This application claims the benefit and priority of Indian Patent Application No. 3974/MUM/2013 filed Dec. 19, 2013. The entire disclosure of the above application is incorporated herein by reference.
This disclosure relates to the failure of capacitors. In particular, but without limitation, this disclosure relates to the identification of a capacitor that has failed.
Electrical power can be provided for use in the form of a Direct Current (DC) voltage and also in the form of an Alternating Current (AC) voltage that has been rectified by applying an AC voltage waveform to a half- or full-wave rectifier so as to produce a rectified voltage. Rectified voltages typically exhibit voltage ripple and may be smoothed by a capacitor in order to reduce the ripple.
Aspects and features of the present disclosure are set out in the appended claims.
There is described herein a capacitor failure indication circuit, the capacitor failure indication circuit being arranged for connection between a first circuit node and a second circuit node, wherein: the first circuit node is the common connection point of a first capacitor and a second capacitor that are connected in series; the second circuit node is the common connection point of a first resistor and a second resistor that are connected in series; the series connected first and second capacitors are connected in parallel to the series connected first and second resistors; the ratio of the impedance of the second capacitor to the sum of the impedances of the first and second capacitors is the same as the ratio of the impedance of the second resistor to the sum of the impedances of the first and second resistors, the capacitor failure indication circuit comprising: a first Zener diode having its anode arranged for connection to the first circuit node; a second Zener diode having its anode arranged for connection to the second circuit node; a first Light Emitting Diode, LED, having its anode connected to the cathode of the first Zener diode and its cathode connected to the cathode of the second Zener diode; and a second LED having its anode connected to the cathode of the second Zener diode and its cathode connected to the cathode of the first Zener diode.
There is also described herein a capacitor failure indication circuit comprising: a first Zener diode; a second Zener diode; a first Light Emitting Diode, LED, having its anode connected to the cathode of the first Zener diode and its cathode connected to the cathode of the second Zener diode; and a second LED having its anode connected to the cathode of the second Zener diode and its cathode connected to the cathode of the first Zener diode.
These circuits use only a few components in order to indicate component failure when a voltage difference between two potential dividers occurs. By making optical triggering or indications, the capacitor failure indication circuits are able to electrically isolate the supply voltage (which may be at a high voltage) from any control circuitry arranged to process the indication (which may be at a low voltage). Furthermore, by using multiple LEDs, the capacitor failure indication circuits are able to convey information with regard to which of the capacitors is faulty—thereby reducing fault diagnosis times and facilitating repair.
Also, by using a pair of parallel connected potential dividers (respectively formed by the first and second capacitors and the first and second resistors) and detecting a voltage difference between nodes of those potential dividers, fluctuations in the voltage supplied across the potential dividers, or creepage of that voltage, do not cause false indications. As system size is a concern when a low voltage circuit is implemented along with the DC link area of a power system, the use of optocouplers advantageously enables a PCB design that reduces the spacing required for isolation between high voltages and low voltages.
As the capacitor failure indication circuits are connected between nodes of the potential dividers, they are not exposed to the full DC voltage with respect to either ground or the negative power rail that is developed at the nodes and so can be used for nodes that are designed to operate at voltages that are in excess of the voltages that the components of the capacitor failure indication circuits—for example as may occur in multi-level voltage converters. Put another way, the voltage ratings of individual capacitor failure indication circuit components are not dependent on the DC voltage with respect to ground and the current rating of the components of the indication circuit depends only on the resistors used in the potential dividers. However, those resistors do limit the flow of high current during differential nodes at the time of capacitor failure.
By providing an indication of capacitor failure before the whole circuit fails, the voltage supply to the circuit may be disrupted, for example by disconnecting the power supply or removing a thyristor gate signal and/or by connecting a inrush resistor to the DC rail and so further component damage or indeed catastrophic failure may be avoided.
When the capacitor failure indication circuit further comprises the first and second resistors, the first and second resistors beneficially have dual functionality as they not only enable the capacitor failure indication circuit to determine voltage imbalances as would be caused by capacitor failure, but also function as bleed resistors by which charge stored in the capacitors can be discharged following turn off.
