Backup power system and method

• US 5,579,197 A
• Filed: 01/24/1995
• Issued: 11/26/1996
• Est. Priority Date: 01/24/1995
• Status: Expired due to Term

• Current Assignee: Waukesha Electric Systems, Inc.
• Original Assignee: Best Power Technology, Inc. (SPX Corporation)
• Inventors: Cane, Michael J., Mengelt, Kevin R., Schultz, Mark L.
• Primary Examiner(s): Gaffin, Jeffrey A.
• Assistant Examiner(s): Jackson, Stephen W.
• Application Number:
  US08/377,540
• Time in Patent Office: 672 Days
• Field of Search: 361/93, 361/115, 361/18, 361/90, 307/66
• US Class Current: 361/93.4
• CPC Class Codes: H02J 9/062 for AC powered loads

Abstract

A backup power system has power supply lines extending from input terminals, connectable to a main AC power system, and output terminals, connectable to a load, with a relay connected in a power supply line. The AC input power is monitored and when a fault in the power is detected, the relay is opened and an inverter is simultaneously turned on to provide backup power from a battery to the output terminals at a phase and frequency synchronized with the AC input voltage before the fault occurs. When the AC power system power is restored, the inverter power is again synchronized with the AC input power at the input terminals, the relay switch is closed and the inverter is turned off to allow the main power system to provide power to the load. The inverter may be providing power to the power lines before the relay contacts are opened to minimize the disruption of power supplied to the load during transfers. The switching of the switching devices in the inverter is cut off if the current drawn by the inverter from the battery exceeds a current limit level, but is turned on again after a short period of time less than a cycle of the AC waveform to again attempt to provide power from the inverter to the load. This process may be repeated, if necessary, to provide power to loads which require higher currents during start-up of the load than during normal operation after start-up.

Claims

1. A backup power system connectable to a main AC power system at input terminals and to a load at output terminals, comprising:

(a) a battery;

(b) power supply lines forming a main power supply path from the input terminals to the output terminals to normally supply power from an AC power system connected to the input terminals to a load connected to the output terminals such that an AC voltage at the output terminals is synchronized in phase and frequency to an AC voltage at the input terminals;

(c) a relay having switchable relay contacts connected in at least one of the power supply lines in the main power supply path and including a control coil responsive to a control signal to switch the relay contacts from a position providing conduction continuity in the power supply line to a position breaking conduction continuity through the power supply line, the relay being the only switching device in the power supply path so that an electrically continuous main power path is provided from the input terminals to the output terminals when the relay contacts are closed;

(d) a transformer having a secondary connected to the power supply lines between the relay contacts and the output terminals and a primary coupled to the secondary;

(e) an inverter having gate controlled switching devices connected to receive DC power from the battery and having an output connected to provide AC power to the primary of the transformer when the switching devices are switched; and

(f) control means, connected to provide control signals to the control coil of the relay and to the gates of the gate controlled switching devices of the inverter, and including means for sensing the voltage at the input terminals and determining when a power line fault occurs in the main AC power system, and upon occurrence of a fault for providing a control signal to the relay control coil to open the relay contacts and for simultaneously turning on the inverter by providing control signals to the gates of the switching devices of the inverter to generate an AC output voltage waveform at the output of the inverter and thereby at the secondary of the transformer to provide AC output power across the output terminals, the controller monitoring the phase and frequency of the AC input voltage before the fault occurs and controlling the gates of the inverter to provide AC output voltage from the inverter which is synchronized in phase and frequency to the AC input voltage from the AC power system before the fault, wherein the control means further includes means for sensing the current drawn from the battery through the inverter to the load and for turning off the control signals to the gates of the switching devices when a selected current limit level is reached for a selected short period of time less than a cycle of the AC waveform, for thereafter turning on the control signals to the gates of the switching devices to provide the AC voltage waveform from the inverter and for again turning off the signals to the gates if the current drawn from the battery through the inverter exceeds the selected current limit level.

2. The backup power system of claim 1 wherein the switching devices of the inverter are connected to opposite end terminals of the secondary of the transformer and the battery is connected to a center tap of the transformer, wherein the control means provides control signals to the gates of the switching devices to switch them in a push-pull manner to provide a quasi-square wave output voltage across the secondary of the transformer.

