Multiphase power supply with plural series connected cells and failed cell bypass

• US 5,986,909 A
• Filed: 05/21/1998
• Issued: 11/16/1999
• Est. Priority Date: 05/21/1998
• Status: Expired due to Term

• Current Assignee: Siemens AG
• Original Assignee: Robicon Corp. (Siemens AG)
• Inventors: Aiello, Marc F., Hammond, Peter W.
• Primary Examiner(s): STERRETT, JEFFREY L
• Application Number:
  US09/082,888
• Time in Patent Office: 544 Days
• Field of Search: 363/34, 363/36, 363/37, 363/50, 363/53, 363/56, 363/65, 363/69, 363/70, 363/71, 363/72, 363/95, 363/98
• US Class Current: 363/65
• CPC Class Codes: B60L 15/007 Physical arrangements or structures of drive train converters specially adapted for the propulsion motors of electric vehicles
• CPC Class Codes: H02M 1/325 with means for allowing continuous operation despite a fault, i.e. fault tolerant converters
• CPC Class Codes: H02M 7/49 Combination of the output voltage waveforms of a plurality of converters
• CPC Class Codes: Y02T 10/64 Electric machine technologies in electromobility

Abstract

A high output level is maintained in power supplies having multiple cells in each leg. Failed cells in any leg are bypassed to provide a current path through the respective leg. All of the unfailed cells are utilized while maintaining equal magnitude between phases and a balance phase relationship in the line-to-line output voltage. The invention may be utilized in conjunction with a peak voltage reduction circuit, and a by-pass switch.

Claims

1. A method of operating a multiphase power supply having a plurality of converter cells connected in series in each of a plurality of legs each of said legs connected between a node and a respective line and such supply having line-to-line voltage outputs between pairs of said legs comprising:

(a) detecting a failed cell in any of said legs;

(b) forming a current path in any of said legs having at least one failed cell by providing a bypass around each of said failed cell; and

(c) controlling the cells in the legs of said power supply to maximize said line-to-line voltage outputs, and to keep all line-to-line voltage outputs generally equal in magnitude.

2. The method of claim 1 further comprising maintaining the line-to-line phase generally balanced.

3. The method of claim 1 further comprising maintaining the line-to-line voltage generally equal in magnitude by adjusting the leg-to-leg phase relationship.

4. The method of claim 3 wherein said adjusting comprises calculating leg-to-leg phase angles to produce generally balance line-to-line voltage.

5. The method of claim 3 wherein said adjusting of the leg-to-leg phase angle is according to predetermined angles based upon the number of failed cells in each of said legs.

6. The method of claim 5 wherein said predetermined angles are obtained from tables of values.

7. The method of claim 1 further comprising increasing a command signal to each non-bypassed of said converter cells in a leg having at least one failed cell.

8. The method of claim 7 wherein said increasing of said command signal is an amount generally equal to the ratio of the total number of cells in said leg to the number of non-bypassed cells in said leg.

9. The method of claim 1 further wherein said controlling further comprises increasing the magnitude of the output during a portion of the cycle of non-bypassed cells in each of said leg having at least one failed cell.

10. The method of claim 1 wherein said controlling further comprises increasing the magnitude of the output during a portion of the cycle of non-bypassed cells in each of said leg having no failed cells.

11. The method of claim 10 wherein said controlling further comprises increasing the magnitude of the output during a portion of the cycle of non-bypassed cells in each of said leg having at least one failed cell.

12. The method of claim 1 further comprising reducing the peak voltage demands between legs.

13. The method of claim 1 further comprising pulse width modulating said converter cells with a command signal.

14. The method of claim 1 further comprising generating voltage commands to provide peak voltage reduction and modifying such commands in response to detecting at least one failed cell.

15. The method of claim 14 wherein said modifying further comprises increasing said commands by amount generally equal to the ratio of the total number of cells in one of said legs to the number of non-bypassed cells in said one of said legs.

16. A method of operating a multiphase power supply having a plurality of converter cells connected in series in each of a plurality of legs each of said legs connected between a node and a respective line and such supply having line-to-line voltage outputs between pairs of said legs comprising:

(a) detecting a failed cell in any of said legs;

(b) forming a current path in any of said legs having at least one failed cell by providing a transfer of at least one of the input and output of each of said failed cells; and

(c) controlling the cells in the legs of said power supply to maximize said line-to-line voltage outputs, and to keep all line-to-line voltage outputs generally equal in magnitude.

