CN101584106B - 扩展变速驱动器中的有源转换器的同步运作的系统和方法 - Google Patents

扩展变速驱动器中的有源转换器的同步运作的系统和方法 Download PDF

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CN101584106B
CN101584106B CN2008800026150A CN200880002615A CN101584106B CN 101584106 B CN101584106 B CN 101584106B CN 2008800026150 A CN2008800026150 A CN 2008800026150A CN 200880002615 A CN200880002615 A CN 200880002615A CN 101584106 B CN101584106 B CN 101584106B
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H·R·施尼茨卡
S·阿迪杰马诺尔
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Johnson Controls Technology Co
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Abstract

用于具有有源转换器的变速驱动器的同步运作的系统和方法，包括在完全线放空期间将有源转换器的同步运作扩展到AC干线电压。相位角控制电路包括方波放大器、与之关联的第一锁相环电路、以及第二锁相环电路。方波放大器接收AC电源，并将矩形的输出信号输出到一对锁相环(PLL)电路。具有第一滞后-超前滤波器的第一PLL电路配置有高截止频率，以为该转换器级提供相位角参数；包括第二滞后-超前滤波器的第二锁相环电路配置有低截止频率，以为该滞后-超前滤波器提供在干线中断期间存储干线电压的相位角的能力。

Description

扩展变速驱动器中的有源转换器的同步运作的系统和方法
相关申请的交叉引用
本专利申请要求于2007年1月22日申请的美国临时专利申请No.60/885,932的优先权。
技术领域
本申请总体涉及变速驱动器。本申请更具体地涉及用于具有有源转换器的变速驱动器的同步运作的系统和方法。
背景技术
用于加热、通风、空调和制冷(HVAC&R)应用的变速驱动器(VSD)通常包括整流器或转换器、DC链路和逆变器。驱动器技术的近期进展已引入了有源转换器的概念。有源转换器为驱动器提供了将正弦输入电流负载提供到电力干线的能力，这减轻了低阶谐波电流使干线的分配电压产生低阶谐波电压畸变的问题。
比起常规VSD，合并有有源转换器技术以提供功率因数校正和降低的输入电流谐波的VSD也向电机定子绕组生成了显著更高水平的共模RMS和峰-峰电压。这个共模电压可以经由多种杂散机器电容耦合到电机的转子，这导致电机和压缩机轴承颤动(fluting)，并且这些导致流经机器轴承的电流的共模电压可能造成电机和/或压缩机的过早的轴承损坏。
使用同步d-q参考帧的有源转换器控制方法的适当运作，要求知晓输入线-线电压的瞬时相位角。假如参考帧角不正确或未知，那么具有有源转换器的变速驱动器(VSD)的输入功率因数和谐波畸变输入电流就不能被适当地控制。假如要求VSD承受(ride-through)输入线-线电压的扩展丧失并当电力恢复时重新同步到输入主线，那么就需要一种在干线丧失期间保持期待的d-q参考帧角的装置。另外，还要求一种快速跟踪回到输入干线线-线电压并生成该线-线电压的实际相位角的装置。
需要一种系统和/或方法，其满足这些需要之一个或多个或者提供其他有利特征的。从本说明书，其他特征和优点将变得显而易见。所公开的教导延伸至落入权利要求范围的实施方案，不论它们是否实现了一个或多个前述需求。
发明内容
