Input reference signal generation systems and methods

• US 10,305,373 B2
• Filed: 01/30/2017
• Issued: 05/28/2019
• Est. Priority Date: 04/15/2016
• Status: Active Grant

• Current Assignee: Copeland Corporation LLC (Emerson Electric Company)
• Original Assignee: Emerson Climate Technologies Incorporated (Emerson Electric Company)
• Inventors: Green, Charles E.
• Primary Examiner(s): Torres-Rivera, Alex
• Application Number:
  US15/419,394
• Publication Number:
  US 20170302161A1
• Time in Patent Office: 848 Days
• Field of Search: 323205, 323207, 363 44, 363 76, 363 77, 363 84, 363 89
• CPC Class Codes: H02M 1/0025 Arrangements for modifying reference values, feedback values or error values in the control loop of a converter
• CPC Class Codes: H02M 1/08 Circuits specially adapted for the generation of control voltages for semiconductor devices incorporated in static converters
• CPC Class Codes: H02M 1/12 Arrangements for reducing harmonics from ac input or output
• CPC Class Codes: H02M 1/15 using active elements
• CPC Class Codes: H02M 1/4208 Arrangements for improving power factor of AC input
• CPC Class Codes: H02M 1/4225 using a non-isolated boost converter
• CPC Class Codes: H02M 1/4291 by using a Buck converter to switch the input current
• CPC Class Codes: H02M 1/44 Circuits or arrangements for compensating for electromagnetic interference in converters or inverters
• CPC Class Codes: Y02B 70/10 Technologies improving the efficiency by using switched-mode power supplies [SMPS], i.e. efficient power electronics conversion e.g. power factor correction or reduction of losses in power supplies or efficient standby modes

Abstract

A power factor correction (PFC) system includes a PFC circuit that receives an alternating current (AC) voltage and that, using a switch, generates a direct current (DC) voltage from the AC voltage. A zero crossing module determines a zero crossing of the AC voltage based on: a first voltage and a first time when the AC voltage transitioned from less than a first predetermined voltage to greater than the first predetermined voltage; and a second voltage and a second time when the AC voltage transitioned from less than a second predetermined voltage to greater than the second predetermined voltage. The first predetermined voltage is negative, and the second predetermined voltage is positive. A reference module, based on the zero crossing, generates a sinusoidal reference signal corresponding to the AC voltage in phase and frequency. A switching control module controls switching of the switch based on the sinusoidal reference signal.

Claims

1. A power factor correction (PFC) system comprising:

a PFC circuit that receives an alternating current (AC) input voltage and that, using a switch, generates a direct current (DC) output voltage from the AC input voltage;

a first zero crossing module that calculates a first zero crossing of the AC input voltage based on;

a first voltage and a first time stored in response to a determination that the AC input voltage transitioned from less than a first predetermined voltage to greater than the first predetermined voltage; and

a second voltage and a second time stored in response to a determination that the AC input voltage transitioned from less than a second predetermined voltage to greater than the second predetermined voltage,

wherein the first predetermined voltage is less than zero, and

wherein the second predetermined voltage is greater than zero;

a reference module that, based on the first zero crossing, generates a sinusoidal reference signal that corresponds to the AC input voltage at least in phase and frequency; and

a switching control module that controls switching of the switch based on the sinusoidal reference signal.

2. The PFC system of claim 1 further comprising:

a second zero crossing module that calculates a second zero crossing of the sinusoidal reference signal based on;

a first value of the sinusoidal reference signal and a third time stored in response to a determination that the sinusoidal reference signal transitioned from greater than a third predetermined voltage to less than the third predetermined voltage; and

a second value of the sinusoidal reference signal and a fourth time stored in response to a determination that the sinusoidal reference signal transitioned from greater than a fourth predetermined voltage to less than the fourth predetermined voltage,

wherein the fourth predetermined voltage is less than zero, and

wherein the third predetermined voltage is greater than zero,

wherein the reference module generates the sinusoidal reference signal further based on the second zero crossing.

3. The PFC system of claim 2 wherein the reference module generates the sinusoidal reference signal based on a difference between the first zero crossing of the AC input voltage and the second zero crossing of the sinusoidal reference signal.

