NL1044240B1 - Smart universal permanent magnet voltage regulator/rectifier. - Google Patents

Smart universal permanent magnet voltage regulator/rectifier. Download PDF

Info

Publication number
NL1044240B1
NL1044240B1 NL1044240A NL1044240A NL1044240B1 NL 1044240 B1 NL1044240 B1 NL 1044240B1 NL 1044240 A NL1044240 A NL 1044240A NL 1044240 A NL1044240 A NL 1044240A NL 1044240 B1 NL1044240 B1 NL 1044240B1
Authority
NL
Netherlands
Prior art keywords
rectifier
voltage
een
mosfet
deze
Prior art date
Application number
NL1044240A
Other languages
Dutch (nl)
Inventor
Marcus Henricus Johannes Van Erp Ing
Rudy Coppens Ing
Original Assignee
Ultimate Rectifier B V
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Ultimate Rectifier B V filed Critical Ultimate Rectifier B V
Priority to NL1044240A priority Critical patent/NL1044240B1/en
Application granted granted Critical
Publication of NL1044240B1 publication Critical patent/NL1044240B1/en

Links

Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02J—CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J7/00—Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries
    • H02J7/14—Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries for charging batteries from dynamo-electric generators driven at varying speed, e.g. on vehicle
    • H02J7/1469—Regulation of the charging current or voltage otherwise than by variation of field
    • H02J7/1492—Regulation of the charging current or voltage otherwise than by variation of field by means of controlling devices between the generator output and the battery
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02J—CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J7/00—Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries
    • H02J7/0029—Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries with safety or protection devices or circuits
    • H02J7/00309—Overheat or overtemperature protection
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02J—CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J7/00—Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries
    • H02J7/0047—Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries with monitoring or indicating devices or circuits
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M7/00—Conversion of ac power input into dc power output; Conversion of dc power input into ac power output
    • H02M7/02—Conversion of ac power input into dc power output without possibility of reversal
    • H02M7/04—Conversion of ac power input into dc power output without possibility of reversal by static converters
    • H02M7/12—Conversion of ac power input into dc power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode
    • H02M7/21—Conversion of ac power input into dc power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal
    • H02M7/217—Conversion of ac power input into dc power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only
    • H02M7/219—Conversion of ac power input into dc power output without possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only in a bridge configuration
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M1/00—Details of apparatus for conversion
    • H02M1/0083—Converters characterised by their input or output configuration
    • H02M1/0085—Partially controlled bridges
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
    • H02M1/00—Details of apparatus for conversion
    • H02M1/32—Means for protecting converters other than automatic disconnection
    • H02M1/325—Means for protecting converters other than automatic disconnection with means for allowing continuous operation despite a fault, i.e. fault tolerant converters

Landscapes

  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Control Of Charge By Means Of Generators (AREA)

Abstract

De uitvinding heeft betrekking op een spanningsregelaar-gelijkrichter die wordt toegepast op een permanent magneet dynamo om een batterij op te laden. Deze permanent magneet dynamo's worden veelal toegepast in gemotoriseerde tweewielers zoals motorfietsen, scooters, sneeuwscooters etc. om de 5 batterij op te laden. Wat is gezien in de markt is dat veel spanningsregelaars-gelijkrichters een korte levensduur hebben. Het grootste deel van de kapotte spanningsregelaar komt door oververhitting. Om dit te voorkomen zijn al enkele jaren MOSFET-spanningsregelaars-gelijkrichters op de markt die minder warm worden. Helaas zijn deze spanningsregelaars erg duur vanwege het gebruik van een geavanceerd regelcircuit. Dit regelcircuit zorgt voor een stabielere uitgangsspanning bij de batterij. MOSFET 10 spanningsregelaars-gelijkrichters hebben ook één groot nadeel, ze creëren voltage pieken bij het uitschakelen van de MOSFET's waardoor ze een geavanceerd regelcircuit nodig hebbe om deze pieken eruit te filteren. De uitvinding is opgebouwd uit twee delen, het eerste deel bestaat uit een eenvoudige manier om uitgangspanning van de gelijkrichter regulator te meten zonder deze voltage pieken. Dit wordt gedaan door tussen schakelmomenten van de MOSFET's in, de uitgangspanning te meten. Op dit moment 15 is er een stabiele spanning zonder deze voltage pieken. Het tweede deel is een eenvoudig manier om te zorgen dat de spanningsregelaar-gelijkrichter niet te warm kan worden. Bij een te hoge temperatuur worden de MOSFET's in de spanningsregelaar-gelijkrichter ingeschakeld waardoor de dynamo fases worden kortgesloten naar de negatieve pool van de spanningsregelaar-gelijkrichter. Door deze twee aanpassingen kan deze spanningsregelaar-gelijkrichter worden toegepast op veel meer verschillende permanent 20 magneet dynamo's en wordt de levensduur aanzienlijk verbetert. 1044240

