Dynamic voltage sag correction

• US 6,118,676 A
• Filed: 11/04/1999
• Issued: 09/12/2000
• Est. Priority Date: 11/06/1998
• Status: Expired due to Term

• Current Assignee: Rockwell Automation, Inc.
• Original Assignee: Soft Switching Technologies Corp. (Rockwell Automation, Inc.)
• Inventors: Schneider, Robert, Brumsickle, William E., Kranz, William R., Luckjiff, Glen, Divan, Deepakraj M.
• Primary Examiner(s): NGUYEN, MATTHEW VAN
• Application Number:
  US09/433,993
• Time in Patent Office: 313 Days
• Field of Search: 363/16, 363/17, 363/34, 363/36, 363/37, 363/39, 363/40, 363/97, 363/98, 363/131, 363/132, 323/207-210, 323/237, 323/246, 318/375, 318/376, 318/459, 318/478, 318/479
• US Class Current: 363/34
• CPC Class Codes: H02J 3/1814 wherein al least one reactive element is actively controlled by a bridge converter, e.g. unified power flow controllers [UPFC]
• CPC Class Codes: H02J 3/28 Arrangements for balancing of the load in a network by storage of energy
• CPC Class Codes: H02M 5/458 using semiconductor devices only
• CPC Class Codes: Y02E 40/10 Flexible AC transmission systems [FACTS]

Abstract

A low cost, small size, light weight, and highly effective system and method for providing dynamic power line voltage sag correction is provided. A dynamic voltage sag corrector includes a static bypass switch and a regulator/storage module connected together in parallel between input terminals and output terminals. Under normal operating conditions, the static bypass switch is closed, and a normal line voltage level is provided directly from the input terminals to the output terminals via the static bypass switch. When a voltage sag condition is indicated, the static bypass switch is opened, and the regulator/storage module is controlled to provide a near normal output voltage signal to the output terminals. The regulator/storage module includes a power conversion circuit which is controlled to provide the desired output voltage signal by adding a voltage level on storage capacitors to the available input line voltage signal. The components of the dynamic voltage sag corrector are selected to provide voltage sag correction for a duration sufficient to provide correction of 90-95% of voltage sag/drop conditions which are likely to be encountered. The size, cost, and weight of the dynamic voltage sag corrector is thereby reduced. The dynamic voltage sag corrector may also provide surge condition correction, may be configured to provide extended duration voltage sag correction to a priority portion of a load, may provide support to a load even if there is a complete break in an input power line, and may be employed in single or multi-phase applications.

Claims

1. A dynamic voltage sag corrector, comprising:

(a) input terminals;

(b) output terminals;

(c) a bypass switch connected between the input terminals and the output terminals and responsive to bypass switch control signals to open and close the bypass switch;

(d) a power conversion and storage module connected in parallel with the bypass switch between the input terminals and the output terminals, wherein the power conversion and storage module includes a rectifier for rectifying power available at the input terminals, an energy storage device for storing the rectified power, and an inverter responsive to inverter control signals to provide an AC signal from energy stored in the energy storage device in parallel with the bypass switch; and

(e) system controller means for detecting a voltage sag condition when an AC line voltage signal provided to the input terminals drops below a selected low line voltage threshold level, for providing a bypass switch control signal to the bypass switch to open the bypass switch in response to the detection of a voltage sag condition, for providing inverter control signals to the inverter to control the inverter to provide an AC output voltage signal at approximately a pre-voltage sag condition voltage level to the output terminals in response to the detection of the voltage sag condition by adding a voltage level of the storage device to a voltage level of the AC line voltage signal, for detecting a termination of the voltage sag condition when the AC line voltage signal returns to approximately a pre-voltage sag condition voltage level, for terminating the providing of inverter control signals to the inverter in response to the detected termination of the voltage sag condition, and for providing a bypass switch control signal to the bypass switch to close the bypass switch in response to the detected termination of the voltage sag condition.

2. The dynamic voltage sag corrector of claim 1 wherein the bypass switch includes anti-parallel connected thyristors.

3. The dynamic voltage sag corrector of claim 2 wherein the system controller includes means for providing inverter control signals to the inverter to control the inverter to provide a commutation signal to the bypass switch to drive a current through the bypass switch to zero before providing the inverter control signals to the inverter to control the inverter to provide the AC output voltage signal.

