Converter system

• US 4,136,382 A
• Filed: 01/18/1978
• Issued: 01/23/1979
• Est. Priority Date: 01/18/1978
• Status: Expired due to Term

• Current Assignee: Exxon Research and Engineering Company (Exxon Mobil Corporation)
• Original Assignee: Exxon Research and Engineering Company (Exxon Mobil Corporation)
• Inventors: Ricci, Ronald L.
• Primary Examiner(s): Shoop, William M.
• Application Number:
  US05/870,515
• Time in Patent Office: 370 Days
• Field of Search: 307/10 R, 320/2, 320/57, 320/59, 320/60, 363/123, 363/125, 363/128, 363/129, 363/136, 363/137
• US Class Current: 363/137
• CPC Class Codes: B60L 50/51 characterised by AC-motors
• CPC Class Codes: B60L 53/20 characterised by converters located in the vehicle
• CPC Class Codes: B60L 53/24 Using the vehicle's propulsion converter for charging
• CPC Class Codes: H02J 2207/20 Charging or discharging characterised by the power electronics converter
• CPC Class Codes: H02J 7/02 for charging batteries from ac mains by converters
• CPC Class Codes: H02M 7/757 using semiconductor devices only
• 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 10/92 Energy efficient charging or discharging systems for batteries, ultracapacitors, supercapacitors or double-layer capacitors specially adapted for vehicles
• CPC Class Codes: Y02T 90/12 Electric charging stations
• CPC Class Codes: Y02T 90/14 Plug-in electric vehicles

Abstract

A converter in one embodiment including six solid-state switches arranged as a three-phase bridge circuit operable in a first mode for inverting the DC voltage from a battery into a plural phase AC output voltage, and operable in a second mode as a single-phase bridge rectifier for controllably rectifying single-phase AC line voltage into a DC voltage. An AC relay in its de-energized state has switch contacts for connecting the three-phase AC output voltage to three output terminals, and the battery voltage across the bridge circuit for inversion. A single-phase AC line voltage is connected to the converter for energizing the relay, for disconnecting the bridge from the output terminals, for connecting the AC line voltage to the bridge for rectification thereof, and for reversing the connections of the battery to the bridge. A microprocessor is preprogrammed for controlling the operation of the bridge circuit for either the inversion or rectification modes of operation.

Claims

1. A conversion system operable to a first condition for inverting a DC voltage from a battery to a three-phase AC output voltage, and operable to a second condition in response to a single-phase AC voltage, for rectifying the single-phase AC voltage to a DC voltage for charging the battery, said system comprising:

a mode terminal where a mode signal is produced;

said battery having a positive terminal and a negative terminal;

first and second input terminals for receiving a single-phase AC voltage;

first through third output terminals where first, second and third phases, respectively, of said three-phase AC output voltage are developed;

a reference terminal for receiving a source of reference potential;

first through sixth solid-state switches, each having a control electrode receptive of a control signal, and a main current conduction path between first and second electrodes having a relatively high impedance in the presence of a low-level control signal, and a relatively low impedance in the presence of a high-level control signal, the second electrodes of said first through third switches being individually connected to the first electrodes of said fourth through sixth switches, respectively;

an AC relay having an operating coil connected across said first and second input terminals, first through third normally-closed single-pole-single-throw switch contacts connected between said first through third output terminals and the common connections between said first and fourth, second and fifth, and third and sixth solid-state switches, respectively, first and second normally-open single-pole-single-throw switch contacts connected between said first and second input terminals and the common connections of said second and fifth, and third and sixth solid-state switches, respectively, a first single-pole-double-throw switch having a pole connected to the positive terminal of said battery, a normally-closed contact connected in common to the first electrodes of said first through third solid-state switches, and a normally-open contact connected in common to the second electrodes of said fourth, fifth and sixth solid-state switches, a second single-pole-double-throw switch having a pole connected to the negative terminal of said battery, a normally-closed contact and a normally-open contact connected individually to the normally-open and normally-closed contacts, respectively, of said first single-pole-double-throw switch, and a third single-pole-double-throw switch having a pole connected to said mode terminal, a normally-open contact connected to the positive terminal of said battery, and a normally-closed contact connected to said reference terminal; and

controller means for producing first through sixth control signals for operating said first through sixth solid-state switches, respectively, whereby whenever said single-phase AC voltage is applied between said first and second input terminals, said coil of said AC relay is energized for connecting the poles of said switches of said relay to their respective normally-open contacts, and disconnecting the poles from their associative normally-closed contacts, causing said mode signal to be at said reference potential level, said controller means being responsive to said mode signal at this time for operating said solid-state switches for said first condition of said system, and whenever said single-phase AC voltage is not applied between said first and second input terminals, said relay is de-energized with its switches being returned to their "normal" states, said controller means is responsive to said mode signal having a positive voltage level at this time for operating said solid-state switches for said second condition of said system.