Description

i
Smart universal permanent magnet voltage regulatorfrectifier.
FIELD OF THE INVENTION:
The invention relates to a battery charging system consisting of a permanent magnet alternator, comprising different phases connected to a rectifier and a voltage regulator. A common use case of this invention is for motorcycles, quads, scooters, buggies, snowmobiles, and watercrafis. However, a vollage regulatorfrectifier can be used on any permanent magnet alternator for controlling the output voltage. The output voltage of a voltage regulator/rectifier is often connected to a battery.
BACKGROUND OF INVENTION:
A voltage regulator/rectifier is an essential part of any charging system. The voltage regulator/rectifier is responsible for a stable output voltage on the battery. The rectification and battery voltage monitoring can be implemented in different ways. The most common way is with the use of diodes and shunt transistors.
The diodes are placed in a diode bridge circuit and ensure the conversion from Alternating Current (AC) to
Direct Current (DC). The Silicon Controlled Rectifier (SCR) transistors in combination with a Zener diode are used for voltage regulation. When the output voltage gets too high, the resulting energy will be shunted to the ground. This circuit comes with a big drawback, the heat generation of the SCR's is very high. Due to the heat generation, the components exceed their junction temperature and the voltage regulator/rectifier fails as a result of overheating.
Many old voltage regulators of this type are failing after a few years due to the overheating problem. To overcome this problem the Metal-Oxide-Semiconductor Filed-Effect Transistor (MOSFET) voltage regulator/rectifier has been invented. A MOSFET is also a transistor type, but with a different working principle. The main improvement over the SCR is a lower vallage drop what results in a reduction in power losses. These MOSFET voltage regulators/rectifiers are equipped with Schottky diodes instead of “normal” diodes. Schotiky diodes have a significantly lower voltage drop. Therefore, the MOSFET voltage regulator/rectifier achieves a higher efficiency that results in a reduction of the power losses and therefore less heat dissipation, this ensures a longer lifespan,
The voltage output of any kind of voltage regulator/rectifisr must be stable. If the voltage output is not stable the lighting of the vehicle may flicker and/or reduce the battery lifespan. For MOSFET voltage regulatorsfrectifiers ifs harder to get a stable voltage output because the MOSFET switches very fast from the cut-off region to the linear region and vice versa. These rapid transitions generate voltage spikes on the output of the voltage regulaturrectilier. Those spikes interfere with the control circuit of the voltage regulator if not filtered properly. The MOSFET voltage regulator/rectifiers are already a big improvement in the market but still do not have the desired durability,
The voltage regulator/rectifiers at this moment still do not achieve the desired durability. And that's why our invention is conceived. To overcome the {wo main problems that common voltage regulatorsfrectifiers have.
The two problems are defined as degreased lifespan dus to overheating and extensive circuitry that is required to get a stable output voltage when using MOSFETs in a voltage regulator/rectifier.
Conventional battery charging systems that are using the MOSFET type as semiconductor are all suffering from extensive analog circuitry to filter and to switch the MOSFET gates to control the battery voltage. Using
MOSFETs inside of a permanent magnet-based alternator application results in high dV/dT vollage spikes atthe oulputof the voltage regulator/rectifier. Therefore a trade-off has {o be made, the faster the MOSFETs switches a reduced amount of heat is generated. Conversely, the faster the swilching, the higher the switching voltage spikes become. These spikes give problems when measuring the battery voltage. The spike heights and widths are changing constantly depending on allernalor speed and changing output loads. Those spikes are created by inductances in the Printed Circuit Board (PCB) and cables. Therefore, extensive analog circuitry or big capacitance is needed directly at the alternator to filter out those switching spikes.
A big capacitance is already available in the form of a battery. This battery will filter out all of the spikes created by the MOSFETs. But this battery is not directly placed at the voltage regulatorfrectifier. The battery is placed a certain distance from the voltage regulator/rectifier, Because the battery is placed a certain distance away from the voltage regulator/rectifier those spikes are interfering with the measurement circuit.
The spikes ars not interfering with the electronics after the battery because the battery can De seen as a big capacitance that absorbs the energy in the spikes,
The easiest approach to measure simple and accurate battery voltage is by adding another wire from the voltage regulator/rectifier to the battery. This solution is not preferred because adding an extra wire to an existing application is not a plug-and-play solution, Most voltage regulator/rectifier companies offer voltage regulatorsirectifiers that are suitable for a brand and type-specific model. They match the analog circuitry on a specific alternator and load. The downside of this approach is that multiple types are needed in different applications what means a lot of dissimilar stock is required,
Voltage spikes are seen as a major issue for MOSFET voltage regulatorfrectifiers to further reduce power losses in the form of heat and at the same time make a MOSFET voltage regulatorirectifier that is more reliable.
The voltage spikes occur just after the switching interval of the MOSFETs, This invention is to prevent these spikes are measured without extensive analog filtering or a big capacitance near the voliage requlatorfrectifier, With the use of a microcontroller and an Analog-Digital Converter (ADC), the measurement timing can be selected when to measure the output voltage. if the timing is between switching periods and not at switching periods the measured voltage is without unknown spikas and therefore much less analog circuitry is needed to filter out those spikes. The output voltage can be better controlied within a certain range and the rectifier can be applied to multiple alternators and loads without changing the analog circuitry.
