CHOKE WITH CURRENT SENSOR

• US 20120187883A1
• Filed: 01/26/2011
• Published: 07/26/2012
• Est. Priority Date: 01/26/2011
• Status: Active Grant

• Current Assignee: Rockwell Automation Technologies Incorporated (Rockwell Automation, Inc.)
• Original Assignee: Rockwell Automation Technologies Incorporated (Rockwell Automation, Inc.)
• Inventors: Valdez, Carlos Rodriguez, Tallam, Rangarajan, Kerkman, Russel
• Granted Patent: US 8,704,481 B2
• Time in Patent Office: Days
• US Class Current: 318/490
• CPC Class Codes: H02H 3/165 for three-phase systems
• CPC Class Codes: H02H 7/10 for converters; for rectifiers forming part of the control circuit of the converter, see the relevant group in H02M
• CPC Class Codes: H02M 1/123 Suppression of common mode voltage or current
• CPC Class Codes: H02M 1/126 using passive filters

Abstract

The present invention relates generally to systems and methods for detecting ground faults (i.e., line-to-ground faults) in motor drive systems. In particular, the embodiments described herein include a common mode choke of a motor drive system having additional (i.e., secondary) turns wound around a core of the common mode choke. These secondary turns are in addition to and separate from a plurality of sets of primary turns wound around the core of the common mode choke, each set of primary turns corresponding to a phase of AC power to which the common mode choke is directly coupled. The secondary turns terminate in series with a burden resistor. Ground faults may be detected by monitoring the voltage across the burden resistor. More specifically, the embodiments described herein include a controller including program instructions for receiving signals indicative of the voltage across the burden resistor, and for monitoring the voltage across the burden resistor to determine when ground faults occur in the motor drive system.

Claims

1. A motor drive system, comprising:

converter circuitry configured to receive input three-phase alternating current (AC) power from an AC power source and convert the three-phase AC power into direct current (DC) power;

a DC bus configured to receive the DC power from the converter circuitry;

inverter circuitry configured to receive the DC power from the DC bus and convert it into controlled frequency output AC power for use by a three-phase motor; and

a common mode choke having a plurality of sets of primary windings and a set of secondary windings separate from the plurality of sets of primary windings, each set of primary windings directly connected to a phase of AC power, wherein the set of secondary windings are not directly connected to a phase of AC power, and wherein the set of secondary windings terminate with a burden resistor.

2. The motor drive system of claim 1, comprising a controller configured to detect ground faults by monitoring the voltage across the burden resistor.

3. The motor drive system of claim 2, wherein the controller is configured to detect ground faults in a first mode for operational frequencies below a cut-off frequency, and the controller is configured to detect ground faults in a second mode for operational frequencies above the cut-off frequency.

4. The motor drive system of claim 3, wherein the controller is configured to detect ground faults in the first mode assuming that a referred resistance of the burden resistor is substantially greater than a self-impedance of each of the sets of primary windings.

5. The motor drive system of claim 3, wherein the controller is configured to detect ground faults in the second mode assuming that a referred resistance of the burden resistor is substantially smaller than a self-impedance of each of the sets of primary windings.

6. The motor drive system of claim 1, wherein the common mode choke is electrically coupled between the AC power source and the converter circuitry.

7. The motor drive system of claim 1, wherein the common mode choke is electrically coupled between the inverter circuitry and the motor.

8. The motor drive system of claim 1, wherein the common mode choke is directly coupled to the DC bus.

9. A method, comprising:

monitoring signals indicative of a voltage across a burden resistor in series with a set of secondary turns wound around a core of a common mode choke of a motor drive system; and

determining whether a ground fault has occurred in the motor drive system based on changes in the voltage across the burden resistor over time.

10. The method of claim 9, wherein each set of primary turns associated with a respective phase of alternating current (AC) power.

11. The method of claim 10, comprising determining whether a ground fault has occurred in the motor drive system in a first mode for operational frequencies below a cut-off frequency, and determining whether a ground fault has occurred in the motor drive system in a second mode for operational frequencies above the cut-off frequency.

12. The method of claim 11, comprising determining whether a ground fault has occurred in the motor drive system in the first mode assuming that a referred resistance of the burden resistor is substantially greater than a self-impedance of each of the sets of primary turns.

13. The method of claim 11, comprising determining whether a ground fault has occurred in the motor drive system in the second mode assuming that a referred resistance of the burden resistor is substantially smaller than a self-impedance of each of the sets of primary turns.

14. The method of claim 9, comprising monitoring signals indicative of the voltage across the burden resistor in series with the set of secondary turns wound around the core of the common mode choke, which is electrically coupled between an alternating current (AC) power source and converter circuitry of the motor drive system.

15. The method of claim 9, comprising monitoring signals indicative of the voltage across the burden resistor in series with the set of secondary turns wound around the core of the common mode choke, which is electrically coupled between inverter circuitry of the motor drive system and a motor.

16. The method of claim 9, comprising monitoring signals indicative of the voltage across the burden resistor in series with the set of secondary turns wound around the core of the common mode choke, which is directly coupled to a direct current (DC) bus of the motor drive system.

17. A common mode choke system, comprising:

a plurality of sets of primary windings, wherein each set of primary windings is directly connected to a phase of alternating current (AC) power; and

a set of secondary windings separate from the sets of primary windings, wherein the set of secondary windings are not directly connected to a phase of AC power, and wherein the set of secondary windings terminate with a burden resistor.

18. The common mode choke system of claim 17, comprising a controller configured to detect ground faults by monitoring the voltage across the burden resistor.

19. The common mode choke system of claim 18, wherein the controller is configured to detect ground faults in a first mode for operational frequencies below a cut-off frequency, and the controller is configured to detect ground faults in a second mode for operational frequencies above the cut-off frequency.

20. The common mode choke system of claim 17, wherein each of the plurality of sets of primary windings is connected to a respective phase of AC power for a motor drive system.