最近做了一个半桥结构充电电路,调试了很久上面的MOS管总是发热,进行很多尝试,仍然无法解决,恳请大家帮忙.
参数如图:
380V输入、输出70V*1.5A=105W;
MOS管:IRFBG30;
整流二极管:MUR860;
驱动电路:IR2102;
高频变压器:磁芯EC35,
原边46匝/0.25mm双线并绕
副边16匝/0.6mm
工作频率:40KHz;
我把现象说得详细些,大家耐心看,
工作现象:
(一).40KHz工作时,变压器原边未加隔直电容情况下,当直流输出1A时(设计为1.5A)上臂MOS管发热严重,20秒左右就烫手,30秒时手不敢碰
,估计能到100°C,而下桥臂只是温热而已,感觉还以接受.全过程变压器温度正常,也无明显噪音.
采取措施及现象:
(1)测量分压电容两侧电压,上桥臂电压比下桥臂电压高20%左右.怀疑是偏压造成单管发热.......采取如下措施.
(2)开始怀疑是变压器副边绕线不平衡所致,但采用双组线并绕,取一组头尾对接作为抽头方式重新缠绕变压器后,电压不平衡现象仍没有
消除,单管发热依旧.
(3)考虑到可能是功率管之间的差异造成的电压,分别多次更换了上下臂的管子,一直是上桥臂电容电压高,其发热现象也未消除.
(4)在变压器原边加3.3uF隔直电容,分压电容的电压平衡了,变压器输出波形正负半周也平衡了,但是上桥臂MOS管依然发热.
(5)怀疑上桥臂驱动信号驱动不足,使MOS管在一定时间内处于放大状态导致管子发热,对驱动电路部分原件参数进行了经过一些调整,在
空载时驱动波形如图1.1(图片比较模糊,大家原谅啊,不过还是可以看出波形),脉宽4us,电压15V,上升时间不到0.5US.当接上负载时上桥
臂驱动波形如图1.2和图1.3所示(高压,没敢两路波形一起测,下桥臂波形良好不波动,也无毛刺,所以未拍照).图1.3是动态拍照,可以看
出驱动信号来回变化的两个轮廓.不知道是不是这个变化使管子发热.(后面变压器波形也变化,也可能是驱动信号变化引起的,请大家帮忙
分析)
(6)图2.1.是上臂MOS管漏源极电压Uds,(动态显示).可以看到是有两种来回变化的波形轮廓,组成.对这两种波形捕捉拍照如图2.2、图
2.3所示.
图2.2中箭头1、2所示为上下管分别导通时上管漏源电压,可以看出导通完全.但是在图图2.1中箭头4所指可以看出什么那?,是不是
可以认为上桥臂MOS管在某一时刻没有完全截止,以至电压没有达到箭头2所指的位置.(不知道我这么分析对不对)
图3.1~图3.4是下桥臂MOS管漏源电压波形,有重影的是动态显示情况下拍的照.
图4.1、图4.2是变压器原边电压波形.
图5.1~图5.3是变压器副边电压波形.
(二)20KHz工作时,变压器有噪音.不知道是不是在两管交替导通时驱动信号毛刺造成了很短时间的直通,使变压器产生噪音.
(三)380V输入电压突然加入时,有时MOS管栅、源极(G、S)烧通.是什么原因那? 是不是电路中MOS管加上双向稳压管就可以避免那?
弄了很久,单管发热问题不能解决,恳请大家帮忙啊!!!
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半桥电路上桥臂MOS管发热严重-----弄了很久,恳请大家帮忙分析啊!
