Power converter and integrated DC choke therefor

• US 9,054,599 B2
• Filed: 03/15/2012
• Issued: 06/09/2015
• Est. Priority Date: 03/15/2012
• Status: Active Grant

• Current Assignee: Rockwell Automation Technologies Incorporated (Allen-Bradley Co., Inc.)
• Original Assignee: Rockwell Automation Technologies Incorporated (Allen-Bradley Co., Inc.)
• Inventors: Wei, Lixiang, Xiao, Yuan, Zargari, Navid, Lukaszewski, Richard
• Primary Examiner(s): Nguyen, Matthew
• Assistant Examiner(s): DANG, TRINH Q
• Application Number:
  US13/421,509
• Publication Number:
  US 20130242623A1
• Time in Patent Office: 1,181 Days
• Field of Search: 363/65, 363 34- 37, 363/67, 363/69, 363/71, 363/51, 363/58, 363/70, 318/798, 318/799, 318/801, 318/803
• US Class Current: 1/1
• CPC Class Codes: H02M 1/0043 Converters switched with a phase shift, i.e. interleaved non-isolated DC/DC converters H02M3/1586
• CPC Class Codes: H02M 1/0064 Magnetic structures combining different functions, e.g. storage, filtering or transformation
• CPC Class Codes: H02M 5/458 using semiconductor devices only
• CPC Class Codes: H02M 7/493 the static converters being arranged for operation in parallel

Abstract

A power conversion system with multiple parallel connected motor drives including a plurality of rectifiers and a corresponding inverters connected by windings of a single common mode choke.

Claims

1. A power conversion system, comprising:

first and second rectifiers individually comprising a rectifier input to receive AC electrical input power, a rectifier DC output with first and second DC output nodes, and a circuit operative to provide DC output power at the rectifier DC output, the rectifier inputs of the first and second rectifiers being coupled with one another;

first and second inverters individually comprising an inverter DC input with first and second DC input nodes, an inverter AC output, and an inverter switching network operative to provide AC output power to a load, the inverter AC outputs of the first and second inverters being coupled with one another; and

a single choke structure comprising;

a single core structure, a first pair of coils wound around the single core structure and coupled between the rectifier DC output of the first rectifier and the inverter DC input of the first inverter, and a second pair of coils wound around the single core structure and coupled between the rectifier DC output of the second rectifier and the inverter DC input of the second inverter, the first and second pairs of coils being mutually coupled to one another via the single core structure to control common mode voltages.

2. The power conversion system of claim 1:

wherein the first pair of coils includes;

a first coil coupled between the first DC output node of the first rectifier and the first DC input node of the first inverter, and

a second coil coupled between the second DC output node of the first rectifier and the second DC input node of the first inverter; and

wherein the second pair of coils includes;

a third coil coupled between the first DC output node of the second rectifier and the first DC input node of the second inverter, and

a fourth coil coupled between the second DC output node of the second rectifier and the second DC input node of the second inverter.

3. The power conversion system of claim 1, wherein the first and second rectifiers individually include a plurality of switching devices individually coupled between the rectifier input and one of the DC output nodes and operative according to corresponding rectifier switching control signals to provide DC output power at the rectifier DC output.

4. The power conversion system of claim 1, wherein the rectifiers, the inverters, and the single choke are located within a single housing.

5. The power conversion system of claim 1, wherein the rectifiers, the inverters, and the single choke are located within a single housing.

6. The power conversion system of claim 1, wherein the first and second rectifiers are switching rectifiers synchronized with one another.

7. The power conversion system of claim 2, wherein the first and second rectifiers individually include a plurality of switching devices individually coupled between the rectifier input and one of the DC output nodes and operative according to corresponding rectifier switching control signals to provide DC output power at the rectifier DC output.

8. The power conversion system of claim 2, wherein the rectifiers, the inverters, and the single choke are located within a single housing.

9. The power conversion system of claim 3, comprising at least one controller providing a first set of rectifier switching control signals to the switching devices of the first rectifier and a second set of rectifier switching control signals to the switching devices of the second rectifier, wherein the at least one controller provides the second set of rectifier switching control signals synchronized with the first set of rectifier switching control signals.

10. The power conversion system of claim 6, wherein the first and second rectifiers are operated according to switching control signals phase shifted with respect to one another.

