High voltage power converter with a configurable input

• US 9,787,175 B2
• Filed: 10/10/2014
• Issued: 10/10/2017
• Est. Priority Date: 08/07/2014
• Status: Active Grant

• Current Assignee: Astec International Limited (Emerson Electric Company)
• Original Assignee: Astec International Limited (Emerson Electric Company)
• Inventors: Phadke, Vijay Gangadhar
• Primary Examiner(s): Torres-Rivera, Alex
• Application Number:
  US14/512,084
• Publication Number:
  US 20160043633A1
• Time in Patent Office: 1,096 Days
• Field of Search: 323207, 323266, 323268, 323271, 323272, 363 44- 48, 363 52- 53, 363 65- 67, 363 69, 363 70, 363 84, 363 86, 363125
• CPC Class Codes: H02M 1/0064 Magnetic structures combining different functions, e.g. storage, filtering or transformation
• 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 1/10 Arrangements incorporating converting means for enabling loads to be operated at will from different kinds of power supplies, e.g. from ac or dc
• CPC Class Codes: H02M 1/4216 operating from a three-phase input voltage H02M1/4233 takes precedence
• CPC Class Codes: H02M 1/4225 using a non-isolated boost converter
• CPC Class Codes: H02M 3/285 Single converters with a plurality of output stages connected in parallel parallel operation of a plurality of converters in dc distribution networks H02J1/10
• CPC Class Codes: H02M 3/33538 of the forward type H02M3/3353, H02M3/33569 take precedence
• CPC Class Codes: Y02B 70/10 Technologies improving the efficiency by using switched-mode power supplies [SMPS], i.e. efficient power electronics conversion e.g. power factor correction or reduction of losses in power supplies or efficient standby modes

Abstract

A high voltage power converter has first, second, and third switches for receiving an alternating-current input. A control power factor correction (PFC) rail is connected to each of the first, second, and third switches. A slave PFC rail is connected to each of the first, second, and third switches for providing a substantially identical output compared to an output of the control PFC rail. The control PFC rail output and the slave PFC rail output are each connected to an output stage and the output stage is for connection to a load.

Claims

1. A high voltage power converter comprising:

first, second, and third switches for receiving an alternating-current (AC) input;

a control power factor correction (PFC) rail connected to each of the first, second, and third switches for receiving the AC input, the control PFC rail including a control power stage having an inductor;

a slave PFC rail connected to each of the first, second, and third switches for receiving the AC input and providing an output substantially identical to an output of the control PFC rail, the slave PFC rail including a slave power stage having an inductor;

wherein the first, second, and third switches are configurable to adapt the high voltage power converter for operating in a first inclusive input voltage range between 170 VAC and 265 VAC and a second inclusive input voltage range between 340 VAC and 530 VAC;

wherein the inductor of the control power stage and the inductor of the slave power stage have a common core;

wherein the control PFC rail output and the slave PFC rail output are each connected to an output stage; and

wherein the output stage is for connection to a load.

2. The high voltage power converter of claim 1, wherein each of the first, second, and third switches are one of mechanical switches, relays, and wiring terminals.

3. The high voltage power converter of claim 1, wherein the high voltage power converter is adapted for operating in the first inclusive input voltage range when the first and second switches are closed and the third switch is open.

4. The high voltage power converter of claim 3, wherein the high voltage power converter is adapted for operating in the second inclusive input voltage range when the first and second switches are open and the third switch is closed.

5. The high voltage power converter of claim 1, wherein the control PFC rail includes:

the control power stage connected to each of the first, second, and third switches;

a control PFC converter connected to the control power stage; and

a control direct-current to direct-current (DC-DC) converter connected to the control PFC converter.

6. The high voltage power converter of claim 5, wherein the slave PFC rail includes:

the slave power stage connected to each of the first, second, and third switches;

a slave PFC converter connected to the slave power stage; and

a slave direct-current to direct-current (DC-DC) converter connected to the slave PFC converter.

7. The high voltage power converter of claim 6, wherein each of the control and slave power stages include a filter circuit and a rectifier circuit.

8. The high voltage power converter of claim 7, wherein the control PFC converter has an input capacitor having first and second leads and the slave PFC converter has an input capacitor having first and second leads corresponding to the control PFC converter capacitor first and second leads, wherein the inductor of the control power stage is a control boost inductor of the control PFC converter and the inductor of the slave power stage is a slave boost inductor of the slave PFC converter, and wherein the control boost inductor of the control PFC converter is connected to the control PFC converter input capacitor first lead and the slave boost inductor of the slave PFC converter is connected to the slave PFC converter input capacitor second lead.

