Transformerless DC-to-AC power converter and method

• US 6,198,257 B1
• Filed: 10/01/1999
• Issued: 03/06/2001
• Est. Priority Date: 10/01/1999
• Status: Expired due to Term

• Current Assignee: Metropolitan Industries, Inc. (Emecole Metro, LLC)
• Original Assignee: Metropolitan Industries, Inc. (Emecole Metro, LLC)
• Inventors: Potter, Richard W., Belehradek, Anton
• Primary Examiner(s): BERHANE, ADOLF D
• Application Number:
  US09/410,391
• Time in Patent Office: 522 Days
• Field of Search: 323/222, 323/282, 323/901, 363/37, 363/59, 363/60, 363/49
• US Class Current: 323/222
• 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: H02M 7/48 using discharge tubes with control electrode or semiconductor devices with control electrode
• CPC Class Codes: Y10S 323/901 Starting circuits

Abstract

A system and method for generating an AC power output signal from a DC power input signal. The system incorporates a transformerless DC-to-DC boost regulator including a plurality of boost stages coupled in series for receiving a DC input signal and producing a boosted DC power signal. The system further incorporates a DC-to-AC converter coupled to the transformerless DC-to-DC boost regulator, for receiving the boosted DC power signal and generating an AC power output signal. A control element is coupled to both the DC-to-DC boost regulator and the DC-to-AC converter. In at least one embodiment, the system and method for generating an AC power output signal from a DC power input signal are used in connection with an uninterruptible power supply.

Claims

1. A transformerless uninterruptible power supply for providing motor starting currents in excess of rated operating currents comprising:

AC power input terminals for receiving an AC power input signal;

DC power input terminals for receiving a DC power input signal;

AC power output terminals for producing an AC power output signal;

a power conversion circuit for generating backup AC power output signal from a DC power input signal comprising;

a control element;

a transformerless DC-to-DC boost regulator, coupled to the control element, including a plurality of switched transformerless boost stages coupled in series for receiving a DC input signal and producing a boosted DC power signal wherein at least one of the stages comprises a series coupled inductor and a diode for substantially providing applied DC power, from the DC power input terminals, as the boosted DC power signal, when the inductor saturates due to an AC motor starting current being drawn from the AC power output terminals, and

a transformerless DC-to-AC converter coupled to the transformerless DC-to-DC boost regulator and the control element, for receiving the boosted DC power signal and generating a backup AC power output signal;

a sense circuit coupled to the AC power input terminals for sensing the integrity of the AC power input signal; and

a switch circuit coupled to the AC power input terminals, the power conversion circuit for receiving the backup AC power output signal, and the sense circuit, wherein the switch circuit couples the AC power input signal to the AC power output terminals when the integrity of the of AC power input signal is above a predetermined threshold, and couples the backup AC power output signal to the AC power output terminals when the integrity of the AC power input signal is below a predetermined threshold.

2. The uninterruptible power supply as in claim 1, wherein the DC power input terminals receive power from one or more batteries.

3. A supply as in claim 1 wherein the members of the plurality of boost stages are substantially identical with each including an inductor coupled in series with a diode whereby when in an over current starting condition, due to a stationary motor receiving AC power from the AC power output terminals, at least some of the inductors saturate thereby transferring DC power applied to the input of the respective boost stage through the respective saturated inductor to the output of the respective boost stage.

4. A supply as in claim 3 wherein the DC-to-AC converter comprises a plurality of substantially identical switching elements coupled as first and second sets of elements wherein each set is coupled across first and second output terminals of the boost regulator with the AC power output terminals coupled between selected switching elements of each set thereby providing, at least intermittently, a transformerless conductive path between the DC power input terminals and the AC power output terminals.

5. An AC motor starting system comprising:

a DC input port;

a plurality of four terminal series connected, transformerless DC boost circuits and a transformerless, bridge configured DC-to-AC conversion current wherein the boost circuits each exhibit a substantially identical circuit topology which includes;

an inductor having a DC power input and wherein an output of the inductor is coupled to an anode of a diode wherein the cathode is coupled to a DC power output, a capacitor coupled between the cathode and a common ground line and a switching element is coupled between the anode of the diode and the common ground line wherein two input terminals for the respective boost circuit are coupled to the inductor'"'"'s input and the common ground line and wherein two output terminals for the respective boost circuit are coupled to the cathode and the common ground line wherein one boost circuit has input terminals coupled to the DC input port and another boost circuit has output terminals coupled to input terminals of the DC-to-AC conversion circuit wherein a pair of AC output terminals therefrom can be coupled to an AC motor wherein motor starting surge currents saturate at least some of the inductors thereby maintaining at least a minimal AC output voltage amplitude while starting the motor.

6. A system as in claim 5 which includes at least one battery as a source of DC energy.

7. A system as in claim 6 wherein the DC-to-AC conversion circuit includes a plurality of bridge connected field effect transistors.

8. A system as in claim 6 wherein the at least one battery provides energy at a selected voltage and in response to motor starting surge currents, inductors in at least some of the boost circuits saturate resulting in an AC output peak-to-peak amplitude on the order of twice the selected battery voltage for the duration of the surge currents.

9. A system as in claim 6 configured as an uninterruptable power supply with AC input ports for AC utility supplied energy, and a switching circuit to switch between utility supplied AC and AC from the conversion circuits output terminals.