[go: up one dir, main page]

US20190319549A1 - Interleaved parallel inverters with integrated filter inductor and interphase transformer - Google Patents

Interleaved parallel inverters with integrated filter inductor and interphase transformer Download PDF

Info

Publication number
US20190319549A1
US20190319549A1 US16/461,245 US201716461245A US2019319549A1 US 20190319549 A1 US20190319549 A1 US 20190319549A1 US 201716461245 A US201716461245 A US 201716461245A US 2019319549 A1 US2019319549 A1 US 2019319549A1
Authority
US
United States
Prior art keywords
output
series
turns
inductor
power
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US16/461,245
Other languages
English (en)
Inventor
Robert Pasterczyk
Jason Elliott
Zbigniew Wolanski
Benjamin Wun Wang Tam
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Schneider Electric Solar Inverters USA Inc
Original Assignee
Schneider Electric Solar Inverters USA Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Schneider Electric Solar Inverters USA Inc filed Critical Schneider Electric Solar Inverters USA Inc
Priority to US16/461,245 priority Critical patent/US20190319549A1/en
Publication of US20190319549A1 publication Critical patent/US20190319549A1/en
Abandoned legal-status Critical Current

Links

Images

Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M7/00—Conversion of AC power input into DC power output; Conversion of DC power input into AC power output
    • H02M7/42—Conversion of DC power input into AC power output without possibility of reversal
    • H02M7/44—Conversion of DC power input into AC power output without possibility of reversal by static converters
    • H02M7/48—Conversion of DC power input into AC power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode
    • H02M7/493—Conversion of DC power input into AC power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode the static converters being arranged for operation in parallel
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/34—Special means for preventing or reducing unwanted electric or magnetic effects, e.g. no-load losses, reactive currents, harmonics, oscillations, leakage fields
    • H01F27/38—Auxiliary core members; Auxiliary coils or windings
    • H01F27/385—Auxiliary core members; Auxiliary coils or windings for reducing harmonics
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M1/00—Details of apparatus for conversion
    • H02M1/0061—Details of apparatus for conversion using discharge tubes
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M1/00—Details of apparatus for conversion
    • H02M1/12—Arrangements for reducing harmonics from AC input or output
    • H02M1/126—Arrangements for reducing harmonics from AC input or output using passive filters
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M1/00—Details of apparatus for conversion
    • H02M1/0043—Converters switched with a phase shift, i.e. interleaved
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M1/00—Details of apparatus for conversion
    • H02M1/0064—Magnetic structures combining different functions, e.g. storage, filtering or transformation
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M1/00—Details of apparatus for conversion
    • H02M1/0067—Converter structures employing plural converter units, other than for parallel operation of the units on a single load
    • H02M1/007—Plural converter units in cascade
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M1/00—Details of apparatus for conversion
    • H02M1/0067—Converter structures employing plural converter units, other than for parallel operation of the units on a single load
    • H02M1/0074—Plural converter units whose inputs are connected in series
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M1/00—Details of apparatus for conversion
    • H02M1/0067—Converter structures employing plural converter units, other than for parallel operation of the units on a single load
    • H02M1/0077—Plural converter units whose outputs are connected in series
    • H02M2001/0064—
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M7/00—Conversion of AC power input into DC power output; Conversion of DC power input into AC power output
    • H02M7/42—Conversion of DC power input into AC power output without possibility of reversal
    • H02M7/44—Conversion of DC power input into AC power output without possibility of reversal by static converters
    • H02M7/48—Conversion of DC power input into AC power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode
    • H02M7/483—Converters with outputs that each can have more than two voltages levels
    • H02M7/49—Combination of the output voltage waveforms of a plurality of converters
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/50—Photovoltaic [PV] energy
    • Y02E10/56—Power conversion systems, e.g. maximum power point trackers

