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  • Controllable Universal Supply

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    US Patent application

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    US Patent application

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    55 Ansichten25 Seiten

    Controllable Universal Supply

    Hochgeladen von

    harzu
    US Patent application

    Copyright:

    © All Rights Reserved
    Als PDF herunterladen oder online auf Scribd lesen
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    von 25
    us: us United States cz) Patent Application Publication co) Pub. No.: US 2011/0157942 A1 oy as () Babcock et al. UNIVERSAL SUPPLY WITH REACTIVE POWER MANAGEMENT Inventors: Paul M, Babcock, Spokane Valley WA (US): David J. Babeoek, Spokane, WA (US): Philip Ne Smith, Spokane Valley, WA (US) Assignee: FLYBACK ENERGY INC, Spokane Valley, WA (US) Appl.No: 121980,826 Filed Dee. 28,2010 Related US. Application Data Provisional application No. 61/290.287, filed on Dec 28, 2000, provisional application No. 61/290.283 fied on Dee. 28, 2009, at Ht 20 AI (43) Pub, Date Jun. 30, 2011 ublication Classification (1) neck HOM 7706 (2006.01), (2) US.C 363/126 r ABSTRACT Apparatus and associated methods involve controllable sup- phy adapted for controlling switch phasing and pulse width to Substantially equalize power in adjacent quadrants of asim. ‘Soidal souree voltage ‘waveform io regulate reactive poster ‘deawa from the source, In an illustrative example, the supply ‘may, in some embodiments, deliver power toa load.ata level responsive to # commanded input signal. In some examples, the power supplied to the load may be adjusted according wo ‘the Gammand input signal wa selected valu within an oper ating range. In some examples the operating range may ineude a portion or all of 0 to 100% of rte load. Various tembodiments may be adapted to supply tnipolar or bipolar Joad excitation. In some embodiments high power factor may bemainiained overa substantial range of commanded power to the load. Certain embodiments may eahance supply elle ciency by capturing and recyeling inductive load energy Patent Application Publication Jun, 30,2011 Sheet 1 of 12 US 2011/0157942 Al 100 & Energy Processing Module 108 Power Stage 1 1200 so 188 189 165 | 169 Voltage Limiter Control Controlier }# + input FIG.4 Patent Application Publication Jun, 30,2011 Sheet 20f12 US 2011/0157942 Al Lr00 FIG.2 US 2011/0157942 AI Jun, 30,2011 Sheet 3 of 12 Patent Application Publication Vea FIG. 3 Patent Application Publication Jun, 30,2011 Sheet 4 of 12 US 2011/0157942 Al FIG. 4 Patent Application Publication Jun, 30,2011 Sheet Sof 12 US 2011/0157942 Al «07, Patent Application Publication Jun. 30, 2011 Sheet 6 of 12 US 2011/0157942 AL Tag oan eR we Hl —— = 1 — L LJ eS = = Jrorice TP Input essomea om | 3 [ee = es = = =e Care vena |] 08 Ld bf Gon FiG.6 Patent Application Publication Jun, 30,2011 Sheet 70f12 US 2011/0157942 Al Adjust Pulse Receive Power Width, PW input Command signal, P* Monitor Power, P and_power factor, Calculate T1 to equalize PF, during adjacent quadrant power measurement of same polarity window NSO” eo | Calculaie new Apply T1, T2 to el control switches FIG. 7 Patent Application Publication Jun. 30,2011 Sheet 8 of 12 US 2011/0157942 AL ap | q { Ce Cy agra west co ~ | Powe Stooe 2 _ YY. 1 ao | “Yeoic ipa Sartor aa FIG.8 Patent Application Publication Jun, 30,2011 Sheet 9 of 12 US 2011/0157942 Al Li FIG. 9 Patent Application Publication Jun, 30,2011 Sheet 10 of 12 US 2011/0157942 Al 1000 ix B15, » 510 Cray Promeang ave ie Co = ‘ = Ht 1010 oy fA | 830 das | = = Aes (a) 1050 815 oe » Enapy Penang Mote —} +7 C rowersuse |] hrons> se 5H mn 1065 J (b) diosa 1050 1065 Line Frequency Rectifier 400 Hz DC-DC Battery a with PFC and oc Charger with + Flyback Capture Buss Flyback Capture iv @) ©) (c) FIG. 10 Patent Application Publication Jun, 30,2011 Sheet 11 of 12 US 2011/0157942 Al Patent Application Publication Jun, 30,2011 Sheet 12 of 12 US 2011/0157942 Al 525 Watts 35% POA Tiedg Delay FIG, 11 US 2011/0157942 Al CONTROLLABLE UN WITH REACTIVE POWER MANAGEMENT (CROSS-REFERENCE TO RELATED "APPLICATIONS, 10001) This application claims benefit to U.S. application Ser. No. 61/290,253, eitled “Supply for Lighting Systems, 4s filed