Adjustable AC/DC conversion topology to regulate an isolated DC load with low AC ripple

Patent metadata

Field	Value
Publication number	US-11976376-B2
Application number	US-202117193408-A
Country	US
Kind code	B2
Filing date	Mar 5, 2021
Priority date	Mar 21, 2017
Publication date	May 7, 2024
Grant date	May 7, 2024

Abstract

Systems, methods and power converters are disclosed to provide regulated individual DC output signals to anode structures using a PWM inverter to generate a first AC signal, a sinewave filter to provide a filtered AC signal, a multiphase isolation transformer to provide a plurality of isolated AC signals, a multi-pulse diode bridge rectifier to provide a DC rectifier output signal, an output filter to provide a filtered DC rectifier output signal, and a blocking diode to provide the filtered DC rectifier output signal.

First claim

The following is claimed:

1. A system, comprising:
a plurality of power converter modules individually including a first output to provide a DC output signal, the individual power converter modules including:
an adjustable voltage, adjustable frequency pulse width modulation (PWM) inverter to generate a first AC signal according to a desired fundamental inverter AC output frequency and a voltage reference,
an LC sinewave filter, including an input to receive the first AC signal, and an output to provide a filtered AC signal,
a multiphase isolation transformer, including a primary winding to receive the filtered AC signal, and a multiphase secondary to provide a plurality of isolated AC signals,
a multi-pulse diode bridge rectifier, including a plurality of rectifier inputs to receive the plurality of isolated AC signals, and a rectifier output to provide a DC rectifier output signal,
an output filter, including an input to receive the DC rectifier output signal, and an output to provide a filtered DC rectifier output signal, and
a blocking diode, including an anode connected to the output of the output filter, and a cathode to provide the filtered DC rectifier output signal;
wherein the PWM inverter regulates the filtered DC rectifier output signal by adjusting the first AC signal at least partially according to a feedback signal from the output filter.

2. The system of claim 1 , wherein the PWM inverter provides the first AC signal at a signal frequency in a range of about 120 Hz to about 600 Hz.

3. The system of claim 2 , wherein the PWM inverter provides the first AC signal at a signal frequency in a range of about 180 Hz to about 300 Hz.

4. The system of claim 2 , wherein the PWM inverter provides the first AC signal at a signal frequency of about 180 Hz.

5. The system of claim 1 , wherein the PWM inverter includes a six pulse inverter switching circuit, including three pairs of upper and lower switching devices individually coupled between a DC bus node and a corresponding one of three output nodes to provide the first AC signal as a three phase AC signal.

6. The system of claim 1 , wherein the plurality of power converter modules operate according to a profile that defines setpoints for the individual power converter modules.

7. The system of claim 1 , wherein the multiphase isolation transformer is a six-phase transformer with an electrostatic shield connected to a ground.

8. The system of claim 1 , wherein the multiphase isolation transformer is a nine-phase transformer with an electrostatic shield connected to a ground.

9. The system of claim 1 , further comprising an input rectifier to provide a DC input signal to the PWM inverter.

10. The system of claim 1 , wherein the LC sinewave filter comprises an inductor associated with each phase, and a capacitor connected between a respective one of the inductors for each phase and a common connection.

11. The system of claim 1 , wherein the LC sinewave filter is an LCL filter having first and second inductors associated with each phase, and a capacitor connected between a respective one of the second inductors for each phase and a common connection.

12. A power converter to provide a DC output signal, comprising:
an adjustable voltage, adjustable frequency pulse width modulation (PWM) inverter to generate a first AC signal according to a desired fundamental inverter AC output frequency and a voltage reference;
an LC sinewave filter, including an input to receive the first AC signal, and an output to provide a filtered AC signal;
a multiphase isolation transformer, including a primary winding to receive the filtered AC signal, and a multiphase secondary to provide a plurality of isolated AC signals;
a multi-pulse diode bridge rectifier, including a plurality of rectifier inputs to receive the plurality of isolated AC signals, and a rectifier output to provide a DC rectifier output signal;
an output filter, including an input to receive the DC rectifier output signal, and an output to provide a filtered DC rectifier output signal; and
a blocking diode, including an anode connected to the output of the output filter, and a cathode to provide the filtered DC rectifier output signal;
wherein the PWM inverter regulates the filtered DC rectifier output signal by adjusting the first AC signal at least partially according to a feedback signal from the output filter.

13. The power converter of claim 12 , wherein the PWM inverter provides the first AC signal at a signal frequency in a range of about 120 Hz to about 600 Hz.

14. The power converter of claim 13 , wherein the PWM inverter provides the first AC signal at a signal frequency in a range of about 180 Hz to about 300 Hz.

15. The power converter of claim 13 , wherein the PWM inverter provides the first AC signal at a signal frequency of about 180 Hz.

16. The power converter of claim 12 , wherein the PWM inverter includes a six pulse inverter switching circuit, including three pairs of upper and lower switching devices individually coupled between a DC bus node and a corresponding one of three output nodes to provide the first AC signal as a three phase AC signal.

17. The power converter of claim 12 , wherein the multiphase isolation transformer is a six-phase transformer with an electrostatic shield connected to a ground.

18. The power converter of claim 12 , wherein the multiphase isolation transformer is a nine-phase transformer with an electrostatic shield connected to a ground.

19. The power converter of claim 12 , further comprising an input rectifier to provide a DC input signal to the PWM inverter.

20. A method, comprising:
generating a plurality of DC voltage signals according to a profile defining setpoints for individual power converter modules, including for each power converter module:
generating a first AC signal at a frequency in a range of about 120 Hz to about 600 Hz using a pulse width modulation (PWM) inverter,
filtering the first AC signal to generate a filtered AC signal using an LC sinewave filter,
generating a plurality of isolated AC signals according to the filtered AC signal using a multiphase isolation transformer,
rectifying the isolated AC signals to generate a DC rectifier output signal using a multi-pulse diode bridge rectifier,
filtering the DC rectifier output signal to generate a filtered DC rectifier output signal using an output filter,
regulating the filtered DC rectifier output signal by adjusting the first AC signal at least partially according to a feedback signal from the output filter, and
providing the filtered DC rectifier output through a blocking diode.

Assignees

• Rockwell Automation Tech Inc

Inventors

• Guskov Nickolay N
• Skibinski Gary L
• Liu Zhijun
• Sarver William John

Classifications

• C25D21/12 Primary

  Process control or regulation (controlling or regulating in general G05) · CPC title

• C25D17/00 Primary

  Constructional parts, or assemblies thereof, of cells for electrolytic coating · CPC title

• C25D17/02

  Tanks; Installations therefor · CPC title

• H02M1/14 Primary

  Arrangements for reducing ripples from DC input or output · CPC title

• H02M3/335

  using semiconductor devices only · CPC title