US20160072403A1 - Pwm rectifier including capacitance calculation unit - Google Patents

Pwm rectifier including capacitance calculation unit Download PDF

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Publication number
US20160072403A1
US20160072403A1 US14/849,056 US201514849056A US2016072403A1 US 20160072403 A1 US20160072403 A1 US 20160072403A1 US 201514849056 A US201514849056 A US 201514849056A US 2016072403 A1 US2016072403 A1 US 2016072403A1
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Prior art keywords
voltage
power
smoothing capacitor
unit
capacitance
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US14/849,056
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English (en)
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Masakazu Niwa
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Fanuc Corp
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Fanuc Corp
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Priority to US15/387,581 priority Critical patent/US9923477B2/en
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    • 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
    • H02M5/00—Conversion of ac power input into ac power output, e.g. for change of voltage, for change of frequency, for change of number of phases
    • H02M5/40—Conversion of ac power input into ac power output, e.g. for change of voltage, for change of frequency, for change of number of phases with intermediate conversion into dc
    • H02M5/42—Conversion of ac power input into ac power output, e.g. for change of voltage, for change of frequency, for change of number of phases with intermediate conversion into dc by static converters
    • H02M5/44—Conversion of ac power input into ac power output, e.g. for change of voltage, for change of frequency, for change of number of phases with intermediate conversion into dc by static converters using discharge tubes or semiconductor devices to convert the intermediate dc into ac
    • H02M5/453—Conversion of ac power input into ac power output, e.g. for change of voltage, for change of frequency, for change of number of phases with intermediate conversion into dc by static converters using discharge tubes or semiconductor devices to convert the intermediate dc into ac using devices of a triode or transistor type requiring continuous application of a control signal
    • H02M5/458—Conversion of ac power input into ac power output, e.g. for change of voltage, for change of frequency, for change of number of phases with intermediate conversion into dc by static converters using discharge tubes or semiconductor devices to convert the intermediate dc into ac using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only
    • H02M5/4585—Conversion of ac power input into ac power output, e.g. for change of voltage, for change of frequency, for change of number of phases with intermediate conversion into dc by static converters using discharge tubes or semiconductor devices to convert the intermediate dc into ac using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only having a rectifier with controlled elements
    • 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
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
    • G01R31/00—Arrangements for testing electric properties; Arrangements for locating electric faults; Arrangements for electrical testing characterised by what is being tested not provided for elsewhere
    • G01R31/40—Testing power supplies
    • 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
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
    • G01R27/00—Arrangements for measuring resistance, reactance, impedance, or electric characteristics derived therefrom
    • G01R27/02—Measuring real or complex resistance, reactance, impedance, or other two-pole characteristics derived therefrom, e.g. time constant
    • G01R27/26—Measuring inductance or capacitance; Measuring quality factor, e.g. by using the resonance method; Measuring loss factor; Measuring dielectric constants ; Measuring impedance or related variables
    • 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
    • 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
    • H02M7/2173—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 biphase or polyphase circuit arrangement

Definitions

  • the present invention relates to a PWM rectifier that converts AC power to DC power by controlling a switching element using a PWM signal (pulse width modulation signal).
  • a motor control device for driving a motor in a machine tool, an industrial machine, a forming machine, an injection molding machine, or various types of robots uses AC power, to which AC power input from the AC power supply side is once converted to DC power and the DC power is further converted, as drive power of a motor attached to each drive shaft is known.
  • a motor control device includes a rectifier configured to rectify AC power supplied from the AC power supply side and output DC power and an inverter connected to a DC link on the DC side of the rectifier and configured to carry out bilateral power conversion between DC power at the DC link and drive power for a motor or AC power which is regenerative power, and controls the speed, torque, or rotor position of a motor connected to the AC side of the inverter.
  • Such rectifiers include a rectifier using a diode rectification method.
  • a rectifier using a diode rectification method has an advantage of low price but also has a disadvantage that power line harmonics or reactive power increases.
  • PWM rectifier a rectifier using pulse width modulation (hereinafter, referred to as PWM rectifier) has been spreading because of requirements for a reduction in power line harmonics or a reduction in reactive power.