Further aspects and areas of applicability will become apparent from the description provided herein. It should be understood that various aspects of this disclosure may be implemented individually or in combination with one or more other aspects. It should also be understood that the description and specific examples herein are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
Examples of the present disclosure will now be explained with reference to the accompanying drawings in which:
Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.
In industrial applications, voltage converters can be provided with three phase AC voltages of 400V that, when rectified produce nominal DC voltages of 500V or above. Capacitors rated at 400V or 450V cannot be safely connected across such a nominal voltage and so, in order to allow safe operation and prolong component lifetime, a plurality of capacitors (called bulk capacitors) are connected in series to the rectifier output. Even though the bulk capacitors are connected in series, power loss and variations in operating temperatures will affect the lifetime of the bulk capacitors and eventually one of the bulk capacitors will fail. However, unless such a failure is quickly identified, it will likely result in the remaining bulk capacitor(s) being exposed to an elevated voltage which can then cause the remaining bulk capacitor(s) to fail.
The first and second capacitors 114 and 116 and the first and second resistors 118 and 120 respectively act as voltage dividers. Accordingly, the voltage at circuit node 136 is dependent on the ratio of the impedance of the second capacitor 116 to the sum of the impedances of the first and second capacitors 114, 116 and the voltage at circuit node 138 is dependent on the ratio of the impedance of the second resistor 120 to the sum of the impedances of the first and second resistors 118, 120. In this instance, the first and second capacitors 114 and 116 have the same capacitances and the first and second resistors 118 and 120 have the same resistances and so, in normal operation, the voltage at circuit node 136 will be approximately half of the voltage that is supplied by the voltage source 112 (approximately 15 volts) and the voltage at circuit node 138 will also be approximately half of the voltage that is supplied by the voltage source 112. Accordingly, in normal operation there is little or no potential difference between the first and second circuit nodes 136 and 138 and so neither of the first or second Zener diodes 122 and 124 is reversed biased by a voltage that is greater than their Zener breakdown voltage and so no current flows between the circuit nodes 136 and 138. In order to avoid false triggering of the circuit of
In the event that the first capacitor 114 fails so as to short out its connections, then the voltage supplied by the voltage source 112 will be developed entirely across the second capacitor 116 and so the voltage at the first circuit node 136 will be significantly in excess of the voltage at the second circuit node 138. When the voltage at the first circuit node 136 is in excess of the voltage at the second circuit node 138 by a voltage that is equal to or greater than the sum of the forward voltage of the first Zener diode 122 plus the forward voltage of the first LED 126 plus the Zener breakdown voltage of the second Zener diode 124, current (which will be limited by the second resistor 120) will flow from the first circuit node 136 to the second circuit node 138 via the first LED 126 which will accordingly illuminate and consequently turn on the base of the first phototransistor 128.
In the event that the first capacitor 114 fails by open circuiting its connections then the voltage at the first circuit node 136 will fall below the voltage at the second circuit node 138. When the voltage at the second circuit node 138 is more than that at the first circuit node 136 by an amount that is greater than or equal to the sum of the forward voltage of the second Zener diode 124 plus the forward voltage of the second LED 132 plus the Zener breakdown voltage of the first Zener diode 122, then current will flow from the first circuit node 138 to the second circuit node 136 and the second LED 132 will illuminate and consequently turn on the base of the second phototransistor 134.
In the event that the second capacitor 116 fails and short circuits its terminals, then the voltage at the first circuit node 136 will drop below the voltage at the second circuit node 138 and the second LED 132 will illuminate thereby triggering the base of the second phototransistor 134.
In the event that the second capacitor 116 fails and open circuits its terminals, then the voltage at the first circuit node 136 will rise and the first LED 126 will illuminate and trigger the base of the first phototransistor 128.
