Push-pull inverter with snubber energy recovery

• US 7,180,759 B2
• Filed: 11/03/2004
• Issued: 02/20/2007
• Est. Priority Date: 11/03/2004
• Status: Active Grant

• Current Assignee: Square D Company (Schneider Electric SE)
• Original Assignee: Square D Company (Schneider Electric SE)
• Inventors: Kocher, Mark John, Liptak, Julius Michael, MacKenzie, John Kenneth IV
• Primary Examiner(s): Riley; Shawn
• Application Number:
  US10/980,006
• Publication Number:
  US 20060092676A1
• Time in Patent Office: 839 Days
• Field of Search: 363/56.08, 363/25, 363/134
• US Class Current: 363/56.08
• CPC Class Codes: H02M 3/337 in push-pull configuration H02M3/33576 takes precedence; with self-oscillating arrangements H02M3/3382, H02M3/3385

Abstract

A power inverter comprises a push-pull inverter circuit that includes a transformer having a primary winding coupled to a DC bus and a secondary winding coupled to an AC bus, main power switches coupling each end of the primary winding to a DC return, and one or more supplemental power switches coupling at least one end of the primary winding to a snubber bus. The supplemental switch at a given end of the primary winding forms a buck-mode converter in combination with the primary winding and the associated free-wheeling diode at that end of the primary winding, and can be controlled by a switching controller to effect energy transfer between the snubber bus and DC bus. The switching controller can be configured to control power flow between the DC, AC, and snubber buses by controlling the common-mode and differential-mode voltages of the primary winding via main/supplemental power switch control.

Claims

1. A power inverter comprising:

a DC-to-AC converter circuit including a transformer having a primary winding coupled to a DC bus and a secondary winding coupled to an AC bus, said primary winding having a first switch and first free-wheeling diode coupled to a first end, and a second switch and second free-wheeling diode coupled to a second end;

a snubber circuit coupled to each end of the primary winding, and configured to limit voltage transients on the primary winding; and

a third switch coupling the first end of the primary winding to the snubber circuit, thereby forming a first DC-to-DC converter from the third switch, the primary winding, and the first free-wheeling diode, said first DC-to-DC converter operative to control energy transfer between the snubber circuit and the DC-to-AC converter circuit.

2. The power inverter of claim 1, further comprising a fourth switch coupling the second end of the primary winding to the snubber circuit, thereby forming a second DC-to-DC converter from the fourth switch, the primary winding, and the second free-wheeling diode, said second DC-to-DC converter operative to control energy transfer between the snubber circuit and the DC-to-AC converter circuit.

3. The power inverter of claim 2, further comprising a switching controller configured to generate switching control signals for the first and second DC-to-DC converters to control energy transfer between the snubber circuit and the DC-to-AC converter circuit.

4. The power inverter of claim 1, further comprising a switching controller configured to generate switching control signals for the first and second switches in a pre-charge mode of power inverter operation to effect a desired pre-charging of snubber circuit.

5. The power inverter of claim 1, further comprising a switching controller configured to generate switching control signals for the third switch that are in timed coordination with switching control signals generated for one or both the first and second switches, to effect a desired amount of energy transfer between the snubber circuit and the DC-to-AC circuit.

6. The power inverter of claim 1, further comprising a switching controller configured to generate switching control signals for the first, second, and third switches, such that the first DC-to-DC converter operates as a buck converter that returns energy from the snubber circuit to the DC-to-AC converter circuit.

7. A power inverter comprising:

a push-pull inverter circuit comprising an inverter circuit transformer having a switched primary winding with a first switch and first free-wheeling diode at a first end of the primary winding and a second switch and second free-wheeling diode at a second end of the primary winding;

a snubber circuit to limit voltage transients on the primary winding; and

a first DC-to-DC converter circuit formed using the primary winding and operative to control energy transfer between the snubber circuit and the push-pull inverter circuit.

8. The power inverter of claim 7, wherein first and second switches comprise first and second transistor switches, each having an associated diode, and wherein the first free-wheeling diode comprises the diode associated with the first transistor switch and the second free-wheeling diode comprises the diode associated with the second transistor switch.

9. The power inverter of claim 7, wherein the first DC-to-DC converter circuit includes a third switch coupling an energy storage device of the snubber circuit to the first end of the primary winding, such that the first DC-to-DC converter circuit is formed from the third switch, the primary winding, and the first free-wheeling diode.

