power converter to emit direct current voltage and method to emit the same

专利摘要:
AC / DC ENERGY CONVERSION SYSTEM AND MANUFACTURING METHOD. A power converter has a transformer with three primary windings configured to receive respective phases of a three-phase alternating current (AC) input signal in a delta configuration and three secondary windings, each divided into two parts, in which the parts are coupled together in a regular hexagon. The power converter includes a rectifier having a first rectifier path coupled between the secondary winding leads and a positive output from the power converter and a second rectifier path coupled between the secondary winding leads and a negative output. One of the secondary windings can be inverted in relation to the other secondary windings. The primary windings can be divided with a corresponding secondary winding interposed between parts of the primary. One path may have a different inductance than the other path.
公开号:BR112013021363B1
申请号:R112013021363-9
申请日:2012-02-24
公开日:2020-11-03
发明作者:Kaz Furmanczyk；Randy Stepheson
申请人:Crane Electronics, Inc；
IPC主号:

专利说明:

CROSS REFERENCE TO RELATED ORDERS
The present application claims benefit under 35 U.S.C. 119 (e) to the series 61 / 464,000 provisional U.S. patent application filed February 24, 2011, which is incorporated herein by reference in its entirety. BACKGROUND OF THE INVENTION Field of the Invention
The present disclosure relates, in general, to systems, methods and articles for converting alternating current (AC) into direct current (DC), such as AC / DC converters including primary and secondary winding transformers and a rectifier. Description of the State of the Art
AC / DC converters are generally used to convert alternating current sources to direct current sources. AC / DC converters, such as those used in avionics, usually include a transformer and a rectifier. In many applications, a transformer converts a first AC signal with a first voltage level to a second AC signal with a second voltage level, and a rectifier converts the second AC signal to a DC signal.
A transformer typically includes at least two windings of electrically conductive material, such as a wire. The windings are spaced with sufficient proximity that an electric current flow through one winding induces an electric current to flow in the other winding when connected to a load. The windings through which the current is conducted are usually called primary windings, whereas the windings in which the current is induced are usually called secondary windings. The transformer can also include a core, for example, a magnetic or ferrous core extending between the windings.
A rectifier typically includes a plurality of diodes or thyristors configured to convert an AC signal to a DC signal. For example, a full bridge rectifier can be used to convert an AC signal to a DC signal. Additional devices can be used to provide power conditioning, such as interphase transformers, balancing inductors, interphase reactors, filters, etc.
In many applications, the size and / or weight of the transformer is an important factor in obtaining a practical and / or commercially successful device. For example, energy converters for use in avionics generally need to be lightweight and may need to occupy a small volume. Such applications, however, usually require high performance, such as high current and low noise energy conversion. Many applications may, or alternatively, require low-cost power converters.
Costs can be dictated by a number of factors, including the type of materials, quantity of materials and / or complexity of manufacture, among other factors. BRIEF SUMMARY OF THE INVENTION
In one embodiment, a power converter comprises a transformer including: three primary windings configured to receive respective phases from a three-phase alternating current (AC) input signal in a delta configuration; and three secondary windings, each divided into two parts, the secondary winding parts coupled together in a closed regular hexagon, with each part of each secondary winding having at least two leads and the leads distributed at regular angles in the closed regular hexagon; a first rectification path coupled between the derivations of the secondary windings and a positive output of the energy converter and having an inductance; and a second rectification path coupled between the derivations of the secondary windings and a negative output of the energy converter and having an inductance different from the inductance of the first rectification path. In one embodiment, one of the secondary windings has a polarity opposite to that of the other secondary windings. In one embodiment, one of the primary windings has a polarity opposite to that of the other primary windings and a secondary winding corresponding to the first primary winding has a polarity opposite to that of the other secondary windings. In one embodiment, the first primary and the corresponding secondary winding have the same polarity. In one embodiment, each primary winding is divided into two parts and each secondary winding is interposed between two parts of a corresponding primary winding. In one embodiment, the first rectification path comprises 12 rectifiers, each coupled to a respective derivation of the secondary windings through respective couplings having a first inductance, and the second rectification path comprises 12 rectifiers, each coupled to a respective derivation of the secondary windings through respective couplings having a second inductance different from the first inductance. In one embodiment, the couplings of the first grinding path have a different length than the length of the couplings of the second grinding path. In one embodiment, each of the couplings in the first grinding path comprises an inductor. In one embodiment, the first rectification path comprises: a first plurality of rectifiers containing cathodes coupled to each other; an inductor coupled between the cathodes of the first plurality of rectifiers and the positive output; a second plurality of rectifiers containing cathodes coupled to each other; and an inductor coupled between the cathodes of the second plurality of rectifiers and the positive output. In one embodiment, the first grinding path comprises a conductor having a different length than a corresponding conductor length from the second grinding path. In one embodiment, the inductance of the first rectification path is at least five times the inductance of the second rectification path. In one embodiment, the derivations of the secondary windings are distributed at substantially identical central angles in the regular hexagon. In one embodiment, two taps in a secondary winding part are in adjacent turns of the secondary winding part. In one embodiment, the transformer comprises three substantially identical coils, each coil comprising one of the primary windings and a corresponding secondary winding. In one embodiment, the transformer comprises a transformer core and the coils are wrapped in the transformer core. In one embodiment, the coils are positioned next to each other in a row and a central coil has a different polarity than one of the other coils.
In one embodiment, a method comprises: coupling three primary windings of a transformer to each other in a differential configuration to receive respective phases of a three-phase alternating current; couple divided parts of the three secondary transformer windings together in a regular hexagonal configuration; providing a plurality of leads distributed at regular angles in the secondary windings, each split secondary winding part having at least two leads; forming a first rectification path between the plurality of leads and a positive output, the first rectification path having an inductance; and forming a second rectification path between the plurality of taps and a negative output, the second rectification path having an inductance different from the inductance of the first rectification path. In one embodiment, the transformer comprises a first, second and third coil, and the method comprises: positioning the first, second and third coils together in a row with the second coil separating the first and third coils, the secondary windings of the second coil having a polarity different from the polarity of the secondary windings of the first coil and the third coil. In one embodiment, the transformer comprises a first, second and third coil, and the method comprises: placing the first, second and third coils together in a row with the second coil separating the first and third coils, the second coil having a different polarity polarity of the first coil and the third coil. In one embodiment, the primary windings are divided into first and second primary parts and the parts of each secondary winding are interspersed between the first and second primary parts of a respective primary winding. In one embodiment, the inductance of the first rectification path is at least five times the inductance of the second rectification path.
In one embodiment, a power converter comprises: means for converting three-phase alternating current (AC) energy signals into multiphase AC energy signals; first means for rectifying multiphase AC power signals; second means for rectifying multiphase AC power signals; first coupling means for coupling the conversion means to the first rectifying means and for coupling the first rectifying means to a first output of the energy converter; and second coupling means for coupling the conversion means to the second rectifying means and for coupling the second rectifying means to a second output of the energy converter, wherein the first coupling means have an inductance different from an inductance of the second means coupling. In one embodiment, the conversion means comprises a transformer including: a primary including three primary windings configured to couple to respective phases of an AC power signal in a delta configuration; and a secondary including three secondary windings, each secondary winding corresponding to a respective primary winding and divided into two parts, wherein the parts of the secondary windings are coupled together in a closed hexagon and each part of a secondary winding comprises at least two leads. In one embodiment, two of the secondary windings have a polarity opposite to that of the other secondary winding. In one embodiment, one of the primary windings has a polarity opposite to that of the other primary winding and the corresponding secondary winding has a polarity opposite to that of the other secondary windings. In one embodiment, each of the primary windings is divided into two parts and the two parts of the corresponding secondary winding are interspersed between the two parts of the corresponding primary winding. In one embodiment, the first coupling means comprise an inductor coupled between the first rectifying means and the conversion means. In one embodiment, the first coupling means comprise an inductor coupled between the first rectifying means and the first output of the energy converter. In one embodiment, the conversion means is configured to convert the three-phase alternating current (AC) energy signals into phase-dose AC energy signals and the energy converter is configured to provide a twenty-four pulse DC voltage . In one embodiment, the inductance of the first coupling means is at least five times the inductance of the second coupling means.