一个实施方案涉及一种变速驱动器系统，其被配置为接收处于固定AC输入电压的输入AC电压，并提供处于可变电压和可变频率的输出AC电。该变速驱动器包括：连接到提供输入AC电压的AC电源的转换器级(stage)，该转换器级被配置为将输入AC电压转换成升高的DC电压；连接到转换器级的DC链路，该DC链路被配置为对来自转换器级的升高的DC电压进行滤波和存储；和连接到DC链路的逆变器级，该逆变器级被配置为将来自DC链路的升高的DC电压转换成具有可变电压和可变频率的输出AC电。该变速驱动器还包括以下至少之一：用于防止因共模和差模滤波而造成的轴承侵蚀磨损的滤波器；相位角跟踪系统，其用于保持在所有条件下--包括有源转换器控制方法中有两个锁相环(PLL)的条件下--下知晓输入AC干线线-线电压相位角，这两个PLL包括具有相对高的滤波器截止频率和小值集成电容器的超前-滞后滤波器；集成旁路有源转换器配置，其用于在最大频率和电压--其等于供应给VSD的电力线干线频率--运作的受VSD控制的系统，该有源转换器配置具有接触器旁路，以消除当该系统被要求在最大频率运作时与VSD关联的丧失损失；液体冷却或制冷剂冷却(refrigerant-cooled)的感应器，其中该液体冷却或制冷剂冷却的感应器；电源组件，其包含(1)膜基DC链路电容器、(2)安置在至少一个电源电子模块上的多个塑料冷却器、(3)多个有源转换器IGBT模块、(4)至少一个薄片铜母线、(5)至少一个门驱动器控制板、(6)至少一个逆变器门电阻器控制板、和(7)至少一个转换器门电阻器控制板；以及由塑料材料组成的冷却器模块，其可以在约100摄氏度的连续使用温度下运作。
另一个实施方案涉及一种在完全线放空(line dropout)期间将有源转换器的同步运作扩展到AC干线电压(mains voltage)的方法。
另一个实施方案涉及一种具有改进的全速效率的、基于有源转换器的变速驱动器系统。
另一个实施方案涉及一种液体冷却或制冷剂冷却的感应器。该液体冷却或制冷剂冷却的感应器可以用在任何可用液体或制冷剂冷却且需要减小磁性构件的尺寸和重量的应用中。
在此描述的实施方案的特定优点是，集成旁路有源转换器配置可以用于在最大频率和电压--其等于被供应给VSD的电力线干线频率--运作的受VSD控制的系统。接触器旁路消除了当该系统被要求在最大频率运作时与VSD关联的损失。
一个优点是降低了在RMS和峰值两方面施给电机定子的共模电压应力，由此减轻了与过早机器轴承损坏和过早地面绝缘损坏关联的问题。另一个优点是降低了在RMS和峰值两方面施给电机定子的差模电压应力，由此减轻了与过早机器匝间(turn-to-turn)定子绕组损坏关联的问题。最后，该应用解决了与有源转换器运作关联的传导EMI/RFI辐射的问题。
本发明将以下构件合并成紧凑、轻量、易用且低成本的电源组件：(1)膜基DC链路电容器、(2)用于电源电子模块的塑料冷却器、(3)有源转换器IGBT模块、(4)薄片铜母线、(5)门驱动器控制板、(6)逆变器门电阻器控制板、和(7)转换器门电阻器控制板。
此外，合并了有源转换器技术的变速驱动器要求使用三相感应器，其比常规的基于无源转换器的VSD设计物理上大、耗能且昂贵。所公开的发明的另一个优点是，通过使用对感应器铁心的液体或制冷剂冷却，减小了感应器的尺寸、重量和成本，这正是基于有源转换器的VSD要求的。
替代性示例性实施方案涉及在权利要求中被总体陈述的其他特征和特征组合。
附图说明
从下文结合附图进行的详细描述中将更全面地理解本申请，在附图中相同的参考数字指示相同的元件，在附图中：
图1A和1B示意性地图示了总体系统配置；
图2A和2B示意性地图示了变速驱动器的实施方案；
图3示意性地图示了制冷系统；
图4是有源转换器干线角保持控制装置的框图。
具体实施方式
在转向详细图示示例性实施方案的附图之前，应理解，本申请不限于下文中阐述或附图中图示的细节或方法。也应理解，本文的措词和术语仅为了描述的目的，不应被视为限制。
图1A和1B总体图示了系统配置。AC电源102供应变速驱动器(VSD)104，其给一个电机106(见图1A)或多个电机106(见图1B)供电。电机106优选地用来驱动制冷或冷冻机系统(总体见图3)的相应压缩机。AC电源102将单相或多相(例如三相)、固定电压和固定频率的AC电从位于某地的AC电网或分配系统提供到VSD 104。AC电源102优选地可以根据相应的AC电网将200V、230V、380V、460V或600V的AC电压或线电压以线频率50Hz或60Hz供应给VSD 104。
