Some of the most common power modules in switching power supply technology

The rapid development of computer technology has led humans into the information society, and has also promoted the rapid development of power module technology. In the 1980s, the computer used a switching power supply to complete the computer power generation. Then switching power supply technology has entered the field of electronics and electrical equipment.

The development of computer technology has proposed green computers and green power modules. Green computers refer to personal computers and related products that are harmless to the environment. Green power refers to efficient power-saving power supplies related to green computers. According to the US Environmental Protection Agency's June 17, 1992 "Energy Star" program, the table A type of personal computer or related peripheral device, if the power consumption in a sleep state is less than 30 watts, it meets the requirements of a green computer, and improving power efficiency is a fundamental way to reduce power consumption. For a current 200 watt switching power supply with 75% efficiency, the power supply itself consumes 50 watts of energy.

The rapid development of the communications industry has greatly promoted the development of communication power. The high-frequency miniaturized switching power supply and its technology have become the mainstream of modern communication power supply systems. In the field of communication, a rectifier is generally referred to as a primary power source, and a direct current-direct current (DC/DC) converter is referred to as a secondary power source. The function of the primary power supply is to convert the single-phase or three-phase AC grid into a DC power source with a nominal value of 48V. At present, in the primary power supply for the program-controlled switch, the traditional phase-controlled regulated power supply has been replaced by the high-frequency switching power supply. The high-frequency switching power supply (also called the switching rectifier SMR) operates at high frequency through the MOSFET or IGBT, and the switching frequency. Generally controlled in the range of 50-100 kHz, achieving high efficiency and miniaturization. In recent years, the power capacity of switching rectifiers has been continuously expanded, and the stand-alone capacity has been expanded from 48V/12.5A and 48V/20A to 48V/200A and 48V/400A.

Due to the wide variety of integrated circuits used in communication equipment, the power supply voltage is also different. In the communication power supply system, a high-power density high-frequency DC-DC isolated power supply module is used, and the intermediate bus voltage (generally 48V DC) is converted into Various DC voltages are required, which can greatly reduce the loss and facilitate maintenance, and it is very convenient to install and increase. Generally, it can be directly mounted on the standard control board. The requirement for the secondary power supply is high power density. As communication capacity continues to increase, communication power capacity will continue to increase.

The DC/DC converter converts a fixed DC voltage into a variable DC voltage. This technology is widely used in the continuously variable transmission and control of trolley buses, subway trains, electric vehicles, and at the same time, the above control is accelerated and stable. Responsive performance and at the same time receive the effect of saving energy. Replacing the varistor with a DC chopper saves energy (20~30)%. The DC chopper can not only function as a voltage regulator (switching power supply), but also effectively suppress the harmonic current noise of the grid side.

The secondary power supply DC/DC converter of the communication power supply has been commercialized, and the module adopts high frequency PWM technology, the switching frequency is about 500 kHz, and the power density is 5W~20W/in3. With the development of large-scale integrated circuits, power modules are required to be miniaturized. Therefore, it is necessary to continuously increase the switching frequency and adopt a new circuit topology. At present, some companies have developed and produced two technologies using zero current switching and zero voltage switching technology. The secondary power module has a large increase in power density.

Uninterruptible power supplies (UPS) are high-reliability, high-performance power supplies that are required for computers, communication systems, and where uninterrupted applications are required. The AC mains input is converted to DC by the rectifier, part of the energy is charged to the battery pack, and the other part of the energy is converted into AC through the inverter, and sent to the load via the transfer switch. In order to still provide energy to the load in the event of an inverter failure, another alternate power source is implemented by a power transfer switch.

Modern UPS generally adopts pulse width modulation technology and modern power electronic devices such as power MOSFETs and IGBTs, and the noise of the power supply is reduced, and the efficiency and reliability are improved. The introduction of microprocessor hardware and software technology can realize intelligent management of UPS, remote maintenance and remote diagnosis.

At present, the maximum capacity of online UPS can be made up to 600kVA. The development of ultra-small UPS is also very fast, and there are already various specifications of products such as 0.5kVA, lVA, 2kVA, 3kVA. '

The inverter power supply is mainly used for frequency conversion speed regulation of AC motors, and its position in the electric drive system is becoming more and more important, and huge energy-saving effects have been obtained. The main circuit of the inverter power supply adopts the AC-DC-AC scheme. The power frequency power supply is turned into a fixed DC voltage through a rectifier, and then a PWM high frequency converter composed of a high power transistor or an IGBT converts the DC voltage into a voltage and variable frequency AC output, and the power output waveform is approximated to a sine wave. It is used to drive AC asynchronous motor to achieve stepless speed regulation.

International inverter power supply products below 400kVA have been introduced. In the early 1980s, Toshiba Corporation of Japan first applied AC variable frequency speed control technology to air conditioners. By 1997, its market share had reached more than 70% of Japanese household air conditioners. Inverter air conditioners have the advantages of comfort and energy saving. In the early 1990s, China began to research inverter air conditioners. In 1996, it introduced production lines to produce inverter air conditioners, and gradually formed a hot spot for the development and production of inverter air conditioners. It is expected that a climax will be formed by around 2000. In addition to the variable frequency power supply, the inverter air conditioner also requires a compressor motor suitable for variable frequency speed regulation. Optimized control strategy, selected functional components, is the further development direction of air conditioning variable frequency power supply development.

The high-frequency inverter rectifier welding machine power supply is a new type of welding machine power supply with high performance, high efficiency and low cost, which represents the development direction of today's welding machine power supply. Due to the commercialization of IGBT high-capacity modules, this power supply has broad application prospects.

