Control system for powering plural inductive loads from a single inverter source

• US 5,523,631 A
• Filed: 08/25/1993
• Issued: 06/04/1996
• Est. Priority Date: 08/25/1993
• Status: Expired due to Term

• Current Assignee: Inductotherm Corp
• Original Assignee: Inductotherm Corp
• Inventors: Gazdzik, Walter P., Fishman, Oleg S., Rotman, Simeon Z.
• Primary Examiner(s): Shoop, Jr., William M.
• Assistant Examiner(s): KAPLAN, JONATHAN STUART
• Application Number:
  US08/112,819
• Time in Patent Office: 1,014 Days
• Field of Search: 307/31, 307/32, 307/33, 307/34, 307/35, 307/38, 307/39, 307/40, 307/41, 373/104, 373/108, 219/661, 219/662, 219/663, 219/665, 219/666
• US Class Current: 307/38
• CPC Class Codes: H02M 3/1555 for the generation of a regulated current to a load whose impedance is substantially inductive
• CPC Class Codes: H02M 7/48 using discharge tubes with control electrode or semiconductor devices with control electrode
• CPC Class Codes: H05B 6/067 for melting furnaces

Abstract

A control system for controlling overshoot and undershoot power values when switching power from a single inverter power source to a plurality of inductive loads, or a single load having a plurality of zones, having different resonant frequencies. The control system causes a preselected amount of power to be drawn from the inverter power source and delivered to the loads, or zones in a time-shared manner. The control system varies the phase shift between load voltage and load current and selectably adjusts the amount of variation in response to overshoot and/or undershoot of power drawn from the inverter and delivered to a load or zone which can occur when switching between loads or zones.

Claims

1. A control system for controlling overshoot and undershoot power values when switching power from an output of a single inverter power supply to at least a selected one of plural inductive loads, each inductive load having a respective resonant frequency associated therewith, the inverter power supply having an inverter output switch therein and being adjustable for outputting a preselected amount of power, the system comprising:

(a) load switching means for selectably switching the inverter output among selected ones of the plural inductive loads in a time-shared manner;

(b) means for measuring power output from the inverter and detecting overshoot or undershoot power values occurring when switching from one inductive load to another;

(c) time delay source for connection to the load switching means for starting a delay time period upon switching from one inductive load to another and for generating and outputting a signal at a preselected end of said delay time period, the signal triggering the inverter output switch to deliver the power output of the inverter to the load switching means for switching to the selected load; and

(d) means for adjusting the preselected end of the delay time period during a subsequent switching operation from one load to another in response to the measured overshoot or undershoot power values by an amount calculated to reduce subsequent power overshoot or undershoot.

2. A control system according to claim 1, further comprising

(e) means for storing separate delay time period ending values based on the power overshoot or undershoot associated with switching between successive inductive loads, the delay time periods being separately provided in response to the separately stored values upon switching to each successive inductive load.

3. A control system according to claim 2 wherein the time delay source includes a control voltage level, the time delay source generating and outputting the triggering signal upon attaining the control voltage level, the time period values representing the control voltage level, the control voltage level having an original control voltage level and a level associated with each inductive load.

4. A control system according to claim 3, wherein the control voltage level is determined in accordance with the formula ##EQU2## where:

V_old is the original control voltage;

V_new is the control voltage for the successive inductive load;

P₁ is the set power amount of the inverter source; and

P₂ is the power amount of overshoot or undershoot.

5. A control system according to claim 4, wherein the equation in the formula is performed during the first cycle of switching to successive loads and is subsequently performed only when the means for measuring power output detects overshoot or undershoot power values outside preselected limits.

6. A control system according to claim 5 further comprising

(g) a memory for storing values representative of a control voltage, the values being updated in the memory whenever a new control voltage level is determined.

7. A control system according to claim 4 further comprising

(g) a memory for storing values representative of a control voltage, the values being updated in the memory whenever a new control voltage level is determined.

8. A control system according to claim 3 wherein the control voltage for one of said loads is fixed at the preselected fixed value, the control voltage level varying for the other of said loads in accordance with the level associated with each of the inductive loads.

9. A control system according to claim 2, wherein the delay time period for one of said loads is fixed, the time periods being adjusted from the fixed time period for the other of said loads.

10. A control system according to claim 1, wherein the plural inductive loads include either plural inductive furnaces or plural zones of a single inductive load.

11. A control system according to claim 1, further comprising

(e) means for detecting zero crossings of current in the inverter connected to the inductive load switching means, wherein the inductive load switching means switches at zero crossings of current in the inverter.

31. A control system according to claim 1, further comprising

(e) means for reducing the mount of power output from the inverter power supply during a first switching cycle among the plural inductive loads.