VSD 104从AC电源102接收具有特定固定线电压和固定线频率的AC电，并以所需电压和所需频率将AC电提供到电机106，所需电压和所需频率都可改变以满足特定需求。优选地，VSD 104可以将具有高于及低于电机106的额定电压和频率的电压和频率的AC电提供到电机106。在另一个实施方案中，VSD 104仍可以提供高于及低于电机106的额定频率的频率，但仅可以提供等于或低于电机106的额定电压的电压。电机106优选地是感应电机，但可以是任何类型的能够以可变速度运作的电机。该感应电机可以具有任何合适的磁极布置，包括二极、四极或六极。
图2A和2B图示了VSD 104的不同实施方案。VSD 104可以具有三级：转换器级202、DC链路级204、和具有一个逆变器206(见图2A)和多个逆变器206(见图2B)的输出级。转换器202将来自AC电源102的固定线频率、固定线电压的AC电转换成DC电。DC链路204对来自转换器202的DC电进行滤波，并提供能量存储构件。DC链路204可以由电容器和感应器组成，它们是展现出高可靠性和非常低的故障率的无源器件。最后，在图2A的实施方案中，逆变器206为电机106将来自DC链路204的DC电转换成具有可变频率、可变电压的AC电，并且，在图2B的实施方案中，多个逆变器206并联连接到DC链路204，每个逆变器206为相应的电机106将来自DC链路204的DC电转换成具有可变频率、可变电压的AC电。逆变器206可以是电源模块，其可以包括功率晶体管、绝缘门双极晶体管(IGBT)电源开关、和用引线接合技术互连的反向二极管。此外，应理解，VSD 104的DC链路204和逆变器206可以包括上述不同构件，只要VSD 104的DC链路204和逆变器206可以为电机106提供适当的输出电压和频率。
根据图1B和2B，逆变器206被控制系统联合控制，以使每个逆变器206基于被提供给每个逆变器206的公共控制信号或控制指令，为相应的电机提供处于相同所需电压和频率的AC电。在另一个实施方案中，逆变器206被控制系统个别地控制，以允许每个逆变器206基于被提供给每个逆变器206的分离的控制信号或控制指令，为相应的电机106提供处于不同所需电压和频率的AC电。这个能力允许VSD 104的逆变器206独立于连接到其他逆变器206的其他电机106和系统的要求，更有效地满足电机106及系统需求和负载。例如，一个逆变器206可以为一个电机106提供全功率，而另一个逆变器206为另一个电机106提供半功率。在任一实施方案中，逆变器206的控制可以通过控制面板或其他合适的控制器件来执行。
对于被VSD 104驱动的每个电机106，在VSD 104的输出级中都有相应的逆变器206。可以被VSD 104驱动的电机106的数目取决于被合并到VSD 104中的逆变器206的数目。在一个实施方案中，VSD 104中可以合并有2或3个逆变器206，其并联连接到DC链路204并用于驱动相应的电机106。虽然VSD 104可以具有2至3个逆变器206，但应理解，可以使用超过3个逆变器206，只要DC链路204可以为每个逆变器206提供并维持适当的DC电压。
图3总体图示了使用图1A或2A的系统配置和VSD 104的制冷或冷冻机系统的一个实施方案。如图3所示，HVAC、制冷或液体冷冻机系统300包括压缩机302、冷凝器装置304、液体冷冻机或蒸发器装置306、和控制面板308。压缩机302被电机106驱动，电机106被VSD 104供电。VSD 104从AC电源102接收具有特定固定线电压和固定线频率的AC电，并以所需电压和所需频率将AC电提供到电机106，所需电压和所需频率可改变以满足特定需求。控制面板308可以包括多种不同构件，诸如：模拟-数字(A/D)转换器、微处理器、非易失性存储器和接口板，以控制制冷系统300的运作。控制面板308也可以用来控制VSD 104和电机106的运作。