  • FIG. 4 is a diagram illustrating a configuration of a general motor control device including a PWM rectifier.
  • a motor control device 101 includes a PWM rectifier 1 configured to convert AC power from a commercial three-phase AC power supply 3 (hereinafter, simply referred to as AC power supply) to DC power and an inverter 2 configured to convert the DC power output from the PWM rectifier 1 to AC power with a desirable frequency, which is supplied as drive power of a motor 4 , or convert AC power regenerated from the motor 4 to DC power, and controls the speed, torque, or rotor position of the motor 4 , which is connected to the AC side of the inverter 2 .
  • the PWM rectifier 1 and the inverter 2 are connected to each other through a DC link. In the DC link, a smoothing capacitor 5 is incorporated, as will be described later.
  • a boost reactor 6 is connected on the AC power supply 3 side of the PWM rectifier 1 .
  • the PWM rectifier 1 is mainly configured with a main circuit unit 11 that is a bridge circuit composed of a switching element and a diode connected thereto in inverse-parallel and a PWM control unit 12 that generates a PWM control signal to control a switching operation of the switching element in the main circuit unit 11 .
  • the main circuit unit 11 of the PWM rectifier 1 is configured with a bridge circuit with the number of phases corresponding to the number of phases of the AC power supply 3 .
  • the main circuit unit 11 of the PWM rectifier 1 is correspondingly a three-phase full-bridge circuit.
  • the smoothing capacitor 5 is connected in parallel to smooth DC output from the PWM rectifier 1 .
  • the PWM control unit 12 of the PWM rectifier 1 generates a PWM control signal based on an AC voltage value on the AC power supply 3 side, which is detected by an AC voltage detection unit 32 , an AC current value on the AC power supply 3 side, which is detected by an AC current detection unit 33 , and a DC voltage across the smoothing capacitor 5 (i.e., DC voltage across the DC link which is disposed between the main circuit unit 11 of the PWM rectifier 1 and the inverter 2 ), which is detected by a DC voltage detection unit 13 .
  • the PWM control signal is generated so as to generate AC power with a power factor of 1 in the main circuit unit 11 of the PWM rectifier 1 and keep a DC voltage which is output from the PWM rectifier 1 (i.e., DC voltage across the smoothing capacitor 5 ) at a desirable value and applied to the switching element in the main circuit unit 11 of the PWM rectifier 1 .
  • the PWM rectifier 1 is capable of carrying out a regenerative operation (reverse conversion operation) to convert DC power to AC power with a switching operation by the switching element inside the PWM rectifier 1 being controlled by the PWM control signal and returning regenerative energy, which is returned through the inverter 2 , further to the AC power supply 3 side.
  • a regenerative operation reverse conversion operation
  • the smoothing capacitor 5 needs to have been charged in a period from immediately after the activation of the motor control device 101 until before the start of driving the motor 4 (i.e. before the start of a power conversion operation by the inverter 2 ).
  • charging of the smoothing capacitor 5 before the start of driving the motor 4 will be referred to as initial charging.
  • initial charging When energy has not been stored in the smoothing capacitor 5 at the start time of the initial charging, a large inrush current flows through the main circuit unit 11 of the PWM rectifier 1 .
  • the larger the capacitance of the smoothing capacitor 5 becomes the higher the generated inrush current becomes.
  • an initial charging circuit 31 is generally disposed between the main circuit unit 11 of the PWM rectifier 1 and the smoothing capacitor 5 or on the three-phase AC input side of the main circuit unit 11 of the PWM rectifier 1 .
  • the example in FIG. 4 illustrates a case in which the initial charging circuit 31 is disposed between the main circuit unit 11 of the PWM rectifier 1 and the smoothing capacitor 5 .
  • the initial charging circuit 31 includes a switch unit 41 and a charging resistor 42 which is connected to the switch unit 41 in parallel.
