Modular static power converter connected in a multi-level, multi-phase, multi-circuit configuration
First Claim
1. A static power converter comprising:
- at least one isolated DC power source;
an array of power converter modules connected in a multi-level, multi-phase, multi-circuit configuration wherein;
(a) each phase comprises a plurality of circuits and each circuit comprises a parallel configuration of multi-level phase drivers; and
(b) each multi-level phase driver comprises a plurality of H-bridges connected in series; and
each H-bridge comprises two pairs of power semiconductors, each pair connected in series between positive and negative terminals of an isolated DC power source, a midpoint node of the series-connected power semiconductors being connected to corresponding midpoint nodes in adjacent H-bridges, thereby permitting a maximum output voltage to be produced which is equal to the sum of the DC voltages applied to the bridges; and
control means for controlling the power semiconductors which interleaves gate signals applied to the H-bridges of the array of multi-level phase drivers;
the interleaving being arranged according to an algorithm whereby normal and complementary triangle carrier waveforms of a desired switching frequency are established for each level of a multi-level phase driver, and are phase shifted with respect to each other by an angle α
lvl =360°
/l, where l is the number of levels of the multi-level phase driver and whereby normal and complementary triangle carrier waveforms of the desired switching frequency are established for the multi-level phase drivers of the multiple circuits such that the carrier waveform for each circuit of a level of interest is phase-shifted with respect to the corresponding circuits of the same level by the angle α
ckt =α
lvl /2k where k is the number of static power converter circuits.
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Accused Products
Abstract
In the particular embodiments described, an unlimited voltage static power converter includes an array of multi-level phase drivers consisting of a plurality of H-bridge power modules connected in series. The midpoint node of the series-connected power semiconductors is connected to corresponding midpoint nodes in adjacent H-bridges to achieve a desired high output voltage using available power switch ratings. A three-dimensional multi-level, multi-phase, multi-circuit array of H-bridges permits the use of the static power converter for high power applications, while providing a high degree of power quality. The power semiconductor switches are operated in accordance with a two-dimensional interleaved pulse width modulation algorithm which produces a waveform with a switching frequency that can be more than an order of magnitude higher than the switching frequency of a single power switch. PWM complementary triangle carrier waves are used for individual PWM control of each H-bridge in each multi-level phase driver, resulting in a two-dimensional interleaved control algorithm. Injection of harmonic or non-harmonic content into the PWM reference waveform further reduces harmonic and non-harmonic content of the output voltage waveforms. Part-load efficiency is increased using unique load partitioning methods, five of which are described herein.
173 Citations
46 Claims
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1. A static power converter comprising:
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at least one isolated DC power source; an array of power converter modules connected in a multi-level, multi-phase, multi-circuit configuration wherein; (a) each phase comprises a plurality of circuits and each circuit comprises a parallel configuration of multi-level phase drivers; and (b) each multi-level phase driver comprises a plurality of H-bridges connected in series; and
each H-bridge comprises two pairs of power semiconductors, each pair connected in series between positive and negative terminals of an isolated DC power source, a midpoint node of the series-connected power semiconductors being connected to corresponding midpoint nodes in adjacent H-bridges, thereby permitting a maximum output voltage to be produced which is equal to the sum of the DC voltages applied to the bridges; andcontrol means for controlling the power semiconductors which interleaves gate signals applied to the H-bridges of the array of multi-level phase drivers; the interleaving being arranged according to an algorithm whereby normal and complementary triangle carrier waveforms of a desired switching frequency are established for each level of a multi-level phase driver, and are phase shifted with respect to each other by an angle α
lvl =360°
/l, where l is the number of levels of the multi-level phase driver and whereby normal and complementary triangle carrier waveforms of the desired switching frequency are established for the multi-level phase drivers of the multiple circuits such that the carrier waveform for each circuit of a level of interest is phase-shifted with respect to the corresponding circuits of the same level by the angle α
ckt =α
lvl /2k where k is the number of static power converter circuits. - View Dependent Claims (6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19)
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2. A static power converter comprising:
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at least one isolated DC power source; an array of power converter modules connected in a multi-level multi-phase, multi-circuit configuration wherein; (a) each phase comprises a plurality of circuits and each circuit comprises a parallel configuration of multi-level phase drivers; and (b) each multi-level phase driver comprises a plurality of H-bridges connected in series; and
each H-bridge comprises two pairs of power semiconductors, each pair connected in series between positive and negative terminals of an isolated DC power source, a midpoint node of the scries-connected power semiconductors being connected to corresponding midpoint nodes in adjacent H-bridges, thereby permitting a maximum output voltage to be produced which is equal to the sum of the DC voltages applied to the bridges; andcontrol means for controlling the power semiconductors wherein the interleaving is arranged according to an algorithm whereby normal and complementary triangle carrier waveforms of a desired switching frequency are established for each level of a multi-level phase driver, and are phase shifted with respect to each other by an angle α
lvl =360°
/2l, where l is the number of levels of the multi-level phase driver and normal and complementary triangle carrier waveforms of the desired switching frequency are established for the multi-level phase drivers of the multiple circuits such that the carrier waveform of each circuit of the level of interest is phase-shifted with respect to the corresponding circuits of the same level by the angle α
ckt =α
lvl /k where k is the number of static power converter circuits.