on Dec. 28, 2009 by Babcock. etal. and to US. ‘application Ser No, 61/290,257 entitled “Rectifier Systems," ‘sled on Dec. 28, 2009 by Baboock, et al, the entire con- tents of each of which are fully incomporated by reference herein ‘TECHNICAL FIELD 10002] Various embodiments relate to operating variable contol of loads supplied from AC sources BACKGROUND {0003} | Many elecrially-operated systems andl devices have inductance. Some inductive devices, such as DC (diteot ‘curent) motors sutomotive ignition systems, and some elec tromagnes, can operate when supplied with a unidirectional ‘current. Some inductive deviees, such as transformers, AC. (alternating current) motors, and fluorescent lights, operate ‘hen supplied with «bidirectional current 10004} In genera, inductive elements ea store energy in @ magnetic field. Typically, the magnetic field is supported by ‘an electri current flowing through the inductive element Inductance may bea funetion ofthe characteristics of a mage netic ux path, For example, inductance in some elements may depend on material propos of a core (ex air, too, ‘and fete) in the fox path, andor a fax density saturation level 10005] ‘The amount of energy stored in a magnetic field of tn inductive element can bea function ofthe inductance and the current, In general, the amount of energy stored in the magnetic field inreases as current increases, and decreasesas the current deereases. Accordingly, when the current tough the inductive element is zero, the Stored inductive energy is alsa 70, 10006] | One characteristic ofan ideal indetor is that a volt age across the inductor i proportional to is indvetance and the time rate of change of current. This concept may be represented by 2 formula as: V-Ldil 10007] Under certain conditions, the energy stored in aa Induetorcan generate potentially uncontrolled lage voltages. ‘This effect may be refered to by tens such a reverse elec tromotive force (REMP), flyback voltage, or “inductive kick” As an illustrative example, if an inductor is being supplied curent through a switch, and that switch is rapidly ‘opened, then the inductor may havea relatively large change ‘ofeurent (large di in a relatively short perio of time (small, ‘), As a consequence, the inductor coud penerate a corre spondingly lage voltage (large V). 10008] "In some applications, the energy stored in an indue- tormay be capable of generating sufficiently large voltages to ‘damage or destroy, for example, an unprotected switch In some systems, stored inductive encray may be dissipated as heat SUMMARY, [0009] Apparatus and associated methods involve a con- teollable supply adapted for controlling switch phasing and Jun. 30, 2011 pulse wid fo substantially equalize power in adjacent quad fants of a sinusoidal source voltage wavelonm to regulate reactive power drawn from the source. Ia an illustrative example, the supply may, in some embodiments, deliver power toa Toad in response toa commanded input signal. In Some examples, the power supplied to the load may be adjusted according tothe command input signal toa selected ‘value within an operating range In same examples, the oper ating range may include a portion or all of Oto TOP 0 rated Toad, Various embodiments may be adapted to supply unipo- Jar or bipolar load excitation. In some embodiments, high power fictor may be maintained over a substantial range of ‘commanded power to the load, Certain embodiments may enhance supply eliceney by capturing and recycling indue- tive load energy. [0010] In one exemplary aspect, a method of managing reactive power, the method inlidesretfying a substantially sinusoidal source voage waveform from a souree toa rect- fied voltage node, providing a switch arranged to selectively couple the rectified voltage node to load and determining & pulse widih value for turning on the switeh to deliveradesied average power 1o the load. The method further includes ‘eccisng infomation about relative power drawn from the source during adjacent quadrants ofthe source voltage wave- orm, determining a suiteh tim on delay time wo substantially ceualize power between adjacent quadrants of the same polarity, and, controlling the switch during at Feast two sue- ‘cessive half eyles ofthe source voltage waveform according to the determined switch turn on delay time. 