4. The dynamic voltage sag corrector of claim 1 wherein the power conversion and storage module includes:

(i) a pair of rectifying devices connected together at a first node, one rectifying device connected to conduct into the node and the other rectifying device connected to conduct away from the node,

(ii) a pair of storage capacitors connected together at a second node,

(iii) a pair of controllable inverter switching devices responsive to the inverter control signals to turn the inverter switching devices on and off connected together at a third node, and

(iv) a pair of DC bus lines connecting the pairs of rectifying devices, storage capacitors, and inverter switching devices in parallel, wherein the input terminals are connected to the first and second nodes and the output terminals are connected to the first and third nodes such that the bypass switch is connected between the second and third nodes.

5. The dynamic voltage sag corrector of claim 4 wherein the rectifying devices are diodes.

6. The dynamic voltage sag corrector of claim 4 wherein the controllable inverter switching devices include IGBTs with anti-parallel connected diodes.

7. The dynamic voltage sag corrector of claim 4 wherein the means for providing inverter control signals to the inverter includes pulse width modulation means for providing high frequency switching device control signals to the inverter switching devices to control the inverter switching devices to provide an AC output voltage signal at approximately a pre-voltage sag condition voltage level.

8. The dynamic voltage sag corrector of claim 7 comprising additionally a low pass filter connected between the third node and the output terminals to filter high frequency components from the AC output voltage signal.

9. The dynamic voltage sag corrector of claim 1 wherein the system controller means includes a programmable integrated circuit.

10. The dynamic voltage sag corrector of claim 1 wherein the means for detecting a voltage sag condition includes means for monitoring an AC line voltage signal provided to the input terminals.

11. The dynamic voltage sag corrector of claim 8 wherein the means for detecting a voltage sag condition includes means for determining an RMS value of the monitored AC line voltage signal, means for comparing the RMS value of the monitored AC line voltage signal to a low line voltage threshold set point, and means for indicating the detection of a voltage sag condition when the RMS value of the monitored AC line voltage signal is less than the low line voltage threshold set point.

12. The dynamic voltage sag corrector of claim 1 wherein the selected low line voltage threshold level is between approximately 90% and 100% of a nominal AC line voltage signal level.

13. The dynamic voltage sag corrector of claim 1 wherein the means for providing the inverter control signals to the inverter includes means for providing inverter control signals to the inverter to control the inverter to provide an AC output voltage signal between approximately 90% and 100% of a nominal AC line voltage signal level.

14. The dynamic voltage sag corrector of claim 1 wherein the means for detecting the termination of the voltage sag condition includes means for monitoring the AC line voltage signal provided to the input terminals, means for determining an RMS value of the monitored AC line voltage signal, means for comparing the RMS value of the monitored AC line voltage signal to an acceptable line voltage threshold set point, and means for indicating the detection of the termination of the voltage sag condition when the RMS value of the monitored AC line voltage signal exceeds the acceptable line voltage threshold set point.

15. The dynamic voltage sag corrector of claim 14 wherein the acceptable line voltage threshold set point is selected to be higher than the low line voltage threshold level.

16. The dynamic voltage sag corrector of claim 1 wherein the system controller includes means for monitoring a current level on the output terminals before a voltage sag condition is detected, means for comparing the monitored current level with a current overload threshold set point, and means for preventing the providing of the bypass switch control signal to the bypass switch to open the bypass switch and for preventing the providing of inverter control signals to the inverter when the monitored current level exceeds the current overload threshold set point.

17. The dynamic voltage sag corrector of claim 1 wherein the system controller includes means for detecting a voltage surge condition when the AC line voltage signal provided to the input terminals exceeds a selected high line voltage threshold level, for providing a bypass switch control signal to the bypass switch to open the bypass switch in response to the detection of the voltage surge condition, for providing inverter control signals to the inverter switching devices to control the inverter to provide an AC output voltage signal at approximately a pre-voltage surge condition voltage level to the output terminals in response to the detection of the voltage surge condition, for detecting a termination of the voltage surge condition when the AC line voltage signal returns to approximately a pre-voltage surge condition voltage level, for terminating the providing of inverter control signals to the inverter in response to the detected termination of the voltage surge condition, and for providing a bypass switch control signal to the bypass switch to close the bypass switch in response to the detected termination of the voltage surge condition.

18. The dynamic voltage sag corrector of claim 17 wherein the selected high line voltage threshold level is between approximately 100% and 110% of a nominal AC line voltage signal level.

