Power conversion and distribution system

• US 5,982,645 A
• Filed: 06/29/1993
• Issued: 11/09/1999
• Est. Priority Date: 08/25/1992
• Status: Expired due to Fees

• Current Assignee: Square D Company (Schneider Electric SE)
• Original Assignee: Square D Company (Schneider Electric SE)
• Inventors: Rajagopalan, Ramamoorthy, Mazur, David, Ton-That, Giao Mong, Levran, Alexander, Nowosielski, Joseph Marion, Mabboux, Henri
• Primary Examiner(s): BERHANE, ADOLF D
• Application Number:
  US08/084,366
• Time in Patent Office: 2,324 Days
• Field of Search: 363/34, 363/37, 363/67, 363/71, 307/64, 307/66, 307/82
• US Class Current: 363/37
• CPC Class Codes: H01F 27/2866 Combination of wires and sheets
• CPC Class Codes: H01F 27/306 Fastening or mounting coils or windings on core, casing or other support
• CPC Class Codes: H02J 9/062 for AC powered loads
• CPC Class Codes: H02J 9/067 using multi-primary transformers, e.g. transformer having one primary for each AC energy source and a secondary for the loads
• CPC Class Codes: H02M 3/33584 Bidirectional converters
• CPC Class Codes: H02M 7/219 in a bridge configuration

Abstract

A power conversion system is described which includes a power input for accepting a waveform at a given power level and frequency, and a power output for providing an output waveform at a second given power level. A DC to AC converter accepts a waveform based on an input wave form from the power input and converts the waveform to an AC waveform having a frequency at least approximately an order of magnatude higher than the frequency of the input waveform for application to a DC to AC converter output. An AC converter accepts the output waveform from the DC to AC converter output and provides a converted waveform from an output of the AC converter to the power output. A coupling device operates at the frequency of the converter output for coupling the output of the DC to AC converter to the AC converter.

Claims

1. A high efficiency power conversion system comprising:

a. at least two system input terminals connected to an external alternating current (AC) power source;

b. impedance means having input, output, and neutral terminals, said input electrically connected to said system input terminals, said neutral electrically connected to a ground plane;

c. alternating current to direct current conversion means having at least two input terminals and at least two output terminals, said input terminals electrically connected to said output terminals of said impedance means, said alternating current to direct current conversion means converting AC power supplied by the external alternating current power source into a DC output;

d. at least one power conversion means having at least two input terminals and at least two output terminals, said input terminals electrically connected to said output terminals of said alternating current to direct current converter means, said power conversion means converting the DC output of said alternating current to direct current conversion means to at least one predetermined voltage, said predetermined voltage selectable as a DC voltage or an AC voltage having a predetermined frequency; and

e. a storage backup coupled to said DC output for storing energy supplied from said DC output and for supplying energy to said DC output when said external AC power source is below a predetermined level.

2. The device as described in claim 1 in which said power conversion means further comprises:

first conditioning means for converting said DC output of said alternating current to direct current conversion means into a high frequency alternating current signal, said first conditioning means having at least two input terminals and at least two output terminals, said input terminals electrically connected to said input terminals of said power conversion means;

at least one high frequency transformer having at least two input terminals and at least two output terminals, said input terminals electrically connected to said output terminals of said first conditioning means;

at least one second conditioning means having at least two input terminals and at least two output terminals, said input terminals of said second conditioning means connected to said output terminals of said high frequency transformer, said second conditioning means converting the high frequency signal generated by said first conditioning means and passed through said high frequency transformer into at least one predetermined electrical signal having a predetermined voltage and predetermined frequency.

3. The device as described in claim 2 in which said first conditioning means generates an AC signal having a frequency greater than 10 kHz.

4. The device as described in claim 2 in which the frequency of operation of said first conditioning module is synchronized with the phase and frequency of operation of said second conditioning module.

5. The device as described in claim 4 in which the frequency of operation of said first conditioning means is the same as the frequency of operation of said second conditioning means, the frequency of operation of said first conditioning means leading the frequency of operation of said second conditioning means by a predetermined phase shift.

