• 专利附录
  • 专利说明
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    • 专利摘要:
    energy conversion apparatus and system. power converter modules and parallel conversion systems are presented, in which the modules are provided in a rotating housing having ac and dc electrical connections and an interior including an alternation circuit with alternation devices connected individually between a corresponding ac node a corresponding dc node for operation as a rectifier or inverter and an internal filter circuit with inductors connected individually between a corresponding ac node of the alternation circuit and a corresponding ac electrical connection, with a built-in fan or fan to cool the filter circuit during operation.
    公开号:BR102014024946B1
    申请号:R102014024946-0
    申请日:2014-10-06
    公开日:2021-07-27
    发明作者:Lixiang Wei；Robert M. Michalski；Yogesh Patel；Bruce W. Weiss；Brian P. Brown
    申请人:Rockwell Automation Technologies, Inc.；
    IPC主号:
    专利说明:

    [001] Energy conversion systems convert electrical input energy from one form to another to drive a load. Motor drive type power converters are used in a variety of applications to provide electrical power to drive a motor load. For example, motor drives may be needed to drive low voltage as well as high voltage motors, and multiple motor drives can be connected in parallel to accommodate high load requirements. In a typical situation, AC input power is initially converted by an active or passive rectifier circuit to provide a DC bus voltage for use by one or more output inverters to create: variable frequency, variable amplitude AC output power to drive an induction motor load. For the initial rectification of AC input power, active front-line rectifiers (AFE) can be used, including actively controlled switching devices to create and maintain a regulated DC bus voltage and can implement various additional functions such as correction. of power factor (PFC). In other cases, passive or front-line fundamental frequency (FFE) rectifiers can be used and input filters are usually connected between the AC power source and the passive rectifier input. output(s), internal inverter alternation devices selectively connect the DC input power cables to specific AC motor cables to create the output shapes necessary to drive the motor at a desired speed, position, torque, etc. , and the output filter circuits can be connected between the inverter output and the rationed motor for motor protection.Further, parallel inverter configurations can include papal inductors, connected between the two outputs. or more inverters connected in parallel. In general, variability in the requirements of a given motor drive application often requires custom design and configuration of system components and their interconnections, including the necessary power converters and filter components, which are then connected together to form an energy conversion system. In order to accommodate a wide variety of power conversion system specifications, while minimizing system cost, it is therefore desirable to provide modular components that can be used in building two or more different types and forms of systems. SUMMARY
    [002] One or more aspects of the present disclosure are now summarized to facilitate a basic understanding of the disclosure, where this summary is not a complete overview of the disclosure, and is not intended to identify certain elements of the disclosure, nor to delineate its scope. Rather, the main purpose of this summary is to present several concepts of revelation in a simplified form beforehand; of the more detailed description that is presented hereafter. The present disclosure provides energy conversion systems and apparatus, in which an energy converter module includes alternation circuits and integrated magnetic components or filter circuits to facilitate the construction of a wide variety of application-specific energy conversion systems, while facilitating ease of fabrication using common components and controlling costs. In addition, the illustrated power conversion module apparatus may include integral cooling fans or fans to facilitate the cooling of filter inductors to further reduce the cost, complexity and space of the final power conversion system.
    [003] In accordance with one or more aspects of the present disclosure, an energy conversion apparatus is provided that includes an enclosure with AC and DC electrical connections, where the enclosure provides an interior in which an alternation circuit and a circuit are located with the filter circuit at a lower level than the alternating circuit. In certain implementations, filter circuits include a plurality of inductors connected between the alternating circuit and a corresponding AC connection, thereby facilitating use as output filters if the apparatus is used as an alternating inverter, or as inductors input filter for use of active or passive rectifier. The apparatus can therefore be easily adapted for use as a front-line rectifier, active or passive, or as an output inverter, with integrated filter circuits, which are easily configured for a variety of applications and functions, including protection motor, drive paralleling, will operate fundamental front line (FFE) and/or active front line (AFE) as required. In addition, exemplary embodiments can optionally provide a compact modular design with integral bearings or wheels that can be easily rolled into position in a control panel or other facility for interconnecting with other system components to provide a motor drive or otherwise. of energy conversion system.
    [004] In certain embodiments, the filter circuit can accommodate filter resistors for parallel connection with a corresponding one of the filter inductors, thereby facilitating the provision of L-R output filters to protect the motor for inverter applications. The apparatus may also include a fan fan assembly below the filter circuit within the interior of the housing to cool the filter circuit and possibly other components during operation, thereby further facilitating compact system design without the need. of external filter inducers and associated cooling fans. Other embodiments may also include an integral DC bus capacitor circuit that provides a bank of capacitor components for stable DC bus voltage operation if the apparatus is configured for use as a rectifier or an inverter. Certain implementations also accommodate the inclusion of two or more balancing resistors for connection across the DC bus, which can also be used in drive or rectifier configurations. The alternating circuit, moreover, may include alternators such as IGBTs and/or diode, thereby facilitating their use as front-line active (AFE) or line-front, fundamental (FFE) rectifiers.
    [005] A power conversion system is provided, in accordance with further aspects of the disclosure, including two or more converter modules individually configured as active front-line alternation rectifiers and including a housing, AC and DC connections, a alternation circuit, an integral filter circuit between the alternation circuit and the c and ac connections, as well as a control board, all located within the interior of the enclosure, where the AC outputs of the converter modules are wired together for operation in parallel to drive a single load, such as a motor.