  • the switch unit 41 is turned off (opened) only in the initial charging period of the smoothing capacitor 5 immediately after the activation of the motor control device 101 and maintains the off-state (closed state) in a regular operation period during which the motor control device 101 drives the motor 4 . More specifically, by turning off (opening) the switch unit 41 in the initial charging period from immediately after the activation of the motor control device 101 until before the start of driving the motor 4 , DC power output from the main circuit unit 11 flows into the smoothing capacitor 5 through a charging resistor 42 and the smoothing capacitor 5 is charged. When the smoothing capacitor 5 has been charged to a peak value of the AC voltage at the AC power supply 3 , the switch unit 41 is turned on (closed) and the initial charging operation is finished.
  • the PWM rectifier 1 theoretically needs to output a DC voltage value higher than or equal to the peak value of the AC voltage at the AC power supply 3 . Therefore, after the finish of the initial charging operation for the smoothing capacitor 5 , the PWM control unit 12 , by making the switching element in the main circuit unit 11 carry out a switching operation, boosts a DC voltage across the smoothing capacitor 5 to a voltage higher than the peak value of the AC voltage on the AC power supply 3 side.
  • a boost for the smoothing capacitor 5 in a period from after the finish of the initial charging for the smoothing capacitor 5 until before the start of driving the motor 4 will be referred to as initial boost.
  • the inverter 2 After the finish of the initial charging operation and the initial boost operation, the inverter 2 starts a power conversion operation and transitions to a regular operation mode in which the inverter 2 supplies the motor 4 with drive power, and the motor 4 is driven based on the AC drive power output from the inverter 2 .
  • the smoothing capacitor 5 is a product with a limited life, which decreases the capacitance thereof (also referred to as capacitor capacity) by repeating charge and discharge.
  • capacitor capacity also referred to as capacitor capacity
  • a problem is caused in that a ripple current which flows through the DC link increases and fluctuation of the DC voltage grows. Therefore, it is important to measure the capacitance of the smoothing capacitor 5 accurately.
  • a smoothing capacitor 5 the performance of which is judged to have deteriorated as a result of the measurement needs to be replaced.
  • Methods to estimate the capacitance of a smoothing capacitor disposed in a DC link of a rectifier include a method in which, as disclosed in, for example, Japanese Unexamined Patent Publication No. 05-76180, the capacitance is calculated by calculating a time constant based on a DC voltage value across the smoothing capacitor (DC voltage across the DC link) in initial charging and dividing the calculated time constant by the resistance value of a charging resistor.
  • FIG. 5 is a diagram illustrating a capacitor voltage in initial charging in the invention disclosed in Japanese Unexamined Patent Publication No. 05-76180.
  • the capacitance C of the smoothing capacitor is estimated by measuring the time t 1 at which the DC voltage reaches a voltage of 0.63 V, which is 0.63 times of a peak value V of the AC voltage on the AC power supply side, and dividing the measured time t 1 by the resistance value R of the charging resistor.
  • the methods to estimate the capacitance of a smoothing capacitor also include a method in which, as disclosed in, for example, International Publication No. 2010/055556, the capacitance is calculated by estimating an amount of charge that flows into a DC link in the initial charging of the smoothing capacitor and dividing the charge amount by the DC voltage at the finish of the initial charging.
  • the capacitance is calculated by assuming an approximation that an inflowing current to the smoothing capacitor in an initial charging period is equal to the absolute value of the AC current on the AC power supply side, calculating the amount of charge that is stored in the smoothing capacitor from an integral value in initial charging, and dividing the charge amount by the DC voltage at the finish of the initial charging.
  • the capacitance of the smoothing capacitor to be estimated depends on the peak value of the AC voltage on the AC power supply side and the resistance value of the charging resistor, it is not possible to measure the capacitance of the smoothing capacitor accurately when the peak value of the AC voltage and the resistance value of the charging resistor contain errors.
  • an object of the present invention is to provide a small and low-cost PWM rectifier that is capable of accurately measuring the capacitance of a smoothing capacitor which is connected to the DC output side in parallel.