6. The device as described in claim 2 in which the high frequency transformer further comprises:

a first coil winding consisting of one or more turns of an insulated electrical conductor;

a second coil winding consisting of one or more turns of an insulated, electrical conductive material selectively surrounding and enclosing the majority of said first coil winding;

said first coil winding formed in a rectangular shape;

said second coil winding surrounding and enclosing said first coil winding along the length of said rectangle formed by said first coil winding.

7. The device as described in claim 3 in which the first conditioning means further comprises:

at least two input terminals;

a direct current input signal connected to said input terminals;

at least two switching elements connected to each of said input terminals, each of said switching elements having an input terminal, an output terminal, and a control terminal, said input terminal of said switching element electrically connected to said input terminals;

energy storage means electrically connected to said input terminal of each of said switching elements and said output terminal of each of said switching elements;

said output terminal of said switching elements electrically connected to said input terminals of said high frequency transformer;

said second conditioning means further comprising;

at least one set of output lines having a first output line and a second output line;

at least two secondary switching elements electrically connected to each of the output terminals of said high frequency transformer, each of said secondary switching elements having at least an input line and an output line, said input line of said secondary switching elements electrically connected to said output terminal of said high frequency transformer;

first control means for controlling activation of said switching elements of said first conditioning means; and

second control means for controlling activation of said switching elements of said second conditioning means.

8. The device as described in claim 7 in which said switching elements connected to said input terminals are configured to comprise a first switching matrix having at least a first configuration and a second configuration;

in said first configuration, said switching matrix electrically connecting one of said input terminals to one of said input lines of said transformer and electrically connecting another of said input terminals to another of said input lines of said transformer, allowing current to flow in a first direction through said input terminals of said high frequency transformer;

said second configuration electrically deactivating said switching elements which are activated in said first configuration, and electrically activating other switching elements connected to said input terminals and said input terminals of said high frequency transformer, allowing current to flow in a direction opposite said first direction through said input terminals of said high frequency transformer.

9. A power conversion system comprising:

a. a power input for accepting an input waveform at a given power level and frequency;

b. an AC to DC converter coupled to the power input for generating a DC voltage bus from said input waveform;

c. a DC to AC converter coupled to the DC voltage bus for generating an AC waveform having a frequency at least approximately an order of magnitude higher than the frequency of the input waveform;

d. a coupling device operating at the frequency of the DC to AC converter for coupling the AC waveform to a plurality of AC converters, each of said plurality of AC converters selectively operable as an AC to DC or AC to AC converter to provide an output waveform at a second given power level; and

e. a storage backup coupled to said DC bus for storing energy supplied from said DC bus and for supplying energy to said DC bus when said input power level is below a predetermined level.

10. The power conversion system of claim 9 wherein the power input further comprises means for accepting an AC waveform.

11. The power conversion system of claim 10 wherein the AC to DC converter includes an input filter network and a high speed switch network.

12. The power conversion system of claim 11 wherein the AC to DC converter includes a switch control circuit and a feedback circuit for controlling the operation of the high speed switch circuit in part as a function of the DC bus.

13. The power conversion system of claim 9 wherein the DC to AC converter includes means for converting a DC input waveform from said DC bus to an AC waveform having a frequency greater than approximately 10 kHz.

14. The power conversion system of claim 9 wherein the DC to AC converter includes a switching matrix and a switching matrix control for controlling the operation of the switches so that the switches are respectively activated when each respective switch has approximately 0 volts across the switch.

15. The power conversion system of claim 9 wherein each of said plurality of AC converters selectively operable as an AC to AC converter to provide an AC output includes a cycloconverter.

16. The power conversion system of claim 9 wherein each of said plurality of AC converters selectively operable as an AC to DC or AC to AC converter includes a switching matrix and a switching matrix control for controlling the operation of the switches, said switching matrix control operating at a predetermined frequency.

17. The power conversion system of claim 16 wherein said predetermined frequency is equal to the frequency of the DC to AC converter, said AC converter functional as an AC to DC converter for generating a DC output waveform.

18. The power conversion system of claim 16 wherein said predetermined frequency differs from the frequency of the DC to AC converter by a fixed amount, said AC converter functional as an AC to AC converter for generating an AC output waveform having a frequency equal to the fixed amount.

19. The power conversion system of claim 9 wherein the coupling device includes a high frequency transformer.

20. The power conversion system of claim 19 wherein the high frequency transformer includes means for accepting an AC signal at greater than approximately 10 kHz.