4. The PFC system of claim 2 wherein the third predetermined voltage is equal to the second predetermined voltage, and

wherein the fourth predetermined voltage is equal to the first predetermined voltage.

5. The PFC system of claim 4 wherein the reference module generates the sinusoidal reference signal further based on one-half of one period difference between the first zero crossing of the AC input voltage and the second zero crossing of the sinusoidal reference signal.

6. The PFC system of claim 2 wherein:

the first and second predetermined voltages are equal in magnitude, and

the third and fourth predetermined voltages are equal in magnitude.

7. The PFC system of claim 1 further comprising a filter module that filters values of the AC input voltage measured using a voltage sensor and that produces the first and second voltages based on the filtering.

8. The PFC system of claim 7 further comprising:

a filter correction module that determines a correction for the first zero crossing based on a frequency of the AC input voltage,

wherein the reference module generates the sinusoidal reference signal further based on the correction.

9. The PFC system of claim 1 wherein the first zero crossing module calculates the first zero crossing of the AC input voltage based on the first voltage, the first time, the second voltage, and the second time using linear interpolation.

10. The PFC system of claim 1 further comprising a current demand module that determines a current demand based on the sinusoidal reference signal,

wherein the switching control module transitions the switch from an ON state to an OFF state when a measured current through an inductor of the PFC circuit is greater than the demanded current.

11. A power factor correction (PFC) method comprising:

by a PFC circuit, receiving an alternating current (AC) input voltage and, using a switch, generating a direct current (DC) output voltage from the AC input voltage;

calculating a first zero crossing of the AC input voltage based on;

a first voltage and a first time stored in response to a determination that the AC input voltage transitioned from less than a first predetermined voltage to greater than the first predetermined voltage; and

a second voltage and a second time stored in response to a determination that the AC input voltage transitioned from less than a second predetermined voltage to greater than the second predetermined voltage,

wherein the first predetermined voltage is less than zero, and

wherein the second predetermined voltage is greater than zero;

based on the first zero crossing, generating a sinusoidal reference signal that corresponds to the AC input voltage at least in phase and frequency; and

controlling switching of the switch based on the sinusoidal reference signal.

12. The PFC method of claim 11 further comprising:

calculating a second zero crossing of the sinusoidal reference signal based on;

a first value of the sinusoidal reference signal and a third time stored in response to a determination that the sinusoidal reference signal transitioned from greater than a third predetermined voltage to less than the third predetermined voltage; and

a second value of the sinusoidal reference signal and a fourth time stored in response to a determination that the sinusoidal reference signal transitioned from greater than a fourth predetermined voltage to less than the fourth predetermined voltage,

wherein the fourth predetermined voltage is less than zero, and

wherein the third predetermined voltage is greater than zero,

wherein generating the sinusoidal reference signal includes generating the sinusoidal reference signal further based on the second zero crossing.

13. The PFC method of claim 12 wherein generating the sinusoidal reference signal includes generating the sinusoidal reference signal based on a difference between the first zero crossing of the AC input voltage and the second zero crossing of the sinusoidal reference signal.

14. The PFC method of claim 12 wherein the third predetermined voltage is equal to the second predetermined voltage, and

wherein the fourth predetermined voltage is equal to the first predetermined voltage.

15. The PFC method of claim 14 wherein generating the sinusoidal reference signal includes generating the sinusoidal reference signal further based on one-half of one period difference between the first zero crossing of the AC input voltage and the second zero crossing of the sinusoidal reference signal.

16. The PFC method of claim 12 wherein:

the first and second predetermined voltages are equal in magnitude, and

the third and fourth predetermined voltages are equal in magnitude.

17. The PFC method of claim 11 further comprising:

filtering values of the AC input voltage measured using a voltage sensor; and

producing the first and second voltages based on the filtering.

18. The PFC method of claim 17 further comprising:

determining a correction for the first zero crossing based on a frequency of the AC input voltage,

wherein generating the sinusoidal reference signal includes generating the sinusoidal reference signal further based on the correction.

19. The PFC method of claim 11 wherein calculating the first zero crossing includes calculating the first zero crossing of the AC input voltage based on the first voltage, the first time, the second voltage, and the second time using linear interpolation.