  • the PWM rectifier includes a main circuit unit configured to carry out power conversion between AC power on the AC side thereof and DC power on the DC side thereof through a switching operation of a switching element being PWM-controlled by a received PWM control signal, a PWM control unit configured to generate and output the PWM control signal to the main circuit unit, a DC voltage detection unit configured to detect a DC voltage across a smoothing capacitor, which is connected to the DC side of the main circuit unit in parallel, a DC voltage storage unit configured to, in an initial boost period during which the smoothing capacitor, which has been initially charged to a peak value of an AC voltage on the AC side of the main circuit unit, is further charged to a voltage higher than the peak value of the AC voltage through a power conversion operation of the main circuit unit, store respective DC voltages detected by the DC voltage detection unit at the start time and the end time of the initial boost period, an input power calculation unit configured to calculate input power flowing into the main circuit unit from the AC side based on an AC voltage and an AC current on the AC
  • the capacitance calculation unit calculates a capacitance C of the smoothing capacitor by the following equation.
  • the PWM rectifier may further include a capacitance drop judgment unit configured to judge whether or not the capacitance calculated by the capacitance calculation unit is lower than a predetermined value, and a warning signal output unit configured to output a warning signal when the capacitance drop judgment unit judges that the capacitance is lower than the predetermined value.
  • the PWM rectifier may further include a notification unit configured to prompt the replacement of the smoothing capacitor, which is connected to the DC side of the main circuit unit in parallel, when the warning signal output unit outputs the warning signal.
  • the PWM rectifier may further include a stop instruction unit configured to instruct stop of a switching operation of the switching element in the main circuit unit when the warning signal output unit outputs the warning signal.
  • FIG. 1 is a principle block diagram of a PWM rectifier according to an embodiment
  • FIG. 2 is a flowchart illustrating calculation processing of the capacitance of a smoothing capacitor 5 of the PWM rectifier 1 illustrated in FIG. 1 ;
  • FIG. 3 is a principle block diagram of a PWM rectifier according to a variation of the embodiment
  • FIG. 4 is a diagram illustrating a configuration of a general motor control device including a PWM rectifier
  • FIG. 5 is a diagram illustrating a capacitor voltage in initial charging in an invention disclosed in Japanese Unexamined Patent Publication No. 05-76180.
  • a PWM rectifier is disposed in a motor control device which is connected to an inverter through a DC link having a smoothing capacitor
  • the PWM rectifier is not particularly limited to use as a rectifier in a motor control device, and the PWM rectifier may be applied to any device that has a configuration in which a PWM rectifier and an inverter are connected through a DC link having a smoothing capacitor.
  • a load connected to the configuration is also not particularly limited to a motor.
  • FIG. 1 is a principle block diagram illustrating a PWM rectifier according to an embodiment.
  • a motor control device 100 includes a PWM rectifier 1 according to the embodiment and an inverter 2 that is connected to a DC link, which is a circuit on the DC side of the PWM rectifier 1 .
  • a smoothing capacitor 5 is disposed in the DC link.
  • a commercial three-phase AC power supply 3 is connected to the AC power supply side of the motor control device 100 , i.e. the AC power supply side of the PWM rectifier 1 , through a boost reactor 6 , and a three-phase motor 4 is connected to the AC motor side of the motor control device 100 , i.e. the AC motor side of the inverter 2 .
  • the motor control device 100 which drive-controls a motor 4 does not particularly limit the present invention, and the present invention is applicable to a motor control device that drive-controls a plurality of motors 4 .
  • the type of the motor 4 driven by the motor control device 100 also does not particularly limit the present invention.
  • the motor 4 may be an induction motor or a synchronous motor.
  • the motor 4 may be, for example, a single-phase motor or another polyphase motor.
  • Inverters 2 of the same number as the number of motors 4 are connected in parallel. Although, in the embodiment, a single inverter 2 is disposed since a single motor 4 is driven-controlled, when a plurality of motor 4 are driven-controlled, a plurality of inverters 2 are disposed to supply each motor 4 with drive power individually.
  • the type of the inverter 2 also does not particularly limit the present invention. Any type of inverter may be used as long as the inverter carries out bilateral power conversion between DC power at the DC link and AC power which is drive power or regenerative power of the motor 4 .