10. The power inverter of claim 9, wherein the third switch comprises a transistor switch that includes an associated diode, and wherein that associated diode serves as a snubber diode connecting the first end of the primary winding to the snubber circuit.

11. The power inverter of claim 9, wherein the first and third switches comprise a half-bridge transistor circuit including a high-side transistor switch serving as the third switch coupling the first end of the primary winding to the snubber circuit and a low-side transistor switch serving as the first switch coupling the first end of the primary winding to a DC return node.

12. The power inverter of claim 11, wherein a diode associated with the high-side transistor switch serves as a snubber diode for the first end of the primary winding, and wherein a diode associated with the low-side transistor switch serves as the first free-wheeling diode.

13. The power inverter of claim 7, further comprising a second DC-to-DC converter circuit formed using the primary winding and operative to control energy transfer between the snubber circuit and the push-pull inverter circuit, said first DC-to-DC converter circuit formed at the first end of the primary winding and said second DC-to-DC converter circuit formed at the second end of the primary winding.

14. The power inverter of claim 13, wherein the first DC-to-DC converter circuit includes a third switch coupling an energy storage device of the snubber circuit to the first end of the primary winding, such that the first DC-to-DC converter circuit is formed from the third switch, the primary winding, and the first free-wheeling diode, and wherein the second DC-to-DC converter circuit includes a fourth switch coupling an energy storage device of the snubber circuit to the second end of the primary winding, such that the second DC-to-DC converter circuit is formed from the fourth switch, the primary winding, and the second free-wheeling diode.

15. The power inverter of claim 14, wherein the first and third switches comprise low-side and high-side transistor switches, respectively, in a half-bridge transistor circuit, and wherein the second and fourth switches comprises low-side and high-side transistor switches, respectively in a half-bridge transistor circuit.

16. The power inverter of claim 15, wherein diodes included with each low-side transistor switch serve as the first and second free-wheeling diodes, and wherein diodes included with the high-side transistor switches serve as snubber diodes coupling the first and second ends of the primary winding to the snubber circuit.

17. The power inverter of claim 14, wherein the first through fourth switches comprise first through fourth transistors in a full-bridge transistor circuit.

18. The power inverter of claim 7, further comprising a control circuit configured to generate push-pull switching control signals to control the push-pull inverter circuit, and further configured to generate a DC-to-DC converter switching control signal in timed coordination with the push-pull switching control signals to control energy transfer between the push-pull inverter circuit and an energy storage device of the snubber circuit.

19. A power inverter comprising:

a push-pull inverter circuit comprising a transformer having a primary winding coupled to a DC bus and a secondary winding coupled to an AC bus, main power switches coupling each end of the primary winding to a DC return, and one or more supplemental power switches coupling at least one end of the primary winding to a snubber circuit of the power inverter; and

a switching controller configured to control power flow between the DC, AC, and snubber buses by controlling a common-mode and differential-mode voltages of the primary winding via switching control of the main and supplemental power switches.

20. The power inverter of claim 19, wherein the switching controller is configured to recover energy from the snubber circuit by controlling the one or more supplemental power switches in timed coordination with the main power switches.

21. The power inverter of claim 19, wherein the switching controller is configured to operate in a run mode, wherein it carries out desired power conversion operations, and to operate in a pre-charge mode before transitioning to the run mode, wherein it pre-charges an energy storage device of the snubber circuit by switching the main power switches to effect power flow from the DC bus to the snubber bus.

22. The power inverter of claim 21, wherein the power inverter is configured to pre-charge the energy storage device to a desired voltage level, and maintain the energy storage device substantially at that desired voltage level while operating in the pre-charge mode.

23. The power inverter of claim 19, wherein the switching controller is configured to control the differential-mode voltage of the primary winding to effect desired power flow between the DC and AC buses.

24. The power inverter of claim 19, wherein the switching controller is configured to control the common-mode voltage of the primary winding to effect desired power flow between the DC and snubber buses.

25. The power inverter of claim 19, wherein the switching controller is configured to control the common-mode and differential-mode voltages of the primary winding to effect desired power flows between the DC, AC, and snubber buses.

26. The power inverter of claim 19, wherein the switching controller is configured to effect desired power flow from the snubber bus to the DC bus by controlling the respective on-times of the main and supplemental power switches at opposite ends of the primary winding.

27. The power inverter of claim 19, wherein the switching controller is configured to effect desired power flow from the snubber bus to the DC bus by controlling the respective on-times of the main and supplemental power switches at a same end of the primary winding.