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图的标号不清楚,重新传一遍500) {this.resized=true; this.width=500; this.alt='这是一张缩略图,点击可放大。\n按住CTRL,滚动鼠标滚轮可自由缩放';this.style.cursor='hand'}" onclick="if(!this.resized) {return true;} else {window.open('http://u.dianyuan.com/bbs/u/72/3038321228840512.jpg');}" onmousewheel="return imgzoom(this);">500) {this.resized=true; this.width=500; this.alt='这是一张缩略图,点击可放大。\n按住CTRL,滚动鼠标滚轮可自由缩放';this.style.cursor='hand'}" onclick="if(!this.resized) {return true;} else {window.open('http://u.dianyuan.com/bbs/u/72/3038321228840519.jpg');}" onmousewheel="return imgzoom(this);">
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图的标号不清楚,重新传一遍[图片]500){this.resized=true;this.width=500;this.alt='这是一张缩略图,点击可放大。\n按住CTRL,滚动鼠标滚轮可自由缩放';this.style.cursor='hand'}"onclick="if(!this.resized){returntrue;}else{window.open('http://u.dianyuan.com/bbs/u/72/3038321228840512.jpg');}"onmousewheel="returnimgzoom(this);">[图片]500){this.resized=true;this.width=500;this.alt='这是一张缩略图,点击可放大。\n按住CTRL,滚动鼠标滚轮可自由缩放';this.style.cursor='hand'}"onclick="if(!this.resized){returntrue;}else{window.open('http://u.dianyuan.com/bbs/u/72/3038321228840519.jpg');}"onmousewheel="returnimgzoom(this);">
图的标号依次为:
图1.1.驱动信号波形(未加母线电压时)
图1.2.上桥臂驱动信号(带载).jpg?x-oss-process=image/watermark,g_center,image_YXJ0aWNsZS9wdWJsaWMvd2F0ZXJtYXJrLnBuZz94LW9zcy1wcm9jZXNzPWltYWdlL3Jlc2l6ZSxQXzQwCg,t_20
图1.3.上桥臂驱动信号(动态捕捉).jpg?x-oss-process=image/watermark,g_center,image_YXJ0aWNsZS9wdWJsaWMvd2F0ZXJtYXJrLnBuZz94LW9zcy1wcm9jZXNzPWltYWdlL3Jlc2l6ZSxQXzQwCg,t_20
图2.1.上臂Uds(动态显示).jpg?x-oss-process=image/watermark,g_center,image_YXJ0aWNsZS9wdWJsaWMvd2F0ZXJtYXJrLnBuZz94LW9zcy1wcm9jZXNzPWltYWdlL3Jlc2l6ZSxQXzQwCg,t_20
图2.2.上臂Uds.jpg?x-oss-process=image/watermark,g_center,image_YXJ0aWNsZS9wdWJsaWMvd2F0ZXJtYXJrLnBuZz94LW9zcy1wcm9jZXNzPWltYWdlL3Jlc2l6ZSxQXzQwCg,t_20
图2.3.上臂Uds.jpg?x-oss-process=image/watermark,g_center,image_YXJ0aWNsZS9wdWJsaWMvd2F0ZXJtYXJrLnBuZz94LW9zcy1wcm9jZXNzPWltYWdlL3Jlc2l6ZSxQXzQwCg,t_20