  • the inverter 2 may be an inverter that is configured as a PWM inverter having a switching element internally and converts DC power supplied from the DC link side to three-phase AC power with a desirable voltage and a desirable frequency to make the internal switching element carry out switching operation based on a PWM control signal and drive the motor 4 .
  • the motor 4 operates based on the voltage-variable and frequency-variable three-phase AC power supplied by the inverter 2 .
  • the inverter 2 configured as a PWM inverter is capable of returning the regenerative energy produced in the motor 4 to the DC link side by carrying out regenerative operation (forward conversion operation), in which the AC regenerative power is converted to DC power through the switching operation of the internal switching element under the control of the PWM control signal.
  • regenerative operation forward conversion operation
  • the PWM rectifier 1 includes a main circuit unit 11 , a PWM control unit 12 , a DC voltage detection unit 13 , a DC voltage storage unit 14 , an input power calculation unit 15 , an integral power calculation unit 16 , and a capacitance calculation unit 17 .
  • the main circuit unit 11 is configured with a bridge circuit of a switching element and a diode connected to the switching element in inverse-parallel.
  • the switching element include an IGBT, a thyristor, a GTO (Gate Turn-OFF thyristor), and a transistor
  • the type of the switching element itself does not limit the present invention, and other types of semiconductor device may be used.
  • the AC power supply 3 is exemplified by a three-phase AC power supply, it is assumed that the main circuit unit 11 of the PWM rectifier 1 is a three-phase full-bridge circuit.
  • the number of phases of the PWM rectifier 1 does not limit the present invention, and the PWM rectifier 1 may be configured as a full-bridge circuit with the number of phases corresponding to the number of phases of the AC power supply 3 .
  • the main circuit unit 11 of the PWM rectifier 1 may be configured as a single-phase full-bridge circuit correspondingly.
  • the main circuit unit 11 carries out power conversion between AC power on the AC power supply 3 side and DC power at the DC link on the DC side by the switching operation of the switching element being PWM-controlled based on the PWM control signal received from the PWM control unit 12 .
  • a powering operation forward conversion operation
  • a regenerative operation reverse conversion operation
  • the PWM control unit 12 generates and outputs a PWM control signal to the main circuit unit 11 .
  • the PWM rectifier 1 carries out feedback control so that the DC voltage across the smoothing capacitor 5 , which is detected by the DC voltage detection unit 13 , follows a DC voltage command value, which is input from the outside. With this configuration, the DC voltage across the smoothing capacitor 5 is controlled constant.
  • the PWM control unit 12 generates a PWM control signal that makes the main circuit unit 11 carry out an initial boost operation.
  • the smoothing capacitor 5 is connected to the DC side of the main circuit unit 11 in parallel.
  • the smoothing capacitor 5 has not only a function to suppress ripples in the DC output from the main circuit unit 11 of the PWM rectifier 1 or the inverter 2 , but also a function to primarily store DC power output from the main circuit unit 11 or the inverter 2 .
  • the DC voltage detection unit 13 detects a DC voltage across the smoothing capacitor 5 .
  • the initial charging circuit 31 is a circuit to charge the smoothing capacitor 5 with a DC current output from the main circuit unit 11 of the PWM rectifier 1 in an initial charging period before the operation of the motor 4 by the motor control device 100 , and is disposed between the main circuit unit 11 of the PWM rectifier 1 and the smoothing capacitor 5 in the embodiment.
  • the initial charging circuit 31 may be disposed on the AC power supply side of the main circuit unit 11 , and, in a case of a three-phase AC power supply 3 , for example, an initial charging circuit 31 is disposed with respect to each phase of at least two phases among three phases of the three-phase AC input of the main circuit unit 11 .
  • smoothing capacitors 5 when, for example, a plurality of inverters 2 are connected in parallel, smoothing capacitors 5 also have a relation of being connected in parallel to one another. Thus, between the main circuit unit 11 and these smoothing capacitors 5 , an initial charging circuit 31 is disposed.
  • the initial charging circuit 31 includes a switch unit 41 and a charging resistor 42 which is connected to the switch unit 41 in parallel.