压缩机302压缩制冷剂气体，并通过排放线将该气体运送到冷凝器304。压缩机302可以是任何合适类型的压缩机，例如螺杆压缩机、离心压缩机、往复压缩机、涡旋压缩机等等。被压缩机302运送到冷凝器304的制冷剂气体与流体--例如空气或水--进行热交换，并且，与流体进行热交换的结果是，经历相变成为制冷剂液体。来自冷凝器304的已冷凝的液态制冷剂流经膨胀装置(未示出)到蒸发器306。
蒸发器306可以包括用于冷却负载(cooling load)的供应线和返回线的连接。第二液体--例如水、乙烯、氯化钙卤水或氯化钠卤水--经由返回线流到蒸发器306中，并经由供应线流出蒸发器306。蒸发器306中的液态制冷剂与第二液体进行热交换，以降低第二液体的温度。蒸发器306中的制冷液体与第二液体进行热交换的结果是，经历相变成为制冷剂气体。蒸发器306中的气态制冷剂经由抽吸线流出蒸发器306并回到压缩机302，以完成循环。应理解，在系统300中可以使用任何合适的冷凝器304和蒸发器306配置，只要在冷凝器304和蒸发器306中制冷剂获得适当的相变。
HVAC、制冷或液体冷冻机系统300可以包括图3未示出的许多其他特征。这些特征已被有意地省略以简化绘图，从而便于说明。此外，虽然图3图示了具有连接在单个制冷回路中的一个压缩机的HVAC、制冷或液体冷冻机系统300，但应理解，系统300可以具有被如图1A和2A所示的单个VSD或如图1B和2B所示的多个VSD驱动的、连接到一个或多个制冷回路之每个的多个压缩机。
下面参看图4，图示了总体以900指代的干线相位角(MPA)控制系统。控制系统900在输入电压放空期间为AC输入源或干线电压102提供相位角信息的保持。干线电压102被施加到方波放大器901，以由AC输入信号生成基本矩形的输出信号。方波放大器的输出同时被输入到一对锁相环(PLL)902、904。第一PLL 902具有相位检测器918，其用于将参考信号SIG与比较信号COMP进行比较，以检测何时输入信号的相位与受电压控制的振荡器(VCO)922失锁。假如相位检测器918检测到SIG和COMP这两个输入脱离相位锁，那么复位信号从相位检测器918的终端LD输出到单稳态(1-shot)电路924。单稳态电路924生成被输入到采样和保持(S&H)电路910的窄脉冲。相位检测器918的输出误差信号经过滞后-超前滤波器电路906到达VCO 922。来自VCO922的输出信号继而被输入到除以N(divided-by-N)电路926。除以N电路926提供被施加到相位检测器918的COMP终端的比较信号，还输出第二信号，其指示干线电压d-q轴数字角输出快速响应928。
第二PLL 904电路与上述PLL 902配置类似，相位检测器920将输入参考信号SIG与比较信号COMP进行比较，并将误差信号输出到滞后-超前滤波器908。滞后-超前滤波器908具有S&H电路914，其被单稳态电路930和模拟开关916控制。滞后-超前滤波器908具有低截止频率，下面将更完整地描述。VCO 932被输入到除以N电路934，其生成被输入到相位检测器920的COMP信号，并输出第二信号，其指示干线电压d-q轴数字角输出慢速响应936。
控制系统900可以用来保持VSD 104与有源转换器202的同步运作，以降低电流畸变并消除由AC输入干线电压102的重复施加而造成的能量重复生成，从而在VSD 104中提供扩展的承受能力。这两个PLL902、904的使用使得控制系统900能够最大化有源转换器202保持最佳的知晓在所有条件下AC输入源102处的线-线电压相位角的能力。第一PLL 902滞后-超前滤波器906具有相对高的滤波器截止频率和小值集成电容器C1。这个滤波器906为有源转换器202提供了在正常转换器运作条件下进行快速准确的相位角跟踪的能力。滤波器906构件包括电阻器R1、电阻器R2和电容器C1。在一个实施方案中，构件值可以是：电阻器R1为43kΩ、电阻器R2为120kΩ、电容器C1为0.47μF，尽管滞后-超前滤波器906构件R1、R2和C1可改变以调节滤波器906的所需截止频率。第二PLL 904滞后-超前滤波器908具有低截止频率、大值集成电容器C2、以及电阻器R3和R4。