Three-phase inverter for small high speed motors

• US 6,023,420 A
• Filed: 11/17/1998
• Issued: 02/08/2000
• Est. Priority Date: 11/17/1998
• Status: Expired due to Term

• Current Assignee: Creare, LLC.
• Original Assignee: Creare Incorporated
• Inventors: McCormick, John A., Valenzuela, Javier A.
• Primary Examiner(s): Riley, Shawn
• Assistant Examiner(s): Patel, Rajnikant B.
• Application Number:
  US09/193,617
• Time in Patent Office: 448 Days
• Field of Search: 363/131, 363/132, 363/71, 363/46, 336/175, 336/212, 336/184, 336/182, 336/229
• US Class Current: 363/131
• CPC Class Codes: H02M 7/5387 in a bridge configuration
• CPC Class Codes: H02P 27/06 using dc to ac converters or inverters H02P27/05 takes precedence

Abstract

A three-phase inverter for small, high speed motors such as a miniature centrifical compressor which has a low voltage, high current requirement. The inverter is supplied with DC power at 28 volts, and produces power of about 50 to 500 watts at about 15 volts, and at frequencies of about 5 to 9 kilohertz. Six D-type flip-flops with clock inputs produce twelve signals which are provided to six bridge drivers. Each bridge driver controls two MOSFET'"'"'s in series. The MOSFET'"'"'s are supplied with DC power. Outputs are fed to primaries of adjacent transformers in a circular array. The transformer secondaries are arranged in a star configuration to produce stepped voltage and saw-tooth current output wave forms approximating sinusoids in three phases.

Claims

1. A power inverter for generating an alternating current signal at two or more output terminals relative to a neutral terminal, from a direct current signal at a power terminal relative to a ground terminal, comprising

at least four transformers each having a primary winding and a secondary winding, the primary windings of the four transformers being connected in series in a transformer ring, pairs of the secondary windings being connected in series between the neutral terminal and a respective one of the output terminals, the turns ratio between the primary and secondary winding on a first transformer being different from the turns ratio between the primary and secondary winding on a second transformer,

at least four switching circuits each connected to a node between a respective pair of the primary windings in the transformer ring, the switching circuits alternately connecting the nodes to which they are connected to the power terminal and the ground terminal in response to control signals.

2. The power inverter of claim 1 wherein the transformers comprise transformers with larger cores and transformers with smaller cores.

3. The power inverter of claim 2 wherein the primary windings of the transformers with smaller cores alternate with the primary windings of the transformers with larger cores in the transformer ring.

4. The power inverter of claim 2 wherein the pairs of secondary windings connected in series between the neutral terminal and an output terminal comprise a secondary winding of a transformer with a smaller core and a secondary winding of a transformer with a larger core.

5. The power inverter of claim 2 wherein the control signals apply the direct current signal across the primary winding of a smaller transformer for a shorter period of time than across the primary winding of a larger transformer.

6. The power inverter of claim 1 wherein the switching circuit connected to a node comprises a pair of switches, one switch connected between the node and power terminal and one switch connected between the node and ground terminal.

7. The power inverter of claim 6 wherein the switches are driven by signals derived from complementary outputs of a flip-flop circuit.

8. The power inverter of claim 7 wherein the control signals are generated by flip-flop circuits connected in a flip-flop ring such that an output of each flip-flop circuit is connected to the input of the next flip-flop circuit in the flip-flop ring.

9. The power inverter of claim 8 wherein the outputs of adjacent flip-flop circuits in the flip-flop ring are connected to switching circuits at opposite positions in the transformer ring.

10. The power inverter of claim 1 wherein the transformer ring comprises six transformers, the six primary windings of the six transformers being connected in series to form the transformer ring.

11. The power inverter of claim 10 wherein the inverter has three output terminals for producing a three phase alternating current signal, the six secondary windings of the six transformers being arranged into three pairs, each pair of the secondary windings being connected in series between the neutral terminal and a respective one of the output terminals.

12. The power inverter of claim 11 wherein each pair of secondary windings comprises two secondaries from transformers in opposite positions in the transformer ring.

13. A method for generating an alternating current signal at two or more output terminals relative to a neutral terminal, from a direct current signal at a power terminal relative to a ground terminal, comprising

providing at least four transformers each having a primary winding and a secondary winding, the turns ratio between the primary and secondary winding on a first transformer being different from the turns ratio between the primary and secondary winding on a second transformer,

connecting the primary windings of the four transformers in series in a transformer ring,

connecting pairs of the secondary windings in series between the neutral terminal and a respective one of the output terminals,

connecting a switching circuit to each node between a respective pair of the primary windings in the transformer ring,

controlling the switching circuits to alternately connect the nodes to which they are connected to the power terminal and the ground terminal.

14. The method of claim 13 wherein the transformers comprise transformers with larger cores and transformers with smaller cores.

15. The method of claim 14 wherein the primary windings of the transformers with smaller cores are connected alternating with the primary windings of the transformers with larger cores in the transformer ring.

16. The method of claim 14 wherein the pairs of secondary windings connected in series between the neutral terminal and an output terminal comprise a secondary winding of a transformer with a smaller core and a secondary winding of a transformer with a larger core.

17. The method of claim 14 wherein the switching circuits are controlled to apply the direct current signal across the primary winding of a smaller transformer for a shorter period of time than across the primary winding of a larger transformer.

18. The method of claim 13 wherein the switching circuit connected to a node comprises a pair of switches, one switch connected between the node and power terminal and one switch connected between the node and ground terminal.

19. The method of claim 18 wherein the switches of the switching circuit are controlled with signals derived from complementary outputs of a flip-flop circuit.