  • the switch unit 41 is configured with, for example, a mechanical switch, or a semiconductor switching element, such as an IGBT and a thyristor.
  • the switch unit 41 is turned off (opened) only in the initial charging period of the smoothing capacitor 5 immediately after the activation of the motor control device 100 , and maintained at the on-state (closed state) during the regular operation period in which the motor control device 100 drives the motor 4 .
  • the switch unit 41 being turned off (opened) during the initial charging period from immediately after the activation of the motor control device 100 until before the start of driving the motor 4 makes the DC power output from the main circuit unit 11 flow into the smoothing capacitor 5 through the charging resistor 42 to charge the smoothing capacitor 5 .
  • the switch unit 41 is turned on (closed) and the initial charging operation finishes.
  • the PWM control unit 12 since the PWM rectifier 1 theoretically needs to output a DC voltage with a value equal to or higher than the peak value of the AC voltage of the AC power supply 3 , after the finish of the initial charging operation for the smoothing capacitor 5 , the PWM control unit 12 generates a PWM control signal to make the main circuit unit 11 carry out an initial boost operation, in which the DC voltage across the smoothing capacitor 5 , which has been initially charged to the peak value of the AC voltage, is boosted to a voltage value higher than the peak value of the AC voltage.
  • the DC voltage storage unit 14 stores respective DC voltage values detected by the DC voltage detection unit at the start time and the end time of the initial boost period.
  • the DC voltage storage unit 14 may be configured with either a volatile memory or a nonvolatile memory.
  • the input power calculation unit 15 calculates input power that flows into the main circuit unit 11 from the AC side based on an AC voltage on the AC side of the main circuit unit 11 detected by the AC voltage detection unit 32 and an AC current on the AC side of the main circuit unit 11 detected by the AC current detection unit 33 . Since the motor control device 100 uses the AC voltage value and the AC current value on the AC power supply 3 side to drive-control the PWM rectifier 1 , the AC voltage detection unit 32 and the AC current detection unit 33 to detect the AC voltage and the AC current are generally disposed in the motor control device 100 . The input power calculation unit 15 uses the detected values from the AC voltage detection unit 32 and the AC current detection unit 33 for calculation.
  • the integral power calculation unit 16 integrates the input power calculated by the input power calculation unit 15 over the initial boost period and outputs the integrated value as integral power.
  • the capacitance calculation unit 17 calculates the capacitance of the smoothing capacitor based on the DC voltage at the start time of the initial boost period and the DC voltage at the end time of the initial boost period, which are stored in the DC voltage storage unit 14 , and the integral power, which is calculated by the integral power calculation unit 16 .
  • FIG. 2 is a flowchart illustrating calculation processing of the capacitance of the smoothing capacitor 5 in the PWM rectifier 1 illustrated in FIG. 1 .
  • step S 101 the initial charging operation is carried out in step S 101 .
  • the switch unit 41 of the initial charging circuit 31 is turned off (opened), DC power output from the main circuit unit 11 flows into the smoothing capacitor 5 through the charging resistor 42 , and the smoothing capacitor 5 is charged.
  • the switch unit 41 is turned on (closed) and the initial charging operation is finished.
  • the inverter 2 does not operate during the initial charging period.
  • step S 102 the initial boost operation is started in step S 102 .
  • the switch unit 41 of the initial charging circuit 31 is kept on (closed), and no current flows through the charging resistor 42 . Since the inverter 2 has also not operated yet, the AC power taken in from the AC power supply 3 side is converted (rectified) to DC power by the main circuit unit 11 of the PWM rectifier 1 and all stored in the smoothing capacitor 5 .
  • step S 103 the DC voltage storage unit 14 first stores a DC voltage V L , which is detected by the DC voltage detection unit 13 at the start time of the initial boost period, across the smoothing capacitor 5 , which has been initially charged in step S 101 .
  • step S 104 the input power calculation unit 15 , based on the AC voltage on the AC side of the main circuit unit 11 , which is detected by the AC voltage detection unit 32 , and the AC current on the AC side of the main circuit unit 11 , which is detected by the AC current detection unit 33 , calculates input power that flows into the main circuit unit 11 from the AC side.