0011] In various examples, the method may further include controlling a reverse electromotive force associated ‘with rapid turn off of the switch, and capturing indvetive ‘energy storedin the load when the switch disconnects the load {rom the rectified voltage node. Ttmay further inelude retum- ing the captured energy tothe load om a subsequent half eycle fof the source voltage wavefom. In some examples, the ‘method may inchicle providing a capacitor at the retificd voltage node to provide a Teading phase shift to the current awa from the source. Determining. switch tum on delay ‘ime to substantially equalize power between adjacent quad- rans of the same polarity may include determining a delay time with respect to a periodic reference point on the source voltage waveform. The periodic reference point may bea 2er0 cross point, and may be a point at which the sonree voltage ‘waveform isinereasing ordccreasng. Some inyplementations further include receiving power command input signal. The step of determining the pulse width value for tuming on the ‘witch to deliver the desired average power tothe load may Turther include determining pulse widh vale in accordance ‘with the received poser command inp signal. Controlling the sivitch during at least two suecessive half eyeles of the source voltage waveform according 1 the determined switch ‘um on delay time may further include controling the switeh according tothe determined pulse width valve [0012] Censin embodiments may provide one oF more advantages. Forexample, some embodiments may provide an efficiency gain when replacing an existing interface between ‘loa anda tly fed line. For example, vatiousimplemen- tations may compensate for more than the aed switch loss by any or all ofthe following: (i) reaprure and reeyeling of induetive energy stored in the load (e.2, flyback eaptare process): i) educed filtering insertion loss by elimination of bigh frequency filter components to atenate high frequency switching systems; (i) reduced utility rates from manage- US 2011/0157942 Al ment of reactive power consumption: or, (iv) smooth control ‘of load power within a wide coteol range (e.g. dimmabilty {or lighting, or adjustable speed for machines) as needed 10 ‘conserve energy. 10013] | Some implementations may achieve highefiieney, high power ficier (eg, above 09), and power regulation within a wide contro range fora variety of Toads. Fxemplary Toads that may be supplied by various embodiments include, but are not limited to, single phase induction machines (among other machine types), HID lights with power-ogs- Jated ballasts, and battery chargers lor telecommunication applications, for example. Some examples may provide & highly controllable, high power fsetor, low loss, electromag netically quiet, robust, and universal supply module capable ‘of supplying regulated power toa wide range of AC and DC Toad types. 10014] The details of various embodiments are set forth ia the accompanying drawings and the deserption below Other Jeatures and advantages willbe apparent Irom the description and drawings, and from the claims DESCRIPTION OF DRAWINGS 10015], FIG. 1 shows « schematic representation of an ‘exemplary energy processing mosdle with «power stage #0 soppy energy’ from a DC input a DC inductive Tea 10016), FIG. 2 shows a schematic representation of an ‘exemplary powerstage to supply energy from DC inp toa DC indnetve load [0017] FIG. shows plotsofexemplary voltage and current ‘waveforms to illustrate operation of the omer stages of FIGS. 12 0018} FIG. 4 shows a schematic representation of an ‘exemplary power stage to supply enemy from DC input toa DE indvetve load. 10019} FIG. 5 shows a schematic representation of an ‘exemplary psi of power sage to supply’ enor fom a DC Jnput to an AC inductive load. 10020) FIG. 6 shows a block diagram representation of an ‘exemplary neray processing system thi oes the power stages of FIG. So supply energy from an AC input toan AC jndutve load. 0021] FIG. shows a fowebaet of an exemplary process Forcontelling the energy processingsystom ofFIG.6todeaw Jow euctive power fm the AC sure over a rine of eg Javed power tthe load. 0022] FG. & shows an exemplary controllable univers supply configured to manage reactive power drawn rom a AC lity souee 10023] IG. 9 shows exemplary loads for (high inten sity discharge (HID) ihtingepplicatio, and (b) indction machine applications, configured to reeive power from the supply of FIG. 8 10024] FIG. 10 shows an exemplary retifer lad contig tre to conncet to receive power from the supply of FIG. ‘ano supply power an drial baltery care 10025] FIG. 11 shows an exemplary set of letra! wave- forms ilsirating perfomance ofan experimental HID laht Joad a discus With reference to FIG. 9(a) whea supplied bythe supply of FIG, Kovera mngeof powcr levels and sing the proces of FIG. 7. Jun. 30, 2011 [0026] Like reference symbols in the various drawings indicate like elements DETAILED DESCRIPTION OF ILLUSTRATIVE EXAMPLES [0027] FIG. 1 shows an exemplany system 100 in which energy may be supplied 10 inductive and/or resistive loads at ‘controllable rate with high efficieney and low eloctramag- elie noise, The system 100 of this example includes an energy processing module 108 that receives energy at an input, processes the energy, and delivers unidirectional eur rent fo supply energy to a load connected at an output, The ‘module 105 includes a power stage 110 that operates ia response to control signals from a controller 118, In opera- tion, the controller 118 contols the operating states of switches inthe power stage IHD according to a sequence of ‘operating states that may or example, be repeated ina eyel- cal pattem. Inan exemplary cyele of operation, the controller 115 generates a sequence of operating sates that cause the powwerstage 110 (0 store energy from a poser source 120 into ‘an indvetive load 125, contol a reverse electromotive force (REMP) that may develop when the inductive load 128 is sisconnected fromthe source 120, discharge inductive energy from the load into a capacitance, and then discharge the capacitance o store energy back ino the load 125 on 2 sub- sequent cycle In various embodiments, the power stage 10 may deliver substantially unidirectional current Now to the Toad 128. Some embodiments may completely discharge stored inductive energy from the load 128 during each cycle [0028] One exemplary cycle of operation of the power Stage 110 includes a Sequence of operating states as indicated by arwws A, B,C, D-For example, the processing module 105 may draw curent from the power source 120 during sate B ofa eyele, while the power stage 110 may provide for ‘unidirectional current flow through the load 125 (eg, DC ireet curent) motor) during states A, B, C, and D of the cycle. In some applications, additional work may be per- Tormed during sites A, C, and D when no power is being drawn from the power source 120, Fxamples of voltage and ccrent waveforms assoviated with some embodiments ofthe power stage 110 are described in Further detail with reference 1oFIG, Band FIG. 8, [029] In the depicted example, the power stage 110 includes pair of input switches 1304, 1306, which may be operted, ia some embodiments, at a double-pole single throw switch. Some other embodiments (not shawn) may be configured to operate with only one of the input switches 130g, 1305, The input switch 13a connects between an inpt rode 135 and an output node 140, The voltages of the nodes 135, 140 may be referred to herein as Vin, Vout, respectively. After the input switches 1302, 1306 are turned on, aa inp {eurrent (lin) suppliod from the pewter source 120 may 10 the input node 138, and through the input switeh 1304 1 the ‘ipat node 140, An output current (lout) flows from the ‘utat noe 140, through the load 128, and returns thovgh a ‘return ode 145 an the input switch 130 o the power source 120. As will be described below, the current in Irom the power source 120 may begin to Ho sometime after the apt Switches 130g, 130b ae traed on, [0030] ‘The power stage 110 further includes a transitional circuit 150 which may be operated to provides current ow path forthe current lout so as to control aa amplitude of a [REM that may be generated when the inp switches 130, 1306 open and rapidly disconnect the output current lout US 2011/0157942 Al ‘rom the input current ln. As such, the transitional iret 150 ‘may substantially protect the input switches 130a, 1305 from ‘exposure lo potedtially destructive REMF voltages, In the ‘depicted example, the transitional circuit 180 includes un

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