Standby power system

• US 5,790,391 A
• Filed: 11/29/1996
• Issued: 08/04/1998
• Est. Priority Date: 11/29/1996
• Status: Expired due to Fees

• Current Assignee: Powerware Corporation (Eaton Corporation PLC.)
• Original Assignee: General Signal Corporation (SPX Corporation)
• Inventors: Jungwirth, Peter W., Stich, Frederick A., Zahrte, Donald K. Sr.
• Primary Examiner(s): Wong, Peter S.
• Assistant Examiner(s): Vu, Bao Q.
• Application Number:
  US08/758,412
• Time in Patent Office: 613 Days
• Field of Search: 363/24-26, 363/34, 363/37, 363/41, 363/56, 307/66, 307/64, 307/38, 307/39, 307/41, 307/48, 307/46
• US Class Current: 363/24
• CPC Class Codes: H02J 9/062 for AC powered loads
• CPC Class Codes: H02M 1/007 Plural converter units in cascade push-pull DC/DC converters with pre-regulator H02M3/3374; DC-AC converters following a DC-DC stage including a high frequency transformer H02M7/4807; DC-AC converters following a DC-DC conversion stage generating periodically varying voltages H02M7/4826
• CPC Class Codes: Y02B 70/30 Systems integrating technologies related to power network operation and communication or information technologies for improving the carbon footprint of the management of residential or tertiary loads, i.e. smart grids as climate change mitigation technology in the buildings sector, including also the last stages of power distribution and the control, monitoring or operating management systems at local level
• CPC Class Codes: Y04S 20/20 End-user application control systems

Abstract

A standby power system is provided having power conversion, output voltage control, and line-fault detection systems that make possible a significant reduction in the cost of the system. The standby power system provides backup power to a load, such as a computer system, when main AC line power fails. A system DC battery voltage is converted to an AC output voltage signal at line voltage levels by a power conversion system including a high frequency push-pull inverter, a light-weight low-cost high frequency transformer, a rectifier, and a line frequency inverter. The high frequency inverter is controlled to provide high frequency battery voltage pulse bursts separated by low frequency zero voltage dead times which are boosted by the transformer to line voltage levels and rectified by the rectifier. The line frequency inverter is controlled to provide the rectified line voltage level pulse bursts to the standby power system output in the form of a stepped square wave output signal at line frequencies. Rms and peak output voltage control is provided by a system controller based on a single digital output voltage control signal. The system controller detects the occurrence of AC line faults using a single digital line sense signal. Since analog-to-digital conversion of the power system input and output voltage waveforms is not required for line fault detection or output voltage control, the system controller may be implemented using a low-cost microprocessor.

Claims

1. A standby power system including input terminals adapted to be connected to a source of AC power at line frequency and line voltage levels and output terminals adapted to be connected to a load, the load being provided with line power from the source of AC power under normal line operating conditions, a battery, and a power conversion system for providing backup AC power at the line frequency and line voltage levels to the output terminals from the battery voltage to provide backup power to the load when a failure of the source of AC power is detected, the power conversion system comprising:

(a) a high frequency transformer having a primary winding and a secondary winding;

(b) a high frequency inverter including first and second high frequency switching devices, responsive to high frequency switching control signals to turn the high frequency switching devices on, and connected between the battery and the primary winding of the transformer such that when the first high frequency switching device is turned on the battery voltage is applied in a first polarity to the primary winding of the transformer and when the second high frequency switching device is turned on the battery voltage is applied in a second polarity to the primary winding of the transformer, the high frequency transformer and high frequency inverter thereby operating together to boost the battery voltage applied to the primary winding of the transformer to approximately the line voltage level at the secondary winding of the transformer;

(c) a rectifier connected to the secondary winding of the transformer to rectify a signal appearing on the secondary winding to provide a rectified power signal;

(d) a line frequency inverter including first and second line frequency switching devices, responsive to line frequency switching control signals to turn the line frequency switching devices on, and connected between the rectifier and the output terminals of the standby power system such that when the first line frequency switching device is turned on the rectified power signal is applied in a first polarity to the output terminals of the standby power system and when the second line frequency switching device is turned on the rectified power signal is applied in a second polarity to the output terminals;