19. The dynamic voltage sag corrector of claim 17 comprising additionally a dissipation circuit connected across the energy storage device, and wherein the system controller includes means for controlling the dissipation circuit to dissipate excess energy stored in the energy storage device following a voltage surge condition.

20. The dynamic voltage sag corrector of claim 18 wherein the dissipation circuit includes a dissipation resistor connected in series with a dissipation circuit switching device, and wherein the means for controlling the dissipation circuit includes means for turning on the dissipation circuit switching device to allow current to flow from the energy storage device through the dissipation resistor to dissipate excess energy stored in the energy storage device in the dissipation resistor.

21. The dynamic voltage sag corrector of claim 1 wherein the system controller includes means for limiting a duration for which inverter control signals may be provided to the inverter to less than a selected maximum operating duration.

22. The dynamic voltage sag corrector of claim 21 wherein the selected maximum operating duration is less than approximately ten seconds.

23. The dynamic voltage sag corrector of claim 21 wherein selected circuit components in the power conversion and storage module are selected such that the rating of the selected circuit components is such that the selected circuit components cannot be operated for longer than the selected maximum operating duration without exceeding the thermal rating of the selected components.

24. The dynamic voltage sag corrector of claim 21 wherein the system controller includes means for monitoring a time of operation of the inverter and means for selecting the maximum operating duration based on the monitored time of operation.

25. The dynamic voltage sag corrector of claim 24 wherein the system controller includes means for selecting a shorter maximum operating duration if the inverter was recently in operation and a longer maximum operating duration if the inverter was not recently in operation.

26. The dynamic voltage sag corrector of claim 1 comprising additionally means for detecting an extreme voltage sag condition when an AC line voltage signal provided to the input terminals drops below a selected extreme low line voltage threshold level lower than the low line voltage threshold level, and means for providing the AC output voltage signal only to a priority portion of a load connected to the output terminals when an extreme voltage sag condition is detected.

27. The dynamic voltage sag corrector of claim 26 wherein the output terminals include a first output terminal connected to an output side of the bypass switch, second and third output terminals connected to an output of the power conversion and storage module, and a load bypass switch responsive to a load bypass switch control signal connected between the first output terminal and the second output terminal, and wherein the system controller includes means for providing the load bypass switch control signal to the load bypass switch when an extreme voltage sag condition is detected to prevent providing of the AC output voltage signal from the power conversion and storage module to the first output terminal when an extreme voltage sag condition is detected.

28. The dynamic voltage sag corrector of claim 1 wherein the power conversion and storage module includes a multi-phase rectifier for rectifying multiphase power available at the input terminals and a multi-phase inverter responsive to the inverter control signals to provide a multi-phase AC signal in parallel with a plurality of bypass switches.

29. The dynamic voltage sag corrector of claim 28 wherein the multi-phase inverter is a four leg three-phase inverter.

30. The dynamic voltage sag corrector of claim 28 wherein the multi-phase inverter includes a plurality of full bridge inverters connected in parallel with the energy storage device.

31. The dynamic voltage sag corrector of claim 28 including a plurality of transformers for connecting each phase output of the multi-phase inverter in parallel with a plurality of bypass switches.

32. The dynamic voltage sag corrector of claim 1 comprising additionally an additional switching device connected in parallel with and between the rectifier and the energy storage device and responsive to an additional switching device control signal and wherein the system controller includes means for providing the additional switching device control signal to close the additional switching device if there is a complete break in the AC line voltage signal provided to the input terminals.

33. The dynamic voltage sag corrector of claim 32 comprising additionally an inductor connected in series between the rectifier and the energy storage device, and wherein the system controller includes means for providing the additional switching device control signals to control the additional switching device as a boost converter to charge the energy storage device to a voltage level higher than the peak-to-peak level of the AC line voltage signal.

34. A method for correcting a voltage sag condition, comprising the steps of:

(a) connecting an AC load to a source of AC line voltage;

(b) storing energy from the AC line voltage;

(c) detecting a voltage sag condition wherein a voltage level of the AC line voltage drops below a selected low line voltage threshold level and detecting a termination of the voltage sag condition; and

(d) providing an AC output voltage signal to the AC load at approximately a pre-voltage sag condition voltage level by adding the stored energy to the AC line voltage in response to the detection of a voltage sag condition and terminating the providing of the AC output voltage signal to the AC load in response to the termination of the voltage sag condition.

