Balancing current within a modular converter system

• US 9,991,778 B2
• Filed: 02/29/2016
• Issued: 06/05/2018
• Est. Priority Date: 02/29/2016
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Krolak, Matthew J., Liu, Shengyi
• Primary Examiner(s): Moody, Kyle J
• Application Number:
  US15/055,828
• Publication Number:
  US 20170250622A1
• Time in Patent Office: 827 Days
• Field of Search: 363 71, 363 73, 363 79, 363 95, 363142, 363 40, 307 31
• CPC Class Codes: B64D 2221/00 Electric power distribution systems onboard aircraft
• CPC Class Codes: H02J 1/14 Balancing the load in a network
• CPC Class Codes: H02J 2310/44 for aircrafts
• CPC Class Codes: H02M 1/088 for the simultaneous control of series or parallel connected semiconductor devices
• CPC Class Codes: H02M 7/493 the static converters being arranged for operation in parallel
• CPC Class Codes: H02M 7/537 using semiconductor devices only, e.g. single switched pulse inverters

Abstract

To provide current balancing between paralleled first and second inverter units of a modular converter system, a system controller is configured to determine a gate driver offset value based on respective voltages at the phase output nodes of the first and second inverter units. The system controller controls gate drivers for the first and second inverter units based on the determined gate driver offset value. In turn, the gate drivers drive the first and second inverter units with subsequent drive signals such that the amounts of current provided by the first and second inverter units when producing an in-phase power output are balanced.

Claims

1. A method of controlling power output of a modular converter system comprising a plurality of parallel inverter units, the plurality of parallel inverter units comprising a first inverter unit with at least a first phase output node and a second inverter unit with at least a second phase output node, the method comprising:

driving switching elements of the first and second inverter units with initial drive signals to produce an in-phase power output;

determining a gate driver offset value based on respective first and second voltages at the first and second phase output nodes, wherein determining the gate driver offset value comprises;

calculating, for each of the first and second inverter units, a respective applied volt-seconds value, wherein the gate driver offset value is based on a difference between the respective calculated applied volt-seconds values; and

driving, based on the determined gate driver offset value, the switching elements of the first and second inverter units with subsequent drive signals such that respective amounts of current provided by the first and second inverter units when producing the in-phase power output are balanced.

7. The method of claim 1, wherein the gate driver offset value is further based on a difference between the calculated applied volt-seconds values and desired outputs of the first and second inverter units when driven with the initial drive signals.

2. A method of controlling power output of a modular converter system comprising a plurality of parallel inverter units, the plurality of parallel inverter units comprising a first inverter unit with at least a first phase output node and a second inverter unit with at least a second phase output node, wherein each of the first and second phase output nodes are coupled with at least one integrator of the modular converter system, the method comprising:

driving switching elements of the first and second inverter units with initial drive signals to produce an in-phase power output;

determining a gate driver offset value based on respective first and second voltages at the first and second phase output nodes, wherein determining the gate driver offset value comprises;

integrating, using the at least one integrator, each of the first and second voltages relative to at least one reference voltage; and

driving, based on the determined gate driver offset value, the switching elements of the first and second inverter units with subsequent drive signals such that respective amounts of current provided by the first and second inverter units when producing the in-phase power output are balanced.

3. The method of claim 2, wherein the at least one reference voltage comprises a system ground.

4. The method of claim 2, wherein integrating each of the first and second voltages occurs during a switching cycle of the first and second inverter units, the method further comprising:

resetting the at least one integrator upon completion of the switching cycle.

5. The method of claim 4, wherein resetting the at least one integrator occurs upon detecting a rising edge of a control signal provided to gate drivers of the first and second inverter units.

6. The method of claim 2, wherein the at least one integrator comprises first and second integrators, the method further comprising:

integrating, during a first switching cycle of the first and second inverter units, each of the first and second voltages using the first integrator; and

integrating, during a second switching cycle of the first and second inverter units, each of the first and second voltages using the second integrator.

8. A modular converter system, comprising:

a system controller; and

at least first and second inverter units connected in parallel and configured to produce an in-phase power output, each inverter unit of the first and second inverter units respectively comprising;

a pair of switching elements having a phase output node coupled therebetween, and

a pair of gate drivers, each gate driver configured to receive a respective control signal from the system controller and to generate a drive signal to control switching of a respective one of the pair of switching elements,

wherein the system controller is configured to;

calculate, for each of the first and second inverter units, a respective applied volt-seconds value,

determine a gate driver offset value based on respective voltages at the phase output nodes of the first and second inverter units, wherein the gate driver offset value is based on a difference between the respective calculated applied volt-seconds values, and

control, based on the determined gate driver offset value, the gate drivers to drive the first and second inverter units with subsequent drive signals such that amounts of current provided by the first and second inverter units when producing the in-phase power output are balanced.

14. The modular converter system of claim 8, wherein the gate driver offset value is further based on a difference between the calculated applied volt-seconds values and desired outputs of the first and second inverter units when driven with the initial drive signals.

