Unidirectional matrix converter with regeneration system

• US 10,135,353 B2
• Filed: 01/30/2015
• Issued: 11/20/2018
• Est. Priority Date: 01/31/2014
• Status: Active Grant

• Current Assignee: Eaton Intelligent Power Limited (Eaton Corporation PLC.)
• Original Assignee: Eaton Intelligent Power Limited (Eaton Corporation PLC.)
• Inventors: Mir, Sayeed Ahmad
• Primary Examiner(s): Moody, Kyle J
• Application Number:
  US15/115,328
• Publication Number:
  US 20170005586A1
• Time in Patent Office: 1,390 Days
• Field of Search: 363 34, 363 37
• CPC Class Codes: B60L 1/003 to auxiliary motors, e.g. for pumps, compressors
• CPC Class Codes: B60L 15/007 Physical arrangements or structures of drive train converters specially adapted for the propulsion motors of electric vehicles
• CPC Class Codes: B60L 15/20 for control of the vehicle or its driving motor to achieve a desired performance, e.g. speed, torque, programmed variation of speed
• CPC Class Codes: B60L 2200/10 Air crafts
• CPC Class Codes: B60L 2210/20 AC to AC converters
• CPC Class Codes: B60L 50/61 by batteries charged by engine-driven generators, e.g. series hybrid electric vehicles
• CPC Class Codes: H02M 1/44 Circuits or arrangements for compensating for electromagnetic interference in converters or inverters
• CPC Class Codes: H02M 5/458 using semiconductor devices only
• CPC Class Codes: H02M 5/4585 having a rectifier with controlled elements
• CPC Class Codes: Y02T 10/62 Hybrid vehicles
• CPC Class Codes: Y02T 10/64 Electric machine technologies in electromobility
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/7072 Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
• CPC Class Codes: Y02T 10/72 Electric energy management in electromobility

Abstract

An AC-to-AC matrix converter includes a controlled rectifier input stage, an inverter output stage, and a regenerative unit. The controlled rectifier input stage is electrically connected to a power source and configured to convert AC input power from the power source into DC power. The controlled rectifier input stage may be unidirectional. The inverter output stage is electrically connected to a load and operates to convert the DC power into AC output power, which is then fed into the load. The regenerative unit is electrically connected to the inverter output stage and operates control energy generated by the load in a regenerative mode within the inverter output stage. The controlled rectifier input stage may be isolated from the inverter output stage in the regenerative mode.

Claims

1. A matrix converter comprising:

a controlled rectifier input stage electrically connected to a power source and configured to convert AC input power from the power source into DC power, wherein the controlled rectifier input stage is configured to be unidirectional;

an inverter output stage electrically connected to a load and configured to convert the DC power into AC output power, the AC output power fed into the load, the inverter output stage including a plurality of unidirectional switch elements and a plurality of diodes; and

a regenerative unit electrically connected to the inverter output stage and configured to control energy generated by the load in a regenerative mode within the inverter output stage, the regenerative unit being directly connected to the plurality of diodes in parallel to enable the energy to be drawn to the inverter output stage through paths defined by at least one of the plurality of diodes and delivered to the regenerative unit and prevent the energy from flowing into the controlled rectifier input stage in the regenerative mode.

2. The matrix converter of claim 1, wherein the regenerative unit includes an energy dissipating element configured to dissipate the energy generated by the load in the regenerative mode.

3. The matrix converter of claim 1, wherein the regenerative unit includes an energy storing element configured to store the energy generated by the load in the regenerative mode.

4. The matrix converter of claim 3, wherein the regenerative unit is configured to deliver the energy stored in the energy storing element to the load through the inverter output stage when a voltage across the energy storing element is greater than a threshold.

5. The matrix converter of claim 1, wherein the regenerative unit comprises:

an energy dissipating element configured to dissipate the energy generated by the load in the regenerative mode; and

an energy storing element arranged in parallel with the energy dissipating element and configured to store the energy generated by the load in the regenerative mode.