2. The system of claim 1 wherein said controller means includes a microprocessor.

3. The system of claim 2, wherein said microprocessor is programmed to automatically change the relationship between the conduction times or angles of said second, third, fifth and sixth solid-state switches relative to each half-cycle of said single-phase AC voltage, in response to an increasing level of said mode signal as said battery charges, for rectifying a succeedingly smaller portion of the waveform of said single-phase AC voltage, thereby reducing the charging rate of said battery as the latter approaches full charge.

4. The system of claim 1, wherein said first through sixth solid-state switches each include a gate turnoff silicon controlled rectifier having a gate electrode as said control electrode, an anode electrode as said first electrode, and a cathode electrode as said second electrode.

5. The system of claim 1, wherein said first through sixth solid-state switches each include a bipolar switching transistor having a base electrode as said control electrode.

6. A system for providing a three-phase bridge inverter selectively convertible to a single-phase bridge rectifier, comprising:

first through sixth solid-state switches each having a control electrode, a first electrode, and a second electrode, the first electrodes of said first through third solid-state switches being connected together at a first node, the second electrodes of said fourth through sixth solid-state switches being connected together at a second node, the respective second and first electrodes of said first and fourth, second and fifth, and third and sixth switches, being connected together at third, fourth and fifth nodes, respectively;

a source of DC voltage having positive and negative terminals;

first through third output terminals;

a pair of input terminals for receiving a single-phase AC voltage;

a reference terminal for connection to a point of reference potential;

first switching means responsive to the connection of said single-phase AC voltage across said pair of input terminals, for substantially simultaneously (1) connecting said AC voltage across a predetermined two of said third, fourth and fifth nodes;

(2) producing a mode signal having a first level of voltage and responsive to the removal of said AC voltage from said input terminals for substantially simultaneously (1) connecting said third, fourth and fifth nodes to said first, second, and third output terminals, respectively;

(2) said first node to the positive terminal of said source of DC voltage;

(3) said second node to the negative terminal of said source of DC voltage; and

(4) producing said mode signal having a second level of voltage; and

control logic means responsive to said mode signal having said first level of voltage, for applying individual control signals to the control electrodes of the four of said first through sixth solid-state switches associated with said predetermined two of said third through fifth nodes, for operating these four switches as a single-phase bridge rectifier, rectifying said single-phase AC voltage for providing a DC voltage across said first and second nodes, said control logic means also being responsive to said mode signal having said second level of voltage, for applying individual control signals to the control electrodes of said first through sixth solid-state switches, for operating these six switches as up to a three-phase bridge inverter, inverting the DC voltage from said DC voltage source to at least a first, up to second, and third phase AC voltages at said first through third output terminals, respectively.

7. The inverter/rectifier system of claim 6, further including:

said source of DC voltage being a battery;

second switching means responsive to the connection of said single-phase AC voltage across said pair of input terminals, for connecting the positive terminal of said battery to said second node, and the negative terminal of said battery to said first node, thereby permitting recharging of said battery by the DC voltage resulting from the rectification of said single-phase AC voltage.

8. The inverter/rectifier system of claim 7, wherein said control logic means includes a microprocessor system programmed for producing said control signals.

9. In an electric vehicle including a polyphase AC drive motor, and at least one battery having positive and negative terminals as a primary power source, a converter system having a polyphase bridge circuit operable as an inverter, for inverting the DC voltage from said battery to a polyphase AC voltage for application to the windings of said motor, and responsive to single-phase AC line voltage for operating the bridge circuit as a rectifier for rectifying said line voltage into a DC voltage for recharging said battery, said converter system comprising:

first through sixth solid-state current control devices each having a control electrode receptive of a control signal, a first electrode, and a second electrode, said devices being arranged into said bridge circuit having a first node of commonly connected first electrodes of said first through third solid-state devices, a second node of commonly connected second electrodes of said fourth through sixth devices, third, fourth and fifth nodes of commonly connected second and first electrodes of said first and fourth, second and fifth, third and sixth devices, respectively, each one of said devices being responsive to a control signal for conducting current between their respective first and second electrodes;

first and second terminals for receiving single-phase AC line voltage;

first switching means connected to said first and second terminals, responsive to the removal of said AC line voltage from said terminals, for connecting said third, fourth and fifth nodes to individual ones of said three-phase windings of said motor, respectively;