3. The backup power system of claim 1 wherein the control means further measures the voltage at the input terminals after a fault has been detected and determines when normal AC power is available at the input terminals, and after such determination provides a control signal to the control coil of the relay to switch the relay contacts from an open position to a closed position again providing continuity of conduction on the at least one of the power lines in the main power supply path and terminating the control signals to the gates of the switching devices of the inverter as the relay contacts are closed, and wherein the control means synchronizes the output voltage from the inverter in phase and frequency to the AC input power waveform at the input terminals prior to applying the control signal to the relay coil to close the relay contacts.

4. The backup power system of claim 1 wherein the control means repeats the turn-on of the control signals to the gates a selected period of time after a current limit has been reached in a repetitive manner for a selected period of time thereby to allow the inverter to drive a load up to operating condition which has low initial impedance upon start-up.

5. The backup power system of claim 4 wherein the control means terminates providing control signals to the gates of the switching devices if after a selected period of time the turn on of the switching devices results in the current limit level being reached.

6. The backup power system of claim 1 wherein the switching devices are power MOSFETs.

7. The backup power system of claim 6 including means for measuring the current drawn by the inverter from the battery, for comparing the measured current with a selected level of current indicative of an overcurrent, and for providing an output signal when the current drawn by the inverter from the battery exceeds the selected current level to disable the application of gate control signals to the power MOSFETs of the inverter.

8. The backup power system of claim 1 further including a static switch connected in a conducting line between the secondary of the transformer and one of the power lines in the main power supply path and wherein the control means controls the static switch to turn it on when the inverter is turned on to provide power flow from the inverter to the main power supply path and to turn off the static switch at selected times when the inverter is not turned on so that AC power from an AC power system on the power supply lines is not applied to the transformer.

9. The backup power system of claim 8 further including a battery charger connected to receive AC voltage appearing at the primary of the transformer when the secondary of the transformer is connected by the static switch to the AC power lines of the main power path and AC power is applied by an AC power system to the input terminals, the battery charger having a DC output connected to the battery to provide charging current to the battery, and wherein the control means controls the static switch to switch to provide AC power from the main power supply path to the transformer to allow the battery charger to charge the battery.

10. The backup power system of claim 1 wherein the means for determining line faults in the control means includes:

means for sampling the AC voltage at the input terminals at periodic times and providing digital output data corresponding to the sampled input data;

means receiving the digital data corresponding to the sampled AC power signal and for producing a reference waveform at selected sample times during the period of the AC line signal, wherein each reference value at each sample time comprises a selectively weighted average of the value at that sample time in the prior cycle of the AC power system voltage waveform and the previous reference waveform value at that sample time; and

means for determining the absolute value of the difference between the present sampled AC power system voltage waveform and the reference waveform at corresponding times in the AC waveforms for each sample, for adding the difference to a sum at each sample and for subtracting from the sum at each sample a selected decrement value to produce a new sum, for comparing the new sum with a trigger threshold level, and for determining that a line fault has occurred and providing a line fault signal when the sum exceeds the trigger threshold.

11. The backup power system of claim 10 wherein the control means further includes means for squaring the value of each sample of the AC input voltage and adding the squared value together in an accumulator during each cycle, and at the end of each cycle determining that a line fault has occurred and providing a line fault signal if the sum in the accumulator is above a selected high value or is below a selected low value.

12. The backup power system of claim 11 wherein the means responsive to control signals for interrupting the supply of power comprises a relay having switchable relay contacts connected in at least one of the power supply lines in the main power supply path and including a control coil responsive to a control signal to switch the relay contacts from a position providing conduction continuity in the power supply line to a position breaking conduction continuity through the power supply line, a transformer having a secondary connected to the power supply lines between the relay contacts and the output terminals and a primary coupled to the secondary, and an inverter having gate controlled switching devices connected to receive DC power from the battery and connected to provide AC power to the primary of the transformer when the switching devices are switched.

