AC/DC power conversion system and method of manufacture of same

• US 9,419,538 B2
• Filed: 02/24/2012
• Issued: 08/16/2016
• Est. Priority Date: 02/24/2011
• Status: Active Grant

• Current Assignee: Crane Electronics, Inc. (Crane Company)
• Original Assignee: Crane Electronics, Inc. (Crane Company)
• Inventors: Furmanczyk, Kaz, Stephenson, Randy
• Primary Examiner(s): Finch, III, Fred E
• Application Number:
  US14/001,312
• Publication Number:
  US 20140016356A1
• Time in Patent Office: 1,635 Days
• US Class Current: 1/1
• CPC Class Codes: H02M 5/14 for conversion between circuits of different phase number
• CPC Class Codes: H02M 7/043 using transformers or inductors only
• CPC Class Codes: H02M 7/062 Avoiding or suppressing excessive transient voltages or currents
• CPC Class Codes: H02M 7/066 particular circuits having a special characteristic
• CPC Class Codes: H02M 7/068 mounted on a transformer
• CPC Class Codes: H02M 7/08 arranged for operation in parallel

Abstract

A power converter has a transformer having three primary windings configured to receive respective phases of a three-phase alternating current (AC) input signal in a delta configuration and three secondary windings, each split into two portions, wherein the portions are coupled together in a regular hexagon. The power converter includes a rectifier having a first rectifier path coupled between taps of the secondary windings and a positive output of the power converter and a second rectifier path coupled between taps of the secondary windings and a negative output. One of the secondary windings may be reversed with respect to the other secondary windings. The primary windings may be split with a corresponding secondary winding sandwiched between portions of the primary. One of the paths may have a different inductance than the other path.

Claims

1. A power converter, comprising:

a transformer having;

three primary windings configured to receive respective phases of a three-phase alternating current (AC) input signal in a delta configuration; and

three secondary windings each split into two portions, the portions of the secondary windings coupled together into a closed regular hexagon, with each portion of each secondary winding having at least two taps and the taps distributed at regular angles on the closed regular hexagon;

a first rectification path coupled between taps of the secondary windings and a positive output of the power converter and having an inductance; and

a second rectification path coupled between taps of the secondary windings and a negative output of the power converter and having an inductance different from the inductance of the first rectification path, wherein in operation, the difference in inductance causes the first and second rectification paths to convert twelve-phase AC signals into twenty-four pulse direct-current voltage.

2. The power converter of claim 1 wherein the difference in inductance is selected to cause outputs of the secondary windings to be shifted approximately 15 degrees from each other.

3. The power converter of claim 1 wherein,

the first rectification path comprises a first plurality of rectifiers coupled to the positive output;

and

the second rectification path comprises a second plurality of rectifiers coupled to the negative output, wherein an inductance of a coupling path between the first plurality of rectifiers and the positive output is different than an inductance of a coupling path between the second plurality of rectifiers and the negative output.

4. The power converter of claim 3 wherein a length of a lead of the coupling path between the first plurality of rectifiers and the positive output is different than a length of a lead of the coupling path between the second plurality of rectifiers and the negative output.

5. The power converter of claim 1 wherein the first rectification path comprises:

a first plurality of rectifiers having cathodes coupled together;

an inductor coupled between the cathodes of the first plurality of rectifiers and the positive output;

a second plurality of rectifiers having cathodes coupled together; and

an inductor coupled between the cathodes of the second plurality of rectifiers and the positive output.

6. The power converter of claim 1 wherein one of the secondary windings has a polarity opposite of a polarity of the other secondary windings.

7. The power converter of claim 6 wherein each primary winding is split into two portions and each secondary winding is sandwiched between two portions of a corresponding primary winding.

8. The power converter of claim 1 wherein each primary winding is split into two portions and each secondary winding is sandwiched between two portions of a corresponding primary winding.

9. The power converter of claim 1 wherein,

the first rectification path comprises 12 rectifiers, each coupled to a respective tap of the secondary windings through respective couplings having a first inductance;

and

the second rectification path comprises 12 rectifiers, each coupled to a respective tap of the secondary windings through respective couplings having a second inductance different that the first inductance.

10. The power converter of claim 1 wherein the first rectification path comprises a lead having a length different than a length of a corresponding lead of the second rectification path.

11. The power converter of claim 1 wherein the inductance of the first rectification path is approximately five times the inductance of the second rectification path.

12. The power converter of claim 1 wherein the taps of the secondary windings are distributed at substantially identical central angles on the regular hexagon.

13. The power converter of claim 1 wherein two taps on one portion of a secondary winding are on adjacent turns of the portion of the secondary winding.

14. The power converter of claim 1 wherein the transformer comprises three substantially identical coils, each coil comprising one of the primary windings and a corresponding secondary winding.

15. The power converter of claim 14 wherein the coils are positioned next to each other in a row and a center coil has a polarity different than a polarity of the other coils.

16. A method, comprising:

coupling three primary windings of a transformer together in a differential configuration to receive respective phases of a three-phase alternating current;

coupling split portions of three secondary windings of the transformer together into a regular hexagonal configuration;

providing a plurality of taps distributed at regular angles on the secondary windings, each split secondary winding portion having at least two taps;

forming a first rectification path between the plurality of taps and a positive output, the first rectification path having an inductance; and

forming a second rectification path between the plurality of taps and a negative output, the second rectification path having an inductance different than the inductance of the first rectification path, wherein, in operation, the difference in inductance causes the first and second rectification paths to convert twelve-phase AC power signals into twenty-four pulse direct-current voltage.