35. The method of claim 34 wherein the step of storing energy from the AC line voltage includes the steps of rectifying the AC line voltage and providing the rectified AC line voltage to a storage capacitor and wherein the step of providing an AC output voltage signal includes the step of controlling an inverter to provide an AC output voltage signal from the energy stored in the storage capacitor.

36. The method of claim 34 wherein the step of detecting a voltage sag condition includes the steps of monitoring the AC line voltage, determining an RMS value of the monitored AC line voltage, comparing the RMS value of the monitored AC line voltage to a low line voltage threshold set point, and indicating the detection of a voltage sag condition when the RMS value of the monitored AC line voltage is less than the low line voltage threshold set point.

37. The method of claim 34 wherein the selected low line voltage threshold level is between approximately 90% and 100% of a nominal AC line voltage signal level.

38. The method of claim 34 wherein the step of providing an AC output voltage signal to the AC load includes the step of providing an AC output voltage signal between approximately 90% and 100% of a nominal AC line voltage signal level.

39. The method of claim 34 wherein the step of detecting the termination of the voltage sag condition includes the steps of monitoring the AC line voltage, determining an RMS value of the monitored AC line voltage, comparing the RMS value of the monitored AC line voltage to an acceptable line voltage threshold set point, and detecting the termination of the voltage sag condition when the RMS value of the monitored AC line voltage exceeds the acceptable line voltage threshold set point.

40. The method of claim 39 wherein the acceptable line voltage threshold set point is selected to be higher than the low line voltage threshold level.

41. The method of claim 34 comprising additionally the steps of:

(a) detecting a voltage surge condition wherein a voltage level of the AC line voltage exceeds a selected high line voltage threshold level; and

(b) providing an AC output voltage signal to the AC load at approximately a pre-voltage surge condition voltage level in response to the detection of a voltage surge condition.

42. The method of claim 41 wherein the selected high line voltage threshold level is between approximately 100% and 110% of a nominal AC line voltage signal level.

43. The method of claim 41 comprising the additional step of dissipating excess energy stored from the AC line voltage during the voltage sag condition.

44. The method of claim 34 wherein the step of providing the AC output voltage signal to the AC load is limited to less than a selected maximum operating duration.

45. The method of claim 44 wherein the maximum operating duration is selected to be no more than approximately ten seconds.

46. The method of claim 44 comprising the additional steps of monitoring a time of providing the AC output voltage signal to the AC load and selecting the maximum operating duration based on the monitored time of providing the AC output voltage signal to the AC load.

47. The method of claim 46 wherein the step of selecting the maximum operating duration includes the steps of selecting a shorter maximum operating duration if the AC output voltage signal was recently provided to the AC load and selecting a longer maximum operating duration if the AC voltage signal was not recently provided to the AC load.

48. The method of claim 34 comprising the additional steps of:

(a) determining if the voltage level of the AC line voltage drops below the selected low line voltage threshold but exceeds a selected extreme voltage sag line voltage threshold;

(b) providing the AC output voltage signal to an entire load at approximately the pre-voltage sag condition voltage level if the voltage level of the AC line voltage drops below the selected low line voltage threshold but exceeds the selected extreme voltage sag line voltage threshold;

(c) determining if the voltage level of the AC line voltage drops below both the selected low line voltage threshold and the selected extreme voltage sag line voltage threshold; and

(d) providing the AC output voltage signal to only a priority portion of the entire load if the voltage level of the AC line voltage drops below both the selected low line voltage threshold and the selected extreme voltage sag line voltage threshold.

49. The method of claim 34 wherein the step of connecting an AC load to a source of AC line voltage includes the step of connecting a multi-phase AC load to a source of multi-phase AC line voltage, and wherein the step of providing an AC output voltage signal to the AC load includes the step of providing a multi-phase AC output voltage signal to the AC load.

50. The method of claim 34 wherein the step of storing energy from the AC line voltage includes the step of boosting a line-to-line voltage of the AC line voltage and storing the energy from the AC line voltage at a boosted voltage level.