Definitions

  • Embodiments of the present invention relate generally to utility scale power inverters.
  • a power inverter is an electronic device or circuitry that converts direct current (DC) to alternating current (AC).
  • Inverters may be used in a number of different contexts, with different DC power sources (such as lead acid batteries, photovoltaic solar panels, wind turbines, etc), and may be designed to satisfy different power demands of a system.
  • Utility scale solar inverters in particular, convert variable DC output of a photovoltaic (PV) solar panel into a utility frequency AC to provide power to either a commercial electrical grid or a local, off-grid electrical network.
  • Solar inverters are connected to a plurality of photovoltaic cells that provide DC input to the inverter.
  • the inverter comprises at least one DC-to-AC power conversion bridge, associated filter electronics and an AC (output) module.
  • the DC-to-AC power conversion bridge uses a plurality of electronic switches, typically insulated gate bipolar transistors (IGBTs), and diodes to convert the DC input into AC output.
  • IGBTs insulated gate bipolar transistors
  • solar power inverters have special functions adapted for use with photovoltaic arrays, including maximum power point tracking and anti-islanding protection.
  • a sine wave inverter produces a multiple-step sinusoidal AC waveform, although in most cases the output is a choppy or rough approximation of a sine wave, rather than a smooth sine wave.
  • power inverter devices approximate a sine wave output because many electrical products are engineered to work best with a sine wave AC power source.
  • grid-connected inverters are designed to feed power into the electric power distribution system. They transfer synchronously with the line, and should have as little harmonic content as possible.
  • the output from an inverter can be single phase or three-phase.
  • Three-phase inverters are generally used in higher power applications.
  • a basic three-phase inverter consists of three single-phase legs each connected to one of the three load terminals. The operation of the three phase legs is coordinated so that one operates at each 120 degree point of the fundamental output waveform. Certain harmonics are eliminated and other harmonics can be removed by further processing.
  • an LC filter comprising one or more inductor and capacitor can be used to smooth the AC waveform from a single phase inverter (as shown in FIG. 1 ).
  • Such low-pass filters allow the fundamental component of the waveform to pass to the output while limiting the passage of harmonic components.
  • LC filters may similarly be used in connection with a three phase inverter, with an LC filter applied to each output phase of the inverter.
  • inverters When two or more inverters are connected in parallel, their switching times (single phase or 3-phase) can be synchronized or can be offset relative to one another in an “interleaved” configuration. Interleaving is implemented by phase-shifting the switching times of each inverter by a unique multiple of 360°/n, where n is the number of inverters. The switching of the multiple inverters is thereby staggered, and the overall switching frequency may thereby be increased.
  • FIG. 2 shows two 3-phase DC-AC inverters connected in parallel, with output LC filters.
  • Interleaved converters are sometimes magnetically coupled with a coupling inductor, and then share the same output filter.
  • the coupling combines high frequency components (which may be interleaved) and may thereby reduce ripple.
  • FIG. 3 shows a pair of inverters (bridges) magnetically coupled via a coupling inductor which is connected to a shared LC filter. With this arrangement the combined current from bridge 1 and bridge 2 passes through the output filter inductor.
  • some embodiments provide for two or more inverters to be connected in parallel, in an extremely compact configuration, with efficient use of magnetic inductor material (thereby reducing cost). These embodiments may drastically reduce the overall AC filter size and cost, and can provide a filtered AC output quality suitable for the grid.
  • a power electronics system includes a first inverter configured to receive direct current (DC) power from a power source, a second inverter configured to receive DC power from the power source, a first output inductor connected in series to an alternating current (AC) output of the first inverter, a second output inductor connected in series to an AC output of the second inverter, a coupling inductor configured to receive current from the first output inductor and the second output inductor, and an AC power output to provide current from the coupling inductor.
  • DC direct current
  • AC alternating current
  • Some embodiments also include a control system configured to provide a control signal associated with a disturbance frequency, determine an amplitude of oscillation in an output power of the AC power output, wherein the oscillation is caused by the disturbance frequency, detect an islanding condition, if the amplitude of oscillation is below a threshold, and disconnect the grid from the AC power output if the islanding condition is detected.
  • the coupling inductor includes a coil winding around a coupled core and a self-inductance core.
  • the coil winding includes a series of elongated turns.
