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一種高性能工業(yè)電源轉(zhuǎn)換模塊的設(shè)計(jì)與實(shí)現(xiàn)
網(wǎng)絡(luò)安全與數(shù)據(jù)治理
殷宇朝,王營營,劉澤華,霍毅,劉暉,趙斌卿
中電智能科技有限公司
摘要: 針對(duì)工業(yè)過程控制中傳統(tǒng)電源模塊轉(zhuǎn)換效率低、輸出電壓波動(dòng)大、保護(hù)機(jī)制不完善等問題,提出一種集成高效轉(zhuǎn)換、精準(zhǔn)控制、多重保護(hù)及智能通信功能的電源轉(zhuǎn)換模塊。該模塊由濾波電路、有源功率因數(shù)校正電路等12個(gè)核心單元組成,通過PWM閉環(huán)控制與MCU協(xié)同調(diào)節(jié)實(shí)現(xiàn)穩(wěn)定輸出,具備輸入過壓和欠壓、輸出過壓和過流、過溫等多重保護(hù)功能。測(cè)試結(jié)果表明,該模塊轉(zhuǎn)換效率達(dá)89%以上,較傳統(tǒng)電源模塊效率提升5%~10%,輸出電壓精度在±3%以內(nèi),電壓與負(fù)載調(diào)整率均≤1%,優(yōu)于同類產(chǎn)品。該模塊各項(xiàng)性能指標(biāo)滿足工業(yè)自動(dòng)化控制系統(tǒng)對(duì)高可靠性電源的需求,可廣泛應(yīng)用于PLC控制、智能傳感器等對(duì)電源穩(wěn)定性要求嚴(yán)苛的場(chǎng)景,具有較高的實(shí)用價(jià)值與推廣前景。
中圖分類號(hào):TP273;TN86文獻(xiàn)標(biāo)識(shí)碼:ADOI:10.19358/j.issn.2097-1788.2025.12.005引用格式:殷宇朝,王營營,劉澤華,等. 一種高性能工業(yè)電源轉(zhuǎn)換模塊的設(shè)計(jì)與實(shí)現(xiàn)[J].網(wǎng)絡(luò)安全與數(shù)據(jù)治理,2025,44(12):34-38,68.
Design and implementation of a highperformance industrial power conversion module
Yin Yuchao,Wang Yingying,Liu Zehua,Huo Yi,Liu Hui,Zhao Binqing
Intelligence Technology of CEC Co., Ltd.
Abstract: Aiming at the problems of low conversion efficiency, large output voltage fluctuation and inadequate protection mechanisms of traditional power supply modules in industrial process control, this paper proposes a power conversion module that integrates highefficiency conversion, precise control, multiple protection and intelligent communication functions. This module consists of 12 core units, including a filter circuit and an active power factor correction circuit. It achieves stable output through the collaborative regulation of PWM closedloop control and MCU, and is equipped with multiple protection functions such as input overvoltage and undervoltage protection, output overvoltage and overcurrent protection, and overtemperature protection. Test results show that the conversion efficiency of this module reaches more than 89%, which is 5%~10% higher than that of traditional power supply modules. The output voltage accuracy is within ±3%, and both voltage regulation rate and load regulation rate are ≤1%, which is superior to similar products. Various performance indicators of this module meet the requirements of industrial automation control systems for highreliability power supplies. It can be widely applied to scenarios with strict requirements on power supply stability, such as PLC control and intelligent sensors, and has high practical value and promotion prospects.
Key words : power conversion module; PWM control; active power factor correction; protection mechanism; industrial automation

引言

工業(yè)自動(dòng)化控制系統(tǒng)中,各類智能傳感器的穩(wěn)定運(yùn)行高度依賴持續(xù)可靠的電源支持[1-4]。電源轉(zhuǎn)換模塊作為能源供給的核心部件,其性能直接決定了整個(gè)控制系統(tǒng)的安全性與可靠性[5-6]。例如,在精密生產(chǎn)線中,電源輸出電壓的1%波動(dòng)可能導(dǎo)致傳感器測(cè)量誤差擴(kuò)大至5%以上,引發(fā)設(shè)備誤動(dòng)作;而電源轉(zhuǎn)換效率不足則會(huì)導(dǎo)致能源浪費(fèi),同時(shí)增加設(shè)備散熱負(fù)擔(dān),縮短使用壽命。傳統(tǒng)工業(yè)電源模塊存在四大核心問題:一是轉(zhuǎn)換效率瓶頸,由于未集成有源功率因數(shù)校正電路,功率因數(shù)常低于0.7,無功損耗占比較高,轉(zhuǎn)換效率低,線性工業(yè)電源滿載效率為40%~65%、傳統(tǒng)單端反激式電源滿載效率為60%~75%,同時(shí)模塊自身發(fā)熱嚴(yán)重,導(dǎo)致能源利用率低下[7-9];二是控制精度不足、輸出穩(wěn)定性差,多采用開環(huán)或單重閉環(huán)控制,無法根據(jù)負(fù)載變化調(diào)整開關(guān)頻率或拓?fù)淠J?,輸出電壓受輸入電壓波?dòng)與負(fù)載變化影響顯著,難以滿足精密設(shè)備的供電需求[10-14];三是保護(hù)機(jī)制單一,多數(shù)僅具備簡單的過流保護(hù),缺乏過溫、輸入過壓和欠壓等多維防護(hù),在復(fù)雜工業(yè)環(huán)境(如高溫、電壓波動(dòng)頻繁場(chǎng)景)中易發(fā)生故障;四是智能化缺失,缺乏狀態(tài)監(jiān)測(cè)與遠(yuǎn)程通信功能,運(yùn)維人員需現(xiàn)場(chǎng)排查故障,增加了工業(yè)系統(tǒng)的停機(jī)時(shí)間。因此,研發(fā)具備高效、穩(wěn)定、智能特性的電源轉(zhuǎn)換模塊對(duì)工業(yè)過程控制技術(shù)的升級(jí)具有重要意義。針對(duì)上述問題,本文設(shè)計(jì)的電源轉(zhuǎn)換模塊以“高效、穩(wěn)定、可靠、智能”為目標(biāo),通過優(yōu)化電路架構(gòu)與控制策略,實(shí)現(xiàn)三大突破:一是將轉(zhuǎn)換效率提升至85%以上;二是將輸出電壓精度控制在±3%以內(nèi);三是構(gòu)建“監(jiān)測(cè)—保護(hù)—通信”一體化系統(tǒng),實(shí)現(xiàn)全狀態(tài)可視化與遠(yuǎn)程運(yùn)維。


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作者信息:

殷宇朝,王營營,劉澤華,霍毅,劉暉,趙斌卿

(中電智能科技有限公司,北京100083)


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