  • the input power is calculated as instantaneous active power.
  • step S 105 the integral power calculation unit 16 integrates the input power calculated by the input power calculation unit 15 in step S 104 .
  • step S 106 whether or not the initial boost operation has been finished is decided. The decision may be carried out by the integral power calculation unit 16 itself, or by a higher-level control device (not illustrated) of the integral power calculation unit 16 .
  • step S 106 it is decided that the initial boost operation has not been finished, the process returns to step S 104 in which calculation of input power is carried out by the input power calculation unit 15 , and integration of the input power is further carried out in step S 105 .
  • step S 106 it is decided that the initial boost operation has been finished, the process proceeds to step S 107 .
  • the integral power calculation unit 16 integrates the input power calculated by the input power calculation unit 15 over the initial boost period and outputs the integrated value as integral power.
  • integral power W from the start time to the end time of the initial boost period is calculated by the following formula (2).
  • step S 107 the DC voltage storage unit 14 first stores a DC voltage V H , which is detected by the DC voltage detection unit 13 at the end time of the initial boost period, across the smoothing capacitor 5 .
  • step S 108 the capacitance calculation unit 17 calculates the capacitance C of the smoothing capacitor based on the DC voltage V L at the start time of the initial boost period and the DC voltage V H at the end time of the initial boost period, which are stored in the DC voltage storage unit 14 , and the integral power W, which is calculated by the integral power calculation unit 16 .
  • Energy ⁇ that is stored in the smoothing capacitor 5 in the duration from the start time to the end time of the initial boost period is calculated by the following formula (3).
  • the inverter 2 Since the inverter 2 does not operate during the initial boost period as described above and, thus, the AC power taken in from the AC power supply 3 side is converted (rectified) to DC power by the main circuit unit 11 of the PWM rectifier 1 and all stored in the smoothing capacitor 5 , the energy ⁇ stored in the smoothing capacitor 5 in the duration from the start time to the end time of the initial boost period, which is calculated by the formula (3), is equal to the integral power W in the duration from the start time to the end time of the initial boost period, which is calculated by the formula (2). Therefore, the capacitance C of the smoothing capacitor 5 is expressed by the following formula (4).
  • the capacitance calculation unit 17 calculates the capacitance C of the smoothing capacitor 5 by the formula (4), which is derived in the above-described manner.
  • the capacitance C of the smoothing capacitor 5 is calculated based on the DC voltage V L at the start time of the initial boost period and the DC voltage V H at the end time of the initial boost period, which are stored in the DC voltage storage unit 14 , and the integral power W, which is calculated by the integral power calculation unit 16 . Therefore, since, differing from, for example, the invention disclosed in Japanese Unexamined Patent Publication No.
  • the integral power W is calculated based on the formula (2) since the AC power supply 3 is a three-phase power supply, it is possible to carry out an accurate measurement of the capacitance C independently of the number of phases of the AC power supply, differing from the invention disclosed in International Publication No.
  • a result of calculation by the capacitance calculation unit 17 may, for example, be displayed on a display (not illustrated) disposed in the motor control device 100 or stored in a storage means (not illustrated). With this configuration, workers are able to know the capacitance C of the smoothing capacitor 5 every time the PWM rectifier 1 (or motor control device 100 ) is activated, and, thus, decide whether or not the smoothing capacitor 5 has to be replaced.
  • step S 106 it is decided that the initial boost operation has been finished, the inverter 2 in the motor control device 100 is activated. With this operation, the inverter 2 starts a power conversion operation and transitions to a regular operation mode to supply the motor 4 with drive power, and the motor 4 is driven based on the AC drive power supplied from the inverter 2 .
  • FIG. 3 is a principle block diagram of a PWM rectifier according to a variation of the embodiment.
  • a PWM rectifier 1 according to the variation further includes a capacitance drop judgment unit 18 , a warning signal output unit 19 , an notification unit 20 , and a stop instruction unit 21 , using the PWM rectifier described with reference to FIGS. 1 and 2 as a base. Since circuit components other than the above components are the same as the circuit components illustrated in FIG. 1 , the same signs are assigned to the same circuit components as in FIG. 1 and a detailed description thereof will be omitted.
