倍频式700kHz高频大功率感应加热电源的研究
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摘要
感应加热电源广泛应用于各行各业中,这些工艺大都需要高频大功率的电源。目前,高频阶段都是采用功率MOSFET器件。由于MOSFET在高频化下的电压、电流容量等级低,使得其输出功率容量提升受到限制。本课题研究了基于MOSFET的倍频式700kHz大功率感应加热电源逆变电路的拓扑结构,逆变桥两组MOSFET采用并联分时导通,在逆变器输出的两个周期内,每个MOSFET工作一个周期,其工作频率为350kHz。为了进一步提高输出功率,运用MOSFET并联技术增加电流容量,从而提高输出功率。功率调节方式采用分时控制和密度调节复合调功方式,即分时—密度复合控制。论文对倍频式电源的拓扑结构和工作原理做了详细的分析。该功率控制方法是以复杂可编程逻辑器件CPLD为核心,利用VHDL硬件语言软件编程及模块化搭建,并用Quartus仿真软件对其进行了仿真试验,验证了其准确性。同时,设计了基于DSP的电流闭环控制系统,设计了DSP的数字PI调节,给出了功率闭环的整体框图。为保证电源正常运行,并使逆变器始终工作在功率因数接近或等于1的准谐振或谐振状态,以实现逆变器开关器件的零电流或零电压开关,设计了以高速集成锁相环74HC4046为核心的频率跟踪电路,并分析了锁相环的基本原理及数学建模。最后,通过分析比较各种MOSFET驱动电路,选用专用MOSFET驱动芯片IXDD430来完成驱动电路的设计。同时设计了保护及死区时间、启动、补偿时间形成等辅助电路。设计的700kHz的倍频式感应加热电源实验样机,MOSFET工作频率为350kHz,逆变器工作频率为700kHz。控制核心采用Altera公司的EPM1270CPLD产生倍频式感应加热电源分时—密度复合控制的驱动脉冲,利用TI公司的TMS320F2812DSP控制芯片实现功率闭环调节及保护,简化了系统结构。实验结果表明,倍频电源能有效提高电源工作频率,使之满足更多应用场合的需要。
Induction heating power supplies are widely used in all walks of life, these processes are the need for high-power high-frequency power. At present, it uses the MOSFETs as high-frequency phase-power devices. As the MOSFET with the low level voltage and current, the capacity to enhance its output power is limited. This paper researches on an 700kHz double-frequency induction heater based on MOSFET. The main circuit is parallelling MOSFET in each of the traditional MOSFET and time-sharing controling, that is, in the the two cycles of inverter output, each MOSFET works one cycle, the operating frequency is 350kHz. To further enhance the output power, the use of MOSFET technology in parallel to increase current capacity, thereby enhancing the output power. Power regulating method is a new time-sharing PDM power control method of multiple frequency inverter is presented in this paper, which is based on PDM and time-sharing. Then, it analysed the structure and working principle of multiple frequency inverter. The implementation of the power control method is based on complex programmable logic device CPLD as its core. The use of VHDL hardware language programming, module structure and Quartus II simulation verified its accuracy. Meanwhile, a closed-loop system of current and power was designed, and the overall closed-loop block diagram of the power is proposed. Finally, through analysis and comparison of various MOSFET driver circuit, a dedicated MOSFET driver IC IXDD430 is choosed to complete driver circuit design. At the same time, protection and the formation of deadtime , starttime and compensationtime circuit are introducted. Finally a 700kHz multiple frequency inverter is made. MOSFETs’operating frequency is 350kHz, the inverter’s operating frequency is 700kHz. Control core using Altera's EPM1270CPLD produce the control drive pulse of time-sharing control of multiple frequency inverter, the use of TI's TMS320F2812 DSP implement closed-loop power control, simplifying the system architecture. The experimental results show that multiple frequency inverter can effectively improve the power supply frequency, so as to meet the needs of more applications.