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3. A static power converter comprising
at least one isolated DC power source; -
an array of power converter modules connected in a multi-level, multi-phase, multi-circuit configuration wherein; (a) each phase comprises a plurality of circuits and each circuit comprises a parallel configuration of multi-level phase drivers; and
(b) each multi-level phase driver comprises a plurality of H-bridges connected in series; and
each H-bridge comprises two pairs of power semiconductors each pair connected in series between positive and negative terminals of an isolated DC power source, a midpoint node of the series-connected power semiconductors being connected to corresponding midpoint nodes in adjacent H-bridges, thereby permitting a maximum output voltage to be produced which is equal to the sum of the DC voltages applied to the bridges; andcontrol means for controlling the power semiconductors wherein the control means operates so as to apply normal and complementary triangle waveforms to the gates of the H-bridges and including means for producing random switching of normal and complementary triangle carrier waveforms to improve output voltage signal to noise ratio and/or eliminate the need for interleaving of carrier waveforms. - View Dependent Claims (4, 5)
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20. A static power converter comprising:
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(a) at least one isolated DC power source; (b) an array of power converter modules connected in a multi-level, multi-phase, multi-circuit configuration wherein each phase comprises a plurality of circuits and each circuit comprises a parallel configuration of multi-level phase drivers; and (c) each multi-level phase driver comprises a plurality of dual H-bridges connected in series and each dual H-bridge comprises four pairs of power semiconductors, each pair connected in series between positive and negative terminals of the same one of the plurality of isolated DC power sources; (d) an interphase transformer connecting the midpoint nodes of two pairs of semiconductors in each dual H-bridge, the midpoint nodes of the remaining two pairs of semiconductors in each dual H-bridge being available for connection to an adjacent dual H-bridge and the output terminals of each interphase transformer being connected to an adjacent dual H-bridge; and (e) control means for controlling the power semiconductors wherein the control means supplies carrier waveforms in the form of a triangle wave and its complement to each H-bridge and the carrier waveforms within each multi-level phase driver are evenly distributed throughout a PWM period. - View Dependent Claims (21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35)
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36. A multiple circuit motor system comprising a static power converter providing a multi-circuit output and a multiple circuit motor coupled to the power converter so that the multiple motor circuits can be connected in a series, parallel or open configuration of windings according to the required motor speed, voltage and power requirements wherein the static power converter includes an array of power converter modules connected in a multi-level, multi-phase multi-circuit configuration wherein:
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(a) each phase comprises a plurality of circuits and each circuit comprises a parallel configuration of multi-level phase drivers; and (b) each multi-level phase driver comprises a plurality of H-bridges connected in series; and
each H-bridge comprises two pairs of power semiconductors, each pair connected in series between positive and negative terminals of an isolated DC power source, a midpoint node of the series-connected power semiconductors being connected to corresponding midpoint nodes in adjacent H-bridges, thereby permitting a maximum output voltage to be produced which is equal to the sum of the DC voltages applied to the bridges; andcontrol means for controlling the operation of the power semiconductors; and wherein the motor has separate coils driven by the power converter which are loosely coupled by nature of being in separate motor slots.
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37. A multiple circuit motor system comprising a static power converter providing a multi-circuit output and a multiple circuit motor coupled to the power converter so that the multiple motor circuits can be connected in a series, parallel or open configuration of windings according to the required motor speed, voltage and power requirements wherein the static power converter includes an array of power converter modules connected in a multilevel, multi-phase, multi-circuit configuration wherein:
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(a) each phase comprises a plurality of circuits and each circuit comprises a parallel configuration of multi-level phase drivers; and
(b) each multi-level phase driver comprises a plurality of dual H-bridges connected in series and each dual H-bridge comprises four pairs of power semiconductors, each pair connected in series between positive and negative terminals of an isolated DC power source; and(c) an interphase transfonncr connecting the midpoint nodes of two pairs of semiconductors in each dual H-bridge, the midpoint nodes of the remaining two pairs of semiconductors in each dual H-bridge being available for connection to an adjacent dual H-bridge and the output terminals of each interphase transformer being connected to an adjacent dual H-bridge; and control means for controlling the operation of the power semiconductors; and wherein the motor has separate coils driven by the power converter which are loosely coupled by nature of being in separate motor slots.