  • power electronics system includes a first multi-phase inverter configured to receive direct current (DC) power from a power source, a second multi-phase inverter configured to receive DC power from the power source, a first plurality of output inductors, each of the first plurality of output inductors connected in series to an output phase of the first multi-phase inverter, a second plurality of output inductors, each of the second plurality of output inductors connected in series to an output phase of the second multi-phase inverter, a plurality of coupling inductors, each of the plurality of coupling inductors configured to receive current from a respective output inductor of the first plurality of output inductors and a respective output inductor of the second plurality of output inductors, and a multi-phase alternating current (AC) power output to provide current from the plurality of coupling inductors.
  • DC direct current
  • AC multi-phase alternating current
  • Some embodiments also include a control system configured to provide a control signal associated with a disturbance frequency, determine an amplitude of oscillation in an output power of the AC power output, wherein the oscillation is caused by the disturbance frequency, detect an islanding condition, if the amplitude of oscillation is below a threshold, and disconnect the grid from the AC power output if the islanding condition is detected.
  • the coupling inductor includes a coil winding around a coupled core and a self-inductance core.
  • the coil winding includes a series of elongated turns.
  • an inductor coil winding includes a first terminal, a series of concentric turns in a first plane, the series of concentric turns leading in from the first terminal and having a diameter allowing for an opening within the series of concentric turns, a series of elongated turns in a second plane, the series of elongated turns leading in from the series of concentric turns and having a length greater than the diameter of the series of concentric turns, and allowing for an opening within the series of elongated turns, and a second terminal, the second terminal leading out form the series of elongated turns.
  • the series of concentric turns provides main inductance.
  • the series of elongated turns provides coupled inductance.
  • the first terminal is an input terminal electrically connected to an output of an inverter to receive current from the inverter.
  • Some embodiments also include a self-inductance core in the opening within the series of concentric turns and a coupled core in the opening within the series of elongated turns, the coupled core configured to provide a magnetic coupling to another inductor coil winding.
  • a filter assembly includes a first self-inductance core, a second self-inductance core, a coupler core, a first plurality of inductor coil windings, each of the first plurality of inductor coil windings having a series of first turns around the first self-inductance core, and a series of second turns around the first self-inductance core and the coupler core, and a second plurality of inductor coil windings, each of the second plurality of inductor coil windings having a series of first turns around the second self-inductance core, and a series of second turns around the second self-inductance core and the coupler core.
  • the first self-inductance core, the second self-inductance core, and the coupler core each include three limbs, one limb for each of three phases.
  • the first turns of each of the first plurality of inductor coil windings are concentric turns and the first turns of each of the second plurality of inductor coil windings are concentric turns.
  • the second turns of each of the first plurality of inductor coil windings are elongated turns and the second turns of each of the second plurality of inductor coil windings are elongated turns.
  • the first plurality of inductor coil windings is configured to electrically connect to a first inverter at a first terminal to receive an alternating current output from the first inverter and the second plurality of inductor coil windings is configured to electrically connect to a second inverter at a second terminal to receive an alternating current output from the second inverter.
  • the first plurality of inductor coil windings is electrically connected to the second plurality of inductor coil windings at a third terminal configured to provide a combined alternating current from the first and second inverter.
  • Certain embodiments also include a plurality of thermal plates interspersed among the first and second plurality of inductor coil windings and configured to remove thermal energy from the first and second plurality of inductor coil windings.
  • a power electronics system comprises a first inverter configured to receive DC power from a power source, a second inverter configured to receive DC power from the power source, a first output inductor connected in series to an output of the first inverter, a second output inductor connected in series to an output of the second inverter, a coupling inductor configured to receive current from the first output inductor and the second output inductor; and an AC power output.
  • a power electronics system comprises a first multi-phase inverter configured to receive DC power from a power source, a second multi-phase inverter configured to receive DC power from the power source, a first plurality of output inductors, each output inductor connected in series to an output phase of the first multi-phase inverter, a second plurality of output inductors, each output inductor connected in series to an output phase of the second multi-phase inverter, a plurality of coupling inductors configured to receive current from an output inductor of the first plurality of output inductors and a output inductor of the second plurality of output inductors having a corresponding phase, and a multi-phase AC power output.