second switching means connected to said first and second terminals, responsive to the application of said AC line voltage to these terminals, for individually connecting said terminals to and thereby applying said AC line voltage to a predetermined two of said third, fourth and fifth nodes, respectively;

third switching means connected to said first and second terminals, responsive to the application of said AC line voltage across said terminals, for connecting said positive and negative terminals of said battery to said second node and said first node, respectively, and responsive to the removal of said AC line voltage from said terminals for reversing the aforesaid connections of said positive and negative terminals;

a mode terminal for receiving a mode signal;

a reference terminal for connection to a point of reference potential;

fourth switching means connected to said first and second terminals, responsive to the application of said AC line voltage to these terminals, for connecting the positive terminal of said battery to said mode terminal, thereby producing a "high" level mode signal, and responsive to the removal of said AC line voltage from said first and second terminals, for connecting said reference terminal to said mode terminal, thereby producing a "low" level mode signal; and

controller means responsive to said mode signal being "high" for producing control signals for operating the four of said first through sixth solid-state devices associated with said predetermined two of said third, fourth and fifth nodes as a single-phase rectifier, and responsive to said mode signal being "low", for producing control signals for operating said first through sixth solid-state devices as a three-phase bridge inverter.

10. The electric vehicle of claim 9, wherein said controller means is further responsive to the level of the "high" level mode signal, for changing the conduction times or angles of said devices in the rectifier mode relative to each half-cycle of said AC line voltage, for reducing the rate of charging said battery as it approaches full charge.

11. The electric vehicle of claim 10, wherein said controller means includes a preprogrammed microprocessor for generating said control signals.

12. The electric vehicle of claim 9, wherein said first through sixth solid-state switches each consist of a silicon controlled rectifier having a gate electrode as said control electrode, an anode electrode as said first electrode, and a cathode electrode as said second electrode.

13. The electric vehicle of claim 9, wherein said first through sixth solid-state switches each consist of a gate-turnoff silicon controlled rectifier having a gate electrode as said control electrode, and anode and cathode electrodes as said first and second electrodes, respectively.

14. The electric vehicle of claim 9, wherein said first through sixth solid-state switches each consist of an NPN switching transistor having a base electrode, collector electrode, and emitter electrode, as said control, first and second electrodes, respectively.

15. The electric vehicle of claim 9, wherein said first through fourth switching means are all included as individual switches within a single AC relay, said relay having a coil connected between said first and second terminals and energizable by AC line voltage, for operating said first through fourth switching means responsive to said AC line voltage.

16. A converter system selectively operable as a single or polyphase bridge inverter in one mode of operation, or as a single-phase bridge rectifier in another mode of operation, comprising;

said bridge including at least four solid-state current control devices each having a control electrode, and a main current conduction path, individual pairs of said devices having their main current conduction paths connected in series between first and second nodes with the common connections between each pair of devices forming third and fourth nodes, respectively, for a two-phase bridge of four such devices, and third, fourth, and fifth nodes, for a three-phase bridge of six such devices;

a pair of batteries connected in series having free positive and free negative terminals, respectively;

a plurality of output terminals where AC voltages are developed;

for application to a load;

a pair of input terminals for receiving single-phase AC line voltage;

first switching means for normally connecting said free positive and negative terminals across said first and second nodes, respectively, for current flow into said bridge from said batteries during the inversion mode of operation of said bridge, and responsive to said AC line voltage for reversing the connections of said free positive and free negative terminals for current flow into said batteries during the rectification mode of operation of said bridge;

second switching means for normally connecting said third and fourth nodes, and when applicable also said fifth node, to individual ones of said plurality of output terminals responsive to said AC line voltage for opening these connections;

third switching means connected between said pair of input terminals and said third and fourth nodes, respectively, responsive to said single-phase AC line voltage for connecting this voltage across said third and fourth nodes;

a reference terminal for receiving a source of reference potential, connected to the common connection of said pair of batteries;

a mode terminal where a mode signal is developed;

fourth switching means for normally connecting said reference terminal to said mode terminal for providing a first level of mode signal, said fourth switching means being responsive to said AC line voltage for connecting said free positive terminal to said mode terminal, for providing a second level of mode signal; and

controller means connected to said mode terminal, for providing individual control signals to the control electrodes of said solid-state devices, responsive to said mode signal having said first level, for operating said bridge as an inverter, for selectively inverting the DC voltage from said batteries into a single-phase voltage or polyphase AC voltages across given ones of said plurality of output terminals and said reference terminal, and responsive to said second level of said mode signal for providing rectification of said single-phase AC line voltage to a DC voltage for recharging said battery.