In one embodiment, a power converter comprises: means for converting three-phase alternating current (AC) energy signals into twelve-phase AC power signals; first means for rectifying multiphase AC power signals coupled to the conversion means; and second means for rectifying multiphase AC power signals coupled to the conversion means and the first means for rectifying multiphase AC power signals. In one embodiment, the conversion means comprises a transformer including: a primary including three primary windings configured to couple to respective phases of an AC power signal in a delta or differential configuration; and a secondary including three secondary windings, each secondary winding corresponding to a respective primary winding and divided into two parts, wherein the parts of the secondary windings are coupled together in a closed hexagon and each part of a secondary winding comprises two leads. In one embodiment, one of the primary windings has a polarity opposite to that of the other primary winding and the corresponding secondary winding has a polarity opposite to that of the other secondary windings. In one embodiment, the first primary and the corresponding secondary winding have the same polarity. In one embodiment, each of the primary windings is divided into two parts. In one embodiment, the two parts of each secondary winding are interspersed between the two parts of a corresponding primary winding. In one embodiment, the first means for rectifying multiphase AC power signals is coupled between the conversion means and an output of the converter via a first rectification path, the second rectification means are coupled between the conversion means and the output of the converter via a second rectification path, where the first rectification path has an inductance different from an inductance of the second rectification path. In one embodiment, the first rectification path comprises an inductor coupled between the first means for rectifying multiphase AC power signals and the conversion means. In one embodiment, the first rectification path comprises a plurality of inductors coupled between the first means for rectifying multiphase AC power signals and the conversion means. In one embodiment, the first rectification path comprises an inductor coupled between the first means for rectifying multiphase AC power signals and an output from the power converter. In one embodiment, the first means for rectifying multiphase AC power signals comprises first and second branches and the first rectification path comprises a first inductor coupled between the first branch and an output of the power converter and a second inductor coupled between the second branch and the output of the power converter. In one embodiment, the first grinding path comprises a conductor having a different length than a corresponding conductor length from the second grinding path. In one embodiment, the inductor comprises a length of wire. In one embodiment, the inductance of the first rectification path is at least five times the inductance of the second rectification path. In one embodiment, the energy converter does not employ interphase transformers in the rectification paths. In one embodiment, the power converter does not employ input inductors between an AC power source and the conversion means.
In one embodiment, a power converter comprises: a transformer including: three primary windings configured to receive respective phases from a three-phase alternating current (AC) input signal in a delta configuration; and three secondary windings, each divided into two parts, the parts being coupled together in a regular closed hexagon, each part of each secondary having at least two leads and the leads being distributed at substantially identical central angles in the regular hexagon; a first branch of the rectifier coupled between the derivations of the secondary windings and a positive output of the energy converter; and a second branch of the rectifier coupled between the derivations of the secondary windings and a negative output of the power converter. In one embodiment, one of the primary windings has a polarity opposite to that of the other primary windings and a secondary winding corresponding to the first primary winding has a polarity opposite to that of the other secondary windings. In one embodiment, the first primary and the corresponding secondary winding have the same polarity. In one embodiment, the primary windings are divided into two parts. In one embodiment, each secondary winding is interposed between two parts of a corresponding primary winding. In one embodiment, the first branch of the rectifier has an inductance different from that of the second branch of the rectifier. In one embodiment, the first rectification path comprises 12 rectifiers, each coupled to a respective derivation of the secondary windings through respective couplings having a first inductance; and the second branch of the rectifier comprises 12 rectifiers, each coupled to a respective derivation of the secondary windings through respective couplings having a second inductance different from the first inductance. In one embodiment, the couplings of the first branch of the rectifier have a different length than the length of the couplings of the second branch of the rectifier. In one embodiment, each of the couplings in the first branch of the rectifier comprises an inductor. In one embodiment, the first branch of the rectifier comprises: a first plurality of rectifiers containing cathodes coupled to each other; an inductor coupled between the cathodes of the first plurality of rectifiers and the positive output; a second plurality of rectifiers containing cathodes coupled to each other; and an inductor coupled between the cathodes of the second plurality of rectifiers and the positive output. In one embodiment, the first branch of the rectifier comprises a conductor having a length different from the length of a corresponding conductor of the second branch of the rectifier. In one embodiment, the inductance of the first branch of the rectifier is at least five times the inductance of the second branch of the rectifier. In one embodiment, the power converter does not employ interphase transformers between the secondary windings and the outputs of the power converter.
In one embodiment, a transformer comprises: a primary including three primary windings configured to couple the respective phases of an AC power signal in a delta or differential configuration; and a secondary including three secondary windings, each secondary winding corresponding to a respective primary winding and divided into two parts, in which the parts of the secondary windings are coupled together in a closed hexagon and each part of a secondary winding comprises two derivations. In one embodiment, one of the primary windings has a polarity opposite to that of the other primary winding and the corresponding secondary winding has a polarity opposite to that of the other secondary windings. In one embodiment, the first primary and the corresponding secondary winding have the same polarity. In one embodiment, each of the primary windings is divided into two parts. In one embodiment, the two parts of each secondary winding are interspersed between the two parts of a corresponding primary winding. In one embodiment, the closed hexagon is a regular closed hexagon and the leads are distributed at substantially identical central angles in the closed regular hexagon. In one embodiment, two taps in a secondary winding part are in adjacent turns of the secondary winding part. In one embodiment, the transformer comprises three identical coils, each coil comprising one of the primary windings and the corresponding secondary winding. In one embodiment, the transformer additionally comprises a transformer core, in which the coils are wrapped in the transformer core. In one embodiment, the coils are positioned next to each other in a row and a central coil in the row has a different polarity than one of the other coils. In one embodiment, a power converter comprises a transformer as described here.
In one embodiment, a method comprises: forming a first coil having a primary winding and a secondary winding divided into first and second parts; forming a second coil having a primary winding and a secondary winding divided into first and second parts; forming a third coil having a primary winding and a secondary winding divided into first and second parts; couple the primary windings of the first, second and third coils together in a differential configuration; and coupling the secondary winding parts together in a regular hexagonal configuration. In one embodiment, the method additionally comprises: positioning the first, second and third coils together in a row with the second coil separating the first and third coils. In one embodiment, the method further comprises: forming the second coil with a different polarity than the polarity of the first coil and the second coil. In one embodiment, the primary windings of the coils are divided into first and second primary parts and the parts of the secondary windings are interposed between the primary parts of the respective winding. In one embodiment, the method additionally comprises: providing a plurality of taps at regular angles in the secondary windings; form a first rectification path; form a second rectification path; and coupling the taps to the first and second grinding paths. In one embodiment, the first rectification path has an inductance different from an inductance of the second rectification path. In one embodiment, the inductance of the first rectification path is at least five times the inductance of the second rectification path. BRIEF DESCRIPTION OF THE VARIOUS VIEWS OF THE DRAWINGS