  • inventions of the power electronic systems further comprise a control system configured to provide a control signal associated with a disturbance frequency, determine an amplitude of oscillation in an output power of the AC power output, wherein the oscillation is caused by the disturbance frequency, detect an islanding condition, if the amplitude of oscillation is below a threshold, and disconnect the grid from the AC power output if the islanding condition is detected.
  • a control system configured to provide a control signal associated with a disturbance frequency, determine an amplitude of oscillation in an output power of the AC power output, wherein the oscillation is caused by the disturbance frequency, detect an islanding condition, if the amplitude of oscillation is below a threshold, and disconnect the grid from the AC power output if the islanding condition is detected.
  • an inductor coil winding comprises an input with a series of concentric turns in a first plane, the concentric turns having a diameter allowing for an opening within the series of concentric turns that provide main inductance to a filter system.
  • the concentric turns lead into a series of elongated turns in a second plane, the series of elongated turns leading in from the series of concentric turns and having a length greater than the diameter of the concentric turns of the series of concentric turns, and allowing for an opening within the series of elongated turns.
  • the opening within the series of elongated turns being larger than the opening of the within the series of concentric turns to accommodate for a shared inductance.
  • the series of elongated turns leads to an output of the inductor coil.
  • inventions of the present invention provide a filter assembly comprising a first self-inductance core, a second self-inductance core, and a coupler core.
  • the embodiments further comprise a first plurality of inductor coil windings, each inductor coil winding having an input leading to a series of concentric turns in a first plane, the concentric turns having a diameter allowing for an opening within the series of concentric turns.
  • the concentric turns lead to a series of elongated turns in a second plane, the series of elongated turns leading in from the series of concentric turns and having a length greater than the diameter of the concentric turns of the series of concentric turns, and allowing for an opening within the series of elongated turns an output.
  • the first plurality of inductor coil windings are arranged such that the opening within the series of concentric turns of the inductor coil windings accommodate the first self-inductance core, and the opening within the series of elongated turns of the inductor coil windings accommodate the first self-inductance core and the coupler core.
  • a second group of similar inductor coils are arranged such that the opening within the series of concentric turns of the inductor coil windings accommodate the second self-inductance core, and the opening within the series of elongated turns of the inductor coil windings accommodate the second self-inductance core and the coupler core.
  • self-inductance cores and a coupled core of a filter assembly may be provided for three phases in a fully integrated implementation.
  • FIG. 1 is a schematic diagram of single phase power conversion bridge with an AC filter
  • FIG. 2 is a schematic diagram of two three-phase power bridges connected in parallel employing output AC filters
  • FIG. 3 is a schematic diagram of two single phase power conversion bridges coupled via a coupling inductor with a shared output AC filter;
  • FIG. 4 is a schematic diagram of two single phase power conversion bridges, with each bridge having an output AC filter, connected in parallel and coupled via a coupling inductor in accordance with principles of the invention
  • FIG. 5 is a schematic diagram of two three phase power conversion bridges, with each phase of each bridge having an output AC filter, connected in parallel with each phase coupled via coupling inductors in accordance with principles of the invention;
  • FIG. 6 is a perspective view of an example inductor coil in accordance with principles of the invention.
  • FIG. 7 is a perspective view of an example filter assembly for a single phase output of an inverter pair with connections to each inverter bridge in accordance with principles of the invention
  • FIG. 8 is a perspective view of an example 3 -phase inductor assembly in accordance with principles of the invention.
  • FIG. 9 is a top view of the example 3 -phase inductor assembly of FIG. 8 ;
  • FIG. 10 is a perspective view of the example 3 -phase inductor assembly of FIG. 8 including example integrated cooling components;
  • FIG. 11 is a perspective view of the example cooling components of FIG. 10 , apart from the example 3-phase inductor assembly.
  • Embodiments in accordance with principles of the invention can drastically reduce the overall AC filter size and cost, and can provide a filtered AC output quality suitable for the grid.
  • a cooling system may be mechanically integrated into the compact AC filter module for thermal management in some embodiments.
  • FIG. 4 illustrates an example of two single-phase inverters 410 , 420 (bridge 1 and bridge 2 ) connected in parallel, each inverter 410 , 420 having a corresponding output inductor 412 , 422 (L 1 and L 2 ), respectively providing self-inductance.