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38. A multiple circuit motor system comprising a static power converter providing a multi-circuit output and a multiple circuit motor coupled to the power converter so that the multiple motor circuits can be connected in a series, parallel or open configuration of windings according to the required motor speed, voltage and power requirements wherein the static power converter includes an array of power converter modules connected in a multilevel, multi-phase, multi-circuit configuration wherein:
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(a) each phase comprises a plurality of circuits and each circuit comprises a parallel configuration of multi-level phase drivers; and (b) each multi-level phase driver comprises a plurality of H-bridges connected in series; and
each H-bridge comprises two pairs of power semiconductors, each pair connected in series between positive and negative terminals of an isolated DC power source, a midpoint node of the series-connected power semiconductors being connected to corresponding midpoint nodes in adjacent H-bridges, thereby permitting a maximum output voltage to be produced which is equal to the sum of the DC voltages applied to the bridges; andcontrol means for controlling the operation of the power semiconductors; and wherein the motor circuit coils are driven by the power converter and are tightly coupled by nature of being in the same motor slots.
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39. A multiple circuit motor system comprising a static power converter providing a multi-circuit output and a multiple circuit motor coupled to the power converter so that the multiple motor circuits can be connected in a series, parallel or open configuration of windings according to the required motor speed, voltage and power requirements wherein the static power converter includes an array of power converter modules connected in a multilevel, multi-phase, multi-circuit configuration wherein:
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(a) each phase comprises a plurality of circuits and each circuit comprises a parallel configuration of multi-level phase drivers; and (b) each multi-level phase driver comprises a plurality of dual H-bridges connected in series and each dual H-bridge comprises four pairs of power semiconductors, each pair connected in series between positive and negative terminals of an isolated DC power source; and (c) an interphase transformer connecting the midpoint nodes of two pairs of semiconductors in each dual H-bridge, the midpoint nodes of the remaining two pairs of semiconductors in each dual H-bridge being available for connection to an adjacent dual H-bridge and the output terminals of each interphase transformer being connected to an adjacent dual H-bridge; and control means for controlling the operation of the power semiconductors; and wherein the motor has separate coils driven by the power converter which are tightly coupled by nature of being in separate motor slots.
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40. A multiple circuit motor system comprising a static power converter providing a multi-circuit output and a multiple circuit motor coupled to the power converter so that the multiple motor circuits can be connected in a series, parallel or open configuration of windings according to the required motor speed, voltage and power requirements wherein the static power converter includes an array of power converter modules connected in a multilevel, multi-phase, multi-circuit configuration wherein:
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(a) each phase comprises a plurality of circuits and each circuit comprises a parallel configuration of multi-level phase drivers; and (b) each multi-level phase driver comprises a plurality of H-bridges connected in series; and
each H-bridge comprises two pairs of power semiconductors, each pair connected in series between positive and negative terminals of an isolated DC power source, a midpoint node of the series-connected power semiconductors being connected to corresponding midpoint nodes in adjacent H-bridges, thereby permitting a maximum output voltage to be produced which is equal to the sum of the DC voltages applied to the bridges; andcontrol means for controlling the operation of the power semiconductors; and wherein the multiple motor circuits can be reconfigured to allow operation at several motor speeds at substantially similar voltage levels, thereby producing several motor power levels.
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41. A multiple circuit motor system comprising a static power converter providing a multi-circuit output and a multiple circuit motor coupled to the power converter so that the multiple motor circuits can be connected in a series, parallel or open configuration of windings according to the required motor speed, voltage and power requirements wherein the static power converter includes an array of power converter modules connected in a multilevel, multi-phase, multi-circuit configuration wherein:
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(a) each phase comprises a plurality of circuits and each circuit comprises a parallel configuration of multi-level phase drivers; and (b) each multi-level phase driver comprises a plurality of dual H-bridges connected in series and each dual H-bridge comprises four pairs of power semiconductors, each pair connected in series between positive and negative terminals of an isolated DC power source; and (c) an interphase transformer connecting the midpoint nodes of two pairs of semiconductors in each dual H-bridge, the midpoint nodes of the remaining two pairs of semiconductors in each dual H-bridge being available for connection to an adjacent dual H-bridge and the output terminals of each interphase transformer being connected to an adjacent dual H-bridge; and control means for controlling the operation of the power semiconductors; and wherein the multiple motor circuits can be reconfigured to allow operation at several motor speeds at substantially similar voltage levels, thereby producing several motor power levels.
