Method and apparatus for overvoltage protection and reverse motor speed control for motor drive power loss events

• US 9,041,327 B2
• Filed: 06/12/2013
• Issued: 05/26/2015
• Est. Priority Date: 06/12/2013
• Status: Active Grant

• Current Assignee: Rockwell Automation Technologies Incorporated (Rockwell Automation, Inc.)
• Original Assignee: Rockwell Automation Technologies Incorporated (Rockwell Automation, Inc.)
• Inventors: Breitzmann, Robert J., Royak, Semyon, Kasunich, John M.
• Primary Examiner(s): Masih, Karen
• Application Number:
  US13/915,647
• Publication Number:
  US 20140368143A1
• Time in Patent Office: 713 Days
• Field of Search: 318/400.22, 318/380, 363/95, 363/98, 363/131
• US Class Current: 318/400.22
• CPC Class Codes: H02M 1/32 Means for protecting converters other than automatic disconnection
• CPC Class Codes: H02M 5/458 using semiconductor devices only
• CPC Class Codes: H02M 7/5387 in a bridge configuration
• CPC Class Codes: H02P 29/024 Detecting a fault condition, e.g. short circuit, locked rotor, open circuit or loss of load
• CPC Class Codes: H02P 29/0241 the fault being an overvoltage
• CPC Class Codes: H02P 29/025 the fault being a power interruption
• CPC Class Codes: H02P 3/22 by short-circuit or resistive braking

Abstract

Apparatus and methods are presented for mitigating overvoltages and limiting reverse motor speeds for motor drive power loss events, in which a first power dissipation circuit is enabled at the motor drive output to limit reverse rotation of a driven motor load when motor drive power is lost, and a second power dissipation circuit in a DC bus circuit is used to mitigate over voltages following restoration of motor drive power.

Claims

1. A power conversion system, comprising:

an AC output including a plurality of AC output terminals;

a DC bus circuit comprising first and second DC bus nodes and at least one DC bus capacitance connected between the first and second DC bus nodes;

an inverter comprising a DC input with first and second DC input nodes connected to the first and second DC bus nodes, an inverter output with a plurality of inverter output nodes, and a plurality of inverter switching devices individually coupled between one of the DC input nodes and one of the inverter output nodes, the inverter switching devices individually operative to selectively electrically couple the corresponding DC input node with the corresponding inverter output node according to a corresponding inverter switching control signal;

at least one controller operative to provide the inverter switching control signals to cause the inverter to selectively convert DC power from the DC bus circuit to provide AC electrical power to the inverter output;

a first power dissipation circuit coupled with the AC output and operative in a first mode to selectively couple at least one resistive load between at least two of the AC output terminals to dissipate power provided to the system from a load; and

a second power dissipation circuit operative in a first mode to selectively dissipate power in the DC bus circuit;

wherein the at least one controller is operative in response to loss of system input power to provide a first control signal to place the first power dissipation circuit in the first mode to dissipate power provided to the AC output from the load.

2. The power conversion system of claim 1, wherein the at least one controller is operative in response to loss of system input power to disable operation of the inverter by discontinuing provision of the inverter switching control signals prior to placing the first power dissipation circuit in the first mode.

3. The power conversion system of claim 2, wherein the at least one controller is operative in response to resumption of system input power to:

take the first power dissipation circuit out of the first mode to discontinue dissipation of power provided to the AC output from the load; and

provide a second control signal to place the second power dissipation circuit in the first mode to selectively dissipate power in the DC bus circuit.

4. The power conversion system of claim 3, wherein the at least one controller is operative in response to resumption of system input power to enable operation of the inverter by resuming provision of the inverter switching control signals after taking the first power dissipation circuit out of the first mode.

5. The power conversion system of claim 4, wherein the at least one controller is operative to disable the second power dissipation circuit to discontinue dissipation of power in the DC bus circuit after enabling operation of the inverter.

6. The power conversion system of claim 1, further comprising an output filter connected between the inverter output and the AC output, wherein the first power dissipation circuit is connected to at least two of the AC output terminals of the AC output.

7. The power conversion system of claim 1, wherein the first power dissipation circuit comprises:

a rectifier coupled to at least two of the AC output terminals of the AC output and operative to provide a DC output voltage;

a switch; and

at least one resistor connected with the switch in a series circuit across the DC output voltage of the rectifier to dissipate power provided to the system from the load when the switch is on.

8. The power conversion system of claim 7, wherein the switch of the first power dissipation circuit is controlled by the at least one controller.

9. The power conversion system of claim 1, wherein the first power dissipation circuit comprises:

at least one switch with a first terminal connected to one of the AC output terminals of the AC output and a second terminal; and

at least one resistor with a first terminal connected to the second terminal of the at least one switch and a second terminal coupled to another one of the AC output terminals to dissipate power provided to the system from the load when the at least one switch is on.