In the drawings, identical reference numbers identify similar elements or acts, unless otherwise specified by the context. The dimensions and relative positions of the elements in the drawings do not necessarily correspond to the real scale. For example, the shapes of the various elements and angles may not accurately represent the actual scale, and some of these elements can be enlarged and positioned to improve the legibility of the drawings. In addition, the specific shapes of the elements, as drawn, are not intended to infer any information regarding the actual shape of the specific elements, and were selected only for ease of recognition in the drawings.
Figure 1 is a schematic representation of an energy converter.
Figure 1A is a schematic representation of an aircraft power system.
Figure 2 is a schematic representation of an energy converter,
Figure 3 is a schematic representation of an energy converter,
Figure 4 is a schematic representation of an energy converter,
Figure 5 is a schematic representation of an embodiment of a Delta-Hex energy converter.
Figure 6 is a schematic representation of an embodiment of a Delta-Hex energy converter.
Figure 7 is a schematic representation of an embodiment of a Delta-Hex energy converter.
Figure 8 is a schematic representation of an embodiment of a transformer.
Figure 9 is a top view of an embodiment of a transformer.
Figure 10 is a front view of an embodiment of a Delta-Hex energy converter.
Figure 11 is a first side view of the embodiment of a Delta-Hex energy converter of Figure 10.
Figure 12 is a second side view of the embodiment of a Delta-Hex energy converter of Figure 10.
Figure 13 is an isometric view of an embodiment of a Delta-Hex energy converter.
Figure 14 is a graphical representation of a ripple at a DC output of an embodiment of a 6-pulse energy converter.
Figure 15 is a graphical representation of an input current from a 6 pulse energy converter rendering.
Figure 16 is a graphical representation of a ripple at a DC output of an embodiment of a 12-pulse energy converter.
Figure 17 is a graphical representation of an input current from a 12 pulse energy converter rendering.
Figure 18 is a graphical representation of a ripple in a DC output of an embodiment of a 24-pulse energy converter.
Figure 19 is a graphical representation of an input current from a 24 pulse energy converter rendering. DETAILED DESCRIPTION
In the description that follows, certain specific details are presented in order to allow meticulous compression of the various embodiments disclosed. However, those skilled in the related art will recognize that embodiments can be practiced without one or more of these specific details, or with other methods, components, materials, etc. In other cases, well-known structures associated with energy converters, transformers, circuits employing transformers and equipment useful in the manufacture of energy converters and transformers have not been illustrated or described in detail to avoid unnecessarily obscuring the descriptions of the embodiments.
Unless the context explicitly states otherwise, throughout the specification and the claims that follow, the word "understands" and its variations, such as "understand" and "understanding" should be interpreted in an open and inclusive sense, that is, as "including, but not limited to".
Any reference in this report to "an embodiment" means that a specific feature, structure or feature described in relation to the embodiment is included in at least one embodiment. Thus, the occurrences of the expression "in one embodiment" in several sections throughout this specification do not necessarily refer to the same embodiment. Furthermore, the particular aspects, structures or characteristics can be combined in any suitable way in one or more embodiments.
As used in this specification and in the appended claims, the synergistic forms “one”, “one”, “o” or “a” include references in the plural, unless the context indicates otherwise. It should also be noted that the term "or" is generally used in its sense, including "and / or", unless the context indicates otherwise.
The headings and summary of disclosure presented here are for convenience only and do not interpret the scope or meaning of the embodiments.
Figure 1 is a schematic representation of the building blocks of an illustrative power converter 100 configured to convert a three-phase AC input to a DC output. The power converter 100 comprises a three-phase transformer in n-phases 102, and a n-pulse rectifier 104.
Transformer 102 is configured to receive a three-phase input signal 106 and comprises a three-phase primary 108 and an n-phase secondary 110. Transformer 102 is configured to provide an n-phase AC signal 112. Rectifier 104 comprises a plurality of branches 114 coupled to the respective outputs of the n-phase AC signal 112. As illustrated, each branch comprises two diodes 116. Other rectifying devices can be employed, such as thyristors, etc. Rectifier 104 produces a DC output 118.
The upper pulse rectification generally provides lower ripple at the DC output and less distortion of the AC input current, and thus generally results in higher power quality for a power converter. Generally, a 6-pulse converter topology can be considered acceptable for use in avionics equipment with rated power less than 35 VA. A 12-pulse converter topology is generally acceptable for a considerable number of aerospace applications. A 24-pulse topology is typically used for higher power equipment or when high power quality is desired or specified.
Avionics applications can typically employ transformer / rectifier units, such as the power converter 100 in Figure 1, to convert a three-phase AC power source, such as a 115 Volt AC power supply operating at a fixed frequency, such as such as 400 Hz, a 115 Volt AC source of variable frequency from 360 Hz to 800 Hz, a 230 Volt AC source of variable frequency from 360 Hz to 800 Hz, etc., on a DC power source, such as a 28 Volt DC power supply, etc. The load presented to the power converter can typically be between 100 amps and 400 amps. Typical functions for a power converter used in avionics may include feeding short-term overloads to eliminate downstream failures, providing galvanic isolation between an aircraft AC power source and a DC power source, power conditioning to provide power quality acceptable on the AC and DC sides of the power converter for proper operation of the aircraft power system and electrical loads, self-monitoring and fault reporting, etc. Power converters, like the power converter in Figure 1, can be used in other applications and can be configured to provide other functions. Transformer / rectifier power converters can employ topologies that use additional devices, such as interface transformers, balance inductors, interphase reactors, filters, etc., in order to offer the desired functionality, such as acceptable power quality.
Figure 1A is a functional block diagram of an example of an aircraft supply system 150. As illustrated, an engine or turbine for aircraft 152 is configured to drive a generator 154. Generator 154 is configured to provide an AC power to a power converter 156, such as the power converter 100 illustrated in Figure 1. Typically, the power generated in the aircraft is 115 volts AC power at 400 Hz or at a variable frequency. Other voltage levels and frequencies can be employed. The power converter 156 is coupled to a DC bus 158 and is configured to supply a DC power signal to the DC bus 158. One or more loads 160, such as flight equipment, including essential flight equipment, can be coupled to the DC 158 bus and configured to draw power from the DC 158 bus. Typically, flight equipment can use 28 Volt DC power to operate. Other output voltage levels can be used.
Figure 2 is an electrical schematic diagram of an example of a power converter 200 employing the transformer / rectifier topology. The power converter comprises a transformer 210 having a primary 2088 and a Y or star configuration, a first secondary 212 in a Y configuration and a second secondary 124 in a Delta or differential configuration. The energy converter 200 can be used, for example, in aerospace applications. The power converter 200 comprises an input 202 configured to receive a three-phase AC power signal, for example, a 115 Volt AC signal. Input 202 is coupled to the respective filter inductors 204 for each phase input configured to attenuate the EMI emissions generated by a rectifier stage 206.
The outputs of filter inductors 204 are coupled to the respective windings of primary 208 of transformer 210, which has three windings in a Y configuration. The first secondary 212 has three windings in a Y configuration and the second secondary 214 has three windings in a Y configuration. a Delta configuration.
Rectification stage 206 comprises a first full-wave rectification bridge 216 coupled to the windings of the first secondary 212, a second full-wave rectification bridge 218 coupled to the windings of the second secondary 214, and an IPT interphase transformer 222. The voltages the secondary windings of the transformer are offset by 30 degrees from each other, thus the power converter has the power quality characteristics of a 12 pulse rectification. As can be seen in Figure 2, three additional inductors and an IPT transformer were used in order to meet the desired power quality. These additional components add size, weight and cost to the 200 power converter.
Figure 3 is a schematic electrical diagram of a power converter 300 employing a Y / Delta - Zigzag topology to obtain 24-pulse power quality characteristics. The energy converter 300 can be used, for example, in aerospace applications. The power converter 300 comprises an input stage 302, a transformer stage 304 and a rectification stage 306.
Input stage 302 comprises three input inductors 308 configured to receive respective phases from a 3-phase AC power signal, for example, a 115 Volt AC signal at 400 Hz, etc. Input inductors 308 are configured to attenuate EMI emissions generated by rectification stage 306.
