Output power factor control of pulse-width modulated inverter

• US 7,660,139 B2
• Filed: 06/21/2004
• Issued: 02/09/2010
• Est. Priority Date: 06/21/2004
• Status: Active Grant

• Current Assignee: Schneider Electric Solar Inverters Usa, Inc. (Schneider Electric SE)
• Original Assignee: Xantrex International (Schneider Electric SE)
• Inventors: Garabandic, Djordje
• Primary Examiner(s): Berhane; Adolf
• Assistant Examiner(s): Mehari; Yemane
• Application Number:
  US11/630,139
• Publication Number:
  US 20070247876A1
• Time in Patent Office: 2,059 Days
• Field of Search: 363/15, 363/16, 363/17, 363/34, 363/37, 363/42, 363/95, 363/98, 363/131, 363/132, 363/136
• US Class Current: 363/98
• CPC Class Codes: H02M 1/12 Arrangements for reducing harmonics from ac input or output
• CPC Class Codes: H02M 7/53871 with automatic control of output voltage or current
• 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

An inverter operable to supply high power factor electrical power to an AC load including an AC power grid includes a DC bus and a DC to AC converter section of the full bridge type. The inverter further includes a voltage sensor configured to produce an instantaneous output voltage signal representing instantaneous output voltage of the inverter, a rectification circuit configured to produce a rectified output voltage signal, a power signal generator, an output current sensor configured for sensing an output current of the inverter, a rectification circuit configured to produce the rectified output current signal, a sign circuit for producing a signal representing the sign of the output voltage and a control apparatus. The control apparatus includes a scaled rectified voltage signal generator, a pulse width modulation (PWM) signal generator configured to produce a pulse width modulation signal in response to the scaled rectified voltage signal and the rectified output current signal and a switching leg controller circuit configured to control the full bridge switches.

Claims

1. A method of supplying high power factor electrical power to a load from an inverter having first and second switching legs connected to a first common output of the inverter and to first and second DC bus terminals of the inverter, respectively, and third and fourth switching legs connected to a second common output of the inverter and to said first and second DC bus terminals, respectively, the method comprising:

producing a scaled rectified voltage signal in response to a rectified output voltage signal representing rectified instantaneous output voltage of the inverter, a power signal inversely proportional to an average amplitude of the rectified instantaneous output voltage of the inverter, and a reference power signal, wherein producing said scaled rectified output voltage signal comprises multiplying said rectified output voltage signal by a ratio of said reference power signal to said power signal, such that said scaled rectified voltage signal is a scaled version of said rectified output voltage signal that increases when said average amplitude of the rectified output voltage of the inverter increases, and decreases when said average amplitude of the rectified output voltage of the inverter decreases;

producing a pulse width modulation (PWM) signal in response to said scaled rectified voltage signal and a rectified output current signal representing output current of the inverter; and

controlling said first, second, third and fourth switching legs in response to said PWM signal and a sign signal representing a sign of the instantaneous output voltage of the inverter, such that current supplied by the inverter increases when said average amplitude of the rectified output voltage of the inverter increases, and decreases when said average amplitude of the rectified output voltage of the inverter decreases.

2. The method of claim 1 further comprising receiving said rectified output voltage signal.

3. The method of claim 1 further comprising sensing instantaneous output voltage of the inverter and producing said rectified output voltage signal in response to said instantaneous output voltage.

5. The method of claim 1 further comprising producing said power signal by applying a function to a signal representing the output voltage of the inverter.

6. The method of claim 5 wherein applying said function comprises producing an average signal representing said average amplitude of the rectified instantaneous output voltage of the inverter.

7. The method of claim 1 further comprising receiving said reference power signal.

8. The method of claim 1 further comprising receiving said rectified output current signal.

9. The method as claimed in claim 1 further comprising sensing an output current of the inverter and producing said rectified output current signal in response to said output current.

10. The method of claim 1 further comprising producing a compensation signal in response to said rectified output current signal and said scaled rectified output voltage signal.

11. The method of claim 10 wherein producing said compensation signal comprises performing a proportional-integral function on a difference between said scaled rectified voltage signal and said rectified output current signal.

12. The method of claim 11 wherein producing said PWM signal includes producing a voltage pulse having a pulse width dependent upon said compensation signal.

13. The method as claimed in claim 12 further comprising stopping generation of said PWM signal when said instantaneous output current exceeds a reference value.

14. The method as claimed in claim 1 further comprising receiving said sign signal.

15. The method as claimed in claim 1 further comprising producing said sign signal such that said sign signal has a first state when the instantaneous output voltage of the inverter is positive and such that said sign signal has a second state when the instantaneous output voltage of the inverter is negative.