Accordingly, the capacitor failure indication circuit is capable not only of detecting capacitor failure by way of open circuiting, but also by way of closed circuiting. Short circuit failures are generally more significant (and frequent) than open circuit capacitor failures because, if a capacitor open circuits, then the condition of the system will not further deteriorate and the only end result will be that a supplied rectified DC voltage will not be filtered. In contrast, if one of the capacitors short circuits, then it will cause an over voltage or elevated voltage to be developed across one or more adjoining series capacitors which ultimately will cause further, and potentially catastrophic, failure. The capacitor failure indication circuit can differentiate between an open circuit capacitor failure and a closed circuit capacitor failure by comparison of the charge time constant expected if the capacitor was functioning normally. In particular, once a normally functioning capacitor is charged to a voltage equivalent to the nodal voltage 138, current will reduce and the optocoupler will be turned off.
The triggering of the phototransistors of either of the first and second optocouplers 124 or 130 causes the generation of signals that can be used to disconnect the voltage supply 112 (means for doing so not shown). By disconnecting the voltage supply 112 once it has been determined that one of the capacitors has failed, subsequent damage to other capacitors and/or circuit components may be avoided. Furthermore, knowledge of the circumstances that would cause the first or second LED 126, 132 to illuminate can also be used to identify which capacitor has failed. For example, in circumstances where it is expected that a capacitor would only fail by short circuiting, then illumination of the first LED 126 would indicate that the first capacitor 114 had failed and illumination of the second LED 132 would indicate that the second capacitor 116 had failed. Accordingly, signals produced by the first and second phototransistors 128, 134 may be recorded so that, when it is time to repair or maintain the system, a person charged with performing the repair or maintenance operation can determine which capacitor needs to be replaced. As one possibility, a record is made of not only which optocouplers illuminate, but also of how long they illuminate for. That information can subsequently be used to determine whether open or closed circuit capacitor faults occurred and may also be used to identify which capacitor has failed.
By using light to indicate that a capacitor has failed, electrical isolation is provided between the voltage supply and any circuitry used to process signals generated by the phototransistor(s).
As one possibility, instead of using LEDs that are part of an optocoupler, one or more standalone LEDs may be used to provide visual warnings that one of the capacitors has failed.
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As one possibility, a 3 phase contactor may be connected to a three-phase input voltage that is subsequently rectified before supplying the series connected capacitors. Upon determination that one of the LEDs has illuminated, the disruptor circuit 318 sends a signal to the contactor to cut off the supply to the rectifier.
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A person skilled in the art will understand that the concept of extrapolating the circuit of
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The capacitor failure indication circuit described herein may be employed to detect failures of DC interlink capacitors connected in series, as may be employed for devices that use rectified voltages. Example of such devices include: AC/DC Drives, UPS (Uninterruptable Power Supplies), multilevel converters, variable frequency drives, battery banks (for example those that are charged using a rectified AC/DC converter—as may be used to back up an inverter), and solar panels.
Although the present disclosure has been set out with reference to examples in which LEDs, and preferably those contained within sealed optocouplers, are used to indicate capacitor failure, any other electrical light source, for example a light bulb, could be used instead of any of the LEDs described herein. Furthermore, a signal developed by the phototransistor of an optocoupler as a consequence of that optocoupler's LED having illuminated may be used to drive an externally visible LED or an alarm or buzzer in order to provide an external indication of capacitor failure.
Component and voltage values set out herein are provided to assist with the understanding of the present disclosure and the concepts and circuits described herein may equally be implemented using different component and/or voltage values without departing from the scope of the present disclosure.
There is described herein a circuit arranged to detect a voltage imbalance indicative of component failure and, upon such detection, convey an optical signal to indicate that a component appears to have failed.
As one possibility, for any of the examples described above, the position of the first Zener diode, the first (and second if present) LED, and/or the second Zener diode may be transposed in any order so long as the anode and cathode orientations of the diodes with respect to the first and second circuit nodes is maintained. This applies equally to the components of each layer in systems having a plurality of capacitor failure indication circuits. When transposing the components, it can help to view the capacitor failure indication circuit as a plurality of circuit blocks, each having a first and second connection and being connected in series. If one of the blocks has a Zener diode in a particular orientation, another of the blocks has a pair of LEDs, and yet another of the blocks has another Zener diode in a different orientation to that of the other Zener diode, then the blocks may be arranged in any sequence so long as they remain in series and do not have the orientation of their respective components changed. As an example,
The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.
Number | Date | Country | Kind |
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3974/MUM/2013 | Dec 2013 | IN | national |