Apparatus and method for controlling DC-AC power conversion

• US 9,225,256 B2
• Filed: 07/08/2013
• Issued: 12/29/2015
• Est. Priority Date: 07/31/2009
• Status: Active Grant

• Current Assignee: Enphase Energy Incorporated
• Original Assignee: Sunpower Corporation (Totalenergies Se)
• Inventors: Chapman, Patrick L., Kuhn, Brian T., Balog, Robert S., Kimball, Jonathan W., Krein, Philip T., Gray, Alexander, Esram, Trishan
• Primary Examiner(s): Berhane, Adolf
• Assistant Examiner(s): Mehari, Yemane
• Application Number:
  US13/936,744
• Publication Number:
  US 20140003100A1
• Time in Patent Office: 904 Days
• Field of Search: 363/65, 363/71, 363/132
• US Class Current: 1/1
• CPC Class Codes: H02J 3/38 Arrangements for parallely feeding a single network by two or more generators, converters or transformers
• CPC Class Codes: H02M 1/007 Plural converter units in cascade push-pull DC/DC converters with pre-regulator H02M3/3374; DC-AC converters following a DC-DC stage including a high frequency transformer H02M7/4807; DC-AC converters following a DC-DC conversion stage generating periodically varying voltages H02M7/4826
• CPC Class Codes: H02M 1/12 Arrangements for reducing harmonics from ac input or output
• CPC Class Codes: H02M 1/15 using active elements
• CPC Class Codes: H02M 5/458 using semiconductor devices only
• CPC Class Codes: H02M 7/48 using discharge tubes with control electrode or semiconductor devices with control electrode

Abstract

An apparatus and method for controlling the delivery of power from a DC source to an AC grid includes an inverter configured to deliver power from the unipolar input source to the AC grid and an inverter controller. The inverter includes an input converter, an active filter, and an output converter. The inverter controller includes an input converter controller, an active filter controller and an output converter controller. The input converter controller is configured to control a current delivered by the input converter to a galvanically isolated unipolar bus of the inverter. The output converter is configured to control the output converter to deliver power to the AC grid. Additionally, the active filter controller is configured to control the active filter to supply substantially all the power that is deliver by the output controller to the AC grid at a grid frequency.

Claims

1. An apparatus for controlling the delivery of power from a unipolar input source to an alternating-current (AC) grid at a grid voltage and grid frequency, the apparatus comprising:

an inverter comprising;

an input converter configured to deliver power from the unipolar input source to a galvanically isolated unipolar bus;

an active filter configured to supply energy to and absorb energy from the unipolar bus; and

an output converter configured to deliver power from the unipolar bus to the AC grid, and

an inverter controller configured to maintain a voltage of the unipolar bus at a pre-determined value, the inverter controller comprising;

an input converter controller to control a current delivered by the input converter to the unipolar bus;

an output converter controller to control the output converter to deliver power to the AC grid; and

an active filter controller to control the active filter to supply time-varying power to the output converter.

2. The apparatus of claim 1, wherein the active filter controller controls the active filter to supply substantially all of the time-varying power that is delivered to the output converter at the grid frequency and harmonics of the grid frequency.

3. The apparatus of claim 1, wherein the average power delivered to the grid by the output converter is controlled by the output converter controller to be substantially equal to the power delivered by the unipolar source less the substantial total of the power losses in the inverter.

4. The apparatus of claim 1, wherein the power delivered to the grid is controlled by the output controller to comprise an average power component and a time-varying component.

5. The apparatus of claim 4, wherein the active filter controller controls the active filter to deliver substantially all of the time-varying power.

6. The apparatus of claim 5, wherein the active filter is configured as a switching power converter comprising an active filter capacitor and the active filter controller controls the time-varying component by controlling all of the time-varying current that flows in the active filter capacitor.

7. The apparatus of claim 4, wherein the time-varying component comprises a component at twice the grid frequency.

8. The apparatus of claim 6, wherein the active filter controller controls the switches so that the current in the active filter capacitor comprises a time-varying component comprising harmonics at multiples of the grid frequency.

9. The apparatus of claim 6, wherein the active filter controller controls the switches so that the voltage across the active filter capacitor is substantially unipolar.

10. The apparatus of claims 6, wherein the active filter controller is configured to receive a measurement of the unipolar bus voltage, V_bus, and a setpoint value indicative of the said pre-determined value for the unipolar bus voltage, V_Sbus, and to control the current flowing in the active filter capacitor, i_CAF, so that the magnitude of a ripple voltage across the unipolar bus, at the grid frequency and harmonics of the grid frequency, is reduced towards zero.