图3.1.下臂Uds(动态显示)2.jpg?x-oss-process=image/watermark,g_center,image_YXJ0aWNsZS9wdWJsaWMvd2F0ZXJtYXJrLnBuZz94LW9zcy1wcm9jZXNzPWltYWdlL3Jlc2l6ZSxQXzQwCg,t_20
图3.2.下臂Uds(动态显示).jpg?x-oss-process=image/watermark,g_center,image_YXJ0aWNsZS9wdWJsaWMvd2F0ZXJtYXJrLnBuZz94LW9zcy1wcm9jZXNzPWltYWdlL3Jlc2l6ZSxQXzQwCg,t_20
图3.3.下臂Uds(捕捉1).jpg?x-oss-process=image/watermark,g_center,image_YXJ0aWNsZS9wdWJsaWMvd2F0ZXJtYXJrLnBuZz94LW9zcy1wcm9jZXNzPWltYWdlL3Jlc2l6ZSxQXzQwCg,t_20
图3.4.下臂Uds(捕捉2).jpg?x-oss-process=image/watermark,g_center,image_YXJ0aWNsZS9wdWJsaWMvd2F0ZXJtYXJrLnBuZz94LW9zcy1wcm9jZXNzPWltYWdlL3Jlc2l6ZSxQXzQwCg,t_20
图4.1.变压器原边动态显示波形(无隔直电容).jpg?x-oss-process=image/watermark,g_center,image_YXJ0aWNsZS9wdWJsaWMvd2F0ZXJtYXJrLnBuZz94LW9zcy1wcm9jZXNzPWltYWdlL3Jlc2l6ZSxQXzQwCg,t_20
图4.2.变压器原边捕捉波形1(无隔直电容).jpg?x-oss-process=image/watermark,g_center,image_YXJ0aWNsZS9wdWJsaWMvd2F0ZXJtYXJrLnBuZz94LW9zcy1wcm9jZXNzPWltYWdlL3Jlc2l6ZSxQXzQwCg,t_20
图5.1变压器副边动态显示波形(无隔直电容).jpg?x-oss-process=image/watermark,g_center,image_YXJ0aWNsZS9wdWJsaWMvd2F0ZXJtYXJrLnBuZz94LW9zcy1wcm9jZXNzPWltYWdlL3Jlc2l6ZSxQXzQwCg,t_20
图5.2变压器副边捕捉波形3(无隔直电容).jpg?x-oss-process=image/watermark,g_center,image_YXJ0aWNsZS9wdWJsaWMvd2F0ZXJtYXJrLnBuZz94LW9zcy1wcm9jZXNzPWltYWdlL3Jlc2l6ZSxQXzQwCg,t_20
图5.3变压器副边捕捉波形2(无隔直电容).jpg?x-oss-process=image/watermark,g_center,image_YXJ0aWNsZS9wdWJsaWMvd2F0ZXJtYXJrLnBuZz94LW9zcy1wcm9jZXNzPWltYWdlL3Jlc2l6ZSxQXzQwCg,t_20
原理图1.JPG
原理图2.JPG
图1.1.驱动信号波形(未加母线电压时)
图1.2.上桥臂驱动信号(带载).jpg?x-oss-process=image/watermark,g_center,image_YXJ0aWNsZS9wdWJsaWMvd2F0ZXJtYXJrLnBuZz94LW9zcy1wcm9jZXNzPWltYWdlL3Jlc2l6ZSxQXzQwCg,t_20
图1.3.上桥臂驱动信号(动态捕捉).jpg?x-oss-process=image/watermark,g_center,image_YXJ0aWNsZS9wdWJsaWMvd2F0ZXJtYXJrLnBuZz94LW9zcy1wcm9jZXNzPWltYWdlL3Jlc2l6ZSxQXzQwCg,t_20
图2.1.上臂Uds(动态显示).jpg?x-oss-process=image/watermark,g_center,image_YXJ0aWNsZS9wdWJsaWMvd2F0ZXJtYXJrLnBuZz94LW9zcy1wcm9jZXNzPWltYWdlL3Jlc2l6ZSxQXzQwCg,t_20
图2.2.上臂Uds.jpg?x-oss-process=image/watermark,g_center,image_YXJ0aWNsZS9wdWJsaWMvd2F0ZXJtYXJrLnBuZz94LW9zcy1wcm9jZXNzPWltYWdlL3Jlc2l6ZSxQXzQwCg,t_20