  • the capacitance drop judgment unit 18 judges whether or not the capacitance calculated by the capacitance calculation unit 17 is lower than a predetermined value.
  • the above-described predetermined value, which the capacitance drop judgment unit 18 uses in the judgment processing, may be set at, for example, a capacitance value which assures that the smoothing capacitor 5 carries out a normal operation.
  • the warning signal output unit 19 outputs a warning signal when the capacitance drop judgment unit 18 judges that the capacitance is lower than the predetermined value.
  • the notification unit 20 sends out a notification prompting replacement of the smoothing capacitor 5 , which is connected to the DC side of the main circuit unit 11 in parallel.
  • the notification unit 20 include a speaker producing a warning sound to prompt replacement, such as a buzzer and a siren, a light turning on or flashing to prompt replacement, and a display displaying characters and a pattern to prompt replacement. With such the notification unit 20 , workers are able to decide more easily whether or not the smoothing capacitor 5 has to be replaced, compared with plainly displaying a numerical value of the capacitance C of the smoothing capacitor 5 .
  • the stop instruction unit 21 instructs the switching element of the main circuit unit 11 to stop a switching operation.
  • the stop instruction unit 21 issues an instruction to stop the switching operation, the main circuit unit 11 stops an power conversion operation.
  • the stop instruction unit 21 since the PWM rectifier 1 stops the power conversion operation when the capacitance C of the smoothing capacitor 5 is lower than a predetermined value, it is possible to prevent the PWM rectifier 1 from operating in a condition in which a high ripple current or a large DC voltage fluctuation is taking place in the DC link.
  • the illustrated example has a configuration in which the stop instruction unit 21 issues an instruction to stop a switching operation to the PWM control unit 12 and, with this instruction, the PWM control unit 12 outputs a control signal to stop the switching operation of the switching element to the main circuit unit 11
  • another configuration may be employed, as an alternative, in which the stop instruction unit 21 issues an instruction to stop the switching operation directly to the main circuit unit 11 , making the main circuit unit 11 stop the switching operation of the switching element.
  • the above-described PWM control unit 12 , input power calculation unit 15 , integral power calculation unit 16 , capacitance calculation unit 17 , capacitance drop judgment unit 18 , warning signal output unit 19 , and stop instruction unit 21 may be constructed, for example, in a form of software program or in a combination of various types of electronic circuits and a software program.
  • these units are constructed in a form of software program, functions of the above-described respective units are achieved by an arithmetic processing device in the motor control device 100 operating in accordance with the software program. It is also possible to apply the present invention to an existing motor control device by additionally installing software programs achieving these means to an arithmetic processing device in the motor control device.
  • the present invention it is possible to accurately measure the capacitance of the smoothing capacitor without depending on the peak value of the AC voltage on the AC power supply side and the resistance value of the charging resistor, differing from the invention disclosed in Japanese Unexamined Patent Publication No. 05-76180, since the capacitance of the smoothing capacitor is calculated based on the DC voltage at the start time of the initial boost period and the DC voltage at the end time of the initial boost period, which are stored in the DC voltage storage unit, and the integral power over the initial boost period.
  • the integral power which is used in the calculation of the capacitance, is calculated by integrating the input power (instantaneous active power) which is easily calculable using a well-known method, it is possible to accurately measure the capacitance regardless of the number of phases of the AC power supply, differing from the invention disclosed in International Publication No. 2010/055556. Since a DC current detection unit does not have to be newly disposed, it is possible to achieve a low-cost and space-saving PWM rectifier.
  • the calculated capacitance may be displayed on a display or stored in a storage medium, and, with this configuration, workers are able to recognize the capacitance of the smoothing capacitor every time the PWM rectifier is activated, making it possible to easily decide whether or not the smoothing capacitor has to be replaced.
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JP5931148B2 (ja) 2016-06-08
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US9923477B2 (en) 2018-03-20
US20170099012A1 (en) 2017-04-06

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