The working principle of the invention; a Pulse Width Modulation (PWM) signal is generated with a certain period and duty cycle. The duty cycle of this PWM signal is changed upon the output voltage of the rectifier.
The output voltage is measured in-between switch moments of the PWM signal, and not on switch moments.
Another positive side effect of this measurement solution is that the MOSFET switch timing can be set faster what results in slightly higher voltage spikes, but a reduction of the heat generated by the MOSFETs.
There will always be a compromise between allowed spikes and what the battery can absorb, Therefore, this type of MOSFET regulatorfrectifier has higher efficiency. This reduces the biggest chance of failure,
S heat generation. By reducing the heat, the lifespan of the MOSFET vollage regulatorfrectifier will be increased considerably.
The temperature of the voltage regulator/rectifier has a direct impact on the lifespan of the rectifier. Every voltage regulator/rectifier consists of an electrolytic capacitor for filtering and buffering the control circuit input voltage. The main source of this shorter lifespan is the electrolytic capacitor. The lifespan of an electrolytic capacitor shortens exponentially when the working temperature rises.
To ensure that the voltage regulator/rectifier stays below a certain critical temperature the MOSFETs will be set in the linear region when a certain temperature is reached. In this state, the incoming AC will be shorted to the ground. This will stop the flow of current through the rectifier. Now the only heat that is generated arises from the internal Resistance Drain Source (RDS) inside the MOSFETs. This resistance is a few millichms, because of this low resistance, the voltage regulator/rectifier will produce significantly less heat and the voltage regulator/rectifier will cool down, When the temperature is below a certain threshold the voltage regulatorfrectifier starts rectifying again.
This temperature measurement can be implemented in different ways, a common way is to use a Negative
Temperature Coefficient (NTC) to measure the temperature inside the voltage regulator/rectifier and react to this change with analog or digital circuitry.
The working principle of the invention; the rectifier is equipped with a temperatura sensor that measures the temperature inside the rectifier. When the temperature exceeds a certain threshold the control circuit for regulating the battery voltage will switch off. The MOSFETs will be swifched in the linear region to reduce the heat generated by the MOSFETs. The voltage regulator/rectifier cools down and when the temperature is below a certain threshold the voltage regulatorrectifier starts regulating again.
This invention has the following benefits over a normal MOSFET rectifier regulator: ‚One design fits many applications + Longer lifespan due to less heat generation + Fewer components needed + Build-in over-temperature protection + ls more reliable because of fewer components used
BRIEF DESCRIPTION OF ACCOMPANYING DRAWINGS
FIGURE 1: 1. Alternator with permanent magnets. This alternator consists out of two or more phases, The alfernator has an RPM range of a few hundred RPM up to 20.000 RPM. 5 2. Rectifier + regulator, in most cases these two are combined in one package. This part makes from an AC a DC and keeps the voltage around a steady-stale value. A voltage regulator/rectifier consists of two or more phases. 3. The rectifier has for every phase a diode, for this example a Schottky diode. A Schottky diode can switch faster from an open to a closed state and vice versa. This type of diode has also a sigritficantly lower voltage drop than a regular diode. 4. The rectifier has for every phase a transistor, in this example of the MOSFET type. Inside every
MOSFET is from source to drain a diode transition. These diodes act as the lower diodes in the rectifier bridge when the MOSFET is in the off-siate. When switching the MOSFET in the on-state, that particular phase will be directly connected to the ground. When this happens, no closed circuit can be formed and no current can flow to the battery side what results in shunting the power to the battery and controlling the battery voltage. 5. This part consists of the control circuit what consists of at least a microcontroller, analog filtering, and any kind of MOSFET driver. The microcontroller measures and controls the duty cycle of a
PWM signal to control the baltery voliage. Extra functions can be added such as temperature protection, over current protection, etc. 8. Cable from the rectifier to the battery. This cable can vary in length, think of a few centimeters to a few meters, and has some inductance and wire resistance. 7. A battery consists of an ESR and a really big capacitance, the capacity of the battery. This battery can be of any type. 3. The load connected to the battery most likely consists of a lot of inductive loads such as motors, cooling, lighting, etc, 9. Measurement window in between a MOSFET's on or off time. The control circuit measures always the output voltage in a non-switching window. 10. Dotted lines in the graph represent the desirable battery voltage.
The letters in Figure 1. are measurement points in the graph a. This measurement is performed at a gate of one of the MOSFETs. The duty cycle is dependent on the output voltage. A too high output voltage will decrease the duty cycle, a higher output voltage will increase the duty cycle. b. Output voltage measured at the rectifier bridge. As shown in the plot overshoot occurs by a
MOSFET switching off and a bit of undershoot will occur when switching the MOSFET on. ¢. Output voltage measured at the battery, The battery act as a big capacitor that will filter out those unwanted spikes.