9. The high voltage power converter of claim 6, wherein each of the control and the slave PFC converters are boost converters for achieving high power factor corrections and harmonic correction.

10. The high voltage power converter of claim 1, wherein each of the control and slave PFC rails include components having matching specifications.

11. A three phase system comprising a first high voltage power converter according to the high voltage power converter of claim 1, a second high voltage power converter according to the high voltage power converter of claim 1, and a third high voltage power converter according to the high voltage power converter of claim 1, wherein the first high voltage power converter, the second high voltage power converter, and the third high voltage power converter are connected in one of a delta and a wye configuration.

12. A high voltage power converter comprising:

first, second, and third switches for receiving an alternating-current (AC) input;

a control power stage connected to each of the first, second, and third switches to receive the AC input;

a control power factor correction (PFC) converter connected to the control power stage;

a control direct-current to direct-current (DC-DC) converter connected to the control PFC converter;

wherein the control power stage, the control PFC converter, and the control DC-DC converter collectively form a control PFC rail;

a slave power stage connected to each of the first, second, and third switches to receive the AC input;

a slave PFC converter connected to the slave power stage; and

a slave DC-DC converter connected to the slave PFC converter;

wherein the slave power stage, the slave PFC converter, and the slave DC-DC converter collectively form a slave PFC rail providing an output substantially identical to an output of the control PFC rail;

wherein the first, second, and third switches are configurable to adapt the high voltage power converter for operating in a first inclusive input voltage range between 170 VAC and 265 VAC and a second inclusive input voltage range between 340 VAC and 530 VAC;

wherein a control output of the control DC-DC converter and a slave output of the slave DC-DC converter are each connected to an output stage; and

wherein the output stage is for connection to a load.

13. The high voltage power converter of claim 12, wherein each of the first, second, and third switches are one of mechanical switches, relays, and wiring terminals.

14. The high voltage power converter of claim 12, wherein the high voltage power converter is adapted for operating in the first inclusive input voltage range when the first and second switches are closed and the third switch is open.

15. The high voltage power converter of claim 14, wherein the high voltage power converter is adapted for operating in the second inclusive input voltage range when the first and second switches are open and the third switch is closed.

16. The high voltage power converter of claim 12, wherein each of the control and slave power stages include a filter circuit and a rectifier circuit.

17. The high voltage power converter of claim 12, wherein each of the control and the slave PFC converters are boost converters for achieving high power factor corrections and harmonic correction and wherein the control PFC converter has an input capacitor and the slave PFC converter has an input capacitor and wherein a control boost inductor of the control PFC converter is connected to the control PFC converter input capacitor and a slave boost inductor of the slave PFC converter is connected to the slave PFC converter input capacitor.

18. The high voltage power converter of claim 17, wherein the control boost inductor and the slave boost inductor have a common core.

19. A high voltage power converter comprising:

an input for receiving a direct-current (DC) voltage;

first, second, and third switches coupled to the input;

a control voltage rail including a control power stage connected to each of the first, second, and third switches and a control direct-current to direct-current (DC-DC) converter connected to the control power stage; and

a slave voltage rail including a slave power stage connected to each of the first, second, and third switches and a slave DC-DC converter connected to the slave power stage;

wherein the first, second, and third switches are coupled between the input and the control power stage of the control voltage rail and between the input and the slave power stage of the slave voltage rail;

wherein the first, second, and third switches are configurable to adapt the high voltage power converter for operating in a first inclusive input voltage range between 200 VDC and 350 VDC and a second inclusive input voltage range between 400 VDC and 700 VDC;

wherein an output of the control voltage rail and an output of the slave voltage rail are each connected to an output stage; and

wherein the output stage is for connection to a load.

20. The high voltage power converter of claim 19, wherein the high voltage power converter is adapted for operating in the first inclusive input voltage range when the first and second switches are closed and the third switch is open.

21. The high voltage power converter of claim 20, wherein the high voltage power converter is adapted for operating in the second inclusive input voltage range when the first and second switches are open and the third switch is closed.

22. The high voltage power converter of claim 19, wherein the control voltage rail includes an inductor and the slave voltage rail includes an inductor and wherein the inductor of the control voltage rail and the inductor of the slave voltage rail have a common core.