Induction heating power supplies are widely used in all walks of life, these processes are the need for high-power high-frequency power. At present, it uses the MOSFETs as high-frequency phase-power devices. As the MOSFET with the low level voltage and current, the capacity to enhance its output power is limited. This paper researches on an 700kHz double-frequency induction heater based on MOSFET. The main circuit is parallelling MOSFET in each of the traditional MOSFET and time-sharing controling, that is, in the the two cycles of inverter output, each MOSFET works one cycle, the operating frequency is 350kHz. To further enhance the output power, the use of MOSFET technology in parallel to increase current capacity, thereby enhancing the output power. Power regulating method is a new time-sharing PDM power control method of multiple frequency inverter is presented in this paper, which is based on PDM and time-sharing. Then, it analysed the structure and working principle of multiple frequency inverter. The implementation of the power control method is based on complex programmable logic device CPLD as its core. The use of VHDL hardware language programming, module structure and Quartus II simulation verified its accuracy. Meanwhile, a closed-loop system of current and power was designed, and the overall closed-loop block diagram of the power is proposed. Finally, through analysis and comparison of various MOSFET driver circuit, a dedicated MOSFET driver IC IXDD430 is choosed to complete driver circuit design. At the same time, protection and the formation of deadtime , starttime and compensationtime circuit are introducted. Finally a 700kHz multiple frequency inverter is made. MOSFETs’operating frequency is 350kHz, the inverter’s operating frequency is 700kHz. Control core using Altera's EPM1270CPLD produce the control drive pulse of time-sharing control of multiple frequency inverter, the use of TI's TMS320F2812 DSP implement closed-loop power control, simplifying the system architecture. The experimental results show that multiple frequency inverter can effectively improve the power supply frequency, so as to meet the needs of more applications.
引文
1.王庆元,张祥光.机电一体化感应加热设备的应用进展[J].金属热处理,2009,34(2): 118-120.
2.周海,曾少鹏,袁石根.感应加热淬火技术的发展及应用[J].热处理技术与装备,2008, 29(3):9-15.
3.王广成.感应加热在锻造生产中的应用[J].金属加工,2009(3):24-26.
4.梁文林,夏越良.高频感应加热设备的原理、工程计算、调整与维修[M].北京:机械工业出版社,1986.1-15.
5. [英]约翰·戴维斯,彼得·辛普森著,张淑芳等译.感应加热手册[M].北京:国防工业出版社, 1985.5-10.
6.姜士林,赵长汉,感应加热原理与应用[M].天津科技翻译出版公司,1993.3-20.
7. Hammad Abo Zied, Peter Mutschler,Guido Bachmann. A Modular IGBT Converter System for High Frequency Induction Heating Applications, PCIM 2002: 14-16.
8.孙宁,施建华.感应加热工艺与设备的发展状况及趋势(上)[J].金属加工,2009(1):26-28.
9.孙宁,施建华.感应加热工艺与设备的发展状况及趋势(下)[J].金属加工,2009(3):27-29.
10.高传德,林信智.我国感应加热设备企业的发展[J].金属热处理,2007,32(4):103
11.潘天明.现代感应加热装置[M].冶金工业出版社,1996.24-56.
12. Stephen HINCHLIFFE and Leslie HoBSON. High Efficiency DC-AC converters Suitable For High Frequency Induction Process heating Applicatons[J]. IEEE_PESC, April, 1988: 1228-1233.
13. Harris semiconductor, Parallel Operation of Semiconductor switch[J]. Harris Semiconductor, 1998: 1235-1240.
14.董淑惠,李亚斌,田丰.时间分割式IGBT高频感应加热电源的研究[J].电力科学与工程,2007,(04):1-3.
15.王兆安,黄俊.电力电子技术[M].北京:机械工业出版社.2000.43-90.
16.单广伟.基于CPLD的1kW/1MHz PSM功率控制高频感应加热电源的研究[D]:[硕士学位论文].无锡,江南大学通信与控制工程学院,2006.38.
17.李春华,张之超.新型感应加热电源调功方式的仿真[J].黑龙江科技学院学报,2008,18(1): 31-33.