Transformer stage 304 comprises two transformers 310, 312. Each transformer 310, 312 has a core 311, 313. The first transformer 310 has a Y / Zigzag configuration in which the primary coupled to input stage 302 is in a configuration in Y, and the first transformer 310 has two three-phase secondary coupled to rectification stage 306 in a Zigzag configuration. The second transformer 312 has a Delta / Zigzag configuration in which the primary coupled to the input stage 302 is in a Delta configuration, and the second transformer 312 has two three-phase secondary coupled to the rectification stage 306 in a Zigzag configuration.
The rectification stage 306 comprises four full wave rectification bridges 314 coupled to the windings of the respective secondary outputs of the first and second transformers 310, 312. The rectification stage 306 also comprises an interphase set 320, which, as illustrated, comprises three IPT 322 interphase transformers. The power converter 300 has power quality characteristics of a 24 pulse rectification. As can be seen in Figure 3, three input inductors, an additional transformer in the transformer stage with two secondary in each transformer, and three IPT transformers were employed in order to meet the desired power quality. These additional components add size, weight and cost to the 300 power converter.
Figure 4 is a schematic electrical diagram of a 400 power converter with a Delta-Hex topology. The power converter 400 has a transformer 402 and a rectifier 404. Transformer 402 has a primary 406 with three windings coupled in a Delta configuration to an AC input signal, for example, a three-phase 115 volt variable frequency signal, and a secondary 408 with three split windings coupled together in a hexagonal configuration. The secondary windings 408 are coupled to a full-wave rectifier bridge 404. An example of a power converter employing a Delta-Hex topology is described in U.S. Patent No. 4,225,784 issued to Rosa.
Power converters in a Delta-Hex topology use fewer magnetic components than the transformer / rectifier power converter topologies typically used in low voltage / high current applications for which high quality power is desired or specified . Although attempts have been made to use Delta-Hex power converter topologies in applications for which high power quality was desired or specified, in practice, the quality of power produced by Delta-Hex topology power converters was not good enough for use in low voltage / high current power converter applications. For example, the total harmonic distortion in a Delta-Hex power converter topology, such as that illustrated in Figure 4, can typically be 12% or more, which is very high for many high current / low voltage applications, such as various aerospace applications.
Figure 5 is an electrical schematic diagram of an embodiment of an energy converter 500 employing a Delta-Hex topology. The power converter 500 comprises a transformer 502 and a rectifier stage 504. Transformer 502 comprises a primary 506, a secondary 508 and a core 510.
Primary 506 has a first winding A, a second winding B and a third winding C configured to couple with a three-phase AC input signal 512 in a Delta configuration. Each winding A, B, C of primary 506 has a respective first lead 1 and a second lead 2. As illustrated, leads 1, 2 of windings A, B, C of primary 506 are at the ends of windings A, B, C. The reference number assigned to a lead or end of a winding does not necessarily indicate a turn count on the lead or end. Primary windings A, B, C typically have more than one loop. For example, a primary winding, such as winding A of primary 506, can have 61 turns in one embodiment. Other numbers of turns can be used. A polarity of each winding A, B, C of the 506 primary is indicated by a star *.
The secondary 508 comprises a first split secondary winding A1, A2, a second split secondary winding Bi, B2, and a third split secondary winding Ci, C2 coupled together at the ends in a hexagonal configuration. A current in the first winding A of the primary 506 induces a current in the first split winding Ai, A2 of the secondary 508, a current in the second winding B of the primary 506 induces a current in the second split winding Bi, B2 of the secondary 508, and a current in the third winding C of primary 506 induces a current in the third split winding Ci, C2 of secondary 508. Other currents, generally of lesser magnitude, can be induced in other windings.
As illustrated, each split secondary winding has multiple turns, a first part (eg Ai) with half the turns, two ends 3, 6 and two leads 4, 5 and a second part (eg A2) with half the turns , two ex-tremities 7, 10 and two leads 8, 9, with leads 4, 5, 8, 9 configured to be coupled to the 504 grinding stage. In one embodiment, a total of 8 turns can be used, with two turns between taps in the same part of a secondary winding. Other numbers of turns can be used and leads in concretizations with different numbers of turns can be in different turns of the windings. A polarity of each secondary winding 508 is indicated by a star *.
A polarity of the second winding B of the secondary 508 is inverted with respect to a polarity of the first winding A and the third winding C of the secondary 508. For example, a polarity of the second split winding Bi, B2 of the secondary 508 is inverted with respect to a polarity of the first split winding Ai, A2 and the third split winding Ci, C2 of the secondary 508. Reversing the polarity at least partially cancels the leakage fields of the adjacent coils and makes manufacturing simpler by allowing shorter connections between adjacent coils , which can further reduce leakage currents, losses, parasitic effects, etc.
In Delta-Hex topologies, such as the one illustrated in Figure 4, the minimum practical number of turns between the leads in the same part of a secondary winding was 3 or more in order to obtain turns ratios closer to the ideal ones, and, thus, avoiding power quality problems arising from deviations in the turn ratio. In one embodiment, reversing the polarity of the second split winding B1, B2 of the secondary 508 at least partially compensates for the deviations in the ratio of larger turns and the asymmetries of the coil, and thereby facilitates the achievement of an acceptable power quality even when a minimum number of turns between the leads connected to the rectifier stage 504 is reduced to, for example, two turns. Reducing the number of turns between taps facilitates the use of transformers having windings with fewer turns, and thus facilitates smaller, lighter and less expensive transformers and energy converters.
The energy converter 500 comprises a first rectification path 530 and a second rectification path 532 between the derivations of the secondary windings of the transformer 502 and the respective outputs of the energy converter 500, with the first and second rectification paths 530, 532 having different inductances. This difference in inductance provides an additional phase shift in the currents. As illustrated, rectifier stage 504 comprises a first rectifier 514 and a second rectifier 516, configured to provide full wave rectification for each secondary output. The first and second rectifiers 514, 516 may comprise diodes, thyristors, snubbers, etc. The leads are configured to couple with the rectifier stage (for example, leads 4, 5, 8, 9 of each of the secondary windings) in two paths, one of which has a greater inductance than the other, which is illustrated as a 520 inductance. For example, a difference in inductance of the order of 5 micro-Henries can be employed. Other differences in inductances can be employed. In some embodiments, a desired difference in inductance can be obtained by simply providing half of the secondary outputs with longer conductors than the other half of the secondary outputs. The difference in inductance, such as an inductance value 520, can be selected so that the voltages / currents at the secondary outputs 508 of transformer 502 are offset by approximately 15 degrees from each other, resulting in the energy characteristics of a rectification of 24 pulses, without the use of interphase transformers.
A desired difference in inductance between the first grinding path 530 and the second grinding path 532 can be obtained in other ways. For example, a desired difference in inductance between the first rectifying path 530 and the second rectifying path 532 can be obtained by coupling an inductor between node 540 and the positive output of the energy converter 500, coupling an inductor between node 540 and the first rectifier 514 and an inductor between node 540 and the second rectifier 516 (see figure 7), coupling inductors between the derivations of the secondary windings of transformer 502 and the second rectifier 516, coupling a inductor between node 542 and negative output of the energy converter 500, coupling an inductor between node 542 and the first rectifier 514 and an inductor between node 542 and the second rectifier 516, etc. As noted above, the use of conductors of different lengths instead of inductive coils may be sufficient to obtain a desired difference in inductance between the first grinding path 530 and the second grinding path 532.
In one embodiment, transformer 502 comprises three identical or substantially identical coils, each having a primary winding (for example, primary winding A) and a split secondary winding (for example, the split secondary winding Ai, A2 ). Non-identical coils can be used, although substantially identical or typically identical coils can offer higher power quality. Secondary windings can be physically divided as well as logically divided, which can facilitate access to taps. In one embodiment, each part of a split secondary winding can be identical. In one embodiment, the parts of a split secondary winding can be substantially identical. In one embodiment, parts of a split secondary winding can have the same number of turns. In one embodiment, parts of a split secondary winding may have a similar, but different, number of turns. In one embodiment, a primary winding (for example, primary winding A) can be physically divided, which, in some embodiments, provides better power quality by at least partially reducing harmonic distortion, for example, in selected harmonics. For example, a physically split primary can have a split secondary winding interposed between parts of the split primary winding (see coil 810 in Figure 8). A split primary winding can have two identical parts, can have two substantially similar parts with a similar but different number of turns, etc. In one embodiment, the coils can be substantially identical to one of the coils with a polarity opposite to that of a polarity of the other coils. The windings of transformer 502 can comprise, for example, copper, anodized aluminum, combinations thereof, etc.