图2.3.上臂Uds.jpg?x-oss-process=image/watermark,g_center,image_YXJ0aWNsZS9wdWJsaWMvd2F0ZXJtYXJrLnBuZz94LW9zcy1wcm9jZXNzPWltYWdlL3Jlc2l6ZSxQXzQwCg,t_20
图3.1.下臂Uds(动态显示)2.jpg?x-oss-process=image/watermark,g_center,image_YXJ0aWNsZS9wdWJsaWMvd2F0ZXJtYXJrLnBuZz94LW9zcy1wcm9jZXNzPWltYWdlL3Jlc2l6ZSxQXzQwCg,t_20
图3.2.下臂Uds(动态显示).jpg?x-oss-process=image/watermark,g_center,image_YXJ0aWNsZS9wdWJsaWMvd2F0ZXJtYXJrLnBuZz94LW9zcy1wcm9jZXNzPWltYWdlL3Jlc2l6ZSxQXzQwCg,t_20
图3.3.下臂Uds(捕捉1).jpg?x-oss-process=image/watermark,g_center,image_YXJ0aWNsZS9wdWJsaWMvd2F0ZXJtYXJrLnBuZz94LW9zcy1wcm9jZXNzPWltYWdlL3Jlc2l6ZSxQXzQwCg,t_20
图3.4.下臂Uds(捕捉2).jpg?x-oss-process=image/watermark,g_center,image_YXJ0aWNsZS9wdWJsaWMvd2F0ZXJtYXJrLnBuZz94LW9zcy1wcm9jZXNzPWltYWdlL3Jlc2l6ZSxQXzQwCg,t_20
图4.1.变压器原边动态显示波形(无隔直电容).jpg?x-oss-process=image/watermark,g_center,image_YXJ0aWNsZS9wdWJsaWMvd2F0ZXJtYXJrLnBuZz94LW9zcy1wcm9jZXNzPWltYWdlL3Jlc2l6ZSxQXzQwCg,t_20
图4.2.变压器原边捕捉波形1(无隔直电容).jpg?x-oss-process=image/watermark,g_center,image_YXJ0aWNsZS9wdWJsaWMvd2F0ZXJtYXJrLnBuZz94LW9zcy1wcm9jZXNzPWltYWdlL3Jlc2l6ZSxQXzQwCg,t_20
图5.1变压器副边动态显示波形(无隔直电容).jpg?x-oss-process=image/watermark,g_center,image_YXJ0aWNsZS9wdWJsaWMvd2F0ZXJtYXJrLnBuZz94LW9zcy1wcm9jZXNzPWltYWdlL3Jlc2l6ZSxQXzQwCg,t_20
图5.2变压器副边捕捉波形3(无隔直电容).jpg?x-oss-process=image/watermark,g_center,image_YXJ0aWNsZS9wdWJsaWMvd2F0ZXJtYXJrLnBuZz94LW9zcy1wcm9jZXNzPWltYWdlL3Jlc2l6ZSxQXzQwCg,t_20
图5.3变压器副边捕捉波形2(无隔直电容).jpg?x-oss-process=image/watermark,g_center,image_YXJ0aWNsZS9wdWJsaWMvd2F0ZXJtYXJrLnBuZz94LW9zcy1wcm9jZXNzPWltYWdlL3Jlc2l6ZSxQXzQwCg,t_20
原理图1.JPG
原理图2.JPG
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@nihao_nihao
图的标号依次为:图1.1.驱动信号波形(未加母线电压时)图1.2.上桥臂驱动信号(带载).jpg图1.3.上桥臂驱动信号(动态捕捉).jpg图2.1.上臂Uds(动态显示).jpg图2.2.上臂Uds.jpg图2.3.上臂Uds.jpg图3.1.下臂Uds(动态显示)2.jpg图3.2.下臂Uds(动态显示).jpg图3.3.下臂Uds(捕捉1).jpg图3.4.下臂Uds(捕捉2).jpg图4.1.变压器原边动态显示波形(无隔直电容).jpg图4.2.变压器原边捕捉波形1(无隔直电容).jpg图5.1变压器副边动态显示波形(无隔直电容).jpg图5.2变压器副边捕捉波形3(无隔直电容).jpg图5.3变压器副边捕捉波形2(无隔直电容).jpg原理图1.JPG原理图2.JPG
如果你的上臂的驱动象你说的一会高一会低的话,首先你的驱动有问题,不知道你下面的管子的驱动是不是也有类似的问题,建议你还是先找到这个问题再说.