6. The matrix converter of claim 5, wherein the energy dissipating element is a resistor.

7. The matrix converter of claim 5, wherein the energy storing element is a capacitor.

8. The matrix converter of claim 1, wherein the regenerative unit comprises:

an energy dissipating element configured to dissipate the energy generated by the load in the regenerative mode;

a switch element arranged in series with the energy dissipating element;

an energy storing element arranged in parallel with the energy dissipating element and the switch element and configured to store the energy generated by the load in the regenerative mode; and

a control system configured to control the switch element to adjust a voltage across the energy storing element.

9. The matrix converter of claim 8, wherein the switch element is a three-terminal power semiconductor device.

10. The matrix converter of claim 1, wherein the regenerative unit is configured to deliver the energy generated by the load in the regenerative mode into the load.

11. The matrix converter of claim 1, further comprising:

a three-phase AC input connection having first, second, and third input terminals for receiving the AC input power from the power source, wherein the AC input power has three phases; and

a three-phase AC output connection having first, second, and third output terminals for providing the AC output power to the load, wherein the AC output power has three phases,

wherein the controlled rectifier input stage includes first, second, and third input leg circuits and first and second DC links, the first, second, and third input leg circuits electrically connected to the first, second, and third input terminals, respectively, and electrically connected to the first and second DC links, and configured to convert the AC input power into DC power and provide the DC power to the first and second DC links;

wherein the inverter output stage includes first, second, and third output leg circuits, the first, second, and third output leg circuits electrically connected to the first and second DC links and electrically connected to the first, second, and third output terminals, respectively, and, configured to convert the DC power from the first and second DC input terminals into the AC output power and provide the AC output power to the first, second, and third output terminals; and

wherein the regenerative unit is electrically connected to the first, second, and third output leg circuits of the inverter output stage.

12. The matrix converter of claim 11, wherein the regenerative unit includes an energy dissipating element electrically connected in parallel to each of the first, second, and third output leg circuits of the inverter output stage to dissipate the energy generated by the load in the regenerative mode.

13. The matrix converter of claim 11, wherein the regenerative unit includes an energy storing element electrically connected in parallel to each of the first, second, and third output leg circuits of the inverter output stage to store the energy generated by the load in the regenerative mode.

14. The matrix converter of claim 13, wherein the regenerative unit is configured to deliver the energy stored in the energy storing element to the load through the inverter output stage when a voltage across the energy storing element is greater than a threshold.

15. The matrix converter of claim 14, wherein the threshold is greater than a voltage across the first and second DC links.

16. A matrix converter comprising:

a three-phase AC input connection having first, second, and third input terminals for receiving three-phase AC input power from a power source;

a three-phase AC output connection having first, second, and third output terminals for providing three-phase AC output power to a load;

a controlled rectifier input stage having first, second, and third input leg circuits and first and second DC links, the first, second, and third input leg circuits electrically connected to the first, second, and third input terminals, respectively, and electrically connected to the first and second DC links, and configured to convert the three-phase AC input power into DC power and provide the DC power to the first and second DC links;

an inverter output stage having first, second, and third output leg circuits, the first, second, and third output leg circuits electrically connected to the first and second DC links and electrically connected to the first, second, and third output terminals, respectively, and, configured to convert the DC power from the first and second DC input terminals into the three-phase AC output power and provide the three-phase AC output power to the first, second, and third output terminals; and

a regenerative unit electrically connected to the first, second, and third output leg circuits of the inverter output stage and configured to control energy generated by the load in a regenerative mode within the inverter output stage.

17. The matrix converter of claim 16, wherein each of the first, second, and third input leg circuits of the controlled rectifier input stage is configured to be unidirectional.

18. The matrix converter of claim 16, wherein the regenerative unit includes an energy dissipating element electrically connected in parallel to each of the first, second, and third output leg circuits of the inverter output stage to dissipate the energy generated by the load in the regenerative mode.

19. The matrix converter of claim 16, wherein the regenerative unit includes an energy storing element electrically connected in parallel to each of the first, second, and third output leg circuits of the inverter output stage to store the energy generated by the load in the regenerative mode.