  • the outputs are then magnetically coupled via a coupled inductor 430 (L coupled ).
  • L coupled coupled inductor 430
  • FIG. 5 shows a solar inverter system 500 of similar arrangement to FIG. 4 , but for two 3-phase inverters 510 , 520 (bridges) connected in parallel. Corresponding phases (A, B, C) from each of the inverters 510 , 520 are coupled via a coupled inductor 530 .
  • the inverters 510 , 520 of solar inverter system 500 may be DC-to-AC inverters (or “power conversion bridges”), each rated for up to 1 MW (as 2 MW of power cannot be handled by a single inverter). Each inverter produces a 3-phase output.
  • the two bridges are connected in parallel and the 3-phase outputs of the 2 bridges are interleaved (180° out of phase relative to each other).
  • the inverters 510 , 520 on their own may produce an unacceptably rough AC power waveform. Therefore, an AC filter module 540 , consisting of inductor and capacitor components, is used to smooth the waveform.
  • an AC filter would conventionally be large and costly.
  • a classical approach to this problem even after much optimization, requires inductors that cost approximately 9% of the system cost and capacitors that are approximately 2% of the system cost.
  • the inductor used in the classical approach also produces significant energy losses (around 4 kW), which inflates the required cooling system and adds additional cost and volume to the system.
  • switching of the two 3-phase inverters 510 , 520 in the example system 500 may be interleaved, thereby doubling the switching frequency. This essentially doubles the frequency seen by the inductors and therefore the amount of filtering required is reduced.
  • there is a core for each AC phase that provides self-inductance 550 .
  • there is also a third core that provides a coupled inductance 530 between the inverters 510 , 520 (for each phase).
  • Each of the self-inductors 550 is positioned between each inverter 510 , 520 and the respective coupled inductor 530 , per phase.
  • the AC filter module 540 thereby includes coupling between inverters and in some implementations also includes coupling between phases.
  • a solar inverter system may comprise two 3-phase inverters connected in parallel, but a similar approach consistent with principles of the invention can be taken with more than two 3-phase inverters and/or with two or more single phase or other multi-phase inverters.
  • the mechanical design of an AC filter module has multiple novel aspects that allow the technology to be practically and commercially realized.
  • Overall the coupled inductor is 1 ⁇ 3 the total mass and 1 ⁇ 2 the volume of the classical inductors when designed for equivalent losses. This results in a cost reduction of the inductor components. Additional reductions in system cost can be obtained through mechanical integration of cooling, structural features, and size reduction.
  • the coils or windings are wrapped around a central core (often a straight cylindrical rod or a continuous loop or ring, doughnut).
  • a central core often a straight cylindrical rod or a continuous loop or ring, doughnut.
  • Embodiments of the present invention involve a unique winding geometry that is particularly suited for use in embodiments of an AC filter module. An example of such a winding is shown in FIG. 6 .
  • the conductive material of an example winding 600 may have a rectangular cross-section as shown.
  • the conductive material may be one or more strands, and may be multi-strand transpose wire in certain embodiments, e.g., to achieve additional reduction in losses.
  • the winding 600 is shaped to form a series of concentric turns 610 in a first plane for the main inductance, then transitions to a second plane (parallel to the first) and is formed in to a series of concentric elongated turns 620 .
  • the circular opening 612 accommodates a self-inductor core and the elongated opening 622 accommodates a coupled inductor core.
  • the coupled inductor turns 620 also contribute to the self-inductance.
  • the winding 600 may be generally coated in an electrically insulating material, such as a plastic, except for the terminals 630 .
  • FIG. 6 Various embodiments of winding geometry, with respect to the example illustrated in FIG. 6 , offer particular advantages. They are designed to integrate the self and coupled inductor cores, and are designed to stack in a space-efficient manner, with the main inductance turns of one winding in the same plane as the coupled inductance turns of an adjacent winding.
  • the stacks of windings can also be packed together tightly side-by-side because of their quasi-rectangular shape.
  • the flat/planar structure of the windings also allows good thermal contact with thermal plates, such as liquid-cooled thermal plates, which can be interposed between stacked windings, for cooling the assembly (as described in more detail below).
  • Input and output terminals can be conveniently located at almost any desired location around the perimeter of the winding. In conventional windings, one terminal is often located inside the winding where it is less accessible.
  • the cross-section of the winding may be non-rectangular.
  • the number of turns for the main inductance and the coupled inductance can be varied.
  • the shape of the windings need not be as shown.
  • the various winding turns need not be in two planes as shown, e.g., they may be in a single plane or in multiple planes.
  • the winding turns may not have a planar-like configuration like the winding of FIG. 6 . They may, for example, have a helical structure or a more conventional geometry etc.