    [006] According to further aspects of the disclosure, a power conversion system is provided, which includes first and second power converter modules configured as passive rectifiers, each including a housing with an AC input, a DC output , a rectifier circuit, and a filter circuit with a plurality of inductors connected between the rectifier circuit and the AC input, where the AC inputs are connected to each other in parallel. BRIEF DESCRIPTION OF THE DRAWINGS
    [007] The following description and drawings set out certain illustrative implementations of the disclosure in detail, which are indicative of several exemplary ways in which the various principles of the disclosure may be carried out. The illustrated examples, however, are not complete with the many possible realizations of the revelation. Other objectives, advantages and innovative aspects of the disclosure will be set out in the detailed description below, when considered in conjunction with the drawings, in which:
    [008] Figures 1 to 3 are front elevation and side elevation perspective views illustrating an exemplary power converter module having integrated magnetic components and alternation circuits for operation as a rectifier or an inverter, according to a or more aspects of the present disclosure.
    [009] Figure 4 is a partial schematic diagram illustrating additional details of the exemplary power converter module of Figures 1 to 3;
    [010] Figure 5 is a schematic diagram illustrating a voltage source converter motor drive system implemented using a first power converter module configured as an active front-line rectifier (AFE) and a second power converter module. power converter operated as an inverter with an integrated output filter circuit;
    [011] Figure 6 is a schematic diagram illustrating another voltage source converter motor drive system including a first power converter module as a fundamental front-line rectifier (FFE) with an AC input filter including integrated inductors as well as a second power converter module configured as an inverter with an integrated output filter circuit;
    [012] Figure 7 is a schematic diagram illustrating another power conversion system that uses a power converter module with an optional LR filter circuit, as shown in Figures 1 to 4, operating as an alternation inverter to convert input power from a DC power source to provide AC output power to a motor load;
    [013] Figure 8 is a schematic diagram illustrating a non-regenerative voltage source converter type motor drive system including a passive rectifier that provides DC input power to a power converter module that operates with a LR output filter circuit as shown in Figures 1 to 4;
    [014] Figure 9 is a schematic diagram illustrating another non-regenerative motor drive system with a power converter module configured as an inverter without an output filter;
    [015] Figure 10 is a schematic diagram illustrating an exemplary parallel motor drive system with two power converter modules that operate as inverters with integral L-R output filters to drive a single motor load,-
    [016] Figure 11 is a schematic diagram that illustrates another system in parallel with two energy converter modules configured as inverters without output filters to drive a single motor;
    [017] Figure 12 illustrates another motor drive system in parallel with two power converter modules, as shown in Figures 1 to 4, configured as active front-line rectifiers (AFE) with integral input filter inductors for providing a common DC bus for powering a pair of power converter modules as output inverters to drive a single motor load;
    [018] Figure 13 depicts another system in parallel with two power converter modules configured as front-line fundamental rectifiers (FFE) with integral parallel line reactors in the filter circuit, as well as two additional converter modules configured as inverters connected in parallel to drive a motor load;
    [019] Figure 14 is a perspective view showing an exemplary energy converter module with a side panel removed to illustrate the assembly of filter inductors within the interior of the housing;
    [020] Figure 15 is a perspective view illustrating an exemplary filter circuit module with three inductors that can be installed in the power converter module of Figure 14;
    [021] Figure 16 is a perspective view showing the other side of the power converter module with the side panel removed to show the position of optional filter resistors and IGBT heat sink structures within the enclosure;
    [022] Figure 17 is a perspective view illustrating the installation of IGBT switching devices and corresponding heat sinks inside the housing;
    [023] Figure 18 is a perspective view illustrating the installation of an optional DC bus capacitor bank within the power converter module housing;
    [024] Figure 19 is a perspective view illustrating a gate driver board, optional filter circuit inductors and installation of current transducers within the power converter module housing;
    [025] Figure 20 is a perspective view showing the installation of current transducers without filter circuit inductors inside the power converter module housing;
    [026] Figure 21 is a perspective view illustrating the installation of a power interface board (PIB) and a power layer interface board (PLIB) inside the power converter module housing;
    [027] Figure 22 is a perspective view illustrating the installation of a rear wall power cable connection type connector in the converter module housing; and
    [028] Figure 23 is a partial perspective view showing the installation of optional balancing resistors and filter circuit resistors inside the converter module housing. DETAILED DESCRIPTION
    [029] Referring now to the figures, various embodiments or implementations are hereinafter described in conjunction with the drawings, in which like reference numbers are used to refer to like elements throughout the length of the document, and in which the different aspects are not necessarily drawn to scale. Several realizations below describe universal architectures that provide modular power converter apparatus that can be configured and interconnected to perform multiple functions, including, but not limited to, independent inverter systems, parallel and inverter systems, motor drives that provide integral motor protection, active frontline rectifiers and fundamental frontline rectifier applications with integral input filters. Until now, attempts at modular power converter architectures have been limited in providing only one of a small number of features, such as parallel or independent inverters, and separate filter circuits and associated cooling apparatus have been necessary to ensure the protection of the motor and filtration suitable for active rectifier applications. The present disclosure, on the other hand, provides a compact, cost-effective apparatus that can be used in a wide variety of motor drive and other energy conversion applications, thereby facilitating optimal use of the available area. in a given application, while controlling the cost by integrating all necessary components within a single enclosure for shared protection and cooling. Furthermore, the modular design of the various embodiments facilitates the reconfiguration of a given module by using identical or similar busbar work for multiple types of power converters, including use in both regenerative and non-regenerative systems.