20. The method of claim 19 wherein the switches of all switching circuits are controlled with signals derived from flip-flop circuits, further comprising connecting the flip-flop circuits in a flip-flop ring such that an output of each flip-flop circuit is connected to the input of the next flip-flop circuit in the flip-flop ring.

21. The method of claim 20 wherein switching circuits at opposite positions in the transformer ring are controlled by adjacent flip-flop circuits in the flip-flop ring.

22. The method of claim 13 wherein the transformer ring comprises six transformers, the six primary windings of the six transformers being connected in series to form the transformer ring.

23. The method of claim 22 adapted for generating a three phase alternating current signal at three output terminals, the six secondary windings of the six transformers being arranged into three pairs, each pair of the secondary windings being connected in series between the neutral terminal and a respective one of the output terminals.

24. The method of claim 23 wherein each pair of secondary windings comprises two secondaries from transformers in opposite positions in the transformer ring.

25. A power inverter for generating an alternating current signal at two or more output terminals relative to a neutral terminal, from a direct current signal at a power terminal relative to a ground terminal, comprising

at least four transformers including transformers with larger cores and transformers with smaller cores, each transformer having a primary winding and a secondary winding, the primary windings of the four transformers being connected in series in a transformer ring, pairs of the secondary windings being connected in series between the neutral terminal and a respective one of the output terminals,

at least four switching circuits each connected to a node between a respective pair of the primary windings in the transformer ring, the switching circuits alternately connecting the nodes to which they are connected to the power terminal and the ground terminal in response to control signals.

26. The power inverter of claim 25 wherein the primary windings of the transformers with smaller cores alternating with the primary windings of the transformers with larger cores in the transformer ring.

27. The power inverter of claim 25 wherein the pairs of secondary windings connected in series between the neutral terminal and an output terminal comprise a secondary winding of a transformer with a smaller core and a secondary winding of a transformer with a larger core.

28. The power inverter of claim 25 wherein the control signals apply the direct current signal across the primary winding of a smaller transformer for a shorter period of time than across the primary winding of a larger transformer.

29. The power inverter of claim 25 wherein the switching circuit connected to a node comprises a pair of switches, one switch connected between the node and power terminal and one switch connected between the node and ground terminal.

30. The power inverter of claim 29 wherein the switches are driven by signals derived from complementary outputs of a flip-flop circuit.

31. The power inverter of claim 30 wherein the control signals are generated by flip-flop circuits connected in a flip-flop ring such that an output of each flip-flop circuit is connected to the input of the next flip-flop circuit in the flip-flop ring.

32. The power inverter of claim 31 wherein the outputs of adjacent flip-flop circuits in the flip-flop ring are connected to switching circuits at opposite positions in the transformer ring.

33. The power inverter of claim 25 wherein the transformer ring comprises six transformers, the six primary windings of the six transformers being connected in series to form the transformer ring.

34. The power inverter of claim 33 wherein the inverter has three output terminals for producing a three phase alternating current signal, the six secondary windings of the six transformers being arranged into three pairs, each pair of the secondary windings being connected in series between the neutral terminal and a respective one of the output terminals.

35. The power inverter of claim 34 wherein each pair of secondary windings comprises two secondaries from transformers in opposite positions in the transformer ring.

36. A method for generating an alternating current signal at two or more output terminals relative to a neutral terminal, from a direct current signal at a power terminal relative to a ground terminal, comprising

providing at least four transformers including transformers with larger cores and transformers with smaller cores, each having a primary winding and a secondary winding,

connecting the primary windings of the four transformers in series in a transformer ring,

connecting pairs of the secondary windings in series between the neutral terminal and a respective one of the output terminals,

connecting a switching circuit to each node between a respective pair of the primary windings in the transformer ring,

controlling the switching circuits to alternately connect the nodes to which they are connected to the power terminal and the ground terminal.

37. The method of claim 36 wherein the primary windings of the transformers with smaller cores are connected alternating with the primary windings of the transformers with larger cores in the transformer ring.

38. The method of claim 36 wherein the pairs of secondary windings connected in series between the neutral terminal and an output terminal comprise a secondary winding of a transformer with a smaller core and a secondary winding of a transformer with a larger core.

39. The method of claim 36 wherein the switching circuits are controlled to apply the direct current signal across the primary winding of a smaller transformer for a shorter period of time than across the primary winding of a larger transformer.

40. The method of claim 36 wherein the switching circuit connected to a node comprises a pair of switches, one switch connected between the node and power terminal and one switch connected between the node and ground terminal.

41. The method of claim 40 wherein the switches of the switching circuit are controlled with signals derived from complementary outputs of a flip-flop circuit.

42. The method of claim 41 wherein the switches of all switching circuits are controlled with signals derived from flip-flop circuits, further comprising connecting the flip-flop circuits in a flip-flop ring such that an output of each flip-flop circuit is connected to the input of the next flip-flop circuit in the flip-flop ring.

43. The method of claim 42 wherein switching circuits at opposite positions in the transformer ring are controlled by adjacent flip-flop circuits in the flip-flop ring.

44. The method of claim 36 wherein the transformer ring comprises six transformers, the six primary windings of the six transformers being connected in series to form the transformer ring.

45. The method of claim 44 adapted for generating a three phase alternating current signal at three output terminals, the six secondary windings of the six transformers being arranged into three pairs, each pair of the secondary windings being connected in series between the neutral terminal and a respective one of the output terminals.

46. The method of claim 45 wherein each pair of secondary windings comprises two secondaries from transformers in opposite positions in the transformer ring.