低截止频率为滤波器908提供了在干线中断期间将干线电压角存储在PLL的反馈环中的能力。在一个实施方案中，R3、R4和C2的典型构件值可以分别是510kΩ、68kΩ和2.2μF。为了增大在电力中断期间保持干线相位角信息的能力，每个PLL反馈环906、908分别包括采样和保持电路(S&H)910、914，并分别包括模拟开关集成电路912、916。具有模拟开关912、916的S&H电路910、914将所存储的电荷保持在每个滞后-超前滤波器906、908内的集成电容器C1、C2上，并防止电容器C1、C2通过泄漏向相位检测器的输出放电。构件比值R3/R4也被选择，以使当模拟开关916被切换时使得馈给受电压控制的振荡器932的电压的阶跃变化最小化。
每个模拟开关912、916的位置是通过经由干线电压检测器(或干线现有)电路检测干线电压102的总体损失来控制的。采样和保持电路910、914为被合并到每个相位检测器中的控制失锁检测器所控制。VCO输出被馈给除以N位计数器926、934，其中N被选择为随特定应用中所需的相位角分辨率而变化。计数器输出继而被馈回每个相位检测器918、920的第二输入(用COMP表示)，以形成闭环。计数器输出也用来提供代表干线相位角的数位字(digital word)928、936。数位字926、936继而在中断期间支配干线d-q角输出。切换相位角信息的时机的选择因特定应用而异，但通常使用干线电压检测器(干线现有)电路。在一个实施方案中，PLL 902、904可以使用飞利浦半导体公司生产的74HC7046集成电路来实施。74HC7046集成电路包括状态机型相位检测器，其具有失锁检测器和受电压控制的振荡器。该电路设计允许长达1秒的电力中断，而在最差条件下也不会导致超过特定角的相位误差。
虽然附图中图示和本文中描述的示例性实施方案目前是优选的，但应理解，这些实施方案仅以实例方式提供。据此，本申请不限于特定实施方案，而是延伸至无论如何落入所附权利要求的范围的多种变更。任何过程或方法步骤的顺序或次序可以根据不同实施方案来改变或重排。
本申请专注于方法、系统和任何机器可读媒介上用于实现其运作的程序产品。本申请的实施方案可以使用为这个或其他目的合并的现有的计算机处理器--或用于适当系统的专用计算机处理器--或通过硬件系统来实施。
重要的是，注意，该干线相位角控制系统的构建和安排，如多种示例性实施方案所示的，仅是说明性的。虽然在本公开中仅有几个实施方案被详细描述，但阅读本公开的本领域技术人员将意识到，在本质上不脱离权利要求中陈述的新颖性教导和优点的前提下，许多变更是可能的(例如，尺寸、尺度、结构、形状和比例的改变、多种元件、参数值、安装配置、材料使用、颜色、方向等等)。例如，所示为集成形成的元件可以由多个部分或元件构建，元件的位置可以被颠倒或作其他改变，离散元件或位置的本性或数目可以被更改或改变。据此，所有这样的变更都意在被包括在本申请的范围内。任何过程或方法步骤的顺序或次序可以根据不同实施方案来改变或重排。在权利要求中，任何装置加功能条款意在覆盖本文描述的、执行所陈述的功能的结构，不仅包括结构等价物，而且还包括等价结构。在不脱离本申请的范围的前提下，在示例性实施方案的设计、运作条件和安排方面，可以做出其他替换、变更、变化和省略。
如上所记，本申请范围内的实施方案包括程序产品，其包含用于携带或其上存储有机器可执行指令或数据结构的机器可读媒介。这样的机器可读媒介可以是任何可得到的、可以被通用或专用计算机或其他具有处理器的机器访问的媒介。举例说，这样的机器可读媒介可以包含：RAM、ROM、EPROM、EEPROM、CD-ROM，或其他光盘存储器、磁盘存储器或其他磁性存储器件，或任何其他可以被用来携带或存储机器可执行指令或数据结构形式的所需程序代码并可以被通用或专用计算机或其他具有处理器的机器访问的媒介。当信息被转移或经由网络或其他通信连接(有线、无线、或有线无线结合)提供给机器，该机器可能将该连接视为机器可读媒介。这样，任何这样的连接都可能被称为机器可读媒介。机器可执行指令包含，例如，导致通用计算机、专用计算机或专用处理机执行特定功能或功能组的指令和数据。