Most of the inverter welding machine power supply adopts the AC-DC-AC-DC (AC-DC-AC-DC) conversion method. The 50Hz AC power is converted into DC by full-bridge rectification. The PWM high-frequency conversion part composed of IGBT inverts the DC power into a high-frequency rectangular wave of 20kHz. After high-frequency transformer coupling, it is stabilized by the rectification and filtering, and the power supply arc is used.

Due to the harsh working conditions of the welding machine power supply, frequent short-circuit, arcing and open circuit changes, the working reliability problem of the high-frequency inverter type rectifying machine power supply becomes the most critical problem, and it is also the most concerned issue for users. . The microprocessor is used as the pulse width modulation (PWM) related controller. Through the extraction and analysis of multi-parameters and multiple information, the purpose of predicting various working states of the system is achieved, and then the system is adjusted and processed in advance to solve the problem. The current high-power IGBT inverter power supply reliability.

The foreign inverter welding machine can achieve rated welding current of 300A, load duration of 60%, full load voltage of 60~75V, current regulation range of 5~300A and weight of 29kg.

High-power switch-type high-voltage DC power supplies are widely used in large-scale equipment such as electrostatic precipitator, water quality improvement, medical X-ray machines and CT machines. The voltage is as high as 50~l59kV, the current reaches 0.5A and the power can reach 100kW.

Since the 1970s, some Japanese companies have begun to use inverter technology to rectify the mains to a medium frequency of around 3 kHz and then boost. In the 1980s, high-frequency switching power supply technology developed rapidly. Siemens Germany uses power transistors as the main switching components to increase the switching frequency of the power supply to more than 20 kHz. The dry-type transformer technology was successfully applied to the high-frequency high-voltage power supply, and the high-voltage transformer fuel tank was eliminated, so that the volume of the transformer system was further reduced.

The domestic research on electrostatic precipitator high voltage DC power supply has been developed. The mains is rectified into DC, and the full bridge zero current switch series resonant inverter circuit is used to invert the DC voltage into a high frequency voltage, which is then boosted by a high frequency transformer and finally rectified. It is DC high voltage. Under resistive load conditions, the output DC voltage reaches 55kV, the current reaches 15mA, and the operating frequency is 25.6kHz.

When the conventional AC-DC converter is put into operation, a large amount of harmonic current will be injected into the power grid, causing harmonic loss and interference, and at the same time, the power factor of the device network side is deteriorated, that is, the so-called "electric power" Public hazard, for example, when uncontrolled rectification plus capacitor filtering, the third harmonic content of the grid side can reach (70~80)%, and the power factor of the grid side is only 0.5~0.6.

The active power filter is a new type of power electronic device capable of dynamically suppressing harmonics. It can overcome the shortcomings of traditional LC filters and is a promising harmonic suppression method. The filter consists of a bridge switching power converter and a specific control circuit. The difference from the traditional switching power supply is: (1) not only feedback output voltage, but also feedback input average current; (2) current loop reference signal is the product of voltage loop error signal and full-wave rectified voltage sampling signal.

The distributed power supply system uses small power modules and large-scale control integrated circuits as basic components, and uses the latest theoretical and technical achievements to form a building block and intelligent high-power power supply, so that the combination of high-power and low-power is combined to reduce high power. The development pressure of components and high-power devices (centralized) to improve production efficiency.

In the early 1980s, research on distributed high-frequency switching power supply systems focused on the research of converter parallel technology. In the mid-to-late 1980s, with the rapid development of high-frequency power conversion technology, various converter topologies have emerged, combining large-scale integrated circuits and power component technologies to enable the integration of small and medium-sized power devices, thus rapidly Promoted the development of distributed high-frequency switching power supply systems. Since the late 1980s, this direction has become a research hotspot in the international power electronics field. The number of papers has increased year by year, and the application field has been expanding.

The distributed power supply mode has the advantages of energy saving, reliability, high efficiency, economy and convenient maintenance. It has been gradually adopted by large computers, communication equipment, aerospace, industrial control systems, etc. It is also the most ideal power supply for low-voltage power supplies (3.3V) of ultra-high-speed integrated circuits. In high-power applications, such as electroplating, electrolysis power supply, electric locomotive traction power supply, medium frequency induction heating power supply, motor drive power supply and other fields also have broad application prospects.

Modern power electronics technology is the basis for the development of switching power supply technology. With the emergence of new power electronics and circuit topologies for higher switching frequencies, modern power technologies will rapidly evolve with real-world needs. Under the traditional application technology, the performance of the switching power supply is affected due to the limitation of the performance of the power device. In order to greatly exploit the characteristics of various power devices and minimize the impact of device performance on the performance of switching power supplies, the new power supply circuit topology and new control technology can make the power switch work in zero voltage or zero current state. Greatly improve the working frequency, improve the working efficiency of the switching power supply, and design a switching power supply with excellent performance. Power electronics and switching power supply technology continue to advance due to application requirements. The emergence of new technologies will lead to the replacement of many application products, and will open up more updated application areas. The realization of high-frequency switching, modularization, digitization and greening of switching power supplies will mark the maturity of these technologies and realize the combination of high-efficiency electricity and high-quality electricity. In recent years, with the development of the communication industry, the switching power supply for communication with the switching power supply technology as the core has only a market demand of more than 2 billion RMB in China, attracting a large number of scientific and technical personnel at home and abroad to carry out research and development. The replacement of linear power supplies and phase-controlled power supplies by switching power supplies is a general trend. Therefore, the domestic market for power-operated power supply systems that also have billions of output requirements is starting up and will soon develop. There are many other dedicated power supplies and industrial power supplies centered on switching power supply technology that are waiting for people to develop.