13. A backup power system connectable to a main AC power system at input terminals and to a load at output terminals, comprising:

(a) a battery;

(b) power supply lines forming a main power supply path from the input terminals to the output terminals to normally supply power from an AC power system connected to the input terminals to a load connected to the output terminals;

(c) means responsive to control signals for interrupting the supply of power through the main power supply path from the AC power system to the load and for selectively providing AC power from the battery to the power supply path and thence to the load;

(d) control means for providing control signals, upon occurrence of a line fault on the AC power system power provided to the input terminals, to the means responsive to control signals to cause the supply of power to the load to be transferred from the AC power system to the battery, the control means including;

means for sampling the voltage provided by the AC power system to the input terminals at periodic times and providing digital output data corresponding to the sampled input data;

means receiving the digital data for producing a reference waveform at selected sample times during the period of the AC line signal, wherein each reference value at each sample time comprises a selectively weighted average of the value at that sample time in the prior cycle of the AC power system voltage waveform and the previous reference waveform value at that sample time; and

means for determining the absolute value of the difference between the present sampled AC power system voltage waveform and the reference waveform at corresponding times in the AC waveforms for each sample, for adding the difference to a sum at each sample and for subtracting from the sum at each sample a selected decrement value to produce a new sum for comparing the new sum with a trigger threshold level, and for determining that line fault has occurred and providing a line fault signal when the sum exceeds the trigger threshold.

14. The backup power system of claim 13 wherein the control means further includes means for squaring the value of each sample of the AC input voltage and adding the squared value together in an accumulator during each cycle, and at the end of each cycle determining that a line fault has occurred and providing a line fault signal if the sum in the accumulator is above a selected high value or is below a selected low value.

15. A backup power system connectable to a main AC power system at input terminals and to a load at output terminals, comprising:

(a) a battery;

(b) power supply lines forming a main power supply path from the input terminals to the output terminals to normally supply power from an AC power system connected to the input terminals to a load connected to the output terminals;

(c) a controllable switch in at least one of the power supply lines in the main power supply path responsive to a control signal to switch from providing conduction continuity in the power supply line to breaking conduction continuity in the power supply line;

(d) an inverter operatively connected to the power supply lines between the controllable switch and the output terminals, the inverter having gate controlled switching devices connected to receive DC power from the battery and to provide AC power to the power supply lines in the output terminals when the inverter switching devices are switched; and

(e) control means providing control signals to the controllable switch in the main power supply path when a fault occurs in the AC power system power provided to the input terminals and to provide control signals to the gates of the gate controlled switching devices of the inverter to generate an AC output voltage waveform at the output of the inverter and thereby at the output terminals, and further including means for sensing the current drawn from the battery through the inverter to the load and for turning off the control signals to the gates of the switching devices when a selected current limit is reached for a selected short period of time less than a cycle of the AC waveform, for thereafter turning on the control signals to the gates of the switching devices to provide the AC voltage waveform from the inverter and for again turning off the signals to the gates if the current drawn from the battery through the inverter exceeds the selected current limit level.

16. The backup power system of claim 15 wherein the switching devices of the inverter are power MOSFETs.

17. The backup power system of claim 15 wherein the control means repeats the turn-on of the control signals to the gates a selected period of time after a current limit has been reached in a repetitive manner for a selected period of time thereby to allow the inverter to drive a load up to operating condition which has low initial impedance upon start-up.

18. The backup power system of claim 17 wherein the control means terminates providing control signals to the gates of the switching devices of the inverter if after a selected period of time the turn-on of the switching devices results in the current limit level being reached.

19. A method of controlling the switching of switching devices in an inverter of a backup power system which is coupled to output terminals connectable to a load, the backup power system normally providing power on a main power supply path from input terminals connectable to an AC power system to the output terminals when the AC power system power is available and disconnecting the main power path from the AC power system when the AC power system power fails and providing power from a battery through the inverter to the load during the fault on the AC power system, the inverter having gate controlled switching devices responsive to control signals to switch to provide AC power at an output of the inverter, comprising the steps of:

(a) sensing the current drawn from the battery through the inverter to the load;

(b) turning off the control signals to the gates of the switching devices when a selected limit level of current drawn from the battery is reached for a selected short period of time less than a cycle of the AC waveform;

(c) thereafter turning on the control signals to the gates of the switching devices to provide the AC voltage waveform from the inverter; and

(d), again turning off the control signals to the gates if the current drawn from the battery through the inverter again exceeds the selected current limit level.

20. The method of claim 19 wherein the steps of turning off the control signals to the gates for a selected period of time after a current limit has been reached and thereafter turning on the control signals to the gates are repeated for a selected period of time to allow the inverter to drive a load connected to the inverter up to an operating condition, wherein the load has a low initial impedance upon start-up and a higher impedance when it reaches its operating condition.

21. The method of claim 20 including the further step of terminating the repetition of the steps of providing control signals to the gates of the switching devices if, after a selected period of time, the turn-on of the switching devices results in the current limit level being reached.