    [030] Referring initially to Figures 1 to 4, Figures 1 to 3 respectively illustrate in perspective, front and side view of an assembled energy converter apparatus 2, sometimes referred to here as a module of power converter 2, having a housing 4 with a top T, a front side F and a bottom which is supported by roller wheels 6. The front side F, inside the housing 5 to provide forced air flow in one direction upwards which can be vented out of the upper side T of the housing 4 by means of an event opening 12. This advantageously provides cooling for filter circuit components as well as alternation circuit devices (eg, igbts) and other components of module 2.
    [031] Figure 4 presents a partial schematic interpretation of the energy converter module 2, in which a variety of components and subassemblies is positioned inside the interior of the housing 5. As seen in Figure 4, the module 2 includes three connections dej AC 16, such as conductor bars and other electrical connections for which external AC wiring can be connected to module 2. Go! illustrated and described in the context of a three-phase AC connection 16 to phases A', B', C', other single-phase or multiphase AC cones are possible, which may include more than three connections 16. In addition, first and second DC connections (DC+ positive and DC- negative) 18 are provided, whereby external DC power cabling can be connected to module 2. Since module 2 can be configured to operate as a rectifier or as an inverter. , the AC and DC connections 16 and 18 may alternatively be considered as inputs and outputs, depending on the final application. An alternation circuit 20 is located within the interior 5 of the housing 4, and includes alternating devices S1- S6 to selectively convert AC input power to provide DC output power for active (alternating) rectifier applications or, alternatively, to convert input DC power to provide AC output power for inverter applications .N In this case, six S1-S6 alternators are provided for conversion between DC power and three-phase AC power, although any suitable number of alternating ds devices can be used for other single-phase or multi-phase implementations. In addition, although illustrated using IGBT S1-S6 type alternators, any suitable alternating devices can be used, including but not limited to silicon controlled rectifiers (SCRs), gate-deactivation thyristors (GTOs), switched integrated gate thyristors ( IGCTs) etc. In addition, the alternation circuit 20, in certain embodiments, also includes diodes D1-D6, configured as shown in Figure 4, to facilitate active alternation operation as well as provide fundamental front-line rectifier (FFT) operating capability. passive if desired, in which case circuit 20 may be considered a retrieval circuit if the alternating devices S1-S6 are not actively operated or are omitted. Furthermore, the thermal condition of the internal AC nodes of the alternation circuit 20 can be monitored for control purposes using one or more sensors as NTC negative temperature coefficient components, as seen in Figure 4.
    [032] Gate 23 switching control signals are provided to operate the SI-SÉ IGBTs, which can be generated using any suitable controller and driver circuits. As seen in the example in Figure 4, signals 23 are provided in one possible embodiment by a gate actuation board (GDB) 22 which includes suitable actuation and isolation circuits that provide output signals 23 to the gates of IGBTs S1-S6 suitable for its selective alternation operation, based on signaling received directly or indirectly from one or more processors to facilitate pulse amplitude modulated alternation control of circuit 20 to achieve CC-AC or CA-DC conversion, in accordance with any suitable pulse amplitude modulation alternation control technique. The gate drive board 22 is operatively connected to a power interface board (PIB) 24, in this case, which implements inverter power circuits 24a to power and otherwise control the operation of the fan assembly. of fan 14, interface circuitry 24b for thermal sensors associated with AC lines, current feedback interface circuitry 24c for interfacing with current sensors, as discussed further below, as well as I/O circuitry 24d for interfacing with the fan 14, alternating mode power (SMPs) 24c to generate and regulate power levels used internally, as well as grounding circuit 24f to establish a grounded connection between a central point of the DC bus voltage and a chassis connection. housing 4. In addition, the power interface board 24 is operatively connected to a power layer interface board (PLIB) 26 that implements a communication interface to communicate (TX/RX) with one or more external devices, such as a controller or external network (not shown).
    [033] As additionally shown in Figure 4, moreover, a DC capacitance circuit or capacitor bank 28 can optionally be connected between the DC bus lines DC+ and DC- (for example, see also Figure 18 below), and the interior 5 of housing 4 also facilitates the optional inclusion of a pair of balancing resistors 38, as illustrated and further described below in connection with Figure 7 3. Although capacitor bank 28 is illustrated as including six capacitors , any number of capacitors can be provided. On the AC side of the alternation circuit 20, a filter circuit 30 is provided with interconnection and mounting aspects suitable for selective direct connection of the AC electrical connections 16 to the AC nodes of the alternation circuit 20, or for connection of inductors 30L and/or 30R filter resistors between the AC connections 16 and the alternation circuit 20.30, in order to monitor their operating conditions, with signal connections to the power interface board 24.