17. The method of claim 16 wherein,

the first rectification path comprises a first plurality of rectifiers coupled to the positive output;

and

the second rectification path comprises a second plurality of rectifiers coupled to the negative output, wherein an inductance of a coupling path between the first plurality of rectifiers and the positive output is different than an inductance of a coupling path between the second plurality of rectifiers and the negative output.

18. The method of claim 17 wherein a length of a lead of the coupling path between the first plurality of rectifiers and the positive output is different than a length of a lead of the coupling path between the second plurality of rectifiers and the negative output.

19. The method of claim 16 wherein the first rectification path comprises:

a first plurality of rectifiers having cathodes coupled together;

an inductor coupled between the cathodes of the first plurality of rectifiers and the positive output;

a second plurality of rectifiers having cathodes coupled together; and

an inductor coupled between the cathodes of the second plurality of rectifiers and the positive output.

20. The method of claim 16 wherein the transformer comprises first, second and third coils and the method comprises:

positioning the first, second and third coils together in a row with the second coil separating the first and third coils, the second coil having a polarity different than a polarity of the first coil and of the third coil.

21. The method of claim 16 wherein the primary windings are split into first and second primary portions and the portions of the each secondary winding are sandwiched between first and second primary portions of a respective primary winding.

22. The method of claim 16 wherein the difference in inductance is selected to cause outputs of the secondary windings to be shifted approximately 15 degrees from each other.

23. A power converter, comprising:

means for converting three-phase alternating current (AC) power signals into multi-phase AC power signals;

first means for rectifying multi-phase AC power signals;

second means for rectifying multiphase AC power signals;

first means for coupling to couple the means for converting to the first means for rectifying and to couple the first means for rectifying to a first output of the power converter; and

second means for coupling to couple the means for converting to the second means for rectifying and to couple the second means for rectifying to a second output of the power converter, wherein the first means for coupling has an inductance different than an inductance of the second means for coupling, wherein the difference in inductance causes the power converter, in operation, to convert twelve-phase AC power signals into twenty-four pulse direct-current voltage.

24. The power converter of claim 23 wherein the means for converting comprises a transformer having:

a primary including three primary windings configured to couple to respective phases of an AC power signal in a delta configuration; and

a secondary including three secondary windings, each secondary winding corresponding to a respective primary winding and split into two portions, wherein the portions of the secondary windings are coupled together into a closed hexagon and each portion of a secondary winding comprises at least two taps.

25. The power converter of claim 24 wherein one of the primary windings has a polarity opposite of the other primary windings and the corresponding secondary winding has a polarity opposite of the other secondary windings.

26. The power converter of claim 25 wherein the primary windings are each split in two portions and the two portions of the corresponding secondary winding are sandwiched between the two portions of the corresponding primary winding.

27. The power converter of claim 23 wherein the first means for coupling comprises an inductor coupled between the first means for rectifying and the first output of the power converter.

28. The power converter of claim 23 wherein the difference in inductance is configured to cause outputs of the secondary windings to be shifted approximately 15 degrees from each other.

29. A power converter, comprising:

a transformer having;

three primary windings in a delta configuration and coupled to respective phases of a three-phase alternating current (AC) input; and

three secondary windings each split into two portions, the portions of the secondary windings coupled together into a closed regular hexagon, with each portion of each secondary winding having at least two taps with the taps distributed at regular angles on the closed regular hexagon;

a first rectification path coupled between taps of the secondary windings and a positive output of the power converter and having an inductance; and

a second rectification path coupled between taps of the secondary windings and a negative output of the power converter and having an inductance different from the inductance of the first rectification path, wherein the inductance of one of the rectification paths is approximately five times the inductance of the other rectification path and the difference in inductance causes the power converter, in operation, to convert 12-phase AC power signals into 24 pulse direct-current voltage.

30. The power converter of claim 29 wherein,

the first rectification path comprises a first plurality of rectifiers coupled to the positive output;

and

the second rectification path comprises a second plurality of rectifiers coupled to the negative output, wherein an inductance of a coupling path between the first plurality of rectifiers and the positive output is different than an inductance of a coupling path between the second plurality of rectifiers and the negative output.

31. The power converter of claim 30 wherein a length of a lead of the coupling path between the first plurality of rectifiers and the positive output is different than a length of a lead of the coupling path between the second plurality of rectifiers and the negative output.

32. The power converter of claim 29 wherein the first rectification path comprises:

a first plurality of rectifiers having cathodes coupled together;

an inductor coupled between the cathodes of the first plurality of rectifiers and the positive output;

a second plurality of rectifiers having cathodes coupled together; and

an inductor coupled between the cathodes of the second plurality of rectifiers and the positive output.

33. The power converter of claim 29 wherein one of the secondary windings has a polarity opposite of a polarity of the other secondary windings.

34. The power converter of claim 29 wherein the taps of the secondary windings are distributed at substantially identical central angles on the regular hexagon.