Fast switching for power inverter

• US 8,441,826 B2
• Filed: 01/31/2011
• Issued: 05/14/2013
• Est. Priority Date: 01/31/2011
• Status: Active Grant

• Current Assignee: Tesla Inc.
• Original Assignee: Tesla Motors Incorporated (Tesla Inc.)
• Inventors: Kroeze, Ryan, Campbell, Colin, Kalayjian, Nicholas Robert
• Primary Examiner(s): Berhane, Adolf
• Assistant Examiner(s): PHAM, EMILY P
• Application Number:
  US13/018,379
• Publication Number:
  US 20120195085A1
• Time in Patent Office: 834 Days
• Field of Search: 363132-134
• US Class Current: 363/132
• CPC Class Codes: H02M 7/487 Neutral point clamped inverters

Abstract

An apparatus includes an inverter including a high-side switch coupled to a low-side switch, the inverter generating a time-varying drive current from a plurality of drive control signals, a positive rail voltage, and a negative rail voltage wherein controlling the switches to generate the time-varying drive current produces a potential transitory overshoot condition for one of the switches of the inverter; a drive control, coupled to the inverter, to generate the drive control signals and to set a level of each of the rail voltages responsive to a plurality of controller signals; and a controller monitoring one or more parameters indicative of the potential transitory voltage overshoot condition, the controller dynamically adjusting, responsive to the monitored parameters, the controller signals to reduce a risk of occurrence of the potential transitory voltage overshoot condition.

Claims

1. An apparatus, comprising:

an inverter including a high-side switch coupled to a low-side switch, said inverter generating a time-varying drive current from a plurality of drive control signals, a high-side positive rail voltage, a high-side negative rail voltage, a low-side positive rail voltage, and a low-side negative rail voltage wherein controlling the switches to generate said time-varying drive current produces a potential transitory overshoot condition for one of said switches of said inverter;

a drive control, coupled to said inverter, to generate said drive control signals and to set a level of each of said rail voltages responsive to a plurality of controller signals; and

a controller monitoring one or more parameters indicative of said potential transitory voltage overshoot condition, said controller dynamically adjusting, responsive to said monitored parameters, said controller signals to reduce a risk of occurrence of said potential transitory voltage overshoot condition;

wherein said controller signals include a variable regulator signal and wherein said drive control includes a first driver stage coupled to a gate of said high-side switch and a high-side DC bias supply regulation mechanism providing said high-side positive rail voltage and said high-side negative rail voltage to said first drive transistor, said drive control also including a second driver stage coupled to a gate of said low-side switch and a low-side DC bias supply regulation mechanism providing said low-side positive rail voltage and said high-side negative rail voltage to said second drive transistor, wherein said regulation mechanisms each receive a positive supply voltage and a negative supply voltage wherein said regulation mechanisms provide said high-side positive rail voltage and said low-side positive rail voltage at said positive supply voltage and wherein said regulation mechanisms provide said high-side negative rail voltage and said low-side negative rail voltage at a variable negative voltage responsive to said variable regulator signal with said variable negative voltage provided in a range from about zero volts to about said negative supply voltage.

2. An apparatus, comprising:

an inverter including a high-side switch coupled to a low-side switch, said inverter generating a time-varying drive current from a plurality of drive control signals, a high-side positive rail voltage, a high-side negative rail voltage, a low-side positive rail voltage, and a low-side negative rail voltage wherein controlling the switches to generate said time-varying drive current produces a potential transitory overshoot condition for one of said switches of said inverter;

a drive control, coupled to said inverter, to generate said drive control signals and to set a level of each of said rail voltages responsive to a plurality of controller signals; and

a controller monitoring one or more parameters indicative of said potential transitory voltage overshoot condition, said controller dynamically adjusting, responsive to said monitored parameters, said controller signals to reduce a risk of occurrence of said potential transitory voltage overshoot condition;

wherein said time-varying current includes a time-varying amplitude and wherein a DC link capacitance couples said high-side positive rail voltage of said high-side switch with said low-side negative rail voltage of said low-side switch and wherein said parameters include said time-varying amplitude and a voltage across said DC link capacitance and wherein said controller signals include a first series of high-side pulse width modulation (PWM) signals and second series of low-side PWM signals for generation of said time-varying current and wherein said controller signals include a variable regulator signal to set said high-side negative rail voltage and said low-side negative rail voltage at a variable regulated voltage in a range from about zero volts to about a negative supply voltage.

3. The apparatus of claim 2 wherein said regulation mechanisms each include a first voltage regulator coupled to said high-side positive rail voltage and said low-side positive rail voltage and a second voltage regulator coupled to said high-side negative rail voltage and said low-side negative rail voltage and coupled to said first voltage regulator at a reference node wherein said first voltage regulator provides said high-side positive rail voltage and said low-side positive rail voltage with respect to a voltage of said reference node and wherein said second voltage regulator provides a varying negative rail voltage with respect to said reference node voltage in response to said variable regulator signal.

