Frequency converter for different mains voltages

• US 7,221,121 B2
• Filed: 11/21/2002
• Issued: 05/22/2007
• Est. Priority Date: 11/23/2001
• Status: Expired due to Term

• Current Assignee: Danfoss Drives A/S (Danfoss A/S)
• Original Assignee: Danfoss Drives A/S (Danfoss A/S)
• Inventors: Harvest, Nils-Ole, Krogh, Egon, Toennes, Michael, Aupke, Andreas, Skaug, Kenneth
• Primary Examiner(s): Donovan; Lincoln
• Assistant Examiner(s): SMITH, TYRONE W
• Application Number:
  US10/495,854
• Publication Number:
  US 20050068001A1
• Time in Patent Office: 1,643 Days
• Field of Search: 318/138, 318/254, 318430-434, 318/268, 318/439, 318800-811, 318/286, 318/727, 318/767
• US Class Current: 318/807
• CPC Class Codes: F04C 28/08 characterised by varying the rotational speed
• CPC Class Codes: H02M 1/0022 the disturbance parameters being input voltage fluctuations
• CPC Class Codes: H02M 1/0025 Arrangements for modifying reference values, feedback values or error values in the control loop of a converter
• 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 1/10 Arrangements incorporating converting means for enabling loads to be operated at will from different kinds of power supplies, e.g. from ac or dc
• CPC Class Codes: H02M 1/32 Means for protecting converters other than automatic disconnection
• CPC Class Codes: H02M 1/4225 using a non-isolated boost converter
• CPC Class Codes: H02M 5/458 using semiconductor devices only
• CPC Class Codes: H02M 7/53873 with digital control
• CPC Class Codes: H02P 27/047 V/F converter, wherein the voltage is controlled proportionally with the frequency
• CPC Class Codes: H02P 27/06 using dc to ac converters or inverters H02P27/05 takes precedence
• CPC Class Codes: H02P 4/00 Arrangements specially adapted for regulating or controlling the speed or torque of electric motors that can be connected to two or more different electric power supplies vector control H02P21/00
• CPC Class Codes: Y02B 70/10 Technologies improving the efficiency by using switched-mode power supplies [SMPS], i.e. efficient power electronics conversion e.g. power factor correction or reduction of losses in power supplies or efficient standby modes

Abstract

The invention is directed to controlling an electric motor by means of a frequency converter. The frequency converter can be connected to one of several different mains voltages. According to the present invention, the maximum output power of the frequency converter, is limited when the actual mains voltage is lower than the maximum nominal mains voltage, for which the frequency converter is designed, and during the limitation the frequency converter controls the speed of the motor within a power range up to a limited maximum output power. This gives a genuine multi-voltage unit, which can be connected to a wide range of mains voltages.

Claims

1. A method for controlling an electric motor by means of a frequency converter, the method comprising the steps of:

comparing a limit value signal with one or more measured or calculated parameters; and

limiting a maximum output power when the one or more measured or calculated parameters exceeds the limit value signal by reducing a motor frequency generated by an inverter;

wherein the frequency converter is connectable to one of several mains voltages and a control device limits the maximum electrical output power of the frequency converter when an actual mains voltage is lower than a maximum nominal mains voltage for the frequency converter, a converter between a rectifier and the inverter is regulated to output an intermediary circuit voltage that is kept constant during operation at each one of the several mains voltages, and during said limitation of the maximum output power the frequency converter controls a speed of the electric motor within a power range up to the limited maximum output power.

2. The method according to claim 1, wherein on the basis of the one or more measured or calculated parameters the control device limits the maximum electrical output power immediately after connection of the frequency converter to a mains voltage supply, if the one or more measured or calculated parameters exceed the limit value signal.

3. The method according to claim 2, wherein the control device contains a table with limit values and that on the basis of the one or more measured or calculated parameters the control device selects a limit value signal of a desired amplitude.

4. The method according to claim 1, wherein the control device determines the limit value continuously during operation of the frequency converter.

5. The method according to claim 3, wherein the limit value signal is a current limit which is determined as a function of the motor frequency or a measured temperature, or a combination of the motor frequency and the measured temperature.

6. The method according to claim 1, wherein a reference signal for the motor frequency is generated as a difference between a desired motor frequency and a frequency reduction term, the frequency reduction term being generated on the basis of a current difference, a power difference or the intermediary circuit voltage.