    [034] As further shown in Figures 14 to 23 below, the filter circuit 30 is advantageously positioned below the alternation circuit 20 within the housing 3, and is preferably arranged above the fan fan system 14, with this advantageously facilitates cooling by the fan fan system 14. In addition, the location of the filter circuit 30 and its inductors 30L below the level of the alternation circuit 20 advantageously minimizes or reduces the length of the cables used for connect the filter circuit components 30 between the external connectors 10 and the alternation circuit 20. Consequently, less housing space is occupied by these power cables and the interconnections are shorter than in other possible approaches. For example, alternative configurations in which the 30L filter inductors would be arranged above the alternating circuit would require excessive cables and busbar structures running from the upper end of the interior of the housing 5 downwards towards the external connections 10. In addition, the illustrated placement of filter circuit 30 above fan fan assembly 14 and alternation circuit 20 provides more internal space to accommodate larger inductors 30L than would be possible if filter components 30 were located above alternation circuit 20. In addition, although illustrated below as including 30L solid core inductors, 30L air core filter inductors (e.g., colorless) can be used in various embodiments.
    [035] Furthermore, closed loop control for inverter AC output currents and/or AC input current monitoring for active front-line rectifier power factor correction can be facilitated by the provision of transducers or sensors. current 34, which provides signals to power interface board 24 via current sensor module (CS) 35. Alternation control operation may be directed on module 2 by one or more programmed processors located in one or more of plates 22, 24, 26 for implementing various power conversion and/or motor control functions, as known. Furthermore, in certain embodiments, the module 2 control processor components may receive one or more setpoints or desired operating conditions as signals and/or values from an external control component such as a control element and/or external network distributed in a hierarchical manner (not shown).
    [036] Referring now to Figures 5 to 13, several non-limiting configurations and interconnections are presented, illustrating the ease of adapting the integrated energy converter apparatus 2 to a variety of energy conversion system applications and end uses .
    [037] Figure 5 illustrates a complete voltage source converter regenerative motor drive system using two of the converter modules 2. A first module 2 (top right in the figure) is configured as an active front-line rectifier. (AFE) to convert the incoming AC input power to provide a controlled voltage on a DC bus connected to the second module 2. In the second module 2 (bottom of the figure), the DC input power is reversed by the circuit. alternation 20 to provide controlled AC output power to drive a motor load 40. In the implementation of Figure 5, moreover, an AC power source 42 (three-phase, in this example) is connected to the AC terminals of the first converter module power 2 through an optional precharge module 44 and an LCL filter module 46, one or both of which may be omitted in alternative implementations. In operation, the precharge module 44 can advantageously introduce resistive impedance into the AC lines for a controlled time upon system initiation to control or limit inrush current experience by the DC link capacitance of the capacitor circuit 28 in the rectifier module 2, as well as capacitors 28 in the subsequent inverter module 2.
    [038] In the illustrated embodiment, moreover, the rectifier module 2 is configured with shortening cables within the filter circuit 30. in order to electrically connect, directly, the AC input connections to the AC nodes of the circuit. alteration 20, in which the input filtration is provided by the filter module 30L filter inductors and filter resistors connected in series 3 OR, for motor protection with the alternation circuit 20 being pulse amplitude modulated to provide power from controlled AC output to drive motor 40. In this system, moreover, an optional current snubber circuit (not shown) can be connected by DC bus lines DC+, DC- external to the power converter module housings 2. In this embodiment, as in others illustrated and described here, the power converter modules 2 as well as the other modules 44, 46 can be housed commonly in a single control cabinet, in certain implements. tions, with environmental controls and suitable interconnections to leverage an overall engine drive system in a relatively compact form.
    [039] Figure 6 presents another voltage source converter motor drive system with a first power converter module 2 providing fundamental front-line rectification (FFE^ of AC input power received from source 42 through a pre-charge module 44, in which the filter circuit 30 of the rectifier module 2 has filter inductors installed between the AC connections and the AC nodes of the alternation circuit 20. In this case, in addition, the diodes D1- D6 of the alternation circuit operate to provide passive rectification of incoming AC input power to provide a DC output over the DC+, DC- bus lines. Incorporating the integrated magnetic components of the internal filter circuit 30 into the rectifier module 2 , in that example, advantageously allows the elimination of the external filter module 46 used in the above example of Figure 5. In addition, the provision of the fan fan assembly 14 inside 5 of the module 2 provides, Also, cooling for the 30L filter inductors, whereby the cost and space associated with the external filter cooling apparatus is also saved by the combination of integrated magnetic components and internal cooling provided by the modular design 2.
    [040] Figure 7 illustrates an inverter configuration of a module 2 that can be advantageously employed in common DC bus configurations in which two or more inverters 2 obtain DC input power and a single DC source 50. Optional DC preload 52 may be included between the DC source 50 and the module 2 DC connections, for example, to provide selective connection of resistive elements to attenuate excessive inrush currents on initiation. In this example, furthermore, an additional DC bus capacitance circuit 54 may be included between the pre-charge module 52 and the power converter module 2, which may include a capacitor bank, as shown, connected between the lines. DC bus positive and negative DC+, DC-, and may also include balancing resistors as shown and/or a dedicated cooling fan. In certain implementations, moreover, the DC bus capacitance circuits 54 can be implemented by properly configuring and connecting a power converter module 2, as shown in Figures 1 to 4 above, which can be configured for this purpose.