11. The power conversion system of claim 7, comprising at least one controller providing a first set of rectifier switching control signals to the switching devices of the first rectifier and a second set of rectifier switching control signals to the switching devices of the second rectifier, wherein the at least one controller provides the second set of rectifier switching control signals synchronized with the first set of rectifier switching control signals.

12. The power conversion system of claim 9, wherein the at least one controller provides the second set of rectifier switching control signals phase shifted with respect to the first set of rectifier switching control signals.

13. The power conversion system of claim 11, wherein the at least one controller provides the second set of rectifier switching control signals phase shifted with respect to the first set of rectifier switching control signals.

14. A power conversion system, comprising:

first and second rectifiers individually comprising a rectifier input to receive AC electrical input power, a rectifier DC output with first and second DC output nodes, and a circuit operative to provide DC output power at the rectifier DC output, the rectifier inputs of the first and second rectifiers being coupled with one another;

first and second inverters individually comprising an inverter DC input with first and second DC input nodes, an inverter AC output, and an inverter switching network operative to provide AC output power to a load, the inverter AC outputs of the first and second inverters being coupled with one another; and

a single choke comprising;

a first pair of coils coupled between the rectifier DC output of the first rectifier and the inverter DC input of the first inverter, the first pair of coils including;

a first coil coupled between the first DC output node of the first rectifier and the first DC input node of the first inverter, and

a second coil coupled between the second DC output node of the first rectifier and the second DC input node of the first inverter, and

a second pair of coils coupled between the rectifier DC output of the second rectifier and the inverter DC input of the second inverter, the second pair of coils including;

a third coil coupled between the first DC output node of the second rectifier and the first DC input node of the second inverter, and

a fourth coil coupled between the second DC output node of the second rectifier and the second DC input node of the second inverter;

wherein the single choke comprises;

a core structure comprising;

a first leg including first and second ends and an intermediate portion disposed between the first and second ends, a second leg including first and second ends and an intermediate portion disposed between the first and second ends, a third leg extending between the first ends of the first and second legs, and a fourth leg extending between the second ends of the first and second legs,

at least one shunt providing a magnetic flux path between intermediate portions of the first and second legs, the at least one shunt extending between the intermediate portions of the first and second legs, and forming a plurality of gaps between the intermediate portions of the first and second legs and the at least one shunt,

a first winding forming the first coil and forming at least one turn around the first leg between the intermediate portion and the first end of the first leg;

a second winding forming the second coil and forming at least one turn around the first leg between the intermediate portion and the second end of the first leg;

a third winding forming the third coil and forming at least one turn around the second leg between the intermediate portion and the first end of the second leg; and

a fourth winding forming the fourth coil and forming at least one turn around the second leg between the intermediate portion and the second end of the second leg.

15. The power conversion system of claim 14, wherein the first and second rectifiers individually include a plurality of switching devices individually coupled between the rectifier input and one of the DC output nodes and operative according to corresponding rectifier switching control signals to provide DC output power at the rectifier DC output.

16. The power conversion system of claim 14, wherein the rectifiers, the inverters, and the single choke are located within a single housing.

17. The power conversion system of claim 15, comprising at least one controller providing a first set of rectifier switching control signals to the switching devices of the first rectifier and a second set of rectifier switching control signals to the switching devices of the second rectifier, wherein the at least one controller provides the second set of rectifier switching control signals synchronized with the first set of rectifier switching control signals.

18. The power conversion system of claim 17, wherein the at least one controller provides the second set of rectifier switching control signals phase shifted with respect to the first set of rectifier switching control signals.

19. A parallel current source converter system, comprising:

a plurality of current source converters, individually comprising;

a rectifier including a rectifier input, a rectifier DC output with first and second DC output nodes, and a rectifier circuit operative to provide DC output power at the rectifier output,

an inverter including an inverter DC input with first and second inverter DC input nodes, an inverter AC output, and an inverter switching network operative to provide AC output power for driving a load, and

a DC link circuit including a first coil coupled between the first rectifier DC output and the first inverter DC input, and a second coil coupled between the second rectifier DC output and the second inverter DC input,

wherein the rectifier inputs are coupled with one another, and the inverter AC outputs are coupled with one another; and

a single choke structure comprising a single core structure and the first and second coils of the plurality of current source converters, wherein the first and second coils of the plurality of current source converters are wound around the single core structure and are mutually coupled to one another via the single core structure.

20. The system of claim 19, wherein the rectifier circuit comprises a plurality of switches operative to provide DC output power at the rectifier output.