16. The method as claimed in claim 1 wherein controlling said first, second third and fourth switching legs includes shutting off said first and fourth switching legs and controlling an on-state of at least one of said second switching leg and said third switching leg in response to said PWM signal to modulate current through a conduction path comprised of said second and third switching legs when said sign signal indicates a positive instantaneous output voltage and by shutting of f said second and third switching legs and controlling an on-state of at least one of said first switching leg and said fourth switching leg in response to said PWM signal to modulate current through a conduction path comprised of said first and fourth switching legs when said sign signal indicates a negative instantaneous output voltage.

4. The method of 1 further comprising receiving said power signal.

17. An apparatus for supplying high power factor electrical power to a load from an inverter having first and second switching legs connected to a first common output of the inverter and first and second DC terminals of the inverter respectively, and third and fourth switching legs connected to a second common output of the inverter and said first and second DC terminals respectively, the apparatus comprising:

means for producing a scaled rectified voltage signal in response to a rectified output voltage signal representing rectified instantaneous output voltage of the inverter, a power signal inversely proportional to an average amplitude of the rectified instantaneous output voltage of the inverter, and a reference power signal, wherein said means for producing said scaled rectified output voltage signal is configured to multiply said rectified output voltage signal by a ratio of said reference power signal to said power signal such that said scaled rectified voltage signal is a scaled version of said rectified output voltage signal that increases when said average amplitude of the rectified output voltage of the inverter increases, and decreases when said average amplitude of the rectified output voltage of the inverter decreases;

means for producing a pulse width modulation (PWM) signal in response to said scaled rectified voltage signal and a rectified output current signal representing output current of the inverter; and

means for controlling said first, second, third and fourth switching legs in response to said PWM signal and a sign signal representing a sign of said instantaneous output voltage of said inverter such that current supplied by the inverter increases when said average amplitude of the rectified output voltage of the inverter increases, and decreases when said average amplitude of the rectified output voltage of the inverter decreases.

18. The apparatus of claim 17 further comprising means for receiving said rectified output voltage signal.

19. The apparatus of claim 17 further comprising means for sensing instantaneous output voltage of the inverter and means for producing said rectified output voltage signal in response to said instantaneous output voltage.

20. The apparatus of claim 17 further comprising means for receiving a power signal representing power associated with said output voltage signal.

21. The apparatus of claim 17 further comprising means for producing said power signal by applying a function to a signal representing the output voltage of the inverter.

22. The apparatus of claim 21 wherein said means for producing said power signal is configured to produce an average signal representing said average amplitude of the rectified instantaneous output voltage of the inverter.

23. The apparatus of claim 17 further comprising means for receiving said reference power signal.

24. The apparatus of claim 17 further comprising means for receiving a rectified instantaneous supply current signal.

25. The apparatus of claim 17 further comprising means for sensing an output current of said inverter to produce an instantaneous output current signal and means for producing said rectified output current signal in response to said instantaneous output current signal.

26. The apparatus of claim 17 further comprising means for producing a compensation signal in response to said scaled rectified voltage signal and said rectified output current signal.

27. The apparatus of claim 26 wherein said means for producing a compensation signal comprises a proportional-integral circuit for providing said PWM control signal, in response to a difference between said scaled rectified voltage signal and said rectified output current signal.

28. The apparatus of claim 27 wherein said means for producing said PWM signal is configured to produce a voltage pulse having a pulse width dependent upon said compensation signal.

29. The apparatus of claim 28 further comprising means for causing said means for producing said PWM signal to stop producing said PWM signal when said instantaneous output current exceeds a reference value.

30. The apparatus of claim 17 further comprising means for receiving a sign signal representing a sign of said instantaneous output voltage of the inverter.

31. The apparatus of claim 17 further comprising means for producing said sign signal such that said sign signal has a first state when said instantaneous output voltage is positive and such that said sign signal has a second state when said instantaneous output voltage is negative.

32. The apparatus of claim 31 wherein said means for controlling said first, second third and fourth switching legs is configured to shut off said first and fourth switching legs and to control an on state of at least one of said second switching leg and said third switching leg in response to said PWM signal to modulate current through a conduction path comprised of said second and third switching legs when said sign signal indicates a positive instantaneous output voltage and to shut off said second and third switching legs and to control an on state of at least one of said first switching leg and said fourth switching leg in response to said PWM signal to modulate current through a conduction path comprised of said first and fourth switching legs, when said sign signal indicates a negative instantaneous output voltage.

33. The apparatus of claim 17 wherein said means for producing said scaled rectified voltage signal and the means for producing a pulse width modulation signal are contained within a single integrated circuit.