(e) high frequency modulator means for providing high frequency switching control signals at a high frequency alternately to the first and second high frequency switching devices and for periodically interrupting the providing of the high frequency switching control signals at a rate of approximately twice the line frequency, thereby providing high frequency battery voltage pulse bursts separated by lower frequency dead times to the primary winding of the transformer causing approximately line voltage level high frequency pulse bursts separated by lower frequency dead times to appear on the secondary winding of the transformer and be rectified by the rectifier into the rectified power signal; and

(f) output voltage controller means for providing line frequency switching control signals at a low frequency to the first and second line frequency switching devices to apply the rectified power signal in alternating first and second polarities to the output terminals to provide a stepped square wave output signal at the line frequency and line voltage levels on the output terminals, wherein the stepped square wave output signal includes positive and negative voltage steps corresponding to the high frequency pulse bursts on the secondary winding of the transformer separated by zero-voltage dead times corresponding to the lower frequency dead times on the secondary winding of the transformer.

2. The standby power system of claim 1 comprising additionally an output filter connected between the line frequency inverter and the output terminals of the standby power system to filter high frequency components from the stepped square wave output signal appearing on the output terminals.

3. The standby power system of claim 1 wherein the high frequency modulator means includes means for providing high frequency switching control signals to each of the first and second high frequency switching devices at a rate of at least approximately 45 kHz.

4. The standby power system of claim 1 wherein the high frequency switching devices are MOSFETs.

5. The standby power system of claim 1 wherein each of the first and second high frequency switching devices includes a plurality of switching devices connected in parallel.

6. The standby power system of claim 1 wherein the battery is connected at a first terminal of the battery to a center tap of the primary winding of the transformer, wherein the first high frequency switching device is connected between a second terminal of the battery and a first end of the primary winding, and wherein the second high frequency switching device is connected between the second terminal of the battery and a second end of the primary winding.

7. The standby power system of claim 1 wherein the rectifier is a diode bridge.

8. The standby power system of claim 1 wherein the line frequency switching devices are IGBTs.

9. The standby power system of claim 1 wherein the high frequency modulator means includes an integrated circuit pulse width modulator.

10. The standby power system of claim 1 wherein the output voltage controller means includes a microprocessor programmed to provide the line frequency switching control signals.

11. The standby power system of claim 1 wherein the output voltage controller means includes means for providing line frequency switching control signals simultaneously to both of the first and second line frequency switching devices to thereby turn on both of the line frequency switching devices during the zero-voltage dead times.

12. The standby power system of claim 1 wherein the output voltage controller means includes means for controlling the rms voltage level of the output signal by varying the duration of the voltage steps and the zero-voltage dead times of the stepped square wave output signal.

13. The standby power system of claim 12 wherein the output voltage controller means includes means for determining the rms voltage level of the stepped square wave output signal, means for providing an output voltage control signal when the rms voltage level of the output signal exceeds an rms output voltage level threshold, and means for terminating a positive or negative voltage step in the output signal to initiate the zero-voltage dead time in response to the providing of the output voltage control signal.

14. The standby power system of claim 13 wherein the output voltage controller means includes means for controlling the high frequency modulator means to reduce a pulse width of the high frequency switching control signals if the output voltage control signal is provided near the start of a positive or negative voltage step in the output signal.

15. The standby power system of claim 13 wherein the means for determining the rms voltage level of the stepped square wave output signal includes an integration circuit including an integrator resistor connected in series with a capacitor across the output terminals of the standby power system, a piece-wise approximation modification to the integration circuit including two zener diodes connected back-to-back in series with each other and in series with a second resistor, the piece-wise approximation circuit connected in parallel with the integrator resistor and in series with the capacitor, and an rms voltage rectifier for rectifying a voltage across the capacitor to provide a rectified voltage signal whose peak value corresponds approximately to the rms voltage level of the output signal;

and wherein the means for providing the output voltage control signal includes a control signal zener diode connected to the rms voltage rectifier such that the breakdown voltage of the control signal zener diode is exceeded by the rectified rms output voltage signal causing the control signal zener diode to conduct to provide the output voltage control signal when the rms output voltage level of the output signal exceeds the rms output voltage level threshold.

16. The standby power system of claim 13 wherein the output voltage controller means further includes means for determining a peak output voltage level on the output terminals of the standby power system and means for providing the output voltage control signal when the peak output voltage level exceeds a peak output voltage threshold.