    [041] In this implementation, moreover, inverter module 2 is configured to include an internal DC bus capacitor bank and 28, as well as a pair of balancing resistors 38, as shown, although they are omitted, with the bus capacitance of DC bus being provided by the external circuit 54. In other possible alternative implementations, moreover, the external DC bus capacitance circuit 54 can be omitted, with the DC bus capacitance being provided by the integrated capacitor bank 28 of module 2. In addition, the exemplary system of Figure 7 also advantageously provides an output LR filter circuit 30 equipped with 30L filter inductors and 30R filter resistors connected in parallel with each other in each of the AC output lines, as shown, for protection of the motor 40. Other implementations are possible, in which the filter circuit 30 is only equipped with the 30L inductors and/or in which cables or shortening bars nt are installed in filter circuit 30 to directly electrically connect the AC output connections to AC nodes of alternation circuit 20 in module 2.
    [042] Figures 8 and 9 illustrate modular inverter implementations for non-regenerative voltage source converter type motor drive systems. In such systems, a fundamental front-line rectifier (FFE) stage 60 is connected to receive AC input power from source 42, and the illustrated embodiment includes a line reactor 61, a diode circuit 62, an AC filter circuit. Y-connected input capacitor, a DC bus capacitor bank, balancing resistors, and chassis ground circuits for connecting a medium bus voltage to the chassis ground, although any passive rectifier circuit 60 can be used. The resulting DC bus voltage is provided as ume. input to the DC connections of a power converter module 2, which optionally includes balancing resistors 38 and a DC bus capacitance circuit 28, as previously described. The alternation circuit 20 in these examples is operated by the pulse amplitude modulated control signals 23 from the gate driver board 22 to invert the DC bus voltage to create AC output power to drive the motor load. 40. In the realization of Figure 8, an RL 30 filter circuit is provided in the converter module 2, including 30L inductors and 30R resistors for protection of the motor load 40. The system of Figure 9, in contrast, provides direct electrical connections in filter circuit 30 with inductors 30L and parallel resistors 30R being omitted, no internal output filtering provided.
    [043] Figure 10 presents an exemplary parallel inverter motor drive system to drive a single load of motor 40 via two parallel-connected power converter modules 2, configured to operate as inverters. In this example, the filter circuits 30 of the two power converter modules 2 include filter chokes 30L as well as I filter resistors connected in parallel 30R to provide R-L 30 output filters for motor protection. In this case, moreover, the modules 2 each include internal DC bus capacitance circuits 28, as well as balancing resistors 38, although these may be omitted in alternative implementations. Also, the parallel connected inverter stages 2 are each connected to a single DC input power source 50 via a pre-charge module 52 and an external DC capacitance circuit 54, although it is not It is a strict requirement of the various aspects of the present disclosure.
    [044] Figure 11 illustrates another parallel inverter system generally, as described above, in connection with Figure 10, in which the parallel-connected power converter modules 2 include only 30L filter inductors in the 30 filter circuits. It is noted in Figures 10 and 11 that inductors 30L are provided in the filter circuits 30, in both examples, with the system of Figure 11 omitting the parallel filter resistors 30R. In the various implementations, moreover, different inductances may be provided in these two embodiments, as discussed further below, in connection with Figures 14 and 15.
    [045] Figure 12 presents a parallel motor drive system 70, in which a single AC power source 42 is used to provide power to a pair of separate (parallel connected) power converter modules 2, configured as active rectifiers via an optional AC precharge module 44 and an optional LCL filter module 46. In this case, in addition, two separate inverters 2 are provided, which can be implemented using the power converter module described above 2, but other inverter structures can be used in alternative embodiments. In this case, the DC outputs of the rectifier modules 2 are connected to each other, and the AC inputs to the rectifier modules 2 are also connected to each other. In alternative implementations, the DC outputs of the rectifier modules 2 do not need to be connected together, but, on the contrary, they can individually drive a corresponding one of the inverters 2. As I presented in the realization of Figure 12, in addition, the modules ! of active frontline rectifiers 2 include filter circuits 30 having filter inductors 30L, and variable implementations are possible, in which parallel connected filter resistors 30R are provided in filter circuits 30 of modules 2.
    [046] Figure 13 presents another! 80 parallel motor drive system which also utilizes 2 parallel-connected rectifier modules with AC inputs and DC outputs coupled together, although DC outputs do not need to be wired in all possible embodiments. Furthermore, like Figure 12 above, the inverters 2 in system 80 of Figure 13 can, but need not, be implemented using the power converter modules described above. Rectifier modules 2 in system 80, however, are configured to operate as front-line fundamental rectifiers (FFE or passive to create and maintain DC bus voltage for use by output inverters 2. In this regard, as seen in Figure 4 above, the switching circuits 20 of the rectifier modules 2 in Figure 13 include both S1-S6 switching devices and corresponding D1-D6 diodes where the gate driver board 22 in these FFE rectifier implementations can be configured to avoid providing ie alternating control signals to alternators S1-S6, with passive diodes D1-D6 providing fundamental frequency rectification of incoming AC input power. Unlike system 70, in Figure 12, moreover, the LCL filter module 46 is omitted in the system 80 of Figure 13 and the inductors 30L of the filter circuits 30 in the rectifier modules 2 can be of larger inductance values. The fundamental front-line parallel rectifier figuration of Figure 13 takes up less space than the active front-line system 70 of Figure 12.