34. An apparatus for supplying high power factor electrical power to a load from an inverter having first and second switching legs connected to a first common output of the inverter and first and second DC terminals of the inverter respectively, and third and fourth switching legs connected to a second common output of the inverter and said first and second DC terminals respectively, the apparatus comprising:

a scaled rectified voltage signal generator configured to produce a scaled rectified voltage signal in response to a rectified output voltage signal representing rectified instantaneous output voltage of the inverter, a power signal inversely proportional to an average amplitude of the rectified instantaneous output voltage of the inverter and a reference power signal, wherein said scaled rectified voltage signal generator includes a multiplier configured to multiply said rectified output voltage signal by a ratio of said reference power level signal to said power signal such that said scaled rectified voltage signal is a scaled version of said rectified output voltage signal that increases when said average amplitude of the rectified output voltage of the inverter increases, and decreases when said average amplitude of the rectified output voltage of the inverter decreases;

a pulse width modulation (PWM) signal generator configured to produce a pulse width modulation signal in response to said scaled rectified voltage signal and a rectified output current signal representing output current of the inverter; and

a switching leg controller circuit configured to control said first, second, third and fourth switching legs in response to said PWM signal and a sign signal representing a sign of said instantaneous output voltage of said inverter such that current supplied by the inverter increases when said average amplitude of the rectified output voltage of the inverter increases, and decreases when said average amplitude of the rectified output voltage of the inverter decreases.

35. The apparatus of claim 34 further comprising a sensor configured to sense instantaneous output voltage of the inverter and a rectification circuit configured to produce said rectified output voltage signal in response to said instantaneous output voltage.

36. The apparatus of claim 35 further comprising a function circuit configured to perform a function on a signal representing the output voltage of the inverter.

37. The apparatus of claim 36 wherein said function circuit is configured to produce an average signal representing said average amplitude of the rectified instantaneous output voltage of the inverter.

38. The apparatus of claim 34 further comprising an output current sensor configured for sensing an output current of the inverter to produce an instantaneous output current signal and a rectifier circuit configured to produce said rectified output current signal in response to said instantaneous output current signal.

39. The apparatus of claim 34 further comprising a compensation signal generator for producing a compensation signal in response to said scaled rectified voltage signal and said rectified output current signal.

40. The apparatus of claim 39 wherein said compensation signal generator comprises a proportional-integral circuit for providing said compensation signal, in response to a difference between said scaled rectified voltage signal and said rectified output current signal.

41. The apparatus of claim 40 wherein said PWM signal generator is configured to produce a voltage pulse having a pulse width dependent upon said compensation signal.

42. The apparatus of claim 34 wherein said scaled rectified output voltage signal generator and said PWM signal generator are contained within a single common integrated circuit.

43. The apparatus of claim 34 wherein said PWM signal generator is configured to stop producing said PWM signal when said instantaneous output current exceeds a reference value.

44. The apparatus of claim 34 further comprising a signum circuit configured to produce said sign signal in response to said instantaneous output voltage such that said sign signal has a first state when said instantaneous output voltage is positive and such that said sign signal has a second state when said instantaneous output voltage is negative.

45. The apparatus of claim 44 wherein said switching leg controller circuit is configured to shut off said first and fourth switching legs and to control an on-state of at least one of said second switching leg and said third switching leg in response to said PWM signal to modulate current through a conduction path comprised of said second and third switching legs when said sign signal indicates a positive instantaneous output voltage and to shut off said second and third legs and to control an on-state of at least one of said first switching leg and said fourth switching leg in response to said PWM signal to modulate current through a conduction path comprised of said first and fourth switching legs when said sign signal indicates a negative instantaneous output voltage.

46. The apparatus of claim 45 further comprising first, second, third and fourth gate drive circuits in communication with said first, second, third and fourth switching elements respectively and wherein the switching leg controller circuit includes a logic circuit operable to receive the PWM signal and the sign signal and has first, second, third and fourth gate drive outputs in communication with the first, second, third and fourth gate drive circuits respectively.