18. Yue F, Shirai H, Oleg K, Okuno A. Pulse Density Modulated Zero Crrent Soft-switching Series Resonanthigh Frequency Inverter for Consumer Induction-heated Roller[J]. PowerElectronics Specialists Conference, 2002, pesc02. 2002: 1884-1891.
19. Laknath Gamage, Kentarou Fujita, Tarek Ahmed, Akito Fukui, Mutsuo Nakaoka. Series Resonant High Frequency Inverter with Zero Current Switching Pulse Density Modulation for Induction Heated Load[J]. IEEE Trans.vol03: 1739-1744.
20.徐应年,赵阳,康勇.数字恒频移相调功串联谐振逆变电源的研制[J].高电压技术,2008,34(8):1698-1703.
21.初中原,沈锦飞.基于DSP的软开关移相控制100kHz逆变电源的研究[J].电力电子技术,2008,42(1):41-42.
22. Hideaki Fujita, Hirofumi Akagi. Pulse-Density-Modulated Power Control of a 4 kW, 450kHz Voltage-Source Inverter for Induction Melting Applications[J].IEEE, 1996, TRANSCTIONS ON INDUSTRY APPLICATIONS,VOL 32,NO.2, MARCH/APRIL, 279-286.
23.熊一频,沈锦飞,初中原.基于IGBT倍频式180kHz感应加热电源的研究[J].电力电子技术2008,42(11):58-59.
24.李贺,彭咏龙,李亚斌.分时控制MOSFET高频感应加热电源[J].通信电源技术,2008,25(5):7-9.
25.沈锦飞,单广伟,颜文旭,惠晶.PSM功率控制大功率感应加热电源及应用[J].电力电子技术,2006,40(2):84-86.
26.马红斌,沈锦飞.感应加热电源PDM-PSM复合功率控制策略研究[J].电力电子技术,2007.41(5):70-72.
27.周润景,图雅,张丽敏.基于Quartus II的FPGA/CPLD数字系统设计实例[M].北京:电子工业出版社,2007.1-5.
28.苏奎峰,吕强等.TMS320F2812原理与开发[M].北京:电子工业出版社,2005.1-23.
29.蒋峰.全数字控制高频感应加热电源的研究[D]:[硕士学位论文].无锡,江南大学通信与控制工程学院,2008.29-31.
30.初中原.基于IGBT的150kHz大功率感应加热电源的研究[D]:[硕士学位论文].无锡,江南大学通信与控制工程学院,2008.26-27.
31.郭红,沈锦飞.基于锁相环1MHz感应加热电源频率跟踪的研究[J].工业加热,2007,36(6),53-56.
32.远坂俊昭.锁相环( PLL)电路设计与应用[M].北京:科学出版社,2006.1-3.
33. Chyun G. Phase-locked loop technique[J].Digital Object Identifier, 1996, 43(6):122-128.
34.沈海明.基于DSP的400kHz的大功率高频感应加热电源研究[D]:[硕士学位论文].无锡,江南大学通信与控制工程学院,2008.33-41.
35.王生德,刘平,申晋.MM74HC4046在高频感应加热电源中的应用[J].电力电子技术,2007,41(8):73-75.
36. Te-Fang chen, shu cheng. A Novel Zero-Voltage Zero-Current Switching Full-Bridge PWM Converter Using Improved Secondary Active Clamp[J]. Industrial Electronics,2006 IEEE International Symposium on 2006.1359-1362.
37.段海燕.感应加热电源的数字化控制研究[D]:[硕士学位论文].济南,山东大学电力电子与电力传动系,2007.37-40.
38. Yao Feng, He Qixin, Fang Shao2hua. Analysis for a new-voltage power MOSFET Structure. Semiconductor Technology[J].2005,30(11):53-56.
39.张良,黄子平,刘承俊,章林文.MOSFET器件并联实验研究[J].通信电源技术,2007,24(6):5-7.
40.严寒松,周伟松等.高频感应加热电源功率器件MOSFET驱动电路[J].电力电子技术,2007,41(4):91-92.