Claims (3)

ConclusiesConclusions 1. Een spanningsregslaar/gslijkrichter die elektrisch is verbonden met een permanent magneet dynamo die elektrisch vermogen opwekt om een batterij op te laden, bestaande ull; Een gelijkrichter die is opgebouwd met diodes om van een wisselstroom een gelijkstroom te maken. Een schakelbare semiconductor aan elke fase van de dynamo die sen stabiele uitgangsspanning kan verzorgen. Een mest en regel schakeling om de uitgangsspanning van de gelijkrichier regulator aan te sturen rond sen stabiele uitgangsspanning. Een temperatuur sensor om de interne lemperatuur van de spanningsregelaar/gelijkrichter te meten.1. A voltage regulator/rectifier electrically connected to a permanent magnet alternator which generates electrical power to charge a battery consisting of ull; A rectifier built with diodes to convert an alternating current into a direct current. A switchable semiconductor on each phase of the alternator that can provide a stable output voltage. A fertilizer and control circuit to control the output voltage of the rectifier regulator around a stable output voltage. A temperature sensor to measure the internal temperature of the voltage regulator/rectifier. 2. Een spanningsregelsargelijkrichter als beweerd in 1, die de uitgangsspanning meet tussen de schakelmomenten van de semiconductors om de uitgangsspanning van de spanningsregelaar/gelijkrichter te meten zonder voltage pieken.2. A voltage regulator rectifier as claimed in 1, which measures the output voltage between the switching times of the semiconductors to measure the voltage regulator/rectifier output voltage without voltage spikes. 3. Een spanningsregelaar/gelijkrichter als beweerd in 1, die een temperatuur sensor bevat om bij een te hoge temperatuur van de gelijkrichter regulator de semiconductors in een elektrisch geleidende toestand te schakelen zodat de fases van de gelijkrichter worden kortgesloten naar het negatief potentiaal van de spanningsregelaargelijkrichter. Deze toestand van de spanningsregelaar/gelijkrichter voorkomt een te warme spanningsregelaar/gelijkrichter.3. A voltage regulator/rectifier as claimed in 1, which contains a temperature sensor to switch the semiconductors into an electrically conductive state when the temperature of the rectifier regulator is too high so that the phases of the rectifier are short-circuited to the negative potential of the voltage regulator rectifier . This state of the voltage regulator/rectifier prevents overheating of the voltage regulator/rectifier.
NL1044240A 2021-12-21 2021-12-21 Smart universal permanent magnet voltage regulator/rectifier. NL1044240B1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
NL1044240A NL1044240B1 (en) 2021-12-21 2021-12-21 Smart universal permanent magnet voltage regulator/rectifier.