7. The method according to claim 1, wherein the control device reduces both motor frequency and motor voltage.

8. The method according to claim 7, wherein the intermediary circuit voltage after the converter is also reduced.

9. The method according to claim 1, wherein the frequency converter contains a voltage or current sensor for direct or indirect detection of the actual mains voltage.

10. The method according to claim 1, wherein a first current between rectifier and converter is measured and compared to the limit value signal, and that a second current between converter and inverter is measured and compared to a second limit value, and that an over current signal is given when the second current exceeds the second limit value.

11. The method according to claim 10, wherein the second limit value is variable, and that the characteristic of the second limit value can be determined as a function of the nominal power rating of the motor, the actual motor frequency or the torque load on the motor shaft.

12. A frequency converter for controlling an electric motor, the frequency converter comprising:

a rectifier for providing a rectifier output voltage;

a converter for regulating the rectifier output voltage to produce an intermediary voltage;

an inverter for inverting the intermediary voltage and generating a motor frequency; and

a control device;

wherein said frequency converter is connectable to one of several mains voltages, the intermediary voltage is kept constant at each one of several mains voltages and the control device limits the maximum electrical output power of the frequency converter when an actual mains voltage is lower than a maximum nominal mains voltage for the frequency converter by comparing a first limit value signal with one or more measured or calculated parameters and reducing the motor frequency generated by the inverter if the measured or calculated parameter is greater than the first limit value signal; and

wherein a second limit value representing the hardware current limit of the inverter is adjustable during operation of the frequency converter, and that an over current signal is given if a current measuring signal exceeds the second limit value.

13. The frequency converter according to claim 12, further comprising an electronic circuit for detecting an over current condition, the electronic circuit including:

a reference generator for generating the second limit value;

a comparator which compares the current measuring signal with the second limit value which is generated by the reference generator, the comparator giving the over current signal once the current measuring signal is larger than the second limit value; and

a current reference characteristic which is stored in a programmable memory element, the characteristic being dependent on at least one first variable and replaceable by a second characteristic which is dependent on at least one second variable;

wherein the reference generator generates the second limit value as a pulse-width modulated signal on the basis of the current reference characteristic loaded from the programmable memory element.

14. The frequency converter according to claim 13, wherein the first and the second variables are chosen from a set of control parameters including motor frequency, motor temperature and inverter temperature, a set of application parameters including motor size and torque load characteristic of the motor shaft, or from a combination of a control parameter and an application parameter.

15. The frequency converter according to claim 14, wherein one or more variables of the type control parameters and/or one or more variables of the type application parameters are sent to the reference generator as input signal.

16. The frequency converter according to claim 15, wherein the motor frequency is the first variable in the current reference characteristic.

17. The frequency converter according to claim 14, wherein a parameter pair motor frequency and inverter temperature is the first variable in the characteristic.

18. The frequency converter according to claim 12, wherein the second limit value is held constantly at a first level from motor start up to a limit frequency, after which the second limit value is reduced.

19. The frequency converter according to claim 13, wherein the pulse-width modulated current reference signal is led into a low-pass filter, whose output is connected with an input on the comparator.

20. The frequency converter according to claim 14, wherein the current reference characteristic is selectable by using dip-switches or jumpers arranged in the frequency converter or by using serial communication.

21. The frequency converter according to claim 14, wherein the frequency converter measures electrical parameters in the motor and determines the current reference characteristic on the basis of these parameters.

22. The frequency converter according claim 12, wherein the second limit value is formed by a measured motor current or a measured current in the converter, and the measured current is standardised in a standardising circuit having an output, the current measuring signal being available on the standardising circuit output.

23. The frequency converter according to claim 22, wherein the standardising circuit is arranged on one of a printed circuit board comprising control electronics of the frequency converter and a printed circuit board comprising power electronics, the two printed circuit boards being electrically connected with each other.

24. The frequency converter according to claim 23, wherein the standardising circuit comprises ohmic resistors, which ohmic resistors are connected in parallel with a current signal.

25. A frequency converter for controlling an electrical motor, the converter comprising electronic control circuitry wherein a digital controller generates a PWM signal which is led to an analogue lowpass filter and converted into an analogue reference value which is a reference for a current control loop, and an analog current measurement value is a feedback value for said current control loop;

wherein the analogue reference value is led to a first input of a comparator and the analogue current measurement value is led to a second input of the comparator; and

wherein the PWM signal is led into an analogue multiplier placed between the digital controller and the analogue lowpass filter, said analogue multiplier multiplying the PWM signal to a signal representing a curve profile of a mains voltage.