41. Yao Feng, He Qixin, Fang Shao2hua. Analysis for a new-voltage power MOSFET Structure. Semiconductor Technology[J]. 2005, 30(11):53-56.
42. MAXIM. Dual High-speed 1.5A MOSFET Driver MAX4420 [M]. MAXIM Ltd, 1993. 14-16.
43.沈海明,沈锦飞,初中原.基于LCL谐振负载功率合成逆变电源研究[J].计算机仿真,2008,25(4):245-248.
44. Abhijit D. Pathak. IXYS MOSFET Drivers Theory and Applications [M]. IXYS Corporation, 1999. 54-56
45.沈海明,沈锦飞.一种新型高频感应加热用驱动、保护电路[J].开关电源技术,2008(03):33-35.
46.夏小荣,陈辉明,蒋大鹏.一种新型高频感应加热用驱动电路[J].电子器件,2006,29(1):142-144
2.周海,曾少鹏,袁石根.感应加热淬火技术的发展及应用[J].热处理技术与装备,2008, 29(3):9-15.
3.王广成.感应加热在锻造生产中的应用[J].金属加工,2009(3):24-26.
4.梁文林,夏越良.高频感应加热设备的原理、工程计算、调整与维修[M].北京:机械工业出版社,1986.1-15.
5. [英]约翰·戴维斯,彼得·辛普森著,张淑芳等译.感应加热手册[M].北京:国防工业出版社, 1985.5-10.
6.姜士林,赵长汉,感应加热原理与应用[M].天津科技翻译出版公司,1993.3-20.
7. Hammad Abo Zied, Peter Mutschler,Guido Bachmann. A Modular IGBT Converter System for High Frequency Induction Heating Applications, PCIM 2002: 14-16.
8.孙宁,施建华.感应加热工艺与设备的发展状况及趋势(上)[J].金属加工,2009(1):26-28.
9.孙宁,施建华.感应加热工艺与设备的发展状况及趋势(下)[J].金属加工,2009(3):27-29.
10.高传德,林信智.我国感应加热设备企业的发展[J].金属热处理,2007,32(4):103
11.潘天明.现代感应加热装置[M].冶金工业出版社,1996.24-56.
12. Stephen HINCHLIFFE and Leslie HoBSON. High Efficiency DC-AC converters Suitable For High Frequency Induction Process heating Applicatons[J]. IEEE_PESC, April, 1988: 1228-1233.
13. Harris semiconductor, Parallel Operation of Semiconductor switch[J]. Harris Semiconductor, 1998: 1235-1240.
14.董淑惠,李亚斌,田丰.时间分割式IGBT高频感应加热电源的研究[J].电力科学与工程,2007,(04):1-3.
15.王兆安,黄俊.电力电子技术[M].北京:机械工业出版社.2000.43-90.
16.单广伟.基于CPLD的1kW/1MHz PSM功率控制高频感应加热电源的研究[D]:[硕士学位论文].无锡,江南大学通信与控制工程学院,2006.38.
17.李春华,张之超.新型感应加热电源调功方式的仿真[J].黑龙江科技学院学报,2008,18(1): 31-33.
18. Yue F, Shirai H, Oleg K, Okuno A. Pulse Density Modulated Zero Crrent Soft-switching Series Resonanthigh Frequency Inverter for Consumer Induction-heated Roller[J]. PowerElectronics Specialists Conference, 2002, pesc02. 2002: 1884-1891.
19. Laknath Gamage, Kentarou Fujita, Tarek Ahmed, Akito Fukui, Mutsuo Nakaoka. Series Resonant High Frequency Inverter with Zero Current Switching Pulse Density Modulation for Induction Heated Load[J]. IEEE Trans.vol03: 1739-1744.
20.徐应年,赵阳,康勇.数字恒频移相调功串联谐振逆变电源的研制[J].高电压技术,2008,34(8):1698-1703.
21.初中原,沈锦飞.基于DSP的软开关移相控制100kHz逆变电源的研究[J].电力电子技术,2008,42(1):41-42.
