Converter system for powering an electrical load

Patent metadata

Field	Value
Publication number	US-11290026-B2
Application number	US-201916658911-A
Country	US
Kind code	B2
Filing date	Oct 21, 2019
Priority date	Apr 21, 2017
Publication date	Mar 29, 2022
Grant date	Mar 29, 2022

Abstract

A converter system includes a DC bus for each phase of an input AC power signal; a first switching cell for each phase, including first two active switches coupled in series across the DC bus and forming a first switching cell AC pole therebetween, the first switching cell AC pole being coupled to a respective phase; and a second switching cell for each phase, including second two active switches coupled in series across the DC bus and forming a second switching cell AC pole therebetween. The second switching cell AC poles are coupled to each other to form a flying neutral. One of the first switching cell and the second switching cell switches at a frequency at least an order of magnitude greater than the line frequency. The other of the first switching cell and the second switching cell switches at a frequency approximately equal to the line frequency.

First claim

What is claimed is:

1. A converter system for converting an AC power signal having one or more phases at a line frequency from an AC power source to a DC power signal for powering a load, comprising:
a DC bus for each phase of the AC power signal;
a first switching cell for each phase of the AC power signal, each first switching cell including a first pair of active switches coupled in series across the DC bus and a second pair of active switches coupled in series across the DC bus, the first and second pairs of active switches each having a first switching cell AC pole therebetween, the first switch cell AC pole of the first pair of active switches being coupled to a first inductor, and the first switch cell AC pole of the second pair of active switches being coupled to a second inductor, the first and second inductors being coupled together at a common AC pole, the common AC pole being coupled via a third inductor to a respective phase of the AC power source; and
a second switching cell for each phase of the AC power signal, each second switching cell including second two active switches coupled in series across the DC bus and forming a second switching cell AC pole therebetween, wherein the second switching cell AC poles are coupled to each other to form a flying neutral,
wherein the first switching cell is operative to switch at a first frequency at least an order of magnitude greater than the line frequency to convert AC to DC;
wherein the second switching cell is operative to switch at a second frequency approximately equal to the line frequency to convert AC to DC,
wherein each first switching cell further includes decoupling capacitors coupled directly across each active switch of the first and second pairs of active switches and operative to filter out high frequency signals; and a bulk DC link capacitor coupled across the DC bus and operative to limit voltage ripple across the DC bus.

2. The converter system of claim 1 , wherein the first frequency is within or exceeds a range of 20 kHz to 200 kHz.

3. The converter system of claim 1 , wherein the first two active switches and/or the second two active switches are gallium nitride (GaN) devices.

4. The converter system of claim 1 , further comprising:
a transformer for each phase;
a third switching cell for each phase of the AC power signal, each third switching cell including third two active switches coupled in series across the DC bus and forming a third switching cell AC pole therebetween, wherein the third switching cell AC pole is coupled to the transformer for each phase; and
wherein the third switching cells are operative to switch at a third frequency at least three orders of magnitude greater than the line frequency to convert DC to AC; and
a rectifier operative to rectify AC to DC for each phase.

5. The converter system of claim 1 , further comprising a filter neutral coupled to each phase of the AC power source via a capacitor.

6. The converter system of claim 1 , further comprising a chassis ground, wherein the flying neutral is coupled to the chassis ground.

7. The converter system of claim 1 , wherein the second switching cell AC poles are coupled directly to each other without any intervening inductors or capacitors to form the flying neutral.

8. The converter system of claim 4 , wherein the third frequency is within or exceeds a range of 100 kHz to 1 MHz.

9. The converter system of claim 5 , wherein the capacitor is coupled between the common AC pole and the third inductor.

10. The converter system of claim 5 , wherein the flying neutral is coupled to the filter neutral.

11. A converter system for converting an AC power signal having one or more phases at a line frequency from an AC power source to a desired power signal for powering a load, comprising:
a DC bus for each phase of the AC power signal;
a first at least two switching cells, each switching cell of the first at least two switching cells including a first pair of active switches coupled in series across the DC bus and second pair of active switches coupled in series across the DC bus; each of the first and second pairs of active switches having a first AC pole formed therebetween, a first inductor being coupled to the first AC pole formed between the first pair of active switches, and a second inductor being coupled to the first AC pole formed between the second pair of active switches, the first and second inductors being jointed together at a common AC pole; each first pair of active switches and second pair of active switches further including a decoupling capacitor coupled directly across each first pair of active switches and second pair of active switches, and a bulk DC link capacitor coupled across the DC bus and operative to limit voltage ripple across the DC bus; and a third inductor coupled between the common AC pole and the AC power source for each phase;
a second at least two switching cells, each switching cell of the second at least two switching cells including a second at least two active switches coupled in series across the DC bus;
and a second AC pole formed between the second at least two active switches, wherein the second AC poles for each of the second at least two switching cells are coupled together and form a flying neutral, and
wherein the first at least two switching cells are operative to switch at a first frequency at least an order of magnitude greater than the line frequency to convert AC to DC;
wherein the second at least two switching cells are operative to switch at a second frequency approximately equal to the line frequency to convert AC to DC.

12. The converter system of claim 11 , further comprising a converter stage coupled to the DC bus for each phase of the AC power signal and operative to convert DC to AC.

13. The converter system of claim 11 , further comprising a single-phase transformer and a single-phase rectifier for each phase.

14. The converter system of claim 11 , wherein the one or more phases is three-phases, further comprising three (3) single-phase transformers in a wye connection or a delta connection, and a three-phase rectifier coupled to the transformers.

15. The converter system of claim 11 , wherein the load is a motor.

16. The converter system of claim 12 , wherein the converter stage is a half bridge converter.

17. The converter system of claim 12 , wherein the converter stage is a full bridge converter.

18. The converter system of claim 12 , wherein the converter stage includes an AC output terminal; and wherein the converter stage includes a capacitor in series with an inductor on the AC output terminal.

19. The converter system of claim 12 , wherein the converter stage is a parallel resonant converter.

Assignees

• Abb Schweiz Ag

Inventors

• Bala Sandeep
• Kadavelugu Arun Kumar

Classifications

• H02M1/4233

  using a bridge converter comprising active switches · CPC title

• H02M1/4216 Primary

  operating from a three-phase input voltage (H02M1/4233 takes precedence) · CPC title

• H02M7/219 Primary

  in a bridge configuration · CPC title

• Y02B70/10

  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 · CPC title

• H02M1/007

  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 title