New energy vehicles have developed rapidly in the past two years, and the state has also issued a series of policies to provide strong support. In its "Made in China 2025", the Ministry of Industry and Information Technology has clearly defined the strategic goals of energy-saving and new-energy automobile industry development. By 2020, key systems such as power batteries and drive motors have reached the international advanced level, and the domestic market share has reached 80%; by 2025, The annual sales volume of new energy vehicles has reached 3 million.
As early as 1998, Beijing Jingchuan Electronic Technology Development Co., Ltd. provided key IGBT modules for the new energy vehicles designed and produced by China for motor drive of power systems. Now, Jingchuan Electronics has launched a motor drive platform for new energy vehicle power systems, providing mature solutions for Chinese product development engineers to help the development of new energy vehicles in China.
The system structure of the platform is shown in Figure 1. In the specific implementation, the driving part and the control part are arranged separately. The driving and driving power sources are arranged in a PCB board of the same size as the IGBT module, and are independently mounted on the IGBT module. The way to minimize space requirements.
figure 1
In the control part, the main control core adopts Infineon's automotive-grade 32-bit single-chip TC1782, with bus frequency up to 160MHz full temperature range, super floating point computing capability, 32 12bit ADC channels, and various timer structures, making the motor more A combination of algorithms is possible. The TC1782 is a high-performance 32-bit microcontroller with a Haval architecture and an asymmetric dual core (primary core Tricore and peripheral control coprocessor PCP). It supports DSP algorithm instructions, 2.5 Mbytes of FLASH, and 176 Kbytes of RAM. The important peripherals related to motor control of the TC1782 are the general-purpose time array GPTA and digital-to-analog conversion ADC. The GPTA provides a flexible set of timing, comparison and capture functions that can be flexibly combined into a signal detection unit and a signal generation unit for dynamic control of dead time and asymmetry different from edge alignment and center alignment for motor control. PWM output. A digital-to-analog converter module that is triggered by hardware (such as GPTA) and implements synchronous conversion can at least support simultaneous acquisition of two-phase currents in a motor application. The dedicated peripheral control coprocessor PCP can handle most of the interrupt load, so that the main core can centrally handle complex operations for motor control, such as Park transform, Clarke transform, and space vector modulation. Multi-channel signal redundancy and detection, complete and comprehensive on-chip power management and detection, to ensure stable and reliable operation of the processor. The microcontroller implements a space vector (SVPWM) control method, a combination of five modulation algorithms, and an optimized motor control algorithm.
In addition, CPLD is used to complete the expansion of the multi-function window, and the high reliability and high dynamic response control of the motor are achieved through the accurate real-time performance, high reliability logic control and high fast response protection processing capability of the CPLD.
In order to ensure the safety and reliability of the system, the platform uses Infineon's CIC61508 chip to monitor whether the TC1782 works normally, thus making the platform's security level reach the ASIL-D standard.
The control section also features a complete and fast hardware and software fault detection and protection design, dynamic response calibration for drivetrain parameters, and CCP online calibration.
The power port processing is shown in Figure 2.
figure 2
The controller is powered by a body 14V auxiliary battery power supply. At the controller input power inlet, we add multi-stage multi-channel protection processing modules, such as protection against reverse power protection, anti-interference and interference reduction processing, static electricity and lightning surge absorption.
The power distribution of the platform is shown in Figure 3.
image 3
The power DC bus voltage range is 150-380VDC.
The control power supply adopts Infineon's automotive-grade dedicated power supply module, multi-channel output to ensure the minimum system and control logic module power supply stability; the external communication module uses isolated power supply module to ensure effective and reliable electrical isolation and safe insulation of strong and weak electricity; controller External fault diagnosis and user interface interface are powered by independent switching power supply to ensure power supply reliability and safety isolation and electromagnetic compatibility with the internal power supply of the controller; IGBT drive power supply is powered by independent switching power supply, and is fully isolated, and the transformer is strengthened. To ensure effective insulation of strong and weak electricity.
The design of the drive section is shown in Figure 4.
Figure 4
The driver chip selects Infineon's magnetic isolation driver chip 1ED020I12FA2, and drives the IGBT through the power amplifier module to perform effective switching action. After various working conditions test and verification, it can effectively meet the performance requirements, and achieve multi-complex condition policy protection functions such as fast short-circuit protection response, over-temperature response and over-current over-voltage, such as fast over-current protection response, short-circuit condition Fast desaturation without causing overvoltage breakdown, accurate and reliable junction temperature control.
In terms of PCB design, after multiple accurate design considerations and verification improvements, not only the intuitive requirements for minimizing physical space, but also performance enhancements are enhanced. The power supply, ground and signal are layered, the maximum area of ​​the formation is reliable and equal potential, the ground area is physically enveloped by the power supply layer, and the six-way drive power supply is effectively and safely insulated to meet the withstand voltage requirements between strong and weak electricity and high voltage.
The key power output unit power device adopts Infineon's automotive-grade IGBT power module FS800R07A2E3, with ultra-high power density, 175°C ultra-high junction temperature, 45K ultra-high power cycle times, ultra-low parasitic inductance, and ultra-high service life. The automotive grade product process has been verified by stringent automotive grade standards. Its highest peak electrical output power can reach 150KW.
The power unit input DC bus side absorption support capacitor adopts high performance and long life EPCOS metal film capacitor, which has characteristics of large ripple current, low leakage current, low equivalent impedance and low equivalent inductance, so that the bus capacitor group is used. Low temperature fluctuations for high reliability and safety and long service life.
The platform is water-cooled to ensure tight tightness. Using a special proportion of high-purity coolant, under normal operating conditions, the controller performance can be maximized at a coolant circulation rate of 8-12 liters/min. The applicable ambient temperature can reach -40-85 °C. Wide temperature range.
The development of electric vehicles in the world is in a stage of rapid rise. Electric vehicles provide a new opportunity for the Chinese automotive industry. The Chinese automotive industry attaches great importance to the development of new energy vehicles. The motor drive described in this paper applies to permanent magnet synchronization. Or the motor drive and control of the AC asynchronous motor, the controller is optimized from the control strategy, the overall efficiency of the controller is improved, the power performance and the weak magnetic performance of the motor control are fully considered, and a wide speed range is ensured. Long cruising range, fast response characteristics and good dynamic performance. Mature technology, stable work, high efficiency, high reliability, to achieve automotive-level safety standards, can be used as electric drive controllers for electric passenger cars, electric commercial vehicles, electric buses.
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