° C. in the example of
[0034] An exemplary curve illustrating the junction temperature T.sub.J is also included in the diagram of
[0035] In the rated power mode, the system power P.sub.O is limited to the (constant) rated maximum power P.sub.max,rated. Therefore, the junction temperature T.sub.J can rise to temperatures beyond 100° C. In the depicted example, the junction temperature T.sub.J rises from 100° C. to 110° C. as the coolant temperature T.sub.COOL increases from 40° C. to 60° C. (i.e. the critical temperature T.sub.H in the present example).
[0036] If the coolant temperature rises to temperatures above the critical temperature T.sub.H, the system operates in power derating mode and the controller successively reduces the system power P.sub.O dependent on the measured junction temperature T.sub.J and the measured coolant temperature T.sub.COOL In the undesired case that the coolant temperature reaches the switch-off threshold temperature T.sub.OFF or if the junction temperature T.sub.J reaches its absolute maximum rating T.sub.J,max, then the system is shut down (P.sub.O=0 W) to avoid thermal damage. The power derating may be done stepwise and, as a result, corresponding rapid temperature changes may occur as shown at T.sub.COOL=70° C. in the depicted example. It is understood, that
[0037] In
[0038] As can be seen in
[0039] The concept described above is further illustrated by the flow chart depicted in
[0040] The method further includes adjusting a power (see, e.g.,
[0041] The mentioned threshold temperature may be the critical temperature T.sub.H (see bottom diagram of
[0042] In one embodiment, the system controller includes a memory for storing a characteristic curve representing the temperature threshold T.sub.J,set(T.sub.COOL) over the temperature T.sub.COOL the cooling agent. Accordingly, the characteristic curve may be represented by digital values stored in the memory and forming a lookup-table.
[0043] In one example, the look-up table, may include a sequence of temperature values T.sub.J,set(T.sub.COOL), which may be regarded as threshold temperatures that are used in boost mode to control the power P.sub.O of the power electronic system. Thereby, the temperature values T.sub.J,set(T.sub.COOL) depend on the coolant temperature T.sub.COOL. In boost mode (e.g. when T.sub.COOL≤T.sub.R) the system controller 10 may continuously monitor the temperatures T.sub.J and T.sub.COOL, and —when the currently measured junction temperature T.sub.J is below the stored threshold value T.sub.J,set(T.sub.COOL)—the system power P.sub.O is set to a predefined value P.sub.O(T.sub.COOL), which depends on the currently measured coolant temperature T.sub.COOL. Various values for P.sub.O(T.sub.COOL) may be also stored in the look-up table. The values P.sub.O(T.sub.COOL) may be used as reference power, which has been discussed above, e.g., with reference to
[0044] When the temperature T.sub.COOL of the cooling agent is above the critical temperature T.sub.H the system operates in power derating mode controller reduces the power P.sub.O of the power electronic system to a target value lower than the rated maximum power P.sub.max,rated based on the sensed temperature T.sub.J of the semiconductor switch. The power derating may be accomplished stepwise, linearly or in accordance with any other degressive function.
[0045] In one example, the power electronic system includes a plurality of semiconductor switches, wherein the temperature sensor is configured to sense a temperature representing the temperature T.sub.J of at least one of the plurality semiconductor switches. The temperature sensor circuit may include a plurality of sensing elements. These can be integrated in the semiconductor switch, coupled to a chip package or otherwise thermally coupled to the semiconductor switch. The measured coolant temperature T.sub.COOL may be communicated to the system controller by another external device, e.g. by a controller of the cooling subsystem which can communicate with the system controller 10 via a digital communication link.
[0046] Although the invention has been illustrated and described with respect to one or more implementations, alterations and/or modifications may be made to the illustrated examples without departing from the spirit and scope of the appended claims. In particular regard to the various functions performed by the above described components or structures (units, assemblies, devices, circuits, systems, etc.), the terms (including a reference to a “means”) used to describe such components are intended to correspond—unless otherwise indicated—to any component or structure, which performs the specified function of the described component (e.g., that is functionally equivalent), even though not structurally equivalent to the disclosed structure, which performs the function in the herein illustrated exemplary implementations of the invention.