应注意，虽然本文的附图可以示出方法步骤的特定顺序，但应理解，这些步骤地顺序可以与所述不同。而且，两个或多个步骤可以被同时执行。这样的不同将依赖于所选的软件和硬件系统以及设计者的选择。同样地，软件实施可以用具有基于规则的逻辑和其他逻辑的标准编程技术来实现，以实现多种连接步骤、处理步骤、比较步骤和决定步骤。

Claims (15)

1.一种变速驱动器，其被配置为接收处于固定AC输入电压的输入AC电压，并提供处于可变电压和可变频率的输出AC电，该变速驱动器包括：
转换器级，其连接到提供输入AC电压的AC电源，该转换器级被配置为将输入AC电压转换成升高的DC电压；
DC链路，其连接到转换器级，该DC链路被配置为对来自转换器级的升高的DC电压进行滤波和存储；
逆变器级，其连接到DC链路，该逆变器级被配置为将来自DC链路的升高的DC电压转换成具有可变电压和可变频率的输出AC电；并且
相位角控制电路，其包括：
方波放大器、与之关联的第一锁相环电路、和第二锁相环电路；
该方波放大器被配置为接收AC电源，并基于AC电源输出基本矩形的输出信号；
该第一锁相环电路包括第一滞后-超前滤波器，其被配置为具有高滤波器截止频率和第一电容器，以为转换器级提供相位角参数；并且
该第二锁相环电路包括第二滞后-超前滤波器，其被配置为具有低截止频率和第二电容器，以为该第二滞后-超前滤波器提供在干线中断期间将干线电压角存储在第二锁相环电路的反馈环中的能力。
2.权利要求1的变速驱动器，其中第一滞后-超前滤波器包括第一电阻器、第二电阻器，其中第一电阻器具有小于第二电阻器的电阻，并且第一电容器是小值集成电容器。
3.权利要求2的变速驱动器，其中第一电阻器的阻值是43kΩ，第二电阻器的阻值是120kΩ，第一电容器的电容是0.47μF。
4.权利要求3的变速驱动器，其中第二滞后-超前滤波器包括第三电阻器和第四电阻器，其中第三电阻器具有大于第四电阻器的电阻，并且第二电容器是大值集成电容器。
5.权利要求4的变速驱动器，其中第三电阻器的阻值是510kΩ，第四电阻器的阻值是68kΩ，第二电容器的电容是2.2μF。
6.权利要求1的变速驱动器，其中第一锁相环电路和第二锁相环电路中的每个都包括第一采样和保持电路和与该采样和保持电路连通的第一模拟开关，该第一模拟开关被配置为将所存储的电荷保持在第一或第二滞后-超前滤波器内的关联的第一或第二电容器上，并防止关联的第一或第二电容器放电。
7.权利要求2的变速驱动器，其中第一电阻器、第二电阻器和第一电容器是为第一锁相环电路的快速锁定运作而选择的。
8.权利要求4的变速驱动器，其中第三电阻器和第四电阻器基于它们的阻值被选择，以提供第三和第四电阻器的电阻比值，其使当第二模拟开关改变状态时馈给受电压控制的振荡器的阶跃变化最小化。
9.权利要求1的变速驱动器，其中第一锁相环电路和第二锁相环电路中的每个进一步包括模拟开关和干线电压检测器电路，该干线电压检测器电路是通过检测AC电源的输入AC电压的损失来控制的。
10.权利要求9的变速驱动器，其中第一锁相环电路和第二锁相环电路中的每个进一步包括相位检测器电路、受电压控制的振荡器和除以N电路，该相位检测器电路具有失锁检测器，其响应在方波放大器的方波输出和由除以N电路响应受电压控制的振荡器而生成的比较反馈信号之间的相位差。
11.权利要求10的变速驱动器，其中除以N电路的除数N是基于预定应用所需的相位角分辨率来选择的。
12.权利要求11的变速驱动器，其中除以N电路处理受电压控制的振荡器的输出以生成反馈信号，该反馈信号被施加到每个相位检测器电路的输入终端以形成闭环。
13.权利要求12的变速驱动器，其中除以N电路生成代表干线相位角的数位字，该数位字用来控制干线中断期间变速驱动器的输出的d-q角。
14.权利要求13的变速驱动器，其中第一锁相环电路和第二锁相环电路被配置为在AC电源损失期间维持同步运作。
15.权利要求14的变速驱动器，其中AC电源的损失期间长达1秒，同时此期间该驱动器将相位误差维持在预定角限度内。
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