21. The power conversion system of claim 9 further comprising a bidirectional converter coupled to the coupling device for converting the AC waveform from the DC to AC converter to a DC signal for storage during a standby condition and for converting a DC signal from storage to an AC waveform for application to the coupling device under different conditions.

22. The power conversion system of claim 9 further comprising a microprocessor coupled to the power input and to the AC converter for controlling the converted waveform output from the AC converter.

23. The power conversion system of claim 9 further comprising a control circuit which ensures that a vector representing an output current load is synchronized with a vector representing the voltage of the power source to provide maximum power transfer and minimize switching losses.

24. A high efficiency power conversion system comprising:

a. at least two system input terminals connected to an external Alternating Current (AC) power source;

b. an AC to Direct Current (DC) converter having at least two input terminals and at least two output terminals, the input terminals of said AC to DC converter electrically connected to said system input terminals and the output terminals for electrically connecting a DC signal generated from said AC to DC converter;

c. a storage backup coupled to the output terminals for storing energy supplied from said output terminals and for supplying energy to said output terminals when said external AC power source is below a predetermined level;

d. at least two intermediate terminals electrically connected to the output terminals of said AC to DC converter;

e. at least two system output terminals;

f. at least one power conversion module having at least two input terminals and at least two output terminals, said input terminals of said power conversion module electrically connected to said intermediate terminals, said output terminals of said power conversion module electrically connected to said system output terminals; and

g. wherein each of said at least one power conversion modules includes a plurality of AC converters selectively operable as an AC to DC or AC to AC converter to provide a DC or AC output waveform, respectively.

25. The device as described in claim 24 in which the power conversion module further comprises a high frequency transformer having at least two input terminals and at least two output terminals, and at least one conditioning module having at least two input terminals and at least two output terminals, said output terminals of said conditioning module electrically connected to said system output terminals.

26. The device as described in claim 25 wherein said power conversion module further for converting the DC signal applied to the input terminals of the power conversion module to a high frequency AC signal which is electrically connected to the input terminals of said high frequency transformer, said output terminals of said high frequency transformer electrically connected to the input terminals of said conditioning module.

27. The device as described in claim 26 in which the high frequency transformer further comprises:

a. a first coil winding consisting of one or more turns of an insulated electrical conductor;

b. a second coil winding consisting of one or more turns of an insulated, electrical conductive material selectively surrounding and enclosing the majority of said first coil winding;

c. said first coil winding formed in a rectangular shape;

d. said second coil winding surrounding and enclosing said first coil winding along the length of said rectangle formed by said first coil winding.

28. The device as described in claim 24 in which the power conversion module further comprises:

a. a direct current input signal connected to said power conversion module input terminals;

b. at least two primary switching elements each connected to respective ones of each of said power module input terminals, each of said primary switching elements having an input terminal, an output terminal, and a control terminal, each said input terminal of said primary switching element electrically connected to said power conversion module input terminals;

c. a transformer having at least a primary winding and at least one secondary winding, said primary winding having at least a first and second input line, each of said secondary windings having at least a first and second output line;

d. said output terminal of said primary switching elements electrically connected to said primary winding of said transformer;

e. at least one set of output lines having a first output line and a second output line;

f. at least two secondary switching elements electrically connected to each of the output lines of said primary winding of said transformer, each of said secondary switching elements having at least an input line and an output line, said input line of said secondary switching elements electrically connected to said output lines of said primary winding of said transformer;

g. a first control means for controlling the activation of the switching elements connected to the input terminals.

29. The device as described in claim 28 in which said switching elements connected to said input terminals are configured to comprise a first switching matrix having at least a first configuration and a second configuration;

a. in said first configuration, said switching matrix electrically connecting one of said input terminals to one of said input lines of said primary winding, and electrically connecting another of said input terminals to another of said input lines of said primary winding, allowing current to flow in a first direction through said primary winding of said transformer; and

b. said second configuration electrically deactivating said switching elements which are activated in said first configuration, and electrically activating other switching elements connected to said input terminals and said input lines of said primary winding, allowing current to flow in a direction opposite said first direction through said primary winding of said transformer.