Variable speed drive

• US 8,004,803 B2
• Filed: 04/17/2008
• Issued: 08/23/2011
• Est. Priority Date: 05/08/2007
• Status: Expired due to Fees

• Current Assignee: Johnson Controls Technology Company (Johnson Controls International plc)
• Original Assignee: Johnson Controls Technology Company (Johnson Controls International plc)
• Inventors: Schnetzka, Harold R.
• Primary Examiner(s): Leykin; Rita
• Application Number:
  US12/281,803
• Publication Number:
  US 20100229580A1
• Time in Patent Office: 1,223 Days
• Field of Search: 361/42, 361 44- 50, 361/1, 361/31, 361/118, 361/111, 361/117, 363/34, 363/37, 363/44, 363/47, 363/48, 318/459, 318/800, 318/563, 622/281, 622/284, 700 79- 82, 714/1, 324/509, 324/508, 324/541, 324/544, 324/551, 307/326, 323/267, 340/635, 340/649, 340/650, 340/652
• US Class Current: 361/42
• CPC Class Codes: H02H 7/1216 for AC-AC converters
• CPC Class Codes: H02M 1/32 Means for protecting converters other than automatic disconnection
• CPC Class Codes: H02M 5/458 using semiconductor devices only

Abstract

Systems and methods for improved Variable Speed Drives are provided. One embodiment relates to apparatus for common mode and differential mode filtering for motor or compressor bearing protection when operating with Variable Speed Drives, including conducted EMI/RFI input power mains mitigation. Another embodiment relates to a method to extend the synchronous operation of an active converter to the AC mains voltage during complete line dropout. Another embodiment relates to an active converter-based Variable Speed Drive system with Improved Full Speed Efficiency. Another embodiment relates to a liquid- or refrigerant-cooled inductor. The liquid- or refrigerant-cooled inductor may be used in any application where liquid or refrigerant cooling is available and a reduction in size and weight of a magnetic component is desired.

Claims

1. A variable speed drive system configured to receive an input AC voltage at a fixed AC input voltage and provide an output AC power at a variable voltage and variable frequency, the variable speed drive comprising:

a converter stage comprising at least two semiconductor switches for each power phase of the AC power source, the converter stage connected to an AC power source providing the input AC voltage, the converter stage being configured to convert the input AC voltage to a boosted DC voltage;

a DC link connected to the converter stage, the DC link being configured to filter and store the boosted DC voltage from the converter stage;

an inverter stage connected to the DC link, the inverter stage being configured to convert the boosted DC voltage from the DC link into the output AC power having the variable voltage and the variable frequency; and

a controller for interrupting fault current flowing to an input phase of the converter stage in response to at least one current sensor sensing a ground fault on an input of the converter stage

wherein each of the at least two semiconductor switches comprising a pair of reverse blocking (RB) IGBTs inversely connected in parallel.

2. The VSD of claim 1, wherein each of the reverse blocking IGBTs is controllable by the controller to switch the RB IGBTs to a nonconductive state in response to a sensed ground fault current.

3. The VSD of claim 2, wherein each RB IGBT switch is formed by an inverse parallel connection of the pair of the reverse-blocking IGBTs, in the at least two semiconductor switches.

4. The VSD of claim 1, wherein each of the RB IGBTs is controllable by the controller to completely extinguishing a ground fault current.

5. The VSD of claim 3, wherein the controller is configured to extinguish bi-directional current flow in a first semiconductor switch and a second semiconductor switch, for three legs of the converter stage, to ensure a complete disconnect of the VSD from a motor load connected to an output of the VSD.

6. The VSD of claim 2, wherein one RB IGBT of the pair of RB IGBTs of each semiconductor switch is controlled to permit only small pulses of inrush current to reach the DC link.

7. The VSD of claim 6, wherein the RB IGBTs of each semiconductor switch is controlled to conduct the small pulses of inrush current to reach the DC link during a precharge operation of the DC link.

8. The VSD of claim 2, wherein at least one RB IGBT of the pair of RB IGBTs in each semiconductor switch of the pair of semiconductor switches can be controlled to conduct current in one direction at all times.

9. A chiller system comprising:

a refrigerant circuit comprising a compressor, a condenser arrangement and an evaporator arrangement connected in a closed loop;

a drive arrangement connected to the compressor to power the compressor, the drive arrangement comprising a motor and a variable speed drive, the variable speed drive comprising;

a converter stage comprising at least two semiconductor switches for each power phase of the AC power source, the converter stage connected to an AC power source providing the input AC voltage, the converter stage being configured to convert the input AC voltage to a boosted DC voltage;

a DC link connected to the converter stage, the DC link being configured to filter and store the boosted DC voltage from the converter stage;

an inverter stage connected to the DC link, the inverter stage being configured to convert the boosted DC voltage from the DC link into the output AC power having the variable voltage and the variable frequency;

a controller for interrupting fault current flowing to an input phase of the converter stage in response to at least one current sensor sensing a ground fault on an input of the converter stage

wherein each of the at least two semiconductor switches comprising a pair of reverse blocking (RB) IGBTs inversely connected in parallel.

10. The chiller system of claim 9, wherein each of the reverse blocking IGBTs is controllable by the controller to switch the RB IGBTs to a nonconductive state in response to a sensed ground fault current.

11. The chiller system of claim 10, wherein each RB IGBT switch is formed by an inverse parallel connection of the pair of the reverse-blocking IGBTs, in the at least two semiconductor switches.

12. The chiller system of claim 9, wherein each of the RB IGBTs is controllable by the controller to completely extinguishing a ground fault current.

13. The chiller system of claim 11, wherein the controller is configured to extinguish bi-directional current flow in a first semiconductor switch and a second semiconductor switch, for three legs of the converter stage, to ensure a complete disconnect of the chiller system from a motor load connected to an output of the chiller system.

14. The chiller system of claim 10, wherein one RB IGBT of the pair of RB IGBTs of each semiconductor switch is controlled to permit only small pulses of inrush current to reach the DC link.

15. The chiller system of claim 14, wherein the RB IGBTs of each semiconductor switch is controlled to conduct the small pulses of inrush current to reach the DC link during a precharge operation of the DC link.

16. The chiller system of claim 10, wherein at least one RB IGBT of the pair of RB IGBTs in each semiconductor switch of the pair of semiconductor switches can be controlled to conduct current in one direction at all times.