    [047] Referring now to Figures 14 to 23, further details of the illustrated embodiment of the power converter module 2 are illustrated. Figure 14 shows a perspective view of module 2 including inductors 30L, wherein a modular set of three inductors is additionally shown in Figure 15 prior to installation in housing 4. As seen in Figure 14, the interior of housing 5 accommodates the positioning and mounting the 30L modular filter inductors towards the bottom of the housing 4, in this case generally directly above the fan fan assembly 14. In addition, the fan fan assembly 14 and the filter inductors 3 0L are discretely spaced from the inner side wall of housing 4 whereby an air flow path is provided from the bottom of the interior of housing 5 in addition to filter inductors 30L and other components of module 2 to vent 12. Also, as seen in Figure 1 above, thermal sensors 32 can be arranged inside the housing 5, preferably close to the 30L filter inductors, in order to monitor and assess their condition. Thermal connection, there are connections suitable for providing signals to the power interface board 24. As further seen in Figure 14, current sensors or transducers 34 are mounted within the interior of housing 5, and include sensor coils through which the cables are passed to detect the current qu2 flows between the filter inductors 30L and the alternation circuit 20. In addition, Figure 14 further illustrates the rear of the power interface board 24.
    [048] As seen in Figures 14 and 15, the interior 5 of housing 4 provides mounting surfaces and ample space to accommodate different 30L inductor assemblies, where module 2 can be configured in the same way by installing and connecting any desired 30L internal filter inducers for various applications. For example, relatively small inductances can be used for parallel rectifier operation (eg Figure 12 above) when external LCL or other filters 46 are employed, and larger inductances can be used by installing suitable 30L filter inductors in module 2 to allow or facilitate operation without any external filter circuits.
    [049] Figure 16 illustrates another side of an exemplary power converter module 2 with side panels removed, showing the rear side of the installed 30L filter inductors, as well as installed 30R filter resistors. In addition, Figure 16 illustrates the input to fan fan assembly 14 at the bottom of module 2, and also features IGBT 21 heat sink structures and a stab type connector assembly 10 installed on the rear of module 2. Figure 17 it further illustrates the installation of three sets of upper and lower IGBT alternation devices 20 to the interior 5 of housing 4, and subsequent assembly of heat sink structures; corresponding 21 to the rear of the IGBT modules Í0.
    [050] As seen in Figure 18, with the IGBTs 20 installed, a DC bus capacitance circuit module 28 is installed, with the corresponding electrodes being directly mounted to the DC nodes of the alternation circuit 20. Circuit 28 in Figure 18 includes six DC bus capacitors, although other configurations and modular DC bus capacitance circuits 28 can be used, for example a module 28 including 10 capacitors, so different modules 28 can be installed to accommodate different requirements. of DC bus capacitance for an application. This, in turn, allows for easy configuration of module J:28 to advantageously facilitate the elimination of external DC bus capacitance circuits (eg, circuit 54 in Figure 7 above).
    [051] Figure 19 illustrates a gate driver board 22 installed inside the housing 5 for connection to provide the control signals ie alternation 23 to the alternation devices S1-S6 of the alternation circuit 20, and subsequent installation of the transducers current sensing 34 and associated wiring to connect filter inductors 30L to alternation circuit 20. Figure 20 illustrates another possible configuration in which current transducers 34 are installed with corresponding cables for direct connection to the AC terminals of the stab 20 type connector, in which 30L filter j inductors are not included in module 2.
    [052] Figure 21 illustrates the subsequent installation of the power interface board 24 and the power layer interface board 26 to the interior 5 of housing 4. Figure 22 illustrates the installation of a stab-type connector assembly for cable. rear wall power and corresponding cabling 10 in the converter module housing 4, and Figure 23 shows the installation of optional balancing resistors 38 (shown as two pairs of resistors and associated thermal electrodes, as well as the installation of circuit resistors. 30R filter inside 5 of converter module housing 4.
    [053] The illustrated embodiments therefore provide a universal architecture to facilitate the cost-effective and space-efficient implementation of a variety of different motor drive and other power conversion systems, in which component incorporation Integral magnetics via filter circuits 30 and corresponding self-cooling via fan fan assembly 14 provide a robust modular design 4. Apparatus 2 also provides the ability to match filter inductance, DC bus capacitance. , balancing resistors etc., in order to achieve frontline fundamental and/or frontline active rectification with or without suitable adapted AC input filters 30, or for inverter implementations with configurable output filtration for protection of the motor. Energy Conversion Apparatus 2 therefore provides significant advantages over previous designs and approaches that provided only a limited number of functions, without the additional connection of external components. Consequently, the present disclosure provides techniques and apparatus by which the area of application can be utilized to the full, while controlling the costs, without sacrificing capacity, of configuration to accommodate a variety of specific motor drive or other energy conversion applications. .