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42. A multiple circuit motor system comprising a static power converter providing a multi-circuit output and a multiple circuit motor coupled to the power converter so that the multiple motor circuits can be connected in a series, parallel or open configuration of windings according to the required motor speed, voltage and power requirements wherein the static power converter includes an array of power convertor modules connected in a multilevel, multi-phase, multi-circuit configuration wherein:
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(a) each phase comprises a plurality of circuits and each circuit comprises a parallel configuration of multi-level phase drivers; and (b) each multi-level phase driver comprises a plurality of H-bridges connected in series; and
each H-bridge comprises two pairs of power semiconductors, each pair connected in series between positive and negative terminals of an isolated DC power source, a midpoint node of the series-connected power semiconductors being connected to corresponding midpoint nodes in adjacent H-bridges, thereby pemitting a maximum output voltage to be produced which is equal to the sum of the DC voltages applied to the bridges; andcontrol means for controlling the operation of the power semiconductors; and wherein the multiple motor circuits can be reconfigured to allow operation at any of several motor voltages at substantially similar motor speeds.
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43. A multiple circuit motor system comprising a static power converter providing a multi-circuit output and a multiple circuit motor coupled to the power converter so that the multiple motor circuits can be connected in a series, parallel or open configuration of windings according to the required motor speed, voltage and power requirements wherein the static power converter includes an array of power converter modules connected in a multilevel, multi-phase, multi-circuit configuration wherein:
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(a) each phase comprises a plurality of circuits and each circuit comprises a parallel configuration of multi-level phase drivers; and (b) each multi-level phase driver comprises a plurality of dual H-bridges connected in series and each dual H-bridge comprises four pairs of power semiconductors, each pair connected in series between positive and negative terminals of an isolated DC power source; and (c) an interphase transformer connecting the midpoint nodes of two pairs of semiconductors in each dual H-bridge, the midpoint nodes of the remaining two pairs of semiconductors in each dual H-bridge being available for connection to an adjacent dual H-bridge and the output terminals of each interphase transformer being connected to an adjacent dual H-bridge; and control means for controlling the operation of the power semiconductors; and wherein the multiple motor circuits can be reconfigured to allow operation at any of several motor voltages at substantially similar motor speeds.
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44. A static power converter comprising:
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at least one isolated DC power source; an array of power converter modules connected in a multi-level, multi-phase, multi-circuit configuration wherein; (a) each phase comprises a plurality of circuits and each circuit comprises a parallel configuration of multi-level phase drivers having outputs connected in series; and (b) each multi-level phase driver comprises a plurality H-bridges connected in series; and
each H-bridge comprises two pairs of power semiconductors, cach pair connected in series between positive and negative terminal of an isolated DC power sources, a midpoint node of the series-connected power semiconductors being connected to corresponding midpoints in adjacent H-bridges thereby permitting a maximum output voltage to be produced which is equal to the sum of the DC voltages applied to the bridges; and
control means for controlling the power semiconductors.
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45. A static power converter comprising:
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(a) at lease one isolated DC power source; (b) an array of power converter modules connected in a multi-level, multi-phase, multi-circuit configuration wherein each phase comprises a plurality of circuits and each circuit comprises a parallel configuration of multi-phase drivers having outputs connected in series; and (c) each multi-level phase driver comprises a plurality of dual H-bridges connected in series and each dual H-bridge comprises four pairs of power semiconductors, each pair connected in series between positive and negative terminals of the same one of the plurality of isolated DC power sources; and (d) an interphase transformer connecting the midpoint nodes of two pairs of semiconductors in each dual H-bridge, the midpoint nodes of the remaining two pairs of semiconductors in each dual H-bridge being available for connection to an adjacent dual H-bridge and the output terminals of each interphase transformer being connected to an adjacent dual H-bridge; and (e) control means for controlling the power semiconductors.
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46. A multiple circuit motor system comprising a static power converter providing a multi-circuit output and a multiple circuit motor coupled to the power convcrtcr so that the multiple motor circuits can be connected in a series, parallel or open configuration of windings according to the motor speed, voltage and power requirements.
Specification