12. A control system for controlling overshoot and undershoot power values when switching power in a pulse width modulation manner from an output of a single inverter source to plural inductive loads, each inductive load having a respective resonant frequency, the inverter source set for outputting a set amount of power, the system comprising:

(a) inductive load switching means for switching to successive inductive loads, the inverter output being connected to the switching means for directing the inverter output to the successive inductive loads;

(b) an inverter output switch associated with the inverter source;

(c) means for measuring a maximum amount of overshoot and/or undershoot of power which occurs when switching to a successive inductive load, the overshoot and/or undershoot representing drawing by the load of an amount of power greater or less than the amount of power set for outputting by the inverter;

(d) time delay source for connection to the inductive load switching means for starting a time period upon detection of the switching to a successive load and for generating and outputting a signal at the end of a preselected time period, the signal triggering the inverter output switch to deliver the inverter'"'"'s power to the successive load; and

(e) means for adjusting the preselected time period in response to the maximum measured amount of overshoot and/or undershoot, the adjustment occurring during a subsequent switching to the successive loads, thereby reducing subsequent amounts of overshoot and/or undershoot.

13. A control system according to claim 12, further comprising

(f) means for storing separate time period values based on the maximum amount of overshoot and/or undershoot associated with each inductive load, the time periods being separately provided by employing the separately stored values upon switching to each successive inductive load.

14. A control system according to claim 13 wherein the time delay source includes a control voltage level, the time delay source generating and outputting the triggering signal upon attaining the control voltage level, the time period values representing the control voltage level, the control voltage level having an original control voltage level and a level associated with each inductive load.

15. A control system according to claim 14, wherein the control voltage level is determined in accordance with the formula ##EQU3## where:

V_old is the original control voltage;

V_new is the control voltage for the successive inductive load;

P₁ is the set power amount of the inverter source; and

P₂ is the power amount of overshoot or undershoot.

16. A control system according to claim 15, wherein the equation in the formula is performed during the first cycle of switching to successive loads and is subsequently performed only when the means for measuring overshoot and/or undershoot detects overshoot and/or undershoot outside preselected limits.

17. A control system according to claim 16 further comprising

(g) a memory for storing values representative of a control voltage, the values being updated in the memory whenever a new control voltage level is determined.

18. A control system according to claim 15 further comprising

(g) a memory for storing values representative of a control voltage, the values being updated in the memory whenever a new control voltage level is determined.

19. A control system according to claim 14 wherein the control voltage for one of said loads is fixed at the preselected fixed value, the control voltage level varying for the other of said loads in accordance with the level associated with each of the inductive loads.

20. A control system according to claim 13, wherein the preselected time period for one of said loads is a fixed time period, the time periods being adjusted from the fixed time period for the other of said loads.

21. A control system according to claim 12, wherein the plural inductive loads include either plural inductive furnaces or plural zones of a single inductive load.

22. A control system according to claim 12, further comprising

(f) means for detecting zero crossings of current in the inverter connected to the inductive load switching means, wherein the inductive load switching means switches at zero crossings of current in the inverter.

32. A control system according to claim 12, further comprising

(f) means for reducing the amount of power set for outputting from the inverter source during a first switching cycle among the plural inductive loads.

23. A method for controlling the power overshoot and undershoot when switching power in a pulse width modulation manner from an output of a single inverter source to plural inductive loads, each inductive load having a respective resonant frequency, the inverter source set for outputting a set amount of power, the method comprising the steps of:

(a) during a first switching cycle

(i) presetting an initial time delay value which represents the time between when a respective load is switched to receive the inverter source power and when the inverter source is triggered to actually provide the power;

(ii) measuring a maximum amount of overshoot and/or undershoot which occurs when switching to a successive load, the overshoot and/or undershoot representing drawing by the load of an amount of power greater or less than the amount of power set for outputting by the inverter;

(iii) determining a time delay value for each load which will correct the overshoot and/or undershoot;

(iv) loading the time delay values for each load into a memory; and

(b) during subsequent switching cycles

(i) retrieving the time delay values upon switching of the respective load to receive the inverter source power; and

(ii) setting a new time delay value using the value for the respective load, thereby reducing subsequent amounts of overshoot and/or undershoot.

24. A method according to claim 23, wherein the new time delay value represents an increase or decrease from the preset initial time delay value.

25. A method according to claim 23, wherein step (b) further includes the step of

(iii) measuring a maximum amount of overshoot and/or undershoot to ascertain whether a new value should be determined and loaded into the memory;

and

(iv) determining and loading the new value if the overshoot and/or undershoot are outside preselected limits.

26. A method for switching power according to claim 23, wherein the time delay value in step (a)(i) and step (b)(ii) is the time period required for a time delay source to generate and output a triggering signal, the triggering signal causing the inverter source to provide its power to the load switched to receive the power.

27. A method according to claim 26, wherein the time delay source includes a control voltage level, the time delay source generating and outputting the triggering signal upon attaining the control voltage level.

28. A method according to claim 27, wherein the control voltage level is determined in accordance with the formula ##EQU4## where:

V_old is the original control voltage;

V_new is the control voltage for the successive inductive load;

P₁ is the set power amount of the inverter source; and

P₂ is the power amount of overshoot or undershoot,

and wherein the initial time delay value in step (a)(i) is associated with V_old and the new time delay value in step (b)(ii) is associated with V_new.

29. A method according to claim 28, wherein the equation in the formula is performed during the first switching cycle.

30. A method according to claim 23, wherein during the first switching cycle, the inverter source outputs an amount of power less than the set amount of power.