    [054] The above examples are merely illustrative of the various possible realizations of the various aspects of this disclosure, in which changes and/or equivalent modifications will occur to those skilled in the art, upon reading and understanding this specification and the attached drawings. In particular consideration of the various functions performed by the components described above (assemblies, devices, systems, circuits and the like), the terms (including a reference to a "means"' used to describe these components are intended to correspond, unless otherwise stated. as indicated, to any component, such as hardware, software executed by processor or combinations thereof, that performs the specified function of the described component (that is, that is functionally equivalent), although not structurally equivalent to the revealed structure, which performs the function in the implementations of the disclosure. Furthermore, while a particular aspect of the disclosure may have been disclosed in relation to only one of several implementations, as may be desired and advantageous for any particular or particular application. Also, insofar as the terms "including ", "includes", "having", "has", "with" or variants thereof are used in the detailed description and /or in the claims, these terms are intended to be inclusive in a manner similar to the term "comprising".
    权利要求:
    Claims (20)
    [0001]
    1. ENERGY CONVERSION APPLIANCE (2), characterized in that it comprises: a casing (4) defining an interior of casing (5) and having a bottom; a plurality of AC electrical connections (16) for connecting external AC power cables to the power conversion apparatus (2); first and second DC electrical connections (18) for connecting external DC power cables to the power conversion apparatus (2); an alternation circuit (20) located within the housing (5) and including: first and second DC nodes electrically connected, individually, to a corresponding one of the first and second DC electrical connections (18), a plurality of AC nodes electrically coupled individually to a corresponding one of the AC electrical connections (16), and a plurality of switching devices (S1-S6) individually operable to selectively couple a corresponding one of the plurality of AC nodes to a corresponding between the first and second DC nodes, according to a corresponding alternation control signal (23); and a filter circuit (30) located below the alternation circuit (20) within the housing (5) and including a plurality of inductors (30L) electrically connected individually between a corresponding one of the plurality of AC nodes of the alternating circuit (20) and a corresponding one of the plurality of AC electrical connections (16); wherein the housing includes an upper portion spaced vertically from and above the lower portion of the housing, wherein the housing defines a single air flow path between the upper and lower portion, wherein the filter circuit (30 ) is positioned vertically between the alternation circuit (20) and the lower part of the housing, and wherein the alternation circuit (20) is positioned vertically between the filter circuit (30) and the upper part of the housing.
    [0002]
    Apparatus (2) according to claim 1, characterized in that the filter circuit (30) includes a plurality of filter resistors (30R) connected individually in parallel with a corresponding one of the plurality of inductors (30L).
    [0003]
    3. APPARATUS (2) according to claim 2, characterized in that it comprises a fan fan assembly (14) located inside the casing (5) and operative to cool the filter circuit (30) during operation of the apparatus. of energy conversion (2).
    [0004]
    4. APPARATUS (2) according to claim 3, characterized in that it comprises a DC bus capacitance circuit (28) located inside the casing (5) and including at least one capacitor connected between the first and second electrical connections of CC (18).
    [0005]
    5. APPARATUS (2) according to claim 4, characterized in that it comprises a DC bus balancing circuit (38) located inside the casing (5) including first and second balancing resistors connected in series with each other, between the first and second DC electrical connections (18).
    [0006]
    6. APPARATUS (2) according to claim 2, characterized in that it comprises at least one control board (22, 24, 26) located inside the casing (5) and operative to provide the alternation control signals (23 ) to operate the alternation circuit (20) or as (i) an active rectifier to convert power from an AC source connected to the AC electrical connections (16) to provide DC output power to the first and second DC electrical connections (18) with the filter circuit (30) providing an RL input filter, or (ii) as an inverter to convert power from a DC source connected to the DC electrical connections (18) to provide AC output power in the plurality of AC electrical connections (16) with the filter circuit (30) providing an RL output filter.
    [0007]
    APPARATUS (2) according to claim 6, characterized in that it comprises a fan fan assembly (14) located inside the casing (5) and operative to cool the filter circuit (30) during operation of the apparatus. of energy conversion (2).
    [0008]
    8. APPARATUS (2) according to claim 6, characterized in that it comprises a DC bus capacitance circuit (28) located inside the casing (5) and including at least one capacitor connected between the first and second electrical connections of CC (18).
    [0009]
    9. APPARATUS (2) according to claim 1, characterized in that it comprises at least one control board (22, 24, 26) located inside the casing (5) and operative to provide the alternation control signals (23 ) to operate the alternation circuit (20) or as (i) an active rectifier to convert power from an AC source connected to the AC electrical connections (16) to provide DC output power to the first and second DC electrical connections (18) with the filter circuit (30) providing an input filter, or (ii) as an inverter to convert power from a DC source connected to DC electrical connections (18) to provide AC power in the plurality of connections AC electrical (16) with the filter circuit (30) providing an output filter.
    [0010]
    APPARATUS (2) according to claim 1, characterized in that it comprises a fan fan assembly (14) located inside the casing (5) and operative to cool the filter circuit (30) during operation of the apparatus. of energy conversion (2).
    [0011]
    11. APPARATUS (2) according to claim 10, characterized in that it comprises a DC bus capacitance circuit (28) located inside the casing (5) and including at least one capacitor connected between the first and second electrical connections of CC (18).
    [0012]
    12. APPARATUS (2) according to claim 11, characterized in that it comprises a DC bus balancing circuit (38) located inside the casing (5) including first and second balancing resistors connected in series with each other, between the first and second DC electrical connections (18).