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
NL1044240A NL1044240B1 (en) 2021-12-21 2021-12-21 Smart universal permanent magnet voltage regulator/rectifier.

Publications (1)

Publication Number Publication Date
NL1044240B1 true NL1044240B1 (en) 2023-06-29

Family

ID=80625530

Family Applications (1)

Application Number Title Priority Date Filing Date
NL1044240A NL1044240B1 (en) 2021-12-21 2021-12-21 Smart universal permanent magnet voltage regulator/rectifier.

Country Status (1)

Country Link
NL (1) NL1044240B1 (en)

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH11225446A (en) * 1998-02-05 1999-08-17 Shindengen Electric Mfg Co Ltd Battery charging apparatus
EP2362535A1 (en) * 2008-12-22 2011-08-31 Shindengen Electric Manufacturing Co., Ltd. Battery charger
JP2014039472A (en) * 2008-09-30 2014-02-27 Spansion Llc Output-voltage control device, output-voltage control method, and electronic apparatus

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH11225446A (en) * 1998-02-05 1999-08-17 Shindengen Electric Mfg Co Ltd Battery charging apparatus
JP2014039472A (en) * 2008-09-30 2014-02-27 Spansion Llc Output-voltage control device, output-voltage control method, and electronic apparatus
EP2362535A1 (en) * 2008-12-22 2011-08-31 Shindengen Electric Manufacturing Co., Ltd. Battery charger

Similar Documents

Publication Publication Date Title
US9450517B2 (en) Driving apparatus and electric power converter
KR100293892B1 (en) Vehicle generator
US6166500A (en) Actively controlled regenerative snubber for unipolar brushless DC motors
US20100327837A1 (en) Power converter for traction control and transportation system
US20130002227A1 (en) Power converter
US7948276B2 (en) Gate driver circuit, switch assembly and switch system
US9035687B2 (en) Gate clamping
US20150091539A1 (en) Half-bridge gate driver control
US9030851B2 (en) DC bus voltage control method and system
CN105580233B (en) Power conversion device
JP6982236B2 (en) Synchronous rectifier circuit and switching power supply
US20240106347A1 (en) Systems and methods for controlled active discharge for inverter for electric vehicle
US8836292B1 (en) Electric power generation system and method
TWI711249B (en) Output overvoltage sensing system and sensing method
US11722053B2 (en) Over current protection concept for negative load current of power device gate drivers
NL1044240B1 (en) Smart universal permanent magnet voltage regulator/rectifier.
CN108134511B (en) Gate driver with temperature compensated turn-off
KR100995485B1 (en) Method for identifying an overload current of an electric drive
US8461876B2 (en) Semiconductor device
US20230261646A1 (en) Controller of power transisor and control method thereof
US11296686B2 (en) Method for operating an electrical circuit, electrical circuit, and motor vehicle
US11404953B2 (en) Drive circuit for power semiconductor element and power semiconductor module employing the same
US10756616B2 (en) Methods and systems of a rectifier circuit
CN112534720A (en) Driving circuit
EP3373434A1 (en) Dynamic slew rate control