20. The PFC method of claim 11 further comprising determining a current demand based on the sinusoidal reference signal,

wherein controlling switching of the switch includes transitioning the switch from an ON state to an OFF state when a measured current through an inductor of the PFC circuit is greater than the demanded current.

21. A power factor correction (PFC) system comprising:

a PFC circuit that receives an alternating current (AC) input voltage and that, using a switch, generates a direct current (DC) output voltage from the AC input voltage;

a first zero crossing module that calculates a first zero crossing of the AC input voltage based on;

a first voltage and a first time when the AC input voltage transitioned from less than a first predetermined voltage to greater than the first predetermined voltage; and

a second voltage and a second time when the AC input voltage transitioned from less than a second predetermined voltage to greater than the second predetermined voltage,

wherein the first predetermined voltage is less than zero, and

wherein the second predetermined voltage is greater than zero;

a second zero crossing module that calculates a second zero crossing of a sinusoidal reference signal based on;

a first value of the sinusoidal reference signal and a third time when the sinusoidal reference signal transitioned from greater than a third predetermined voltage to less than the third predetermined voltage; and

a second value of the sinusoidal reference signal and a fourth time when the sinusoidal reference signal transitioned from greater than a fourth predetermined voltage to less than the fourth predetermined voltage,

wherein the fourth predetermined voltage is less than zero, and

wherein the third predetermined voltage is greater than zero;

a reference module that, based on the first zero crossing and the second zero crossing, generates the sinusoidal reference signal that corresponds to the AC input voltage at least in phase and frequency; and

a switching control module that controls switching of the switch based on the sinusoidal reference signal.

22. The PFC system of claim 21 wherein the reference module generates the sinusoidal reference signal based on a difference between the first zero crossing of the AC input voltage and the second zero crossing of the sinusoidal reference signal.

23. The PFC system of claim 21 wherein the third predetermined voltage is equal to the second predetermined voltage, and

wherein the fourth predetermined voltage is equal to the first predetermined voltage.

24. The PFC system of claim 23 wherein the reference module generates the sinusoidal reference signal further based on one-half of one period difference between the first zero crossing of the AC input voltage and the second zero crossing of the sinusoidal reference signal.

25. The PFC system of claim 21 wherein:

the first and second predetermined voltages are equal in magnitude, and

the third and fourth predetermined voltages are equal in magnitude.

26. A power factor correction (PFC) system comprising:

a PFC circuit that receives an alternating current (AC) input voltage and that, using a switch, generates a direct current (DC) output voltage from the AC input voltage;

a first zero crossing module that calculates a first zero crossing of the AC input voltage based on;

a first voltage and a first time when the AC input voltage transitioned from less than a first predetermined voltage to greater than the first predetermined voltage; and

a second voltage and a second time when the AC input voltage transitioned from less than a second predetermined voltage to greater than the second predetermined voltage,

wherein the first predetermined voltage is less than zero, and

wherein the second predetermined voltage is greater than zero;

a filter module that filters values of the AC input voltage measured using a voltage sensor and that produces the first and second voltages based on the filtering;

a filter correction module that determines a correction for the first zero crossing based on a frequency of the AC input voltage; and

a reference module that, based on the first zero crossing and the correction, generates a sinusoidal reference signal that corresponds to the AC input voltage at least in phase and frequency; and

a switching control module that controls switching of the switch based on the sinusoidal reference signal.

27. A power factor correction (PFC) system comprising:

a PFC circuit that receives an alternating current (AC) input voltage and that, using a switch, generates a direct current (DC) output voltage from the AC input voltage;

a first zero crossing module that calculates a first zero crossing of the AC input voltage based on;

a first voltage and a first time when the AC input voltage transitioned from less than a first predetermined voltage to greater than the first predetermined voltage; and

a second voltage and a second time when the AC input voltage transitioned from less than a second predetermined voltage to greater than the second predetermined voltage,

wherein the first predetermined voltage is less than zero, and

wherein the second predetermined voltage is greater than zero;

a reference module that, based on the first zero crossing, generates a sinusoidal reference signal that corresponds to the AC input voltage at least in phase and frequency;

a current demand module that determines a current demand based on the sinusoidal reference signal; and

a switching control module that controls switching of the switch based on the sinusoidal reference signal and that transitions the switch from an ON state to an OFF state when a measured current through an inductor of the PFC circuit is greater than the demanded current.