  • FIG. 7 shows an example AC filter assembly 700 for single-phase output of an inverter pair with connections to each inverter bridge.
  • the assembly comprises 16 windings similar to those shown in FIG. 6 (with circular openings to accommodate the cores), stacked in two side-by-side stacks of 8.
  • Self-inductance turns of the 8 windings connected to bridge 1 are wound around self-inductance core 710 .
  • self-inductance turns of the 8 windings connected to bridge 2 are wound around self-inductance core 720 .
  • the coupled inductor turns of all 16 windings are wound around the coupler core 730 .
  • the physically interleaved windings stacked on each core are positioned to cancel what could otherwise be massive losses in the coupler core.
  • FIG. 7 For a pair of inverters with 3-phase (interleaved) output, three separate mechanical assemblies like that shown in FIG. 7 may be used. In certain embodiments, however, the windings and inductors for all three phases of two or more inverters may be integrated into a single, compact assembly. An example of such an assembly is illustrated in perspective view in FIG. 8 . A top view of the same example assembly is illustrated in FIG. 9 .
  • the 1st and 5th limbs of each core are optional, depending on application, and/or the yoke of one or more of the cores may be removed, e.g., in an air core design.
  • a yokeless design for the self-inductor cores is enabled due to the core material magnetic properties and the arrangement of the cores. Such can reduce the core material mass and cost significantly.
  • the self-inductor cores and coupler cores can be made of any suitable magnetic material.
  • the self-inductor cores are powdered iron or powdered iron alloys
  • the coupler cores are pillars or rods made of an amorphous material, with the perimeter constructed from Cold Rolled Grain Oriented laminated steel. Such a composition and construction can improve power losses and dissipation in the magnetic material.
  • FIG. 10 shows an example AC filter module for a pair of interleaved 3-phase inverters comprising the assembly of FIG. 8 integrated with a liquid cooling system rack (shown individually in FIG. 11 below).
  • a liquid cooling system rack shown individually in FIG. 11 below.
  • aluminum thermal plates with internal flow channels may be interposed between the phase A/phase B windings and between the phase B/phase C windings, and above the phase A windings and below the phase C windings.
  • Liquid coolant supplied via a main coolant inlet manifold and coolant lines may be circulated through the plates, in parallel, to cool the electrical and magnetic components, and then directed via corresponding outlet lines and an outlet manifold to an air-cooled heat exchanger.
  • a pair of solid aluminum heat spreader plates may be included to help dissipate heat generated deep inside the module, near the coupler core, for example.
  • Embodiments of an inductor assembly such as the example assembly shown in FIGS. 8-10 , including a compact arrangement of inductor windings for three phases (e.g., as compared to three separate assemblies like that assembly shown in FIG. 7 ), may provide improved compensation and cancellation of noise between coils of the assembly.
  • an assembly or module as shown in FIGS. 8-10 may be potted, e.g., in high temperature, thermally conductive, electrically insulating material.
  • FIG. 11 illustrates the example cooling system components of the module shown in FIG. 10 .
  • the example cooling system includes liquid coolant that is distributed through coolant lines to various thermal plates to remove heat generated from the inductor coils and electrical components.
  • Embodiments of the present invention provide a number of advantages, including the reduction of an AC filter size and cost, through use of a compact configuration, with efficient use of magnetic inductor and conductor materials.
  • Examples and embodiments of AC filter/inductor assemblies described herein have the effect of providing an increased power density.
  • they may provide reduced losses due to lower current from the self-inductors being “upstream” of the coupled inductor, and reduced losses due to the interleaved physical arrangement of the windings on the coupler cores.
  • the reduced losses result in less heat generation, and reduced requirement for cooling.
  • the design of the cores and windings provide for simple assembly, supporting manufacturing feasibility. Further, the design allows for the use of liquid cooling of a filter/inductor, which is generally more cost-efficient than air-cooling, and allows for greater control or optimization of the degree of thermal transfer.
  • windings, arrangements, assemblies, and modules in accord with aspects of those illustrated in FIGS. 4-10 may be beneficially applied to provide electrical filtering to any of numerous power converter applications, including those of solar inverters as described herein, but also of DC-to-DC converters, AC-to-DC converters, and other DC-to-AC converters for applications other than solar.
  • Such arrangements may provide compact and efficient filtering to remove high frequency components from an electrical waveform at inputs and/or outputs of various power converters.
  • Such arrangements may also be beneficially adapted to differing scale of power conversion equipment than those discussed herein. For example, power factor correction (PFC) equipment, uninterruptible power supply (UPS) equipment, and the like.
  • PFC power factor correction
  • UPS uninterruptible power supply

