Converter and inverter support module

• US 5,184,291 A
• Filed: 06/13/1991
• Issued: 02/02/1993
• Est. Priority Date: 06/13/1991
• Status: Expired due to Fees

• Current Assignee: Sundstrand Corporation (Raytheon Technologies Corporation d/b/a RTX)
• Original Assignee: Sundstrand Corporation (Raytheon Technologies Corporation d/b/a RTX)
• Inventors: Metzler, Mark W., Crowe, Lawrence E.
• Primary Examiner(s): BEHA JR, WILLIAM
• Application Number:
  US07/714,798
• Time in Patent Office: 600 Days
• Field of Search: 363/36, 363/37, 363/132, 363/141, 363/144, 307/84, 361/388, 361/393, 361/394
• US Class Current: 363/37
• CPC Class Codes: H02M 5/458 using semiconductor devices only
• CPC Class Codes: H02M 7/003 Constructional details, e.g. physical layout, assembly, wiring or busbar connections
• CPC Class Codes: H02M 7/5387 in a bridge configuration

Abstract

The inverter module according to the present invention includes a component support for supporting components attached thereto, an AC/DC converter attached to the support for converting input AC into DC, inverter switches attached to the support for inverting the DC into single-phase output AC, a switch controller attached to the support for controlling the inverter switches, and connectors for interconnecting the AC/DC converter, the inverter switches, and the switch controller so that input AC is converted to a single phase of output AC.

Claims

1. A module for receiving input AC and for supplying only one phase of output AC, wherein said module can be attached to and/or withdrawn form a module support as a unit, said module comprising:

heat sink means for cooling components attached in cooling relation thereto;

rectifier means for rectifying said input AC into DC, said rectifier means being attached in cooling relation to said heat sink means;

inverter switching means for inverting said DC into said one phase of said output AC, said inverter switching means being attached, at least in part, in cooling relation to said heat sink means, said inverter switching means including an AC filter having an inductor and a capacitor attached to said heat sink means; and

connector means for interconnecting said rectifier means and said inverter switching means so that said input AC, when supplied to said module, is converted to said one phase of said output AC.

2. The module of claim 1 wherein said inverter switching means comprises inverter switches mounted in cooling relation to said heat sink means and switch control means for controlling said inverter switching means, said switch control means being attached to said heat sink means.

3. The module of claim 2 wherein said heat sink means comprises first and second cooling plates separated by a passageway for allowing cooling fluid to flow between said first and second cooling plates, wherein said rectifier means comprises first and second sets of rectifiers, said first set of rectifiers being attached in cooling relation to said first cooling plate and said second set of rectifiers being attached in cooling relation to said second cooling plate, wherein said inverter switches comprises first and second sets of inverter switches, said first set of inverter switches being attached in cooling relation to said first cooling plate and said second set of inverter switches being attached in cooling relation to said second cooling plate, and wherein said switch control means comprises first and second switch controllers, said first and said second switch controllers being attached to said heat sink means, said connector means interconnecting said first set of rectifiers, said first set of inverter switches, and said first switch controller so that said input AC, when supplied to said module, is converted to a first output AC and interconnecting said second set of rectifiers, said second set of inverter switches, and said second switch controller so that said input AC, when supplied to said module, is converted to a second output AC.

4. The module of claim 3 wherein said connector means comprises a transformer connected to said first and second sets of inverter switches so that said first and second output ACs are combined into said one phase of said output AC.

5. The module of claim 1 wherein said heat sink means comprises first and second cooling plates separated by a passageway for allowing cooling fluid to flow between said first and second cooling plates, wherein said rectifier means comprises first and second sets of rectifiers, said first set of rectifiers being attached in cooling relation to said first cooling plate and said second set of rectifiers being attached in cooling relation to said second cooling plate, wherein said inverter switching means comprises first and second sets of inverter switches, and said first set of inverter switches being attached in cooling relation to said first cooling plate and said second set of inverter switches being attached in cooling relation to said second cooling plate, said connector means interconnecting said first set of rectifiers and said first set of inverter switches so that said input AC, when supplied to said module, is converted to a first output AC and interconnecting said second set of rectifiers and said second set of inverter switches so that said input AC, when supplied to said module, is converted to a second output AC.

6. The module of claim 5 wherein said connector means comprises a transformer connected to said first and second sets of inverter switches so that said first and second output ACs are combined into said one phase of said output AC.

7. The module of claim 1 wherein said heat sink means comprises at least a first cooling plate having first and second sides, said heat sink means having a passageway on said first side of said first cooling plate for allowing cooling fluid to cool said first cooling plate, said rectifying means and said inverter switching means being attached directly to said second side of said first cooling plate.

8. The module of claim 7 wherein said inverter switching means comprises inverter switches mounted in cooling relation to said heat sink means and switch control means for controlling said inverter switching means, said switch control means being attached to said heat sink means.

9. The module of claim 8 wherein said passageway has a first side for cooling said first cooling plate and a second side, and said heat sink means comprises gate drive support means for supporting said switch control means on said second side of said passageway.

10. The module of claim 9 wherein said inverter switching means comprises resistors mounted in cooling relation to said second side of said passageway.

11. The module of claim 10 wherein said rectifier means comprises diodes attached in cooling relation to said second side of said first cooling plate and a smoothing capacitor attached to said heat sink means.