28. A power factor correction (PFC) method comprising:

by a PFC circuit, receiving an alternating current (AC) input voltage and, using a switch, generating a direct current (DC) output voltage from the AC input voltage;

calculating a first zero crossing of the AC input voltage based on;

a first voltage and a first time when the AC input voltage transitioned from less than a first predetermined voltage to greater than the first predetermined voltage; and

a second voltage and a second time when the AC input voltage transitioned from less than a second predetermined voltage to greater than the second predetermined voltage,

wherein the first predetermined voltage is less than zero, and

wherein the second predetermined voltage is greater than zero;

calculating a second zero crossing of a sinusoidal reference signal based on;

a first value of the sinusoidal reference signal and a third time when the sinusoidal reference signal transitioned from greater than a third predetermined voltage to less than the third predetermined voltage; and

a second value of the sinusoidal reference signal and a fourth time when the sinusoidal reference signal transitioned from greater than a fourth predetermined voltage to less than the fourth predetermined voltage,

wherein the fourth predetermined voltage is less than zero, and

wherein the third predetermined voltage is greater than zero;

based on the first zero crossing and the second zero crossing, generating the sinusoidal reference signal that corresponds to the AC input voltage at least in phase and frequency; and

controlling switching of the switch based on the sinusoidal reference signal.

29. The PFC method of claim 28 wherein generating the sinusoidal reference signal includes generating the sinusoidal reference signal based on a difference between the first zero crossing of the AC input voltage and the second zero crossing of the sinusoidal reference signal.

30. The PFC method of claim 28 wherein the third predetermined voltage is equal to the second predetermined voltage, and

wherein the fourth predetermined voltage is equal to the first predetermined voltage.

31. The PFC method of claim 30 wherein generating the sinusoidal reference signal includes generating the sinusoidal reference signal further based on one-half of one period difference between the first zero crossing of the AC input voltage and the second zero crossing of the sinusoidal reference signal.

32. The PFC method of claim 28 wherein:

the first and second predetermined voltages are equal in magnitude, and

the third and fourth predetermined voltages are equal in magnitude.

33. A power factor correction (PFC) method comprising:

by a PFC circuit, receiving an alternating current (AC) input voltage and, using a switch, generating a direct current (DC) output voltage from the AC input voltage;

calculating a first zero crossing of the AC input voltage based on;

a first voltage and a first time when the AC input voltage transitioned from less than a first predetermined voltage to greater than the first predetermined voltage; and

a second voltage and a second time when the AC input voltage transitioned from less than a second predetermined voltage to greater than the second predetermined voltage,

wherein the first predetermined voltage is less than zero, and

wherein the second predetermined voltage is greater than zero;

filtering values of the AC input voltage measured using a voltage sensor;

producing the first and second voltages based on the filtering;

determining a correction for the first zero crossing based on a frequency of the AC input voltage;

based on the first zero crossing and the correction, generating a sinusoidal reference signal that corresponds to the AC input voltage at least in phase and frequency; and

controlling switching of the switch based on the sinusoidal reference signal.

34. A power factor correction (PFC) method comprising:

by a PFC circuit, receiving an alternating current (AC) input voltage and, using a switch, generating a direct current (DC) output voltage from the AC input voltage;

calculating a first zero crossing of the AC input voltage based on;

a first voltage and a first time when the AC input voltage transitioned from less than a first predetermined voltage to greater than the first predetermined voltage; and

a second voltage and a second time when the AC input voltage transitioned from less than a second predetermined voltage to greater than the second predetermined voltage,

wherein the first predetermined voltage is less than zero, and

wherein the second predetermined voltage is greater than zero;

based on the first zero crossing, generating a sinusoidal reference signal that corresponds to the AC input voltage at least in phase and frequency;

determining a current demand based on the sinusoidal reference signal; and

controlling switching of the switch based on the sinusoidal reference signal including transitioning the switch from an ON state to an OFF state when a measured current through an inductor of the PFC circuit is greater than the demanded current.