For a three-phase 115 volt AC input signal at 400 Hz and a 28 volt DC output for a 125 amps load, the total harmonic distortion of an embodiment of the power converter 500 in Figure 5 was in the range of 3% to 5 %. The topology of the embodiment in Figure 5 is much simpler than the topologies of the power converters 200, 300 in Figures 2 and 3, and the use of ITP transformers and filter inductors has been avoided by obtaining, at the same time, a less harmonic distortion than Delta-Hex power converters, such as the 400 power converter in Figure 4. Superior electrical performance over the approaches in Figures 2 to 4 can also be obtained. In one embodiment, voltage drops and power dissipation in IPT transformers and input inductors can be avoided, energy efficiencies are improved, rectifier diodes share current equally (which makes it easier to deal with overloads), EMI emissions are lower and AC current distortions are at an acceptable level.
Figure 6 is an electrical schematic diagram of an embodiment of a power converter 600 employing a Delta-Hex topology. The power converter 600 comprises a transformer 602 and a rectifier stage 604. Transformer 602 comprises a primary 610, a secondary 612 and a core 611.
Primary 610 has a first winding A, a second winding B and a third winding C configured to couple with a three-phase AC input signal 612 in a delta configuration. Each winding A, B, C of primary 610 has a respective first lead 1 and a second lead 2. As illustrated, leads 1, 2 of windings A, B, C of primary 610 are at the ends of windings A, B, C. The reference number assigned to a lead or end of a winding does not necessarily indicate a turn count on the lead or end. Primary windings A, B, C typically have more than one loop. For example, a primary winding, such as winding A of primary 610, can have 61 turns in one embodiment. A polarity of each winding A, B, C of the 610 primary is indicated by a star *.
The secondary 612 comprises a first split secondary winding A1, A2, a second split secondary winding Bi, B2, and a third split secondary winding Ci, C2 coupled together at the ends in a hexagonal configuration. A current in the first winding A of the primary 610 induces a current in the first split winding Ai, A2 of the secondary 612, a current in the second winding B of the primary 610 induces a current in the second divided winding Bi, B2 of the secondary 612, and a current in the third winding C of primary 610 induces a current in the third split winding Ci, C2 of secondary 612. Other currents, generally of lesser magnitude, can be induced in other windings.
As illustrated, each split secondary winding has multiple turns, a first part (eg Ai) with half the turns, two ends 3, 6 and two leads 4, 5 and a second part (eg A2) with half the turns , two ex-tremities 7, 10 and two leads 8, 9, with leads 4, 5, 8, 9 configured to be coupled to the 604 grinding stage. In one embodiment, a total of 8 turns can be used, with two turns between taps in the same part of a secondary winding. Other numbers of turns can be used and leads in concretizations with different numbers of turns can be in different turns of the windings. A polarity of each winding of secondary 612 is indicated by a star *.
A polarity of the second split winding Bi, B2 of the secondary 612 is inverted with respect to a polarity of the first split winding Ai, A2θ of the third split winding Ci, C2 of the secondary 612. As discussed above, in the Delta-Hex models, such as illustrated in Figure 4, the minimum practical number of turns between the leads was 3 or more in order to obtain turns ratios closer to the ideal ones, and, thus, to prevent power quality problems arising from the deviations. In one embodiment, reversing the polarity of the second winding B of the primary 610 and the second split winding B1, B2 of the secondary 612 at least partially compensates for the deviations in the ratio of larger turns and the asymmetries of the coil, and thereby facilitates obtaining of an acceptable energy quality even when a minimum number of turns between the taps coupled to the rectifier stage 604 is reduced to, for example, two turns. Reducing the number of turns between taps facilitates the use of transformers having windings with fewer turns, and thus facilitates smaller, lighter and less expensive transformers and energy converters.
Rectification stage 604 comprises a first branch of rectifier 614 and a second branch of rectifier 616. As illustrated, each branch of rectifier 614, 616 includes six diodes 618 coupled in parallel to an optional snubber 620. Other rectifier branch configurations can be employed. As illustrated, each snubber comprises a resistor connected in series to a capacitor. A snubber can comprise, for example, a 4 micro-Farad capacitor coupled in series to a 1 ohm resistor. Other snubbers can be employed and snubbers can be omitted in some embodiments.
The respective anodes of diodes 608 of the first branch of rectifier 614 are coupled to leads 4, 9 of the first split secondary winding Ai, A2, leads 4, 9 of the third split secondary winding Ci, C2 and leads 5, 8 of the second winding split secondary Bi, B2. The respective cathodes of diodes 618 of the second branch of rectifier 616 are coupled to leads 5, 8 of the first split secondary winding Ai, A2, leads 5, 8 of the third split secondary winding Ci, C2 and leads 4, 9 of the second winding split secondary Bi, B2.
The cathodes of the first branch of the rectifier 614 are coupled together and to a positive output of the power converter 600, and the anodes of the second branch of the rectifier 616 are coupled together and to a negative output of the power converter 600. As illustrated, the converter power is configured to provide an output of approximately 28 Volts DC in response to an input of 115 Volts AC. As illustrated, the power converter 600 has an optional output filter 622, an optional output filter 624 and an optional current tap 626, which can be used, for example, to monitor the performance of the power converter 600 and / or loading conditions. Other filter and bypass configurations can be employed.
In one embodiment, transformer 602 comprises three identical coils or substantially identical coils, each having a primary winding (for example, primary winding A) and a split secondary winding (for example, the split secondary winding Ai, A2). Non-identical coils can be used, although substantially identical or typically identical coils can offer higher power quality. Secondary windings can be physically divided as well as logically divided, which can facilitate access to taps. In one embodiment, each part of a split secondary winding can be identical. In one embodiment, the parts of a split secondary winding can be substantially identical. In one embodiment, parts of a split secondary winding can have the same number of turns. In one embodiment, parts of a split secondary winding may have a similar, but different, number of turns. In one embodiment, a primary winding (for example, primary winding A) can be physically divided, which, in some embodiments, provides better power quality by reducing harmonic distortion, for example, by reducing distortion in selected harmonics. In one embodiment, a physically split primary can have a split secondary winding interposed between parts of the split primary winding (see coil 810 of Figure 8). A split primary winding can have two identical parts, can have two substantially similar parts with a similar but different number of turns, etc. In one embodiment, the coils can be substantially identical to one of the coils with a polarity opposite to that of a polarity of the other coils. The windings of transformer 602 can comprise, for example, copper, anodized aluminum, combinations thereof, etc.
In simulations and testing the application of a three-phase 115 Volt AC input signal to an embodiment of the power converter 600 of Figure 6, an output of approximately 28 volts DC was obtained with a total harmonic distortion in the range of 65 to 7.5 %, and input current waveforms consistent with 12 pulse rectification. The topology of the embodiment of Figure 6 is much simpler than the topologies of the power converters 200, 300 of Figures 2 and 3, and the use of ITP transformers and filter inductors was avoided, obtaining, at the same time, a less harmonic distortion than Delta-Hex energy converters, such as the 400 energy converter in Figure 4. Superior electrical performance in relation to the topologies illustrated in Figures 2 to 4 can also be obtained. In one embodiment, voltage drops and power dissipation in IPT transformers and input inductors can be avoided, energy efficiencies are improved, rectifier diodes share current equally (which makes it easier to deal with overloads), EMI emissions are lower and AC current distortions are at an acceptable level.
Figure 7 is an electrical schematic diagram of an embodiment of an energy converter 700 employing a Delta-Hex topology. The power converter 700 comprises a transformer 702 and a rectifier stage 704. Transformer 702 comprises a primary 710, a secondary 712 and a core 711.
Primary 710 has a first winding A, a second winding B and a third winding C configured to couple with a three-phase AC input signal 712 in a Delta configuration. Each winding A, B, C of primary 710 has a respective first lead 1 and a second lead 2. As illustrated, leads 1, 2 of windings A, B, C of primary 710 are at the ends of windings A, B, C. The reference number assigned to a lead or end of a winding does not necessarily indicate a turn count on the lead or end. Primary windings A, B, C typically have more than one loop. For example, a primary winding, such as winding A of primary 710, can have 61 turns in one embodiment. A polarity of each winding A, B, C of primary 710 is indicated by a star *.
The secondary 712 comprises a first split secondary winding Ai, A2, a second split secondary winding Bi, B2, and a third split secondary winding Ci, C2 coupled together at the ends in a hexagonal configuration. A current in the first winding A of the primary 710 induces a current in the first split winding Ai, A2 of the secondary 712, a current in the second winding B of the primary 710 induces a current in the second divided winding Bi, B2 of the secondary 712, and a current in the third winding C of primary 710 induces a current in the third split winding Ci, C2 of secondary 712. Other currents, generally of a lower magnitude, can be induced in the other windings (for example, a current in the first winding A of primary 710 can induce a current in the second split winding Bi, B2 of the secondary 712, but this current will generally be of a magnitude lower than that of a current induced in the first split winding Ai, A2 of the secondary 712 by the current in the first winding A of the primary 710).