17. The standby power system of claim 16 wherein the means for determining the peak output voltage level on the output terminals includes at least two voltage dividing resistors connected in series with each other across the output terminals and a peak voltage rectifier for rectifying the voltage across a one of the voltage dividing resistors to provide a rectified peak output voltage level signal;

and wherein the means for providing the output voltage control signal includes a control signal zener diode connected to the peak voltage rectifier such that the breakdown voltage of the control signal zener diode is exceeded by the rectified peak output voltage level signal causing the control signal zener diode to conduct to provide the output voltage control signal when the peak output voltage level exceeds the peak output voltage threshold.

18. The standby power system of claim 17 wherein the voltage dividing resistors are varistors having variable resistance values selected such that the varistors conduct to clamp the peak output voltage level on the output terminals of the standby power system to a maximum output voltage level when the voltage level across the output terminals of the standby power system exceeds a maximum output voltage level threshold.

19. The standby power system of claim 1 additionally comprising means for detecting a failure of the source of AC power and for transitioning from providing line power to the load to providing backup power to the load when a failure of the source of AC power is detected, including:

(a) means for providing a line sense signal that is active when the input voltage level across the input terminals of the standby power system exceeds a line sense threshold level and that is inactive when the input voltage level is less than the line sense threshold level; and

(b) means for providing the high frequency and line frequency switching control signals to activate the power conversion system to provide backup power to the load when either a duration of a portion of a half-cycle of the source of AC power during which the line sense signal is inactive is greater than a line-loss threshold time or the line sense signal is inactive at a time corresponding to a peak of the half-cycle of the source of AC power.

20. The standby power system of claim 19 wherein the means for providing the line sense signal includes a line sense rectifier connected across the input terminals of the standby power system to provide a rectified line voltage signal, and a line sense zener diode connected to the line sense rectifier such that the breakdown voltage of the line sense zener diode is exceeded by the rectified line voltage signal causing the line sense zener diode to conduct to provide the line sense signal when the input voltage level across the input terminals exceeds the line sense threshold level.

21. A standby power system including input terminals adapted to be connected to a source of AC power at line frequency and line voltage levels and output terminals adapted to be connected to a load, the load being provided with line power from the source of AC power under normal line operating conditions, a battery, and a power conversion system for providing backup AC power at line frequency and line voltage levels on the output terminals from the battery voltage to provide backup power to the load when a failure of the source of AC power is detected, the power conversion system comprising:

(a) power conversion means for providing a stepped square wave output signal at line frequency and line voltage levels to the output terminals of the standby power system from the battery voltage, the stepped square wave output signal including positive and negative voltage steps separated by zero-voltage dead times; and

(b) output voltage controller means for varying the duration of the voltage steps and the zero-voltage dead times of the stepped square wave output signal to control the rms voltage level of the output signal, including means for determining the rms voltage level of the stepped square wave output signal, means for providing an output voltage control signal when the rms voltage level of the output signal exceeds an rms output voltage level threshold, and means for terminating a positive or negative voltage step in the output signal to initiate the zero-voltage dead time in response to the providing of the output voltage control signal.

22. The standby power system of claim 21 wherein the means for determining the rms voltage level of the stepped square wave output signal includes an integration circuit including an integrator resistor connected in series with a capacitor across the output terminals of the standby power system, a piece-wise approximation modification to the integration circuit including two zener diodes connected back-to-back in series with each other and in series with a second resistor, the piece-wise approximation circuit connected in parallel with the integrator resistor and in series with the capacitor, and an rms voltage rectifier for rectifying a voltage across the capacitor to provide a rectified voltage signal whose peak value corresponds approximately to the rms voltage level of the output signal;

and wherein the means for providing the output voltage control signal includes a control signal zener diode connected to the rms voltage rectifier such that the breakdown voltage of the control signal zener diode is exceeded by the rectified rms output voltage signal causing the control signal zener diode to conduct to provide the output voltage control signal when the rms output voltage level of the output signal exceeds the rms output voltage level threshold.

23. The standby power system of claim 22 wherein the output voltage controller means further includes means for determining a peak output voltage level on the output terminals of the standby power system and means for providing the output voltage control signal when the peak output voltage level exceeds a peak output voltage threshold.

