Health monitoring for power converter components

• US 7,804,415 B2
• Filed: 09/14/2007
• Issued: 09/28/2010
• Est. Priority Date: 09/14/2007
• Status: Active Grant

• Current Assignee: Astec International Limited (Emerson Electric Company)
• Original Assignee: Astec International Limited (Emerson Electric Company)
• Inventors: Wang, Zhe, Wang, Lin Guo, Jiang, Huai Gang, Cheng, Wing Ling
• Primary Examiner(s): PHAM, TOAN NGOC
• Application Number:
  US11/901,279
• Publication Number:
  US 20090072984A1
• Time in Patent Office: 1,110 Days
• Field of Search: 340/635, 340/653, 340/654, 340/657, 340/660, 340/3.34, 363/74, 363/76, 324/519, 324/522, 324/548
• US Class Current: 340/635
• CPC Class Codes: G01R 31/343 in operation
• CPC Class Codes: G01R 31/40 Testing power supplies testing photovoltaic devices H02S50/10
• CPC Class Codes: H02M 1/32 Means for protecting converters other than automatic disconnection

Abstract

A power converter including a processor and at least one component whose health in the power converter will degrade over time is disclosed. The processor is configured for monitoring the health of the component over time, and for generating a warning signal when the monitored health of the component reaches a threshold level. A method for monitoring the health of at least one component in a power converter is also disclosed. The method includes monitoring at least one performance characteristic of the power converter. The performance characteristic represents the health of the component. The method further includes comparing the monitored performance characteristic with stored data to determine whether the health of the component has reached a predetermined level, and generating a warning signal after determining the health of the component has reached the predetermined level.

Claims

1. A power converter comprising a processor and a plurality of components whose health in the power converter will degrade over time, the plurality of components including a first capacitor and a fan, the processor configured for monitoring the health of the first capacitor over time by monitoring a first set of one or more performance characteristics of the power converter, the processor configured for monitoring the health of the fan over time by monitoring a second set of one or more performance characteristics of the power converter and the processor configured for generating a warning signal when the monitored health of the first capacitor or the monitored health of the fan reaches a threshold level.

2. The power converter of claim 1 further comprising an alarm configured to activate in response to the warning signal.

3. The power converter of claim 1 wherein the processor is configured for generating a first warning signal when the monitored health of the first capacitor reaches a first threshold level and for generating a second warning signal when the monitored health of the fan reaches a second threshold level.

4. The power converter of claim 3 further comprising a first alarm and a second alarm, the first alarm configured to activate in response to the first warning signal, the second alarm configured to activate in response to the second warning signal.

5. The power converter of claim 3 wherein the power converter includes a second capacitor, and wherein the processor is configured for monitoring the health of the second capacitor over time and for generating a third warning signal when the monitored health of the second capacitor reaches a third threshold level.

6. The power converter of claim 5 further comprising a first alarm, a second alarm, and a third alarm configured to activate in response to the first warning signal, the second warning signal, and the third warning signal, respectively.

7. The power converter of claim 6 wherein the first capacitor is a bulk capacitor and the second capacitor is an output capacitor.

8. The power converter of claim 7 wherein the first alarm, the second alarm and the third alarm each include at least one LED.

9. The power converter of claim 8 wherein each LED has a different color.

10. The power converter of claim 5 further comprising a temperature sensing circuit, an output current sampling circuit and a plurality of ripple voltage sampling circuits.

11. A method for monitoring the health of a capacitor and a fan in a power converter, the method comprising monitoring a first set of one or more performance characteristics representing the health of the capacitor, monitoring a second set of one or more performance characteristics representing the health of the fan, comparing the monitored first set of one or more performance characteristics representing the health of the capacitor with stored data to determine whether the health of the capacitor has reached a first predetermined level, comparing the monitored second set of one or more performance characteristics representing the health of the fan with stored data to determine whether the health of the fan has reached a second predetermined level and generating a warning signal after determining the health of the capacitor has reached said first predetermined level or the health of the fan has reached the second predetermined level.

12. The method of claim 11 wherein the first set of one or more performance characteristics representing the health of the capacitor includes a ripple voltage across the capacitor.

13. The method of claim 12 wherein the capacitor is a bulk capacitor.

14. The method of claim 13 wherein the first set of one or more performance characteristics representing the health of the capacitor further includes an output current level for the power converter.

15. The method of claim 12 wherein the capacitor is an output capacitor.

16. The method of claim 11 wherein the second set of one or more performance characteristics representing the health of the fan includes a temperature and a speed of the fan.

17. The method of claim 11 further comprising activating an alarm in response to the warning signal.

18. The method of claim 17 wherein the alarm is a visual alarm.

19. The method of claim 18 wherein the visual alarm includes at least one LED.

20. The method of claim 11 further comprising sending the generated warning signal to a system hosting the power converter.

21. The method of claim 11 wherein the warning signal is generated by a first processor, the method further comprising sending the generated warning signal to a second processor.