10. The power conversion system of claim 9, wherein the at least one switch of the first power dissipation circuit is controlled by the at least one controller.

11. A method for mitigating motor drive overvoltage and limiting the reverse rotation of a motor load for motor drive power loss events, the method comprising:

selectively disabling operation of a motor drive output inverter in response to loss of motor drive system input power;

selectively coupling a first resistive load circuit to at least two AC nodes between the motor drive output inverter and the motor load in response to loss of the motor drive system input power to limit reverse rotation of the motor load by dissipating power provided to the motor drive from the motor load;

selectively disabling the first resistive load circuit to discontinue dissipation of power provided to the motor drive from the motor load after restoration of motor drive system input power;

selectively enabling operation of the motor drive output inverter after restoration of motor drive system input power to drive the motor load to resume rotation in a forward direction;

selectively connecting a second resistive load to dissipate power in a DC bus circuit of the motor drive after restoration of motor drive system input power; and

thereafter disconnecting the second resistive load to discontinue dissipation of power in the DC bus circuit to resume normal motor drive operation;

wherein selectively coupling the first resistive load circuit to the at least two AC nodes includes providing a first control signal in a first state from a motor drive controller to at least one switch of the first resistive load circuit in response to loss of the motor drive system input power; and

wherein selectively disabling the first resistive load circuit includes providing the first control signal in a second state from the motor drive controller to the at least one switch of the first resistive load circuit after restoration of motor drive system input power.

12. The method of claim 11:

wherein selectively connecting the second resistive load to dissipate power in the DC bus circuit of the motor drive includes providing a second control signal in a first state from the motor drive controller to a switch in the DC bus circuit after restoration of motor drive system input power; and

wherein disconnecting the second resistive load includes providing the second control signal in a second state from the motor drive controller to the switch and in the DC bus circuit.

13. The method of claim 12, wherein operation of the motor drive output inverter is disabled prior to selectively connecting the first resistive load circuit to the at least two AC nodes.

14. The method of claim 11, wherein operation of the motor drive output inverter is disabled prior to selectively connecting the first resistive load circuit to the at least two AC nodes.

15. A non-transitory computer readable medium with computer executable instructions for mitigating motor drive overvoltage and limiting the reverse rotation of a motor load for motor drive power loss events, the computer readable medium having computer executable instructions for:

selectively disabling operation of a motor drive output inverter in response to loss of motor drive system input power;

selectively coupling a first resistive load circuit to at least two AC nodes between the motor drive output inverter and the motor load in response to loss of the motor drive system input power to limit reverse rotation of the motor load by dissipating power provided to the motor drive from the motor load;

selectively disabling the first resistive load circuit to discontinue dissipation of power provided to the motor drive from the motor load after restoration of motor drive system input power;

selectively enabling operation of the motor drive output inverter after restoration of motor drive system input power to drive the motor load to resume rotation in a forward direction;

selectively connecting a second resistive load to dissipate power in a DC bus circuit of the motor drive after restoration of motor drive system input power; and

thereafter disconnecting the second resistive load to discontinue dissipation of power in the DC bus circuit to resume normal motor drive operation;

wherein operation of the motor drive output inverter is disabled prior to selectively connecting the first resistive load circuit to the at least two AC nodes.

16. The non-transitory computer readable medium of claim 15, comprising computer executable instructions for:

selectively coupling the first resistive load circuit to the at least two AC nodes by providing a first control signal in a first state from a motor drive controller to at least one switch of the first resistive load circuit in response to loss of the motor drive system input power; and

selectively disabling the first resistive load circuit by providing the first control signal in a second state from the motor drive controller to the at least one switch of the first resistive load circuit after restoration of motor drive system input power.

17. The non-transitory computer readable medium of claim 16, comprising computer executable instructions for:

selectively connecting the second resistive load to dissipate power in the DC bus circuit of the motor drive by providing a second control signal in a first state from the motor drive controller to a switch in the DC bus circuit after restoration of motor drive system input power; and

disconnecting the second resistive load by providing the second control signal in a second state from the motor drive controller to the switch and in the DC bus circuit.

18. The non-transitory computer readable medium of claim 16, comprising computer executable instructions for disabling operation of the motor drive output inverter prior to selectively connecting the first resistive load circuit to the at least two AC nodes.

19. The non-transitory computer readable medium of claim 15, comprising computer executable instructions for:

selectively connecting the second resistive load to dissipate power in the DC bus circuit of the motor drive by providing a second control signal in a first state from the motor drive controller to a switch in the DC bus circuit after restoration of motor drive system input power; and

disconnecting the second resistive load by providing the second control signal in a second state from the motor drive controller to the switch and in the DC bus circuit.

20. The non-transitory computer readable medium of claim 15, comprising computer executable instructions for disabling operation of the motor drive output inverter prior to selectively connecting the first resistive load circuit to the at least two AC nodes.