Landscapes

  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Inverter Devices (AREA)
US16/461,245 2016-11-16 2017-11-15 Interleaved parallel inverters with integrated filter inductor and interphase transformer Abandoned US20190319549A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
US16/461,245 US20190319549A1 (en) 2016-11-16 2017-11-15 Interleaved parallel inverters with integrated filter inductor and interphase transformer

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US201662422838P 2016-11-16 2016-11-16
US16/461,245 US20190319549A1 (en) 2016-11-16 2017-11-15 Interleaved parallel inverters with integrated filter inductor and interphase transformer
PCT/US2017/061727 WO2018093848A1 (fr) 2016-11-16 2017-11-15 Inverseurs parallèles intercalés avec un inducteur à filtre intégré et un transformateur interphase

Related Parent Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2017/061727 A-371-Of-International WO2018093848A1 (fr) 2016-11-16 2017-11-15 Inverseurs parallèles intercalés avec un inducteur à filtre intégré et un transformateur interphase

Related Child Applications (1)

Application Number Title Priority Date Filing Date
US16/943,501 Continuation US20210175820A1 (en) 2016-11-16 2020-07-30 Interleaved parallel inverters with integrated filter inductor and interphase transformer

Publications (1)

Publication Number Publication Date
US20190319549A1 true US20190319549A1 (en) 2019-10-17

Family

ID=60570240

Family Applications (3)

Application Number Title Priority Date Filing Date
US16/461,245 Abandoned US20190319549A1 (en) 2016-11-16 2017-11-15 Interleaved parallel inverters with integrated filter inductor and interphase transformer
US16/943,501 Abandoned US20210175820A1 (en) 2016-11-16 2020-07-30 Interleaved parallel inverters with integrated filter inductor and interphase transformer
US17/381,984 Active US11588393B2 (en) 2016-11-16 2021-07-21 Interleaved parallel inverters with integrated filter inductor and interphase transformer

Family Applications After (2)

Application Number Title Priority Date Filing Date
US16/943,501 Abandoned US20210175820A1 (en) 2016-11-16 2020-07-30 Interleaved parallel inverters with integrated filter inductor and interphase transformer
US17/381,984 Active US11588393B2 (en) 2016-11-16 2021-07-21 Interleaved parallel inverters with integrated filter inductor and interphase transformer

Country Status (4)

Country Link
US (3) US20190319549A1 (fr)
EP (1) EP3542455B1 (fr)
AU (1) AU2017362229A1 (fr)
WO (1) WO2018093848A1 (fr)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN116246863A (zh) * 2022-12-29 2023-06-09 广东工业大学 一种集成电感、并联交错式电力电子变换电路和逆变器
CN116722757A (zh) * 2023-07-20 2023-09-08 深圳古瑞瓦特电源科技有限公司 一种裂相逆变器

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US11309123B2 (en) 2020-01-07 2022-04-19 Schneider Electric It Corporation Fully integrated inversely weakly coupled power inductor
DE102020211718A1 (de) * 2020-09-18 2022-03-24 Siemens Aktiengesellschaft Netzeinspeisewechselrichter
US11942887B2 (en) * 2021-12-02 2024-03-26 Dana Tm4 Italia S.R.L. Dual segmented motor drive

Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5657217A (en) * 1994-03-02 1997-08-12 Kabushiki Kaisha Yaskawa Denki Multi-coupled power conversion system and control method for the same
US20060043922A1 (en) * 2004-08-25 2006-03-02 Baker Donal E Parallel inverter motor drive with improved waveform and reduced filter requirements
US7046527B2 (en) * 2003-05-09 2006-05-16 Distributed Power, Inc. Power converter with ripple current cancellation using skewed switching techniques
US20060114623A1 (en) * 2003-02-12 2006-06-01 Takuya Domoto Switching type power source device and magnetio resonance imaging device using the same
US7990098B2 (en) * 2007-07-30 2011-08-02 GM Global Technology Operations LLC Series-coupled two-motor drive using double-ended inverter system
US20120113695A1 (en) * 2010-11-08 2012-05-10 Ingeteam Technology, S.A. Control method for converting power, and electronic power converter adapted to carry out said method
US20140152413A1 (en) * 2012-12-05 2014-06-05 Futurewei Technologies, Inc. Coupled Inductor Structure
US20150349626A1 (en) * 2014-05-30 2015-12-03 Hamilton Sundstrand Corporation Output filter for paralleled inverter
US20160329705A1 (en) * 2013-12-18 2016-11-10 Thales Modular and reconfigurable electrical power conversion device

Family Cites Families (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102007063434A1 (de) * 2007-06-29 2009-01-02 Enasys Gmbh Wechselrichtersystem und Steuerverfahren
WO2009132427A1 (fr) * 2008-05-01 2009-11-05 The Governors Of The University Of Alberta Onduleur de tension multiniveau
JP5081063B2 (ja) * 2008-05-22 2012-11-21 本田技研工業株式会社 複合型変圧器、および電力変換回路
KR20120060271A (ko) * 2010-12-01 2012-06-12 한국전기연구원 전류 밸런서를 이용한 인버터 병렬운전 풍력발전 시스템
EP2536018B1 (fr) * 2011-06-17 2015-12-30 Ingeteam Technology S.A. Onduleur avec une pluralité d'onduleurs connectés en parallèle, et procédé
CN103296907B (zh) * 2012-03-02 2015-05-06 台达电子企业管理（上海）有限公司 多重化逆变器及有源电力滤波系统
WO2013174420A1 (fr) * 2012-05-22 2013-11-28 Abb Research Ltd Injection de courant dans un onduleur à deux niveaux connecté en cascade