24. The standby power system of claim 23 wherein the means for determining the peak output voltage level on the output terminals includes at least two voltage dividing resistors connected in series with each other across the output terminals and a peak voltage rectifier connected across a one of the voltage dividing resistors for rectifying the voltage across the one of the voltage dividing resistors to provide a rectified peak output voltage level signal;

and wherein the means for providing the output voltage control signal includes the control signal zener diode connected to the peak voltage rectifier such that the breakdown voltage of the control signal zener diode is exceeded by the rectified peak output voltage level signal causing the control signal zener diode to conduct to provide the output voltage control signal when the peak output voltage level exceeds the peak output voltage threshold.

25. The standby power system of claim 24 wherein the voltage dividing resistors are varistors having variable resistance values selected such that the varistors conduct to clamp the peak output voltage level on the output terminals of the standby power system to a maximum output voltage level when the voltage level across the output terminals of the standby power system exceeds a maximum output voltage level threshold.

26. The standby power system of claim 24 wherein the output voltage controller means includes a microprocessor and wherein the output voltage control signal is provided to the microprocessor via an opto-coupler connected between the control signal zener diode and the microprocessor to maintain isolation between the output terminals of the standby power system and the microprocessor.

27. The standby power system of claim 21 additionally comprising means for detecting a failure of the source of AC power and for transitioning from providing line power to the load to providing backup power to the load when a failure of the source of AC power is detected, including:

(a) means for providing a line sense signal that is active when the input voltage level across the input terminals of the standby power system exceeds a line sense threshold level and that is inactive when the input voltage level is less than the line sense threshold level; and

(b) means for activating the power conversion system to provide backup power to the load when either a duration of a portion of a half-cycle of the source of AC power during which the line sense signal is inactive is greater than a line-loss threshold time or the line sense signal is inactive at a time corresponding to a peak of the half-cycle of the source of AC power.

28. The standby power system of claim 27 wherein the means for providing the line sense signal includes a line sense rectifier connected across the input terminals of the standby power system to provide a rectified line voltage signal, and a line sense zener diode connected to the line sense rectifier such that the breakdown voltage of the line sense zener diode is exceeded by the rectified line voltage signal causing the line sense zener diode to conduct to provide the line sense signal when the input voltage level across the input terminals exceeds the line sense threshold level.

29. A method for providing an AC power signal at line frequency and line voltage levels to the output terminals of a power system such as a backup power system from the voltage provided by a battery, comprising the steps of:

(a) alternately connecting opposite polarities of the battery voltage at a high frequency to the primary winding of a high frequency transformer such that the battery voltage is boosted to approximately the line voltage level on a secondary winding of the transformer;

(b) periodically interrupting the step of connecting the battery voltage to the transformer at a rate of twice the line frequency such that high frequency positive and negative battery voltage pulse bursts separated by lower frequency dead times are applied to the primary winding of the transformer causing approximately line voltage level high frequency positive and negative pulse bursts separated by lower frequency dead times to appear on the secondary winding of the transformer;

(c) rectifying the high frequency pulse bursts appearing on the secondary winding of the transformer to provide a rectified power signal; and

(d) applying the rectified power signal in alternating polarities to the output terminals to provide a stepped square wave output signal at line frequency and line voltage levels on the output terminals, wherein the stepped square wave output signal includes positive and negative voltage steps corresponding to the high frequency pulse bursts on the secondary winding of the transformer separated by zero-voltage dead times corresponding to the lower frequency dead times on the secondary winding of the transformer.

30. The method of claim 29 comprising additionally the step of filtering high frequency signal components from the stepped square wave output signal on the output terminals.

31. The method of claim 29 comprising additionally the step of controlling the rms voltage level of the output signal by varying the duration of the voltage steps and the zero-voltage dead times of the stepped square wave output signal.

32. The method of claim 31 wherein the step of controlling the rms voltage level of the output signal includes the steps of:

(a) providing an output voltage control signal when the rms voltage level of the output signal exceeds an rms output voltage level threshold; and

(b) terminating a positive or negative voltage step in the output signal to initiate the zero-voltage dead time when the output voltage control signal is provided.

33. The method of claim 32 including additionally the step of varying a pulse width of the high frequency battery voltage pulses forming the high frequency battery voltage pulse bursts if the output voltage control signal is provided near the start of a positive or negative voltage step in the output signal.

34. The method of claim 32 including additionally the step of providing the output voltage control signal when the peak output voltage level exceeds a peak output voltage threshold.

35. The method of claim 34 including additionally the step of clamping the peak output voltage level on the output terminals to a maximum output voltage level when the voltage level across the output terminals exceeds a maximum output voltage level threshold.