    [0013]
    13. APPARATUS (2) according to claim 1, characterized in that it comprises a DC bus balancing circuit (38) located inside the casing (5) including first and second balancing resistors connected in series with each other between the first and second DC electrical connections (18).
    [0014]
    14. POWER CONVERSION SYSTEM (70), characterized by comprising: first and second power converter modules (2) configured as active front-line alternation rectifiers (AFE), each individual power converter module (2) comprising: an enclosure (4) defining an enclosure interior (5) and having a bottom, an AC input, including a plurality of AC electrical connections (16), a DC output, including a first and second electrical connections of CC (18), an alternation circuit (20) located inside the enclosure (5) and including: first and second DC nodes electrically connected, individually, to a corresponding one among the first and second DC electrical connections (18 ), a plurality of individually electrically coupled AC nodes as a corresponding one among the AC electrical connections (16), and a plurality of individually operational switching devices (S1-S6) to selectively couple between a corresponding one of the plurality of AC nodes with a corresponding one of the first and second DC nodes, according to a corresponding alternation control signal (23), and a filter circuit (30) located below the alternation circuit ( 20) inside housing (5) and including a plurality of inductors (30L) electrically connected, individually, between a corresponding one of the plurality of AC nodes of the alternation circuit (20) and a corresponding one of the plurality of electrical connections of CA (16), and at least one control board (22, 24, 26) located within the housing (5) and operative to provide the alternation control signals (23) for operating the alternation circuit (20) is as an active rectifier for converting power from an AC source connected to the AC electrical connections (16) to provide DC output power at the first and second DC electrical connections (18) with the filter circuit (30) providing a filter input; wherein the AC inputs of the first and second power converter modules (2) are connected together to receive AC input power; wherein the DC outputs of the first and second power converter modules (2) are connected together to provide DC output power; and wherein the housing includes an upper portion spaced vertically from and above the lower portion of the housing, wherein the housing defines a single air flow path between the upper and lower portion, wherein the filter circuit ( 30) is positioned vertically between the alternation circuit (20) and the lower part of the housing, and wherein the alternation circuit (20) is positioned vertically between the filter circuit (30) and the upper part of the housing.
    [0015]
    A POWER CONVERSION SYSTEM (70) according to claim 14, wherein each individual power converter module (2) is characterized by comprising a fan fan assembly (14) located within the enclosure (5 ) and operative to cool the filter circuit (30).
    [0016]
    16. POWER CONVERSION SYSTEM (80), characterized in that it comprises: first and second power converter modules (2) configured as passive rectifiers, each individual power converter module (2) comprising: an enclosure (4) defining a housing interior (5) and having a bottom, an AC input including a plurality of AC electrical connections (16), a DC output including a first and second DC electrical connections (18), a circuit of rectifier (20) located inside housing (5) and including: first and second DC nodes electrically connected, individually, to a corresponding one of the first and second DC electrical connections (18), a plurality of AC nodes electrically coupled individually to a corresponding one among the AC electrical connections (16), and a plurality of rectifiers (D1-D6) connected individually between a corresponding one of the plurality of AC nodes and a corresponding one within. and the first and second DC nodes, a filter circuit (30) located below the rectifier circuit (20) within the housing (5) and including a plurality of inductors (30L) electrically connected, individually, between a a corresponding one of the plurality of AC nodes of the rectifier circuit (20) and a corresponding one of the plurality of AC electrical connections (16), and wherein the AC inputs of the first and second power converter modules (2) are connected between itself to receive AC input power; wherein the DC outputs of the first and second power converter modules (2) are connected together to provide DC output power; and wherein the housing includes an upper portion spaced vertically from and above the lower portion of the housing, wherein the housing defines a single air flow path between the upper and lower portion, wherein the filter circuit ( 30) is positioned vertically between the alternation circuit (20) and the lower part of the housing, and wherein the alternation circuit (20) is positioned vertically between the filter circuit (30) and the upper part of the housing.
    [0017]
    17. POWER CONVERSION SYSTEM (80) according to claim 16, wherein each individual power converter module (2) is characterized by comprising a fan fan assembly (14) located within the enclosure (5 ) and operative to cool the filter circuit (30).
    [0018]
    Apparatus according to claim 1, characterized in that the lower part of the casing is supported by a plurality of roller wheels (6) to enable the casing to be rolled.
    [0019]
    Apparatus according to claim 10, characterized in that the fan fan assembly (14) is located below the filter circuit (30) inside the casing (5).
    [0020]
    20. APPARATUS according to claim 1, characterized in that the filter circuit (30) includes interconnection and assembly resources for selective direct connection of AC electrical connections with AC nodes of the alternation circuit, or for connection of inductors and /or filter resistors between AC connections and alternating circuit.
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    法律状态:
    2016-09-27| B03A| Publication of a patent application or of a certificate of addition of invention [chapter 3.1 patent gazette]|
    2018-11-06| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|
    2020-03-31| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|
    2021-07-06| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|
    2021-07-27| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 06/10/2014, OBSERVADAS AS CONDICOES LEGAIS. |
    优先权:
    申请号 | 申请日 | 专利标题
    US14/049,266|2013-10-09|
    US14/049,266|US9654021B2|2013-10-09|2013-10-09|Multifunction power converter with option for integrated magnetics|
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