51. A dynamic voltage sag corrector, comprising:

(a) input terminals;

(b) output terminals;

(c) a power conversion and storage module connected between the input terminals and the output terminals, wherein the power conversion and storage module includes an energy storage device and an inverter responsive to inverter control signals to provide an AC signal from energy stored in the energy storage device; and

(d) system controller means for detecting a voltage sag condition when an AC line voltage signal provided to the input terminals drops below a selected low line voltage threshold level, for providing inverter control signals to the inverter to control the inverter to provide an AC output voltage signal at approximately a pre-voltage sag condition voltage level to the output terminals in response to the detection of a voltage sag condition, for detecting a termination of the voltage sag condition when the AC line voltage signal returns to approximately a pre-voltage sag condition voltage level, for terminating the providing of inverter control signals to the inverter in response to the detected termination of the voltage sag condition, and for limiting a duration for which inverter control signals may be provided to less than a selected maximum operating duration.

52. The dynamic voltage sag corrector of claim 51 wherein the selected maximum operating duration is less than approximately ten seconds.

53. The dynamic voltage sag corrector of claim 51 wherein selected circuit components in the power conversion and storage module are selected such that the rating of the selected circuit components is such that the selected circuit components cannot be operated for longer than the selected maximum operating duration without exceeding the thermal rating of the selected components.

54. The dynamic voltage sag corrector of claim 51 wherein the system controller includes means for monitoring a time of operation of the inverter and means for selecting the maximum operating duration based on the monitored time of operation.

55. The dynamic voltage sag corrector of claim 54 wherein the system controller includes means for selecting a shorter maximum operating duration if the inverter was recently in operation and a longer maximum operating duration if the inverter was not recently in operation.

56. A method for correcting a voltage sag condition, comprising the steps of:

(a) connecting an AC load to a source of AC line voltage;

(b) detecting a voltage sag condition wherein a voltage level of the AC line voltage drops below a selected low line voltage threshold level and detecting a termination of the voltage sag condition;

(c) controlling an inverter to provide an AC output voltage signal to the AC load at approximately a pre-voltage sag condition voltage level in response to the detection of a voltage sag condition and terminating the providing of the AC output voltage signal to the AC load in response to the termination of the voltage sag condition; and

(d) limiting the controlling of the inverter to provide the AC output voltage signal to less than a selected maximum operating duration.

57. The method of claim 56 wherein the maximum operating duration is selected to be no more than approximately ten seconds.

58. The method of claim 56 comprising the additional steps of monitoring a time of controlling the inverter to provide the AC output voltage signal to the AC load and selecting the maximum operating duration based on the monitored time of controlling the inverter to provide the AC output voltage signal to the AC load.

59. The method of claim 56 wherein the step of selecting the maximum operating duration includes the steps of selecting a shorter maximum operating duration if the inverter was recently controlled to provide the AC output voltage signal to the AC load and selecting a longer maximum operating duration if the inverter was not recently controlled to provide the AC output voltage signal to the AC load.

60. The method of claim 56 comprising the additional step of selecting components of the inverter such that a rating of the selected circuit components is such that the selected circuit components cannot be operated for longer than the selected maximum operating duration without exceeding the thermal rating of the selected components.

61. A dynamic voltage sag corrector, comprising:

(a) input terminals;

(b) output terminals;

(c) a power conversion and storage module connected to provide an AC signal in series between the input terminals and the output terminals, wherein the power conversion and storage module includes a rectifier connected to the input terminals for rectifying power available at the input terminals, an energy storage device for storing the rectified power, and an inverter responsive to inverter control signals to provide an AC signal from energy stored in the energy storage device in series between the input terminals and the output terminals;

(d) an additional switching device connected in parallel with and between the rectifier and the storage device and responsive to an additional switching device control signal; and

(e) a system controller means for providing inverter control signals to control the inverter to provide an AC output voltage signal to the output terminals and for providing the additional switching device control signal to close the additional switching device if there is a break in an AC line voltage signal provided to the input terminals.

62. The dynamic voltage sag corrector of claim 61 wherein the power conversion and storage module includes a multi-phase rectifier for rectifying multi-phase power available at the input terminals and a multi-phase inverter responsive to the inverter control signals to provide a multi-phase AC signal in series between the input lines and the output lines.

63. The dynamic voltage sag corrector of claim 61 comprising additionally an inductor connected in series between the rectifier and the energy storage device, and wherein the system controller includes means for providing the additional switching device control signals to control the additional switching device as a boost converter to charge the energy storage device to a voltage level higher than the peak-to-peak level of the AC line voltage signal.

64. The dynamic voltage sag corrector of claim 61 comprising additionally a transformer connected to couple the inverter in series between the input terminals and the output terminals.