As illustrated, each split secondary winding has multiple turns, a first part (eg Ai) with half the turns, two ends 3, 6 and two leads 4, 5 and a second part (eg A2) with half the turns , two ex-tremities 7, 10 and two leads 8, 9, with leads 4, 5, 8, 9 configured to be coupled to the 704 grinding stage. In one embodiment, a total of 8 turns can be used, with two turns between taps in the same part of a secondary winding. Other numbers of turns can be used and leads in concretizations with different numbers of turns can be in different turns of the windings. A polarity of each winding of the secondary 712 is indicated by a star *.
A polarity of the second split winding Bi, B2 of the secondary 712 is inverted with respect to a polarity of the first split winding Ai, A2e of the third split winding Ci, C2 of the secondary 712. As discussed above, in Delta-Hex models, as illustrated in Figure 4, the minimum practical number of turns between the leads was 3 or more in order to obtain turns ratios closer to the ideal ones, and, thus, to prevent power quality problems arising from the deviations. In one embodiment, reversing the polarity of the second split winding B1, B2 of the secondary 712 compensates at least partially for deviations in the ratio of larger turns and asymmetries in the coil, and thereby facilitates the achievement of acceptable power quality even when a minimum number of turns between the leads coupled to the rectifier stage 704 is reduced to two turns. Reducing the number of turns between taps facilitates the use of transformers having windings with fewer turns, and thus facilitates smaller, lighter and less expensive transformers and energy converters. Some embodiments can reverse the polarity of primary winding B with respect to primary windings A and C.
Rectification stage 704 comprises a first set of rectifier branches 714A, 714B coupled to a positive output of the power converter 700 and a second set of rectifier branches 716A, 716B coupled to a negative output of the power converter 700. As illustrated , each branch of rectifier 714A, 714B, 716A and 716B includes six diodes 718 coupled in parallel to an optional snubber 720. Other rectifier branch configurations can be employed. As illustrated, each snubber comprises a resistor connected in series to a capacitor. A snubber can comprise, for example, a 4 micro-Farad capacitor coupled in series to a 1 ohm resistor. Other snubbers can be employed and snubbers can be omitted in some embodiments.
Each of the taps 4, 5, 8, 9 of each secondary winding configured to couple to the rectifier stage 704 is coupled to a respective anode of a diode 718 of the first set of branches of the rectifier 714A, 714B and to a respective cathode of a diode 718 of the second rectifier branch set 716A, 716B.
The power converter 700 comprises a first rectification path 730 and a second rectification path 732 between the derivations of the secondary windings of transformer 702 and the outputs of the energy converter 700, with the first and second rectification paths 730, 732 having different inductances. This difference in inductance provides an additional phase shift in the currents. As illustrated, the first rectifying path 730 includes a coupling between the cathodes of diodes 718 of the first set of rectifier branches 714A, 714B and the positive output of the power converter 700, and the second rectifying path 732 includes a coupling between the anodes of diodes 718 of the second set of branches of rectifier 716A, 716B. As illustrated, the difference in inductance between the first rectifying path 730 and the second rectifying path 732 is obtained by coupling inductors 734, 736 to a part of rectifying path 730 by coupling diodes 718 of the first set of rectifier branches 714A, 714B to the positive output of the power converter 700. For example, inductors with an inductance of approximately 5 micro-Henries can be used. Other inductances can be employed, and a desired difference in inductance between the first grinding path 730 and the second grinding path 732 can be obtained in other ways. In some embodiments, a desired difference in inductance can be obtained simply by configuring a part of the rectification path 730 by coupling the first set of rectifier branches 714A, 714B to the positive output of the power converter 700 to be longer or shorter than one part of the rectification path 732 coupling the second set of rectifier branches 716A, 716B to the negative output of the power converter 700. For example, half of the secondary outputs can be configured with larger conductors than the other half of the secondary outputs. The difference in inductance can be selected so that the voltages / currents at the outputs of secondary 712 of transformer 702 are offset by approximately 15 degrees from each other, resulting in energy characteristics of a 24 pulse rectification. Additional examples of ways to obtain a desired difference in inductance between the first rectification path 730 and the second rectification path 732 include placing an inductor between node 740 and the positive output of the power converter 700, placing a pair of inductors between node 742 and the respective rectifier sets of the second set of rectifiers 716A, 716B, place inductors between the derivations of the secondary windings of transformer 702 and the first set of rectifiers 714A, 714B (see Figure 5), place an inductor between node 742 and the negative output of the power converter 700, etc. As noted above, the use of conductors of different lengths instead of inductive coils may be sufficient to obtain a desired difference in inductance between the first grinding path 730 and the second grinding path 732.
In one embodiment, transformer 702 comprises three identical coils or substantially identical coils, each having a primary winding (e.g., primary winding A) and a split secondary winding (e.g., the split secondary winding Ai, Az). Non-identical coils can be used, although substantially identical or typically identical coils can offer higher power quality. Secondary windings can be physically divided as well as logically divided, which can facilitate access to taps. In one embodiment, each part of a split secondary winding can be identical. In one embodiment, the parts of a split secondary winding can be substantially identical. In one embodiment, parts of a split secondary winding can have the same number of turns. In one embodiment, parts of a split secondary winding may have a similar, but different, number of turns. In one embodiment, a primary winding (for example, primary winding A) can be physically divided, which, in some embodiments, provides better power quality by reducing harmonic distortion, for example, in selected harmonics. For example, a physically split primary can have a split secondary winding interposed between parts of the split primary winding (see Figure 8). A split primary winding can have two identical parts, can have two substantially similar parts with a similar but different number of turns, etc. In one embodiment, the coils can be substantially identical to one of the coils having a secondary winding with a polarity opposite to a polarity of the secondary windings of the other coils. The windings of transformer 702 can comprise, for example, copper, anodized aluminum, combinations thereof, etc.
As illustrated, the power converter 700 is configured to provide an output of approximately 28 Volts DC in response to an input of 115 Volts AC. As illustrated, the power converter 700 has an optional input filter 722 and an optional output filter 724. Other filter configurations can be employed.
In simulations and testing the application of a three-phase 115-volt AC input signal to an embodiment of the 700 power converter in Figure 7, an output of approximately 28 volts DC was obtained with total harmonic distortion in the range of 3.3% at 4.2%, with input current waveforms consistent with 24 pulse rectification. The topology of the embodiment in Figure 7 is much simpler than the topologies of the power converters 200, 300 of Figures 2 and 3, and the use of ITP transformers and filter inductors was avoided, obtaining, at the same time, a less harmonic distortion than Delta-Hex energy converters, such as the 400 energy converter in Figure 4. Superior electrical performance in relation to the topologies in Figures 2 to 4 can also be obtained. In one embodiment, voltage drops and power dissipation in IPT transformers and input inductors can be avoided, energy efficiencies are improved, rectifier diodes share current equally (which makes it easier to deal with overloads), EMI emissions are lower and AC current distortions are at an acceptable level.
Figure 8 is a schematic view of an embodiment of a transformer 800, suitable for use, for example, in the embodiments of the power converters illustrated in Figures 5 to 7. Figure 9 is a top view of an embodiment of transformer 800 from Figure 8.
Transformer 800 comprises three coils 810, 820, 830 wrapped in an 802 core. The 802 core can, for example, take the form of a magnetizable or ferrite material, for example, a ferrite rod or bar, samarium cobalt or neodymium-iron-boron. Although not shown, transformer 800 may include a housing.
The first coil 810 comprises a primary winding A divided into an inner winding part 812 and an outer winding part 814. The inner winding part 812 comprises two taps 1, 2 positioned at the ends of the inner winding part 812. The winding part outer winding 814 comprises two leads 11, 12 positioned at the ends of the outer winding part 814. Primary winding A has a first polarity indicated by a star *. The total number of turns of primary A can be selected to facilitate obtaining a desired turn ratio (see, for example, Table 1, below). The total number of turns of primary winding A can be, for example, 181 turns, 121 turns, 61 turns, etc. The total number of turns of the inner winding part 812 of the primary winding A can be, for example, 90, 91, 60, 61, 62, 30, 31 or 32 turns, and the total number of turns of the outer winding 814 of the winding primary A can be, for example, 91, 90, 89, 61, 60, 59, 31, 30 or 29 turns. Other total numbers of turns and numbers of turns in the respective parts can be used. The first coil 810 comprises a split secondary A2 having four ends 3, 6, 7, 10 and four leads 4, 5, 8, 9. As illustrated, the split secondary Ai, A2 is interposed between the first part 812 and the second part 814 from primary A. The secondary winding Ai, A2 has the first polarity as indicated by a star *. The total number of turns of the secondary winding Ai, A2, can be, for example, 22, 16 or 8, with each part Ai, A2 typically having half the total turns, for example, 11, 8 or 4 turns. Other total numbers of turns and numbers of turns in the respective parts can be used.