17. The method of claim 16 further comprising maintaining the line-to-line phase voltages generally balanced.

18. The method of claim 16 further comprising maintaining the line-to-line voltage generally equal in magnitude by adjusting the leg-to-leg phase relationship.

19. The method of claim 18 wherein said adjusting comprises calculating leg-to-leg phase angles to produce generally balance line-to-line voltage.

20. The method of claim 18 wherein said adjusting of the leg-to-leg phase angle is according to predetermined angles based upon the number of failed cells in each of said legs.

21. the method of claim 20 wherein said predetermined angles are obtained from tables of values.

22. The method of claim 16 further comprising increasing a command signal to each non-bypassed of said converter cells in a leg having at least one failed cell.

23. The method of claim 22 wherein said increasing of said command signal is an amount generally equal to the ratio of the total number of cells in said leg to the number of non-bypassed cells in said leg.

24. The method of claim 16 further wherein said controlling further comprises increasing the magnitude of the output during a portion of the cycle of non-bypassed cells in each of said leg having at least one failed cell.

25. The method of claim 16 wherein said controlling further comprises increasing the magnitude of the output during a portion of the cycle of non-bypassed cells in each of said leg having no failed cells.

26. The method of claim 25 wherein said controlling further comprises increasing the magnitude of the output during a portion of the cycle of non-bypassed cells in each of said leg having at least one failed cell.

27. The method of claim 16 further comprising reducing the peak voltage demands between legs.

28. The method of claim 16 further comprising generating voltage commands to provide peak voltage reduction and modifying such commands in response to detecting at least one failed cell.

29. The method of claim 28 wherein said modifying further comprises increasing said commands by amount generally equal to the ratio of the total number of cells in one of said legs to the number of non-bypassed cells in said one of said legs.

30. The method of claim 16 further comprising pulse width modulating said converter cells with a command signal.

31. The method of claim 16 wherein said transfer is pneumatically performed.

32. The method of claim 31 wherein said transfer is through operations of a SPDT transfer switch.

33. The method of claim 32 wherein said operation of said transfer switch is through a source of pressurized fluid remotely located from said SPDT switch contacts and pneumatically connected by a non-electrically conducting tube.

34. The method of claim 33 wherein said source of pressurized fluid is activated by an electrical signal.

35. The method of claim 34 further comprising generating said source with an electrically driven compressor.

36. A multiphase power supply having a line-to-line voltage output comprising:

(a) a plurality of converter cells in series arrangement in each of a plurality of legs each of legs connected between a node and a respective line;

(b) a controller to control the output voltage of each of said cells thereby supplying said line-to-line voltage output between pairs of said legs;

(c) said controller detecting a failed cell in any of said legs and in response thereto removing said failed cell from said series arrangement;

(d) said controller controlling said cell outputs to maximize said line-to-line voltage output and to keep all line-to-line voltage outputs generally equal in magnitude.

37. The multiphase power supply of claim 36 wherein said controller maintains the line-to-line phase voltages generally balanced by controlling the output of operable cells.

38. The multiphase power supply of claim 36 wherein said controller maintains the line-to-line voltage generally equal in magnitude by adjusting the leg-to-leg phase relationship.

39. The multiphase power supply of claim 36 further comprising said controller operating said cells having reduced peak voltage demands.

40. The multiphase power supply of claim 39 further comprising said controller generates voltage commands to provide peak voltage reduction and modifies such commands in response to detection of at least one failed cell.

41. The multiphase power supply of claim 36 wherein said controller adjusts the leg-to-leg phase angle according to a table of predetermined angles based upon the number of failed cells in each of said legs.

42. The multiphase power supply of claim 36 wherein said controller increases the magnitude of cell output during a portion of a cycle of operative cells in each of said leg having no failed cells.

43. The multiphase power supply of claim 36 wherein said controller operates a bypass to remove said failed cell from said series arrangement.

44. The multiphase power supply of claim 36 wherein said controller operates a transfer switch to remove said failed cell from said series arrangement.

45. The multiphase power supply of claim 44 wherein said transfer switch is fluid operated.

46. The multiphase power supply of claim 45 wherein said transfer switch is operated pneumatically from a fluid source remote from high voltage adjacent said transfer switch.

47. The multiphase power supply of claim 45 wherein said fluid source includes a compressor and pneumatic pressure is conveyed to said transfer switch by an electrically non-conducting tube.