Power converter having improved terminal structure

• US 20030133318A1
• Filed: 12/23/2002
• Published: 07/17/2003
• Est. Priority Date: 01/16/2002
• Status: Active Grant

• Current Assignee: Rockwell Automation Technologies Incorporated (Allen-Bradley Co., Inc.)
• Original Assignee: Rockwell Automation Technologies Incorporated (Allen-Bradley Co., Inc.)
• Inventors: Kannenberg, Daniel G., Kaishian, Steven C., Radosevich, Lawrence D., Phillips, Mark G.
• Granted Patent: US 7,187,568 B2
• Time in Patent Office: Days
• US Class Current: 363/131
• CPC Class Codes: H02M 1/44 Circuits or arrangements for compensating for electromagnetic interference in converters or inverters
• CPC Class Codes: H02M 7/003 Constructional details, e.g. physical layout, assembly, wiring or busbar connections
• CPC Class Codes: H05K 7/20927 Liquid coolant without phase change

Abstract

A terminal structure for power electronics circuits reduces the need for a DC bus and thereby the incidence of parasitic inductance. The structure is secured to a support that may receive one or more power electronic circuits. The support may aid in removing heat from the circuits through fluid circulating through the support. The support may form a shield from both external EMI/RFI and from interference generated by operation of the power electronic circuits. Features may be provided to permit and enhance connection of the circuitry to external circuitry, such as by direct contact between the terminal assembly and AC and DC circuit components. Modular units may be assembled that may be coupled to electronic circuitry via plug-in arrangements or through interface with a backplane or similar mounting and interconnecting structures.

Claims

1. A modular power converter comprising:

a support;

a power converter circuit disposed on a first side of the support;

an energy storage or conditioning circuit secured to a second side of the support opposite the first side; and

a terminal assembly secured intermediate the power converter circuit and the energy storage or conditioning circuit and configured to couple the power converter circuit to external circuitry and to the energy storage or conditioning circuit without a bus structure therebetween.

2. The modular power converter of claim 1, wherein the support at least partially defines a reference plane at a desired electrical potential, and wherein the terminal assembly includes an body at the reference desired electrical potential.

3. The modular power converter of claim 1, wherein the support is a single-piece support.

4. The modular power converter of claim 1, wherein the support is a multi-piece support.

5. The modular power converter of claim 1, wherein the power converter circuit comprises an inverter circuit.

6. The modular power converter of claim 1, wherein the power converter circuit comprises a matrix converter.

7. The modular power converter of claim 1, wherein the energy storage or conditioning circuit includes a signal filtering circuit.

8. The modular power converter of claim 1, wherein the energy storage or conditioning circuit includes a capacitor bank.

9. The modular power converter of claim 1, wherein the terminal assembly is configured to receive input DC power and apply the DC power to the power converter circuit and to the energy storage or conditioning circuit.

10. The modular power converter of claim 9, wherein the terminal assembly is configured to output three phase AC power from the power converter circuit.

11. The modular power converter of claim 10, wherein the terminal assembly includes two DC input power conductors disposed intermediate respective output AC power conductors.

12. The modular power converter of claim 1, wherein the support is a fluid cooled support and is adapted to extract heat from the power converter circuit, the energy storage or conditioning circuit and the terminal assembly during operation.

13. The modular power converter of claim 1, wherein the terminal assembly is removably secured to the support.

14. The modular power converter of claim 1, wherein the terminal assembly is secured adjacent to an edge of the support between the first and second sides thereof.

15. A modular power converter comprising:

a support having a first side, a second side opposite the first side, and an edge extending between the first and second sides;

a terminal assembly disposed adjacent to the edge of the support and including DC input terminals for receiving DC input power and AC output terminals for transmitting AC output power;

a power converter circuit supported on the first side of the support and coupled to the DC input terminals and to the AC output terminals of the terminal assembly; and

an energy storage or conditioning circuit supported on the second side of the support and coupled to the DC input terminals and to the power converter circuit via the terminal assembly.