11. The apparatus of claim 10, wherein the active filter controller comprises:

a feedback controller that delivers a feedback control output, i_FB, that is a function of the difference between V_bus and V_Sbus, and

a scaling element that receives a measurement of the voltage across the active filter capacitor, v_CAF, and delivers a scaled control output equal to i_CAFI =i_FB·

(V_bus/v_CAF)

wherein i_CAFI is indicative of a time-varying magnitude of the current that is controlled to flow in the active filter capacitor.

12. The apparatus of claim 11, wherein the active filter controller comprises a voltage limiter configured to deliver to the active filter a setpoint, i_SCAF, for the current that flows in the active filter capacitor, in accordance with the following logic:

i.) if the voltage v_CAF is less than a pre-determined upper voltage limit and greater than a pre-determined lower voltage limit, i_SCAF is set equal to i_CAFI;

ii) if the voltage v_CAF is less than the pre-determined lower voltage limit, i_SCAF is forced to be of a polarity that causes v_CAF to increase above the pre-determined lower voltage limit; and

iii) if the voltage v_CAF is greater than the pre-determined upper voltage limit, i_SCAF is forced to be of a polarity that causes v_CAF to decrease below the pre-determined upper voltage limit.

13. A method for controlling an inverter that is configured to deliver power from a unipolar input source to an alternating-current (“

AC”

) grid at a grid voltage and grid phase, comprising;

delivering a pre-determined amount of power from the unipolar input source to a unipolar bus that is galvanically isolated from the unipolar input source using an input converter;

supplying energy to and absorbing energy from the unipolar bus using an active filter comprising an active filter capacitor;

delivering power from the unipolar bus to the AC grid using an output converter; and

controlling the operation of the inverter using an inverter controller, wherein controlling the operation of the inverter comprises (i) controlling the operation of the input converter to deliver substantially all the average power delivered to the AC grid, (ii) controlling the active filter to deliver substantially all the time-varying power that is delivered to the AC grid, and (iii) regulating the unipolar bus voltage to a first pre-determined value.

14. The method of claim 13, wherein:

delivering the predetermined amount of power comprises delivering the predetermined amount of power from the unipolar input source to the unipolar bus using an input converter comprising a switching power converter, and

controlling the operation of the input converter comprises controlling the input converter using an input converter controller of the inverter controller to deliver the said substantially all the average power delivered to the AC grid.

15. The method of claim 13, wherein:

supplying energy to and absorbing energy from the unipolar bus comprises supplying energy to and absorbing energy from the unipolar bus using an active filter comprising a switching power converter, and

controlling the operation of the active filter comprises controlling the active filter using an active filter controller of the inverter controller to deliver the said substantially all of the time-varying power that is delivered to the AC grid.

16. The method of claim 13, wherein:

delivering power from the unipolar bus to the AC grid comprises delivering power from the unipolar bus to the AC grid using an output converter comprising a switching power converter, and

controlling the operation of the output converter comprises controlling the output converter using an output converter controller of the inverter controller to deliver power to the AC grid.

17. The method of claim 13, wherein controlling operation of the active filter comprises:

sensing the magnitude of the unipolar bus voltage, and

controlling the current in the active filter to reduce the ripple across the unipolar bus towards zero.

18. The method of claim 13, wherein regulating the unipolar bus voltage comprises:

sensing the magnitude of the unipolar bus voltage, and

controlling the magnitude of the current delivered by the output converter to the AC grid to maintain the average value of the unipolar bus voltage at the first pre-determined value.

19. The method of claim 18, further comprising;

providing a second pre-determined value for an average value of the voltage across the active filter capacitor,

comparing the average value of the unipolar bus voltage to the first pre-determined value, and, based upon the comparison, controlling the current in the active filter capacitor to alter the average value of the voltage across the active filter capacitor, and

controlling the magnitude of the current delivered by the output converter to the AC grid to maintain the average value of the voltage across the active filter capacitor at the second pre-determined value.

20. A method for improving efficiency in an inverter that is configured to deliver power from a unipolar input source to an alternating-current (“

AC”

) grid at a grid voltage and grid phase and that operates in accordance with the method of claim 13, the method comprising;

connecting the active filter directly to the unipolar bus.