12. An inverter system for supplying output AC having at least three phases, said inverter system including at least three inverter modules, each module supplying one of said at least three phases of said output AC and being arranged so that it can be attached to and/or withdrawn from a module support as a unit, wherein said inverter modules, when interconnected, forming said inverter system for providing said output AC having said at least three phases, said inverter system comprising:

a module support having at least first, second and third receiving means, each receiving means receiving one of said modules; and

at least three modules for supplying said output AC having said at least three phases, each of said modules having

heat sink means for cooling components attached in cooling relation thereto,

rectifier means for rectifying input AC into DC, said rectifier means being attached in cooling relation to said heat sink means,

inverter switching means for inverting said DC into one of said phases of said output AC, said inverter switching means being attached in cooling relation at least in part to said heat sink means, and

connector means for interconnecting said rectifier means and said inverter switching means so that said input AC, when supplied to said module, is converted to said one of said responding phase of said output AC.

13. The inverter system of claim 12 wherein said inverter switching means on each of said modules comprises a AC filter including an inductor and a capacitor attached to said heat sink means.

14. The inverter system of claim 12 wherein said inverter switching means of each module comprises inverter switches mounted in cooling relation to said heat sink means and switch control means for controlling said corresponding inverter switches, said switch control means being attached to said heat sink means.

15. The inverter system of claim 14 wherein said heat sink means on each of said modules comprises first and second cooling plates separated by a passageway for allowing cooling fluid to flow between said first and second cooling plates, wherein said rectifier means on each of said modules comprises first and second sets of rectifiers, each of said first sets of rectifiers being attached in cooling relation to a corresponding first cooling plate and each of said second sets of rectifiers being attached in cooling relation to a corresponding second cooling plate, wherein said inverter switches on each of said modules comprises first and second sets of inverter switches, each of said first sets of inverter switches being attached in cooling relation to a corresponding first cooling plate and each of said second sets of inverter switches being attached in cooling relation to a corresponding second cooling plate, and wherein said switch control means on each of said modules comprises first and second switch controllers, each of said first switch controllers being attached to a corresponding first cooling plate and each of said second switch controllers being attached to a corresponding second cooling plate, said connector means interconnecting a corresponding first set of rectifiers, first set of inverter switches, and first switch controller so that said input AC, when supplied to said module, is converted to a first output AC and interconnecting a corresponding second set of rectifiers, second set of inverter switches, and second switch controller so that said input AC, when supplied to said module, is converted to a second output AC.

16. The inverter system of claim 15 wherein said first set of rectifiers on each of said modules cooperate interdependently to convert said input AC to DC for use by said first set of inverter switches on each of said modules and said second set of rectifiers on each of said modules cooperate interdependently to convert said input AC to DC for use by said second set of inverter switches on each of said modules.

17. The inverter system of claim 16 wherein said connector means comprises a transformer connected to said first and second sets of inverter switches so that said first and second output ACs are combined into said one phase of said output AC.

18. The inverter system of claim 16 wherein said inverter switching means on each of said modules comprises an AC filter including an inductor and a capacitor attached to said heat sink means.

19. The inverter system of claim 12 wherein said heat sink means on each of said modules comprises first and second cooling plates, separated by a passageway, for allowing cooling fluid to flow therebetween, wherein said rectifier means on each of said modules comprises first and second sets of rectifiers, each of said first sets of rectifiers being attached in cooling relation to a corresponding first cooling plate and each of said second sets of rectifiers being attached in cooling relation to a corresponding second cooling plate, and wherein said inverter switching means on each of said modules comprises first and second sets of inverter switches, each of said first sets of inverter switches being attached in cooling relation to a corresponding first cooling plate and each of said second sets of inverter switches being attached in cooling relation to a corresponding second cooling plate, said connector means interconnecting a first set of rectifiers and a corresponding first set of inverter switches so that said input AC, when supplied to said module, is converted to a first output AC and interconnecting a second set of rectifiers and a corresponding second set of inverter switches so that said input AC, when supplied to said module, is converted to a second output AC.

20. The inverter system of claim 18 wherein said first set of rectifiers on each of said modules cooperate interdependently to convert said input AC to DC for use by said first set of inverter switches on each of said modules and said second set of rectifiers on each of said modules cooperate interdependently to convert said input AC to DC for use by said second set of inverter switches on each of said modules.

21. The inverter system of claim 20 wherein said connector means comprises a in each of said modules connected to said corresponding first and second sets of inverter switches so that said first and second output ACs are combined into a corresponding one of said phases of said output AC.

22. The inverter system of claim 12 wherein said heat sink means on each module comprises a cooling plate having first and second sides, said heat sink means of each module having a passageway on a corresponding first side of a corresponding cooling plate for allowing cooling fluid to cool said corresponding cooling plate, a corresponding rectifying means and inverter switching means being attached directly to a corresponding second side of said corresponding cooling plate.

23. The inverter system of claim 22 wherein said inverter switching means of each module comprises inverter switches mounted in cooling relation to a corresponding cooling plate and switch control means for controlling said corresponding inverter switches, said switch control means of each module being attached to a corresponding cooling plate.

24. The inverter system of claim 23 wherein said passageway of each module has a first side for cooling said corresponding cooling plate and a second side, and each of said heat sink means comprises gate drive support means for supporting a corresponding switch control means on said corresponding second side of said corresponding passageway.

25. The inverter system of claim 24 wherein said said inverter switching means of each module comprises corresponding resistors mounted in cooling relation to a second side of a corresponding passageway.

26. The inverter system of claim 25 wherein each of said rectifier means comprises diodes attached in cooling relation to a corresponding second side of a corresponding cooling plate and smoothing capacitor means attached to a corresponding heat sink means.