47. An inverter operable to supply high power factor electrical power to an AC load including an AC power grid, the inverter comprising:

a DC bus having first and second DC terminals operable to be supplied with power from a DC source;

a DC to AC converter section having;

first and second switching legs connected to a first common AC output and said first and second DC terminals, respectively; and

third and fourth switching legs connected to a second common output of the inverter and said first and second DC terminals respectively;

a voltage sensor configured to produce an instantaneous output voltage signal representing instantaneous output voltage of the inverter;

a first rectification circuit configured to produce a rectified output voltage signal in response to said instantaneous output voltage;

a power signal generator for generating a power signal inversely proportional to an average amplitude of the rectified output voltage;

an output current sensor configured for sensing an output current of the inverter to produce an instantaneous output current signal;

a second rectification circuit configured to produce a rectified output current signal in response to said instantaneous output current signal;

a sign circuit for producing a signal representing the sign of the instantaneous output voltage;

a control apparatus comprising;

a scaled rectified voltage signal generator configured to produce a scaled rectified voltage signal in response to said rectified output voltage signal, said power signal and a reference power signal, wherein said scaled rectified voltage signal generator includes a multiplier configured to multiply said rectified output voltage signal by a ratio of said reference power level signal to said power signal such that said scaled rectified voltage signal is a scaled version of said rectified output voltage signal that increases when said average amplitude of the rectified output voltage of the inverter increases, and decreases when said average amplitude of the rectified output voltage of the inverter decreases;

a pulse width modulation (PWM) signal generator configured to produce a pulse width modulation signal in response to said scaled rectified voltage signal and said rectified output current signal; and

a switching leg controller circuit configured to control said first, second, third and fourth switching legs in response to said PWM signal and said sign signal such that current supplied by the inverter increases when said average amplitude of the rectified output voltage of the inverter increases, and decreases when said average amplitude of the rectified output voltage of the inverter decreases.

48. The inverter of claim 47, wherein said switching leg controller circuit is configured to shut off said first and fourth switching legs and to control an on-state of at least one of said second switching leg and said third switching leg in response to said PWM signal to modulate current through a conduction path comprised of said second and third switching legs when said sign signal indicates a positive instantaneous output voltage and to shut off said second and third switching legs and to control an on-state of at least one of said first switching leg and said fourth switching leg in response to said PWM signal to modulate current through a conduction path comprised of said first and fourth switching legs when said sign signal indicates a negative instantaneous output voltage.

49. The inverter of claim 48 further comprising first, second, third and fourth gate drive circuits in communication with said first, second, third and fourth switching legs respectively and wherein the switching leg controller circuit includes a logic circuit operable to receive the PWM signal and the sign signal and has first, second, third and fourth gate drive outputs in communication with the first, second, third and fourth gate drive circuits respectively.

50. The inverter of claim 49 wherein said scaled rectified voltage signal generator and said PWM signal generator include a common integrated circuit.

51. An inverter operable to supply high power factor electrical power to an AC load including an AC power grid, the inverter comprising:

a DC bus having first and second DC terminals operable to be supplied with power from a DC source;

a DC to AC converter section having;

first and second switching legs connected to a first common AC output and said first and second DC terminals, respectively; and

third and fourth switching legs connected to a second common output of the inverter and said first and second DC terminals respectively;

means for producing a rectified output voltage signal representing rectified output voltage of the inverter;

means for generating a power signal inversely proportional to an average amplitude of the rectified output voltage;

means for producing a rectified output current signal representing instantaneous output current of the inverter;

means for producing a sign signal representing the sign of the output voltage;

a control apparatus comprising;

means for producing a scaled rectified voltage signal in response to said rectified output voltage signal, said power signal and a reference power signal, wherein said means for producing said scaled rectified output voltage signal is configured to multiply said rectified output voltage signal by a ratio of said reference power signal to said power signal such that said scaled rectified voltage signal is a scaled version of said rectified output voltage signal;

means for producing a pulse width modulation signal in response to said scaled rectified voltage signal and said rectified output current signal; and

means for controlling said first, second, third and fourth switching legs in response to said PWM signal and said sign signal such that current supplied by the inverter increases when said average amplitude of the rectified output voltage of the inverter increases, and decreases when said average amplitude of the rectified output voltage of the inverter decreases.

52. The inverter of claim 51, wherein said means for controlling said first, second, third and fourth switching legs is configured to shut off said first and fourth switching legs and to control an on-state of at least one of said second switching leg and said third switching leg in response to said PWM signal to modulate current through a conduction path comprised of said second and third switching legs when said sign signal indicates a positive instantaneous output voltage and to shut off said second and third legs and to control an on-state of at least one of said first switching leg and said fourth switching leg in response to said PWM signal to modulate current through a conduction path comprised of said first and fourth switching legs when said sign signal indicates a negative instantaneous output voltage.

53. The inverter of claim 52 further comprising first, second, third and fourth gate drive circuits in communication with said first, second, third and fourth switching elements respectively and wherein the means for controlling said first, second, third and fourth switching legs includes a logic circuit operable to receive the PWM signal and the sign signal and has first, second, third and fourth gate drive outputs in communication with the first, second, third and fourth gate drive circuits respectively.

54. The inverter of claim 53 wherein said means for producing said scaled rectified voltage signal and said means for producing a PWM signal include a common integrated circuit.