22. Hideaki Fujita, Hirofumi Akagi. Pulse-Density-Modulated Power Control of a 4 kW, 450kHz Voltage-Source Inverter for Induction Melting Applications[J].IEEE, 1996, TRANSCTIONS ON INDUSTRY APPLICATIONS,VOL 32,NO.2, MARCH/APRIL, 279-286.
23.熊一频,沈锦飞,初中原.基于IGBT倍频式180kHz感应加热电源的研究[J].电力电子技术2008,42(11):58-59.
24.李贺,彭咏龙,李亚斌.分时控制MOSFET高频感应加热电源[J].通信电源技术,2008,25(5):7-9.
25.沈锦飞,单广伟,颜文旭,惠晶.PSM功率控制大功率感应加热电源及应用[J].电力电子技术,2006,40(2):84-86.
26.马红斌,沈锦飞.感应加热电源PDM-PSM复合功率控制策略研究[J].电力电子技术,2007.41(5):70-72.
27.周润景,图雅,张丽敏.基于Quartus II的FPGA/CPLD数字系统设计实例[M].北京:电子工业出版社,2007.1-5.
28.苏奎峰,吕强等.TMS320F2812原理与开发[M].北京:电子工业出版社,2005.1-23.
29.蒋峰.全数字控制高频感应加热电源的研究[D]:[硕士学位论文].无锡,江南大学通信与控制工程学院,2008.29-31.
30.初中原.基于IGBT的150kHz大功率感应加热电源的研究[D]:[硕士学位论文].无锡,江南大学通信与控制工程学院,2008.26-27.
31.郭红,沈锦飞.基于锁相环1MHz感应加热电源频率跟踪的研究[J].工业加热,2007,36(6),53-56.
32.远坂俊昭.锁相环( PLL)电路设计与应用[M].北京:科学出版社,2006.1-3.
33. Chyun G. Phase-locked loop technique[J].Digital Object Identifier, 1996, 43(6):122-128.
34.沈海明.基于DSP的400kHz的大功率高频感应加热电源研究[D]:[硕士学位论文].无锡,江南大学通信与控制工程学院,2008.33-41.
35.王生德,刘平,申晋.MM74HC4046在高频感应加热电源中的应用[J].电力电子技术,2007,41(8):73-75.
36. Te-Fang chen, shu cheng. A Novel Zero-Voltage Zero-Current Switching Full-Bridge PWM Converter Using Improved Secondary Active Clamp[J]. Industrial Electronics,2006 IEEE International Symposium on 2006.1359-1362.
37.段海燕.感应加热电源的数字化控制研究[D]:[硕士学位论文].济南,山东大学电力电子与电力传动系,2007.37-40.
38. Yao Feng, He Qixin, Fang Shao2hua. Analysis for a new-voltage power MOSFET Structure. Semiconductor Technology[J].2005,30(11):53-56.
39.张良,黄子平,刘承俊,章林文.MOSFET器件并联实验研究[J].通信电源技术,2007,24(6):5-7.
40.严寒松,周伟松等.高频感应加热电源功率器件MOSFET驱动电路[J].电力电子技术,2007,41(4):91-92.
41. Yao Feng, He Qixin, Fang Shao2hua. Analysis for a new-voltage power MOSFET Structure. Semiconductor Technology[J]. 2005, 30(11):53-56.
42. MAXIM. Dual High-speed 1.5A MOSFET Driver MAX4420 [M]. MAXIM Ltd, 1993. 14-16.
43.沈海明,沈锦飞,初中原.基于LCL谐振负载功率合成逆变电源研究[J].计算机仿真,2008,25(4):245-248.
44. Abhijit D. Pathak. IXYS MOSFET Drivers Theory and Applications [M]. IXYS Corporation, 1999. 54-56
45.沈海明,沈锦飞.一种新型高频感应加热用驱动、保护电路[J].开关电源技术,2008(03):33-35.
46.夏小荣,陈辉明,蒋大鹏.一种新型高频感应加热用驱动电路[J].电子器件,2006,29(1):142-144