9. A modular converter system comprising:

a system controller;

at least first and second inverter units connected in parallel and configured to produce an in-phase power output, each inverter unit of the first and second inverter units respectively comprising;

a pair of switching elements having a phase output node coupled therebetween, and

a pair of gate drivers, each gate driver configured to receive a respective control signal from the system controller and to generate a drive signal to control switching of a respective one of the pair of switching elements;

one or more first integrators coupled with the phase output node of the first inverter unit; and

one or more second integrators coupled with the phase output node of the second inverter unit,

wherein the system controller is configured to;

determine a gate driver offset value based on respective voltages at the phase output nodes of the first and second inverter units, wherein determining the gate driver offset value comprises;

integrating, using the one or more first integrators and the one or more second integrators, each of the first and second voltages relative to at least one reference voltage; and

control, based on the determined gate driver offset value, the gate drivers to drive the first and second inverter units with subsequent drive signals such that amounts of current provided by the first and second inverter units when producing the in-phase power output are balanced.

10. The modular converter system of claim 9, wherein the at least one reference voltage comprises a system ground.

11. The modular converter system of claim 9, wherein integrating each of the first and second voltages occurs during a switching cycle of the first and second inverter units,

wherein the system controller is further configured to reset the one or more first integrators and the one or more second integrators upon completion of the switching cycle.

12. The modular converter system of claim 11, wherein resetting the one or more first integrators and the one or more second integrators occurs upon detecting a rising edge of a control signal provided to the pair of gate drivers of each of the first and second inverter units.

13. The modular converter system of claim 9, wherein the one or more first integrators comprise a first plurality of integrators and the one or more second integrators comprise a second plurality of integrators,

wherein at least one integrator of each of the first plurality and the second plurality of integrators is configured to integrate the respective first and second voltages during a first switching cycle of the first and second inverter units, and

wherein at least another integrator of each of the first plurality and the second plurality of integrators is configured to integrate the respective first and second voltages during a second switching cycle of the first and second inverter units.

15. A non-transitory computer-readable medium comprising computer program code that, when executed by operation of one or more computer processors, performs an operation of controlling power output of a modular converter system comprising a plurality of parallel inverter units,

the plurality of parallel inverter units comprising a first inverter unit with at least a first phase output node and a second inverter unit with at least a second phase output node,

the operation comprising:

communicating with a plurality of gate drivers to drive switching elements of the first and second inverter units with initial drive signals to produce an in-phase power output;

determining a gate driver offset value based on respective first and second voltages at the first and second phase output nodes, wherein determining the gate driver offset value comprises;

calculating, for each of the first and second inverter units, a respective applied volt-seconds value, wherein the gate driver offset value is based on a difference between the respective calculated applied volt-seconds values; and

communicating with the plurality of gate drivers to drive, based on the determined gate driver offset value, the switching elements of the first and second inverter units with subsequent drive signals such that respective amounts of current provided by the first and second inverter units when producing the in-phase power output are balanced.

20. The non-transitory computer-readable medium of claim 15, wherein the gate driver offset value is further based on a difference between the calculated applied volt-seconds values and desired outputs of the first and second inverter units when driven with the initial drive signals.

16. A non-transitory computer-readable medium comprising computer program code that, when executed by operation of one or more computer processors, performs an operation of controlling power output of a modular converter system comprising a plurality of parallel inverter units,

the plurality of parallel inverter units comprising a first inverter unit with at least a first phase output node and a second inverter unit with at least a second phase output node, wherein each of the first and second phase output nodes are coupled with at least one integrator of the modular converter system,

the operation comprising:

communicating with a plurality of gate drivers to drive switching elements of the first and second inverter units with initial drive signals to produce an in-phase power output;

determining a gate driver offset value based on respective first and second voltages at the first and second phase output nodes, wherein determining the gate driver offset value comprises;

integrating, using the at least one integrator, each of the first and second voltages relative to at least one reference voltage; and

communicating with the plurality of gate drivers to drive, based on the determined gate driver offset value, the switching elements of the first and second inverter units with subsequent drive signals such that respective amounts of current provided by the first and second inverter units when producing the in-phase power output are balanced.

17. The non-transitory computer-readable medium of claim 16, wherein integrating each of the first and second voltages occurs during a switching cycle of the first and second inverter units, the operation further comprising:

resetting the integrator upon completion of the switching cycle.

18. The non-transitory computer-readable medium of claim 17, wherein resetting of the integrator occurs upon detecting a rising edge of a control signal provided to gate drivers of the first and second inverter units.

19. The non-transitory computer-readable medium of claim 16, wherein the at least one integrator comprises first and second integrators, the operation further comprising:

integrating, during a first switching cycle of the first and second inverter units, each of the first and second voltages using the first integrator; and

integrating, during a second switching cycle of the first and second inverter units, each of the first and second voltages using the second integrator.