20. The matrix converter of claim 19, wherein the regenerative unit is configured to deliver the energy stored in the energy storing element to the load through the inverter output stage when a voltage across the energy storing element is greater than a threshold.

21. The matrix converter of claim 20, wherein the threshold is greater than a voltage across the first and second DC links.

22. The matrix converter of claim 16, wherein the regenerative unit comprises:

an energy storing element electrically connected in parallel to each of the first, second, and third output leg circuits of the inverter output stage to store the energy generated by the load in the regenerative mode;

an energy dissipating element;

a switch element arranged in series with the energy dissipating element, wherein the energy dissipating element and the switch element are arranged in parallel with the energy storing element; and

a control system configured to control the switch element to adjust a voltage across the energy storing element.

23. The metric converter of claim 16, wherein each of the first, second, and third output leg circuits of the inverter output stage includes an upper arm and a lower arm, the upper arm and the lower arm electrically connected in series, each of the upper and lower arms having a unidirectional switch element and an anti-parallel diode.

24. A matrix converter comprising:

a controlled rectifier input stage electrically connected to a power source and configured to convert AC input power from the power source into DC power, wherein the controlled rectifier input stage is configured to be unidirectional;

an inverter output stage electrically connected to a load and configured to convert the DC power into AC output power, the AC output power fed into the load; and

a regenerative unit electrically connected to the inverter output stage and configured to control energy generated by the load in a regenerative mode within the inverter output stage, wherein the energy does not flow into the controlled rectifier input stage in the regenerative mode, the regenerative unit including;

an energy dissipating element configured to dissipate the energy generated by the load in the regenerative mode;

a switch element arranged in series with the energy dissipating element;

an energy storing element arranged in parallel with the energy dissipating element and the switch element and configured to store the energy generated by the load in the regenerative mode; and

a control system configured to control the switch element to adjust a voltage across the energy storing element.

25. A matrix converter comprising:

a controlled rectifier input stage electrically connected to a power source and configured to convert AC input power from the power source into DC power, wherein the controlled rectifier input stage is configured to be unidirectional;

an inverter output stage electrically connected to a load and configured to convert the DC power into AC output power, the AC output power fed into the load;

a regenerative unit electrically connected to the inverter output stage and configured to control energy generated by the load in a regenerative mode within the inverter output stage, wherein the energy does not flow into the controlled rectifier input stage in the regenerative mode,

a three-phase AC input connection having first, second, and third input terminals for receiving the AC input power from the power source, wherein the AC input power has three phases; and

a three-phase AC output connection having first, second, and third output terminals for providing the AC output power to the load, wherein the AC output power has three phases,

wherein the controlled rectifier input stage includes first, second, and third input leg circuits and first and second DC links, the first, second, and third input leg circuits electrically connected to the first, second, and third input terminals, respectively, and electrically connected to the first and second DC links, and configured to convert the AC input power into DC power and provide the DC power to the first and second DC links;

wherein the inverter output stage includes first, second, and third output leg circuits, the first, second, and third output leg circuits electrically connected to the first and second DC links and electrically connected to the first, second, and third output terminals, respectively, and, configured to convert the DC power from the first and second DC input terminals into the AC output power and provide the AC output power to the first, second, and third output terminals; and

wherein the regenerative unit is electrically connected to the first, second, and third output leg circuits of the inverter output stage.

26. The matrix converter of claim 25, wherein the regenerative unit includes an energy dissipating element electrically connected in parallel to each of the first, second, and third output leg circuits of the inverter output stage to dissipate the energy generated by the load in the regenerative mode.

27. The matrix converter of claim 25, wherein the regenerative unit includes an energy storing element electrically connected in parallel to each of the first, second, and third output leg circuits of the inverter output stage to store the energy generated by the load in the regenerative mode.

28. The matrix converter of claim 25, wherein the regenerative unit is configured to deliver the energy stored in the energy storing element to the load through the inverter output stage when a voltage across the energy storing element is greater than a threshold.

29. The matrix converter of claim 28, wherein the threshold is greater than a voltage across the first and second DC links.