4. The apparatus of claim 2 wherein said time-varying current includes a time-varying amplitude and wherein a DC link capacitance couples said high-side positive rail voltage of said high-side switch with said low-side negative rail voltage of said low-side switch and wherein said parameters include said time-varying amplitude and a voltage across said DC link capacitance and wherein said controller signals include a first series of high-side pulse width modulation (PWM) signals and second series of low-side PWM signals for generation of said time-varying current and wherein said controller signals include said variable regulator signal to set said high-side negative rail voltage and said low-side negative rail voltage at a variable regulated voltage in a range from about zero volts to about said negative supply voltage.

5. The apparatus of claim 2 wherein one or more of said parameters are converted to a root means square signal or a rectified mean signal and wherein said controller signals are generated responsive to said root mean square signal or to said rectified mean signal.

6. The apparatus of claim 2 wherein said controller includes a programmatic control element controlling said PWM signals and wherein said controller includes a discrete hardware element controlling said variable regulator signal.

7. The apparatus of claim 6 wherein said discrete hardware element includes a comparator having an output providing said variable regulator signal wherein said comparator includes a first input receiving a first input voltage derived from said drive current and a second input receiving a preselected voltage threshold to configure said variable regulator signal to reduce said risk.

8. The apparatus of claim 2 including a low pass filter coupled to said first input of said comparator.

9. The apparatus of claim 2 wherein said one or more parameters include an estimate of a junction temperature of one or more said components in a heat rejection path of said inverter and wherein said controller signals are responsive to said junction temperature when setting said high-side negative rail voltage and said low-side negative rail voltage.

10. A method, the method comprising the steps of:

a) calculating a maximum available voltage overshoot for an inverter producing a time-varying drive current;

b) determining a current voltage overshoot for said inverter responsive to said time-varying drive current;

c) operating said inverter in a first operational mode for minimization of switching losses when said current voltage overshoot is not greater than said maximum available voltage overshoot while increasing a risk of occurrence of a potential transitory voltage overshoot condition destructive to said inverter; and

d) operating said inverter in a second operational mode for reduction of said risk of occurrence of said potential transitory voltage overshoot condition when said current voltage overshoot is greater than said maximum available voltage overshoot while increasing switching losses;

wherein said operational modes selectively switch one or more variable voltage regulators to control a negative rail voltage of said inverter with said first operational mode providing a first voltage for said negative rail voltage providing a faster switching time than with said second operational mode providing a second voltage for said negative rail voltage.

11. The method of claim 10 including the steps of oversampling said time-varying drive current, recalculating periodically said maximum available voltage overshoot and redetermining said current voltage overshoot.

12. The method of claim 10 wherein said determining step b) includes querying a lookup table including entries for a range of instantaneous drive currents and associated overshoot voltages.

13. The method of claim 10 wherein said operational modes are set by controlling said negative rail voltage wherein said negative rail voltage for said first operational mode has a voltage magnitude greater than said negative rail voltage for said second operational mode.

14. The method of claim 10 further comprising a DC link capacitance coupling a positive rail voltage of said inverter to said negative rail voltage of said inverter wherein said calculating step includes subtracting a real-time instantaneous voltage across said DC link capacitance from a device rating of a switch of said inverter.

15. The method of claim 10 wherein said second operational mode varies responsive to a magnitude of a difference between said maximum voltage overshoot and said current voltage overshoot.

16. The method of claim 10 wherein said determining step includes querying a lookup table including entries for a range of RMS drive currents or low-pass filtered rectified driver currents and associated overshoot voltages.

17. The method of claim 10 further comprising a DC link capacitance coupling a positive rail voltage of said inverter to said negative rail voltage of said inverter wherein said calculating step includes subtracting a low-pass filtered real-time instantaneous voltage across said DC link capacitance from a device rating of a switch of said inverter.

18. The method of claim 10 wherein said second operational mode is not responsive to a magnitude of a difference between said maximum voltage overshoot and said current voltage overshoot.

19. The method of claim 10 wherein a magnitude of said negative rail voltage in said second operational mode does not vary responsive to a magnitude of a difference between said maximum voltage overshoot and said current voltage overshoot.

20. The method of claim 10 further comprising the step of:

e) low pass filtering said one or more parameters to produce an rms current signal;

wherein said adjusting step d) is responsive to said rms current signal.

21. The method of claim 10 further comprising the steps of:

e) low pass filtering said one or more parameters to produce an rms current signal;

f) comparing said rms current signal to a predetermined threshold allowing non-risky operation for a predetermined range of said rail voltages to produce an comparator output signal;

wherein said adjusting step d) is responsive to said comparator output signal.

22. The method of claim 10 further comprising the step of:

e) estimating a junction temperature of a device in a heat rejection path of said inverter;

wherein said one or more parameters includes said junction temperature.