Power converters for aircraft starter/generators

• US 9,590,521 B2
• Filed: 07/28/2014
• Issued: 03/07/2017
• Est. Priority Date: 07/28/2014
• Status: Active Grant

• Current Assignee: Hamilton Sundstrand Corporation (Rtx Corporation)
• Original Assignee: Hamilton Sundstrand Corporation (Rtx Corporation)
• Inventors: White, Adam M., Kheraluwala, Mustansir
• Primary Examiner(s): Dole, Timothy J
• Assistant Examiner(s): AHMED, YUSEF A
• Application Number:
  US14/444,364
• Publication Number:
  US 20160028321A1
• Time in Patent Office: 953 Days
• US Class Current: 1/1
• CPC Class Codes: H02M 5/458 using semiconductor devices only
• CPC Class Codes: H02M 5/4585 having a rectifier with controlled elements
• CPC Class Codes: H02M 7/483 Converters with outputs that each can have more than two voltages levels

Abstract

A method of converting power includes receiving alternating current (AC) at the first phase leg set of a power conversion system having first and second phase legs sets connected by direct current (DC) leads. The first phase leg set rectifies the received AC power into DC power by switching outer switches of the first phase leg set into an off state. The DC lead conveys the DC power from the first phase leg set to the second phase leg set. The second phase leg set inverts the DC power into AC power.

Claims

1. A method of converting power, comprising:

determining an operating mode of a gas turbine engine selected, wherein the operating mode is selected from a group including a start mode and a generate mode;

receiving AC power at a first set of phase legs;

rectifying the received AC power into DC power using the first set of phase legs;

receiving the rectified DC power at a second set of phase legs by flowing current through a DC link; and

inverting the received DC power into AC power using the second set of phase legs,

wherein at least one of the rectifying and inverting processes further includes switching respective outer switches of the first or second phase leg sets into an off state;

wherein the received AC power is constant frequency AC power, current flows through the DC in a first direction, the inverted AC power is variable frequency AC power when the operating mode is the start mode; and

wherein the received AC power is variably frequency AC power, current flows through the DC in a second direction opposite the first direction, and the inverted AC power is constant frequency AC power when the operating mode is the generate mode.

2. The method as recited in claim 1, wherein the outer switches are a plurality of outer switches in the second set of phase legs, and further including converting received constant frequency AC power into variable frequency AC power in a start mode by routing current through diodes in parallel with the outer switches of the second phase leg set.

3. The method as recited in claim 1, wherein the outer switches are a plurality of outer switches arranged within the first phase leg set, and further including converting received variable frequency AC power into constant frequency AC power in a generate mode by routing current through diodes in parallel with the outer switches of the first phase leg set.

4. The method as recited in claim 1, further including:

switching a power conversion circuit from a start mode to a generate mode by configuring the first phase leg set as a VIENNA rectifier;

receiving variable frequency AC power at the first phase leg set; and

outputting constant frequency AC power at the second phase leg set.

5. The method as recited in claim 1, further including switching a power conversion circuit from a start mode to a generate mode by configuring the first phase leg set as a VIENNA rectifier.

6. The method as recited in claim 5, further including:

reconfiguring the first phase leg set as an inverter;

receiving constant frequency AC power at the second phase leg set; and

outputting variable frequency AC power at the first phase leg set.

7. The method as recited in claim 6, further including selecting a direction of current flow through the DC link according to the determined operating mode of the gas turbine engine.

8. A power conversion system, comprising:

first and second AC phase leg sets connected by a DC link, wherein the phase legs of the first AC phase leg set are variable frequency phase legs, and wherein the second AC phase leg set is a constant frequency phase leg set; and

a controller operatively associated with first and second AC phase leg sets including a processor and a memory, wherein the processor is communicative with the memory and the memory has instructions recorded therein that, when read by the processor, cause the processor to;

determine an operating mode of gas turbine engine;

select a direction of current flow through the DC link according to operating mode of the gas turbine engine by (a) configuring the system to convert power in a start mode by opening a constant frequency phase leg set outer switches, and (b) configuring the system to convert power in a generate mode by opening a variable frequency phase leg set outer switches;

receive AC power at the first AC phase leg set;

rectify the AC power into DC power using the first AC phase leg set;

convey the DC power from the first AC phase leg set to the second AC phase leg set through the DC link; and

invert the DC power into AC power using the second AC phase leg set.

9. The system as recited in claim 8, wherein the instructions further include cause the processor to:

convert received constant frequency AC power into variable frequency AC power by flowing current through a diode arranged in parallel with the constant frequency phase leg set outer switches.

10. The system as recited in claim 8, wherein the instructions further include cause the processor to:

convert received variable frequency AC power into constant frequency AC power by flowing current through diodes arranged in parallel with the variable frequency phase leg set outer switches.

11. The system as recited in claim 8, wherein the instructions further cause the processor to flow current through the DC link in opposite directions in start and generate modes.

12. A power conversion method, comprising:

determining an operating mode of a gas turbine engine, wherein the operating mode includes a start mode and a generate mode;

wherein, when the determined operating mode is the start mode, the method includes;

opening outer switches of a constant frequency phase leg set;

receiving constant frequency alternating current (AC) power at the constant frequency phase leg set;

rectifying the received AC power into direct current (DC) power using the constant frequency phase leg set;

providing the DC power to a variable frequency phase leg set by flowing the DC current through a DC link in a first direction;

inverting the DC power into variable frequency AC power using a variable frequency phase leg set; and

determining to stop converting upon start of the gas turbine engine;

when the operating mode is the generate mode, the method including;

opening the outer switches of the variable frequency phase leg set;

receiving variable frequency AC power at the variable frequency phase leg set;

rectifying the received AC power at the variable frequency phase let set;

providing the DC power to the constant frequency phase leg set by flowing the DC current through the DC in a second direction; and

inverting the DC current into constant frequency AC power using the constant frequency phase leg set.