The second coil 820 comprises a primary winding B divided into an inner winding part 822 and an outer winding part 824. The inner winding part 822 comprises two taps 11, 12 positioned at the ends of the inner winding part 822. The winding part outer winding 824 comprises two leads 1, 1 positioned at the ends of the outer winding portion 824. Primary winding B has a second polarity indicated by a star * and different from the first polarity. The total number of turns of primary B can be selected to facilitate obtaining a desired turn ratio (see Table 1 below). The total number of turns of primary winding B can be, for example, 181 turns, 121 turns, 61 turns, etc. The total number of turns of the inner winding part 822 of the primary winding B can be, for example, 90, 91, 60, 61, 62, 30, 31 or 32 turns, and the total number of turns of the outer winding 824 of the winding primer B can be, for example, 91, 90, 89, 61, 60, 59, 31, 30 or 29 turns. Other total numbers of turns and numbers of turns in the respective parts can be used. The second coil 820 comprises a split secondary Bi, B2 having four ends 3, 6, 7, 10 and four leads 4, 5, 8, 9. As illustrated, the split secondary Bi, B2 is interposed between the first part 822 and the second part 824 of primary B. The secondary winding Bi, B2 has the second polarity as indicated by a star *. The total number of turns of the secondary winding Bi, B2, can be, for example, 22, 16 or 8, with each part Bi, B2 typically having half the total turns, for example, 11, 8 or 4 turns. Other total numbers of turns and numbers of turns in the respective parts can be used.
The third coil 830 comprises a primary winding C divided into an inner winding part 832 and an outer winding part 834. The inner winding part 832 comprises two taps 1, 2 positioned at the ends of the inner winding part 832. The winding part outer winding 834 comprises two leads 11, 12 positioned at the ends of the outer winding part 834. Primary winding C has a first polarity indicated by a star *. The total number of turns of the primary C can be selected to facilitate obtaining a desired turn ratio (see Table 1 below). The total number of turns of the primary winding C can be, for example, 181 turns, 121 turns, 61 turns, etc. The total number of turns of the inner winding part 832 of the primary winding C can be, for example, 90, 91, 60, 61, 62, 30, 31 or 32 turns, and the total number of turns of the outer winding 834 of the winding primer C can be, for example, 91, 90, 89, 61, 60, 59, 31, 30 or 29 turns. Other total numbers of turns and numbers of turns in the respective parts can be used. The third coil 830 comprises a split secondary Ci, C2 having four ends 3, 6, 7, 10 and four leads 4, 5, 8, 9. As illustrated, the split secondary Ci, C2 is interposed between the first part 832 and the second part 834 of primary C. The secondary winding Ci, C2 has the first polarity as indicated by a star *. The total number of turns of the secondary winding Ci, C2, can be, for example, 22, 16 or 8, with each part Ci, C2 typically having half the total turns, for example, 11, 8 or 4 turns. Other total numbers of turns and numbers of turns in the respective parts can be used.
The first coil 810, the second coil 820 and the third coil 830 are positioned next to each other in a row, with the second coil 820 positioned between the first coil 810 and the third coil 830.
The first, second and third coils 810, 820, 830 can typically be identical or substantially identical, with the polarity of the second coil 820 being opposite to the polarity of the first and third coils 810, 830 in one embodiment.
Figure 9 is a top view of an embodiment of the transformer 800 of Figure 8, suitable for use, for example, in the embodiments of the energy converters illustrated in Figures 5 to 7. The transformer comprises a core 802 having three coils wrapped in it, which, as illustrated, are the first, second and third coils 810, 820, 830 of Figure 8. Figure 9 illustrates the couplings of the secondary windings of coils 810, 820, 830 to each other in one embodiment. The third branch 3 of the third coil 830 is coupled to the seventh branch 7 of the first coil 810, the sixth branch 6 of the third coil 830 is coupled to the seventh branch 7 of the second coil 820, the seventh branch 7 of the third coil 830 is coupled to the sixth branch 6 of the second coil 820, the tenth branch 10 of the third coil 830 is coupled to the sixth branch 6 of the first coil 810, the third branch 3 of the first coil 810 is coupled to the tenth branch 10 of the second coil 820 and the tenth branch 10 of the first coil 810 is coupled to the third branch 3 of the second coil 820. The fourth branch 4, the fifth branch 5, the eighth branch 8 and the ninth branch 9 of the respective coils 810, 820, 830 are available for coupling to a rectifier stage ( see, for example, the rectifier stage 704 of Figure 7).
Figures 10 to 12 show front and side views of an embodiment of a power converter 1000, and illustrates an illustrative arrangement of the components of a transformer and rectifier suitable for use, for example, in the embodiment of a power converter 700 of Figure 7 As illustrated, the transformer employs the physical configuration of the embodiment of a transformer 800 of Figures 8 and 9 and the rectifier employs the electrical configuration of the rectifier 704 of the power converter 700 of Figure 7.
Figure 13 is an isometric view of an embodiment of a power converter 1300. The power converter 1300 comprises a transformer 1302 having a coil heatsink 1336, and a rectifier 1304 including a plurality of diodes 1318 coupled to the heatsinks. diode 1338. As illustrated, diode heatsinks 1338 are electrically coupled to diodes 1318, and are configured as conductive bars for positive and negative DC outputs from the 1300 power converter. Although 12 diodes are illustrated, additional diodes can be used in some embodiments. The energy converter can employ, for example, a Delta-Hex topology, such as the topologies illustrated in Figures 5 to 7, etc.
Figures 14 to 19 graphically illustrate typical differences in the quality of energy produced by energy converters employing conversion topologies of 6 pulses, 12 pulses and 24 pulses.
Figure 14 is a graphical representation of a ripple at a DC output of an embodiment of a 6-pulse energy converter. The DC ripple, as illustrated, is about 14 percent of the output voltage. Figure 15 is a graphical representation of an input current from an embodiment of a 6-pulse energy converter. The total harmonic distortion, as illustrated, is approximately 28 to 32 percent.
Figure 16 is a graphical representation of a ripple at a DC output of an embodiment of a 12-pulse energy converter. The DC ripple, as illustrated, is about 3.4 percent of the output voltage. Figure 17 is a graphical representation of an input current from an embodiment of a 12-pulse energy converter. The total harmonic distortion, as illustrated, is approximately 9 to 14 percent.
Figure 18 is a graphical representation of a ripple in a DC output of an embodiment of a 24-pulse energy converter. The CC ripple, as illustrated, is about 0.9 percent. Figure 19 is a graphical representation of an input current from an embodiment of a 24 pulse energy converter. The total harmonic distortion, as illustrated, is approximately 3 to 5 percent.
Table 1 provides some examples of transformer winding turns, branch turn settings, and resulting calculated center / branch errors. Simulations of the embodiments of the energy converters in a Delta-Hex configuration, such as those illustrated in Figures 5 to 12, produced acceptable power quality for the derivation center errors reaching 7.5%. In practice, coils with a total number of turns in the primary winding of 181 or less can typically be used in energy converters used in avionics applications. For topologies like the one illustrated in Figure 4, the power quality is at the limit when the number of turns is 181, and generally very low when the number of spies is less than 181. In contrast, the power quality for the embodiments of the Delta-Hex topologies illustrated in Figures 5 to 7 is generally good enough for use in applications that require a high current and low voltage supply, such as avionics applications.
Table 1
The above description of the illustrated embodiments, including that described in the Summary, is not intended to be exhaustive or to limit the embodiments to the precise forms disclosed. Although specific embodiments and examples are described here for illustrative purposes, several equivalent modifications can be made without departing from the spirit and scope of the disclosure, as will be recognized by those skilled in the related art. The teachings presented here of the various embodiments can be applied to other transformers, rectifiers and energy converters, not necessarily to the illustrative transformers, rectifiers and energy converters described in general above. The teachings presented here of the various embodiments can be applied to other circuits, including other converter circuits, not necessarily to the illustrative converter circuits described in general above.
The various embodiments described above can be combined to obtain additional embodiments. Aspects of the embodiments can be modified, if necessary, to employ systems, circuits and concepts from the various patents, applications and publications discussed here to obtain further additional embodiments.
These and other changes can be made to the embodiments in the light of the detailed description above. In general, in the following claims, the terms used should not be interpreted in such a way as to limit the claims to the specific embodiments revealed in the specification and in the claims, but rather to include all possible embodiments within the broad scope of equivalents to which such claims are designated. Therefore, the claims are not limited to disclosure.

