Multifunction power converter with option for integrated magnetics

Patent metadata

Field	Value
Publication number	US-9654021-B2
Application number	US-201314049266-A
Country	US
Kind code	B2
Filing date	Oct 9, 2013
Priority date	Oct 9, 2013
Publication date	May 16, 2017
Grant date	May 16, 2017

Abstract

Power converter modules and parallel conversion systems are presented in which the modules are provided in a rollable enclosure having AC and DC electrical connections, and an interior including a switching circuit with switching devices individually connected between a corresponding AC node and a corresponding DC node for operation as either a rectifier or an inverter and an internal filter circuit with inductors individually connected between a corresponding AC node of the switching circuit and a corresponding AC electrical connection, with a built-in blower or fan to cool the filter circuit during operation.

First claim

The following is claimed:

1. A power conversion apparatus, comprising:
an enclosure defining an enclosure interior and having a bottom;
a plurality of AC electrical connections for connecting external AC power lines to the power conversion apparatus;
a first and second DC electrical connections for connecting external DC power lines to the power conversion apparatus;
a switching circuit located in the enclosure interior and including:
first and second DC nodes individually electrically connected to a corresponding one of the first and second DC electrical connections,
a plurality of AC nodes individually electrically coupled with a corresponding one of the AC electrical connections, and
a plurality of switching devices individually operative to selectively couple a corresponding one of the plurality of AC nodes with a corresponding one of the first and second DC nodes according to a corresponding switching control signal; and

a filter circuit located below the switching circuit in the enclosure interior and including a plurality of inductors individually electrically connected between a corresponding one of the plurality of AC nodes of the switching circuit and a corresponding one of the plurality of AC electrical connections;
wherein the enclosure includes a top vertically spaced from and above the bottom of the enclosure, wherein the enclosure defines a single airflow path between the top and the bottom, wherein the filter circuit is positioned vertically between the switching circuit and the bottom of the enclosure, and wherein the switching circuit is positioned vertically between the filter circuit and the top of the enclosure.

2. The apparatus of claim 1 , wherein the filter circuit includes a plurality of filter resistors individually connected in parallel with a corresponding one of the plurality of inductors.

3. The apparatus of claim 2 , comprising a blower fan assembly located in the enclosure interior and operative to cool the filter circuit during operation of the power conversion apparatus.

4. The apparatus of claim 3 , comprising a DC bus capacitance circuit located in the enclosure interior and including at least one capacitor connected between the first and second DC electrical connections.

5. The apparatus of claim 4 , comprising a DC bus balancing circuit located in the enclosure interior including first and second balancing resistors connected in series with one another between the first and second DC electrical connections.

6. The apparatus of claim 2 , comprising at least one control board located in the enclosure interior and operative to provide the switching control signals to operate the switching circuit either as (i) an active rectifier to convert power from an AC source connected to the AC electrical connections to provide DC output power at the first and second DC electrical connections with the filter circuit providing an R-L input filter, or (ii) as an inverter to convert power from a DC source connected to the DC electrical connections to provide AC output power at the plurality of AC electrical connections with the filter circuit providing an R-L output filter.

7. The apparatus of claim 6 , comprising a blower fan assembly located in the enclosure interior and operative to cool the filter circuit during operation of the power conversion apparatus.

8. The apparatus of claim 6 , comprising a DC bus capacitance circuit located in the enclosure interior and including at least one capacitor connected between the first and second DC electrical connections.

9. The apparatus of claim 1 , comprising at least one control board located in the enclosure interior and operative to provide the switching control signals to operate the switching circuit either as (i) an active rectifier to convert power from an AC source connected to the AC electrical connections to provide DC output power at the first and second DC electrical connections with the filter circuit providing an input filter, or (ii) as an inverter to convert power from a DC source connected to the DC electrical connections to provide AC output power at the plurality of AC electrical connections with the filter circuit providing an output filter.

10. The apparatus of claim 1 , comprising a blower fan assembly located in the enclosure interior and operative to cool the filter circuit during operation of the power conversion apparatus.

11. The apparatus of claim 10 , comprising a DC bus capacitance circuit located in the enclosure interior and including at least one capacitor connected between the first and second DC electrical connections.

12. The apparatus of claim 11 , comprising a DC bus balancing circuit located in the enclosure interior including first and second balancing resistors connected in series with one another between the first and second DC electrical connections.

13. The apparatus of claim 10 , wherein the blower fan assembly is located below the filter circuit in the enclosure interior.

14. The apparatus of claim 1 , comprising a DC bus balancing circuit located in the enclosure interior including first and second balancing resistors connected in series with one another between the first and second DC electrical connections.

15. The apparatus of claim 1 , wherein the bottom of the enclosure is supported by a plurality of roller wheels to allow the enclosure to be rolled.

16. The apparatus of claim 1 , wherein the filter circuit includes interconnection and mounting features for selective direct connection of the AC electrical connections with the AC nodes of the switching circuit, or for connection of inductors and/or filter resistors between the AC connections and the switching circuit.

17. A power conversion system, comprising:
first and second power converter modules configured as active front-end (AFE) switching rectifiers, each individual power converter module comprising:
an enclosure defining an enclosure interior and having a bottom,
an AC input, including a plurality of AC electrical connections,
a DC output, including a first and second DC electrical connections,
a switching circuit located in the enclosure interior and including:
first and second DC nodes individually electrically connected to a corresponding one of the first and second DC electrical connections,
a plurality of AC nodes individually electrically coupled with a corresponding one of the AC electrical connections, and
a plurality of switching devices individually operative to selectively couple a corresponding one of the plurality of AC nodes with a corresponding one of the first and second DC nodes according to a corresponding switching control signal, and

a filter circuit located below the switching circuit in the enclosure interior and including a plurality of inductors individually electrically connected between a corresponding one of the plurality of AC nodes of the switching circuit and a corresponding one of the plurality of AC electrical connections, and
at least one control board located in the enclosure interior and operative to provide the switching control signals to operate the switching circuit as an active rectifier to convert power from an AC source connected to the AC electrical connections to provide DC output power at the first and second DC electrical connections with the filter circuit providing an input filter;

wherein the AC inputs of the first and second power converter modules are connected to one another to receive AC input power;
wherein the DC outputs of the first and second power converter modules are connected to one another to provide DC output power; and
wher

Assignees

• Wei Lixiang
• Michalski Robert M
• Patel Yogesh
• Weiss Bruce W
• Brown Brian P
• Rockwell Automation Tech Inc

Inventors

• Wei Lixiang
• Michalski Robert M
• Patel Yogesh
• Weiss Bruce W
• Brown Brian P

Classifications

• H05K7/1432

  specially adapted for power drive units or power converters · CPC title

• H02M5/4585 Primary

  having a rectifier with controlled elements · CPC title

• H05K7/14325 Primary

  for cabinets or racks · CPC title