Power converter apparatus and methods using adaptive node balancing

• US 10,381,917 B2
• Filed: 03/23/2017
• Issued: 08/13/2019
• Est. Priority Date: 03/23/2017
• Status: Active Grant

• Current Assignee: Eaton Intelligent Power Limited (Eaton Corporation PLC.)
• Original Assignee: Eaton Intelligent Power Limited (Eaton Corporation PLC.)
• Inventors: Oughton, George William
• Primary Examiner(s): Moody, Kyle J
• Application Number:
  US15/467,475
• Publication Number:
  US 20180275699A1
• Time in Patent Office: 873 Days
• CPC Class Codes: G05F 1/14 using tap transformers or tap changing inductors as final control devices
• CPC Class Codes: H02M 1/14 Arrangements for reducing ripples from dc input or output
• CPC Class Codes: H02M 1/15 using active elements
• CPC Class Codes: H02M 3/155 using semiconductor devices only
• CPC Class Codes: H02M 3/1586 switched with a phase shift, i.e. interleaved
• CPC Class Codes: H02M 5/458 using semiconductor devices only
• CPC Class Codes: H02M 7/44 by static converters
• CPC Class Codes: H02M 7/483 Converters with outputs that each can have more than two voltages levels
• CPC Class Codes: H02M 7/4833 Capacitor voltage balancing

Abstract

An apparatus includes a first winding and a second winding on a core and having first taps coupled in common to a first node of an inverter circuit. The apparatus further includes a switching circuit configured to selectively couple a second tap of the first winding to a second node of the inverter circuit and to selectively couple a second tap of the second winding to a third node of the inverter circuit. The switching circuit may be configured to provide a desired balance of first and second voltages at respective ones of the second and third nodes with respect to the first node. Related methods are also described.

Claims

1. An apparatus comprising:

an inverter circuit; and

a balancer circuit comprising;

a first winding and a second winding on a core in a transformer arrangement and having first taps coupled in common to a first node of the inverter circuit; and

a switching circuit configured to selectively couple a second tap of the first winding to a second node of the inverter circuit and to selectively couple a second tap of the second winding to a third node of the inverter circuit.

2. The apparatus of claim 1, wherein the switching circuit is configured to provide a desired balance of first and second voltages at respective ones of the second and third nodes with respect to the first node.

3. The apparatus of claim 1, wherein the first and second windings have a turns ratio of 1:

1.

4. The apparatus of claim 1, wherein the switching circuit comprises:

a first switch configured to couple the second tap of the first winding to the second node;

a second switch configured to couple the second tap of the second winding to the third node; and

a control circuit configured to control the first and second switches.

5. The apparatus of claim 4, wherein the control circuit is configured to operate both of the first and second switches at a first duty cycle.

6. The apparatus of claim 5, wherein the first duty cycle is less than or equal to 50%.

7. The apparatus of claim 5, wherein the first duty cycle allows a flux in the core to return to zero during periods in which the first and second switches are open.

8. The apparatus of claim 4, wherein the first and second switches comprise respective first and second transistors.

9. The apparatus of claim 5, wherein the core comprises a first core, and wherein the apparatus further comprises:

third and fourth windings on a second core in a transformer arrangement and having first taps coupled in common to the first node;

a third switch configured to selectively couple a second tap of the third winding to the second node; and

a fourth switch configured to selectively couple a second tap of the fourth winding to the third node,

wherein the control circuit is further configured to control the third and fourth switches.

10. The apparatus of claim 9, wherein the control circuit is configured to operate both of the third and fourth switches at a second duty cycle that is complementary to the first duty cycle.

11. The apparatus of claim 9, wherein the inverter circuit comprises a multi-level inverter circuit.

12. The apparatus of claim 1, wherein the first node comprises a neutral of an output of the inverter circuit.

13. An apparatus comprising:

a DC link comprising first and second DC buses;

a balancer circuit coupled to the first and second DC buses and comprising;

first and second windings on a core in a transformer arrangement and having first taps coupled in common to a neutral;

first and second switches configured to selectively couple second taps of respective ones of the first and second windings to respective ones of the first and second DC buses; and

a control circuit configured to control the first and second switches to balance voltages between the first and second DC buses and the neutral.

14. The apparatus of claim 13, wherein the control circuit is configured to operate both of the first and second switches at a duty cycle less or equal to 50%.

15. The apparatus of claim 14:

wherein the core comprises a first core;

wherein the apparatus further comprises;

third and fourth windings on a second core in a transformer arrangement and having first taps coupled in common to the neutral; and

third and fourth switches configured to selectively couple second taps of the third and fourth windings to second taps of respective ones of the first and second DC buses; and

wherein the control circuit is further configured to control the third and fourth switches to balance the voltages between the first and second DC buses and the neutral.

16. A method of operating an inverter, the method comprising:

providing a first winding and a second winding on a core in a transformer arrangement and having first taps coupled in common to a first node of the inverter; and

selectively coupling a second tap of the first winding to a second node of the inverter and a second tap of the second winding to a third node of the inverter using a balancer circuit separate from the inverter to balance first and second voltages at the second and third nodes with respect to the first node.

17. The method of claim 16, wherein the first and second windings have a turns ratio of 1:

1.

18. The method of claim 16, wherein selectively coupling a second tap of the first winding to a second node of the inverter and a second tap of the second winding to a third node of the inverter to balance first and second voltages at the second and third nodes with respect to the first node comprises operating a first switch to couple the second tap of the first winding to the second node at a duty cycle and operating a second switch to couple the second tap of the second winding to the third node at the duty cycle.

19. The method of claim 18, wherein the duty cycle is less than or equal to 50%.

20. The method of claim 16, wherein the first node comprises a neutral.