权利要求:
Claims (21)
[0001]
1. Energy converter to emit 24-pulse direct current voltage, comprising: one transformer (502, 702) including: three primary windings (A, B, C, 506, 706) configured to receive respective phases of an input signal three-phase alternating current (AC) in a delta configuration; and three secondary windings (508, 712, A1, A2, B1, B2, C1, C2), each divided into two parts, the secondary winding parts coupled together in a regular closed hexagon, with each part of each secondary winding having at least two leads (4, 5, 8, 9) and leads (4, 5, 8, 9) distributed at regular angles in the closed regular hexagon; a first rectification path (630, 730) coupled between the derivations of the secondary en-bearings and a positive output of the energy converter; and a second rectification path (532, 732) coupled between the derivations of the secondary windings and a negative output of the energy converter, CHARACTERIZED by the fact that the first rectification path (530, 730) has an inductance and the second rectification (532, 732) has an inductance with a difference from the inductance of the first rectification path (530, 730), which in operation causes the first and second rectification paths (530, 532, 730,732) to convert signals Dose phases AC in the twenty-four pulse direct current.
[0002]
2. Energy converter, according to claim 1, CHARACTERIZED by the fact that the difference in inductance is selected to make the secondary winding outputs (508, 712, A1, A2, B1, B2, C1, C2) are displaced approximately 15 degrees from each other.
[0003]
3. Power converter according to claim 1, CHARACTERIZED by the fact that the first rectification path (530, 730) comprises a first plurality of rectifiers (714A, 714B) coupled to the positive output; and the second rectification path (532, 732) comprises a second plurality of rectifiers (716A, 716B) coupled to the negative output, wherein an inductance of a coupling path between the first plurality of rectifiers and the positive output is different from one inductance of a coupling path between the second plurality of rectifiers and the negative output.
[0004]
4. Energy converter according to claim 3, CHARACTERIZED by the fact that a length of a conductor of the coupling path between the first plurality of rectifiers (714A, 714B) and the positive output is different from the length of a conductor of the coupling path between the second plurality of rectifiers (716A, 716B) and the negative output.
[0005]
5. Energy converter according to claim 1, CHARACTERIZED by the fact that the first rectification path (530, 730) comprises: a first plurality of rectifiers (714A) containing cathodes coupled together; an inductor (734) coupled between the cathodes of the first plurality of rectifiers and the positive output; a second plurality of rectifiers (714B) containing cathodes coupled together; and an inductor (736) coupled between the cathodes of the second plurality of rectifiers and the positive output.
[0006]
6. Energy converter according to claim 1, CHARACTERIZED by the fact that one of the secondary windings (508, 712, A1, A2, B1, B2, C1, C2) has a polarity opposite to that of the other secondary windings .
[0007]
7. Energy converter according to any of the preceding claims, CHARACTERIZED by the fact that each primary winding is divided into two parts and each secondary winding (508, 712, A1, A2, B1, B2, C1, C2) is interposed between two parts of a corresponding primary winding (A, B, C, 506, 706).
[0008]
8. Power converter according to claim 1, CHARACTERIZED by the fact that the first rectification path (530, 730) comprises 12 rectifiers (714A, 714B), each coupled to a respective derivation of the secondary windings (508 , 712, A1, A2, B1, B2, C1, C2) through respective couplings having a first inductance; and the second rectification path (532, 732) comprises 12 rectifiers (716A, 716B), each coupled to a respective derivation of the secondary windings (508, 712, A1, A2, B1, B2, C1, C2) through respective couplings having a second inductance different from the first inductance.
[0009]
Energy converter according to claim 1, CHARACTERIZED by the fact that the first rectification path (530, 730) comprises a conductor having a length different from the length of a corresponding conductor of the second rectification path ( 532, 732).
[0010]
10. Energy converter according to claim 1, CHARACTERIZED by the fact that the inductance of the first rectification path (530, 730) is approximately five times the inductance of the second rectification path (532, 732).
[0011]
11. Energy converter according to claim 1, CHARACTERIZED by the fact that the derivations of the secondary windings (508, 712, A1, A2, B1, B2, C1, C2) are distributed at identical central angles in the regular hexagon.
[0012]
12. Energy converter according to claim 1, CHARACTERIZED by the fact that two taps in one part of a secondary winding (508, 712, A1, A2, B1, B2, C1, C2) are in adjacent turns of the part secondary winding.
[0013]
13. Power converter according to claim 1, CHARACTERIZED by the fact that the transformer (502, 702) comprises three identical coils, each coil comprising one of the primary windings (A, B, C, 506, 706) and one corresponding secondary winding (508, 712, A1, A2, B1, B2, C1, C2).
[0014]
14. Power converter according to claim 13, CHARACTERIZED by the fact that the coils are positioned close to each other in a row and a central coil has a different polarity than the polarity of the other coils.
[0015]
15. Method for emitting 24-pulse direct current voltage, comprising: coupling three primary windings (A, B, C, 506, 706) of a transformer (502, 702) to each other in a differential configuration to receive respective phases of a three-phase alternating current; couple divided parts of the three secondary windings (508, 712, A1, A2, B1, B2, C1, C2) of the transformer together in a regular hexagonal configuration; provide a plurality of taps (4, 5, 8, 9) distributed at regular angles in the secondary windings (508, 712, A1, A2, B1, B2, C1, C2), each secondary winding part divided having at least two leads; forming a first rectification path (530, 730) between the plurality of derivations and a positive output; and form a second rectification path (532,732) between the plurality of derivations and a negative output, CHARACTERIZED by the fact that the first rectification path (530, 730) has an inductance and the second rectification path (532, 732 ) has an inductance with a difference from the inductance of the first rectification path, which in operation, causes the first and second rectification paths (530, 532, 730, 732) to convert phase dose AC energy signals into the current twenty-four continuous pulses.
[0016]
16. Method, according to claim 15, CHARACTERIZED by the fact that, the first rectification path (530, 730) comprises a first plurality of rectifiers coupled to the positive output; and the second rectification path (532, 732) comprises a second plurality of rectifiers coupled to the negative output, wherein an inductance of a coupling path between the first plurality of rectifiers and the positive output is different than an inductance of a path coupling between the second plurality of rectifiers and the negative output.
[0017]
17. Method according to claim 16, CHARACTERIZED by the fact that a length of a conductor of the coupling path between the first plurality of rectifiers (714A, 714B) and the positive output is different than the length of a conductor of the coupling path between the second plurality of rectifiers (716a, 716B) and the negative output.
[0018]
18. Method according to claim 15, CHARACTERIZED by the fact that the first rectification path (530, 730) comprises: a first plurality of rectifiers (714A) containing cathodes coupled together; an inductor (734) coupled between the cathodes of the first plurality of rectifiers and the positive output; a second plurality of rectifiers (714B) containing cathodes coupled together; and an inductor (736) coupled between the cathodes of the second plurality of rectifiers and the positive output.
[0019]
19. Method, according to claim 18, CHARACTERIZED by the fact that the transformer (502, 702) comprises a first, second and third coils, and the method comprises: placing the first, second and third coils together in a row with the second coil separating the first and third coils, the second coil having a different polarity than the polarity of the first coil and the third coil.
[0020]
20. Method according to claim 15, CHARACTERIZED by the fact that the primary windings (A, B, C, 506, 706) are divided into first and second primary parts and the parts of each secondary winding (508, 712, A1, A2, B1, B2, C1, C2) are interposed between the first and second primary parts of a respective primary winding.
[0021]
21. Method, according to claim 15, CHARACTERIZED by the fact that the difference in inductance is selected to cause the outputs of the secondary windings (508, 712, A1, A2, B1, B2, C1, C2) to be displaced 15 degrees from each other.

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同族专利:

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公开号 | 公开日

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US20140016356A1|2014-01-16|

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CN106877685B|2019-01-01|

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EP2678930B1|2020-04-08|

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CA2827741C|2017-08-15|

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CN103582997B|2017-02-15|

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EP2678930A1|2014-01-01|

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EP2678930A4|2018-01-17|

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CN106877685A|2017-06-20|

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CN103582997A|2014-02-12|

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WO2012116263A1|2012-08-30|

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CA2827741A1|2012-08-30|

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US9419538B2|2016-08-16|

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法律状态:
2018-12-18| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|

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2019-08-13| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|

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2020-06-09| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|

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2020-06-30| B15G| Petition not considered as such [chapter 15.7 patent gazette]|

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2020-11-03| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 24/02/2012, OBSERVADAS AS CONDICOES LEGAIS. |

优先权:

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申请号 | 申请日 | 专利标题

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US201161464000P| true| 2011-02-24|2011-02-24|

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US61/464,000|2011-02-24|

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PCT/US2012/026465|WO2012116263A1|2011-02-24|2012-02-24|Ac/dc power conversion system and method of manufacture of same|

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