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@huiyong828
能把变压器计算过程说下,可能存在问题
感谢 ytdfwangwei 和huiyong828 的回复.
IR2102的驱动我感觉已经到了最大能力.就以IR2102短路电流200mA算,IRFBG30的总基极电量80nC(或者结电容Ciss为980pf)计算,上升时间约为0.4uS,我驱动波形,在负载情况下也基本做到了这一点啊.可是为什么如第3图所示,一会10V一会15V来回波动那?
另外我变压器计算采用功率体积法,EER3541磁芯在40KHZ功率输出可以满足105W输出要求.绕组初级绕组就按公式WP=(Ui*100000)/(Kf*Fs*Bw*Ae)=(228V*100000)/(4.0*40000*0.3T*1.07)=44匝,(磁导率Bw取0.3T,Kf=4.0).磁芯结构常数没有查到相应资料,按一般罐形磁芯取得:Kj=433,X=-0.17.变压器是自己手缠的,也没浸胶.
不知道变压器会不会影响驱动波形的变化.
IR2102的驱动我感觉已经到了最大能力.就以IR2102短路电流200mA算,IRFBG30的总基极电量80nC(或者结电容Ciss为980pf)计算,上升时间约为0.4uS,我驱动波形,在负载情况下也基本做到了这一点啊.可是为什么如第3图所示,一会10V一会15V来回波动那?
另外我变压器计算采用功率体积法,EER3541磁芯在40KHZ功率输出可以满足105W输出要求.绕组初级绕组就按公式WP=(Ui*100000)/(Kf*Fs*Bw*Ae)=(228V*100000)/(4.0*40000*0.3T*1.07)=44匝,(磁导率Bw取0.3T,Kf=4.0).磁芯结构常数没有查到相应资料,按一般罐形磁芯取得:Kj=433,X=-0.17.变压器是自己手缠的,也没浸胶.
不知道变压器会不会影响驱动波形的变化.
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@nihao_nihao
感谢ytdfwangwei和huiyong828的回复.IR2102的驱动我感觉已经到了最大能力.就以IR2102短路电流200mA算,IRFBG30的总基极电量80nC(或者结电容Ciss为980pf)计算,上升时间约为0.4uS,我驱动波形,在负载情况下也基本做到了这一点啊.可是为什么如第3图所示,一会10V一会15V来回波动那?另外我变压器计算采用功率体积法,EER3541磁芯在40KHZ功率输出可以满足105W输出要求.绕组初级绕组就按公式WP=(Ui*100000)/(Kf*Fs*Bw*Ae)=(228V*100000)/(4.0*40000*0.3T*1.07)=44匝,(磁导率Bw取0.3T,Kf=4.0).磁芯结构常数没有查到相应资料,按一般罐形磁芯取得:Kj=433,X=-0.17.变压器是自己手缠的,也没浸胶.不知道变压器会不会影响驱动波形的变化.
驱动电阻5欧姆是不是小了点?你把阻值增大点看看驱动波形有没有变化
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@nihao_nihao
图的标号不清楚,重新传一遍[图片]500){this.resized=true;this.width=500;this.alt='这是一张缩略图,点击可放大。\n按住CTRL,滚动鼠标滚轮可自由缩放';this.style.cursor='hand'}"onclick="if(!this.resized){returntrue;}else{window.open('http://u.dianyuan.com/bbs/u/72/3038321228840512.jpg');}"onmousewheel="returnimgzoom(this);">[图片]500){this.resized=true;this.width=500;this.alt='这是一张缩略图,点击可放大。\n按住CTRL,滚动鼠标滚轮可自由缩放';this.style.cursor='hand'}"onclick="if(!this.resized){returntrue;}else{window.open('http://u.dianyuan.com/bbs/u/72/3038321228840519.jpg');}"onmousewheel="returnimgzoom(this);">
兄弟,这是正激类型的电源,滤波电容必须放在电感后,把E15和E0也去掉再说.
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