16. The modular power converter of claim 15, wherein the support at least partially defines a reference plane at a desired electrical potential, and wherein the terminal assembly includes an body at the reference desired electrical potential.

17. The modular power converter of claim 15, wherein the support is a single-piece support.

18. The modular power converter of claim 15, wherein the support is a multi-piece support.

19. The modular power converter of claim 15, wherein the power converter circuit comprises an inverter circuit.

20. The modular power converter of claim 15, wherein the power converter circuit comprises a matrix converter.

21. The modular power converter of claim 15, wherein the energy storage or conditioning circuit includes a capacitor bank.

22. The modular power converter of claim 15, wherein the terminal assembly is configured to output three phase AC power from the power converter circuit.

23. The modular power converter of claim 22, wherein the terminal assembly includes two DC input power conductors disposed intermediate respective output AC power conductors.

24. The modular power converter of claim 15, wherein the support is a fluid cooled support and is adapted to extract heat from the power converter circuit, the energy storage or conditioning circuit and the terminal assembly during operation.

25. The modular power converter of claim 15, wherein the terminal assembly is removably secured to the support.

26. A modular power converter comprising:

a thermal support having first and second sides and configured to receive and to circulate a coolant stream;

a terminal assembly including DC input terminals for receiving DC input power and AC output terminals for transmitting AC output power;

a control circuit;

a drive circuit supported by the thermal support and coupled to the control circuit to receive control signals from the control circuit;

a power converter circuit coupled to the drive circuit and to the DC and AC terminals, the inverter circuit being configured to convert the DC power to controlled frequency AC output power based upon the drive signals; and

an energy storage or conditioning circuit coupled to the DC input terminals and to the power converter circuit via the terminal assembly;

wherein the power converter circuit is supported on the first side of the thermal support and the energy storage or conditioning circuit is supported on the second side of the thermal support, whereby the coolant stream extracts heat from the substrate and the capacitor circuit during operation of the converter circuit.

27. The modular power converter of claim 26, wherein the power converter circuit comprises an inverter circuit.

28. The modular power converter of claim 26, wherein the power converter circuit comprises a matrix converter.

29. The modular power converter of claim 26, wherein the support at least partially defines a reference plane at a desired electrical potential, and wherein the terminal assembly includes an body at the reference desired electrical potential.

30. The modular power converter of claim 26, wherein the support is a single-piece support.

31. The modular power converter of claim 26, wherein the support is a multi-piece support.

32. The modular power converter of claim 26, wherein the energy storage or conditioning circuit includes a capacitor bank.

33. The modular power converter of claim 26, wherein the terminal assembly is configured to output three phase AC power from the power converter circuit.

34. The modular power converter of claim 26, wherein the terminal assembly includes two DC input power conductors disposed intermediate respective output AC power conductors.

35. The modular power converter of claim 26, wherein the support is a fluid cooled support and is adapted to extract heat from the power converter circuit, the energy storage or conditioning circuit and the terminal assembly during operation.

36. The modular power converter of claim 26, wherein the terminal assembly is removably secured to the support.

37. A method for converting DC power to controlled output AC power comprising:

applying input DC power to a converter including a support, a terminal assembly mounted on the support and having DC terminals for receiving the input DC power and output terminals for transmitting the output AC power, a converter circuit mounted on the support and coupled to the DC terminals and to the AC terminals, and an energy storage or conditioning circuit mounted on the support and coupled to the DC terminals and to the power converter circuit via the terminal assembly; and

transferring power between the power converter circuit and the energy storage or conditioning circuit via the terminal assembly.

38. A modular power converter comprising:

means for applying input DC power to a converter including a support, a terminal assembly mounted on the support and having DC terminals for receiving the input DC power and output terminals for transmitting the output AC power, a converter circuit mounted on the support and coupled to the DC terminals and to the AC terminals, and an energy storage or conditioning circuit mounted on the support and coupled to the DC terminals and to the power converter circuit via the terminal assembly; and

means for transferring power between the power converter circuit and the energy storage or conditioning circuit via the terminal assembly.