Patent Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5657217A (en) * 1994-03-02 1997-08-12 Kabushiki Kaisha Yaskawa Denki Multi-coupled power conversion system and control method for the same
US20060114623A1 (en) * 2003-02-12 2006-06-01 Takuya Domoto Switching type power source device and magnetio resonance imaging device using the same
US7046527B2 (en) * 2003-05-09 2006-05-16 Distributed Power, Inc. Power converter with ripple current cancellation using skewed switching techniques
US20060043922A1 (en) * 2004-08-25 2006-03-02 Baker Donal E Parallel inverter motor drive with improved waveform and reduced filter requirements
US7990098B2 (en) * 2007-07-30 2011-08-02 GM Global Technology Operations LLC Series-coupled two-motor drive using double-ended inverter system
US20120113695A1 (en) * 2010-11-08 2012-05-10 Ingeteam Technology, S.A. Control method for converting power, and electronic power converter adapted to carry out said method
US20140152413A1 (en) * 2012-12-05 2014-06-05 Futurewei Technologies, Inc. Coupled Inductor Structure
US20160329705A1 (en) * 2013-12-18 2016-11-10 Thales Modular and reconfigurable electrical power conversion device
US20150349626A1 (en) * 2014-05-30 2015-12-03 Hamilton Sundstrand Corporation Output filter for paralleled inverter

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN116246863A (zh) * 2022-12-29 2023-06-09 广东工业大学 一种集成电感、并联交错式电力电子变换电路和逆变器
CN116722757A (zh) * 2023-07-20 2023-09-08 深圳古瑞瓦特电源科技有限公司 一种裂相逆变器

Also Published As

Publication number Publication date
EP3542455B1 (fr) 2025-08-13
US20210359619A1 (en) 2021-11-18
EP3542455C0 (fr) 2025-08-13
WO2018093848A1 (fr) 2018-05-24
EP3542455A1 (fr) 2019-09-25
US20210175820A1 (en) 2021-06-10
US11588393B2 (en) 2023-02-21
AU2017362229A1 (en) 2019-06-27

Similar Documents

Publication Publication Date Title
US11588393B2 (en) Interleaved parallel inverters with integrated filter inductor and interphase transformer
US7973632B2 (en) Methods and apparatus for electromagnetic component
CN104541345B (zh) 电力转换装置
US8373530B2 (en) Power converter method and apparatus
US8624702B2 (en) Inductor mounting apparatus and method of use thereof
US7855629B2 (en) Methods and apparatus for electromagnetic components
US8902035B2 (en) Medium / high voltage inductor apparatus and method of use thereof
CN101938216B (zh) 电力传输方法及电力传输设备
US8089333B2 (en) Inductor mount method and apparatus
US20090045898A1 (en) Inductor mounting, temperature control, and filtering method and apparatus
US8130069B1 (en) Distributed gap inductor apparatus and method of use thereof
US10121577B2 (en) Integral inductor arrangement
MX2013013989A (es) Dispositivo de conversion de energia.
CN101420171B (zh) 大功率开关电源叠层母排方法
CN112382486B (zh) 一种环形绕组的直线式移相变压器、控制方法及应用
US11309123B2 (en) Fully integrated inversely weakly coupled power inductor
CN113783400A (zh) 功率转换单元
Gierschner et al. A competitive medium frequency AC distribution grid for offshore wind farms using HVDC
CN201294449Y (zh) 一种大功率开关电源b型芯体
CN215870776U (zh) 一种基于超导储能动态电压恢复器的微电网系统
Jeong et al. A Study on the 3-phase 13.2 kV Solid State Transformer for the DC Distribution
Ohata et al. Key Technologies for High-Efficiency and Reliable Solid-State Transformers for DC Microgrids
Chivite-Zabalza et al. Low switching frequency modulation strategies with low impact on the mains, suitable for a for a large power Voltage Sourced converter that employs reduced VA-rating coupling magnetic elements

Legal Events

Date Code Title Description
STPP Information on status: patent application and granting procedure in general

Free format text: NON FINAL ACTION MAILED

STPP Information on status: patent application and granting procedure in general

Free format text: RESPONSE TO NON-FINAL OFFICE ACTION ENTERED AND FORWARDED TO EXAMINER

STPP Information on status: patent application and granting procedure in general

Free format text: NOTICE OF ALLOWANCE MAILED -- APPLICATION RECEIVED IN OFFICE OF PUBLICATIONS

STPP Information on status: patent application and granting procedure in general

Free format text: DOCKETED NEW CASE - READY FOR EXAMINATION

STCB Information on status: application discontinuation

Free format text: ABANDONED -- FAILURE TO PAY ISSUE FEE