Patent Application
20240006984
The present disclosure relates to a power converter that converts alternating-current power into desired power and also relates to a motor driver and a refrigeration cycle applied equipment.
A power converter includes: a converter that rectifies a power supply voltage that is a voltage of an alternating-current power supply; a smoothing capacitor that smooths a rectified voltage output from the converter; and an inverter that converts a direct-current voltage output via the smoothing capacitor into an alternating-current voltage for a load. In other words, the power converter has, between the converter and the inverter, the smoothing capacitor that smooths the voltage output from the converter.
In this type of power converter, power is supplied from the smoothing capacitor to the inverter during a period when the rectified voltage output from the converter is lower than a capacitor voltage that refers to the voltage of the smoothing capacitor. Therefore, a discharge current flows through the smoothing capacitor. During a period when the rectified voltage is higher than the capacitor voltage, the power is supplied from the alternating-current power supply to the inverter. This is when a charge current flows through the smoothing capacitor. In this way, the power converter continuously supplies the power from the inverter to the load.
Smoothing capacitors are generally known to be components having a limited life-span. A capacitor current that refers to the current flowing through the smoothing capacitor is one factor determining the life of the smoothing capacitor. Therefore, if the capacitor current can be reduced, the smoothing capacitor is enabled to have a longer life. However, in order to reduce the capacitor current it is necessary to increase the capacitance of the smoothing capacitor. If the capacitance of the smoothing capacitor increases, higher costs of the smoothing capacitor becomes problematic.
Given such a technical background, Patent Literature 1 cited below describes: a converter circuit that converts alternating-current power into direct-current power; a smoothing capacitor connected in parallel with a direct-current side of the converter circuit; and a power converter that controls a capacitor current flowing through the smoothing capacitor to a set value. In this power converter, a reduced capacitance of the smoothing capacitor is achieved by detecting the capacitor current flowing through the smoothing capacitor and controlling the detected capacitor current to the set value.
However, the technique described in Patent Literature 1 is a technique that causes the capacitor current to follow the set value, namely a command value. When the capacitor current is caused to follow the command value, a target value is fixed to zero. In this case, an integral (I) controller is required for a controller to follow and converge to the target value, which is the fixed value. However, in the cases of the capacitor current cannot be made zero due to a load or an environment during operation, output of the I controller increases to become saturated, and the control accuracy may become degraded.
The present disclosure has been made in view of the above, and an object of the present disclosure is to obtain a power converter adapted to avoid occurrences of degradation of control accuracy and control failure while enabling reduced capacitance of a smoothing capacitor.
In order to solve the above-stated problems and achieve the object, a power converter according to the present disclosure includes a converter, a smoothing capacitor, an inverter, and a controller. The converter is adapted to rectify a power supply voltage applied from an alternating-current power supply. The smoothing capacitor is adapted to smooth a rectified voltage output from the converter into a direct-current voltage including a ripple. The inverter is adapted to convert the direct-current voltage smoothed by the smoothing capacitor into an alternating-current voltage for a motor. The controller is adapted to control such that a first physical quantity representing an operation state of the converter is equal to a second physical quantity representing an operation state of the inverter.
The power converter according to the present disclosure has effects of avoiding occurrences of degradation of control accuracy and control failure and enabling reduced capacitance of the smoothing capacitor.
With reference to the accompanying drawings, a detailed description is hereinafter provided of power converters, a motor driver, and a refrigeration cycle applied equipment according to embodiments of the present disclosure.
The power converter 1 includes: a converter 2; an inverter 3; a smoothing capacitor 4; a controller 12; voltage detectors 9 and 11; and a zero crossing detector 10. The power converter 1 and the motor 110 included in the compressor 120 constitute a motor driver 50.
The voltage detector 9 detects the power supply voltage Vs applied to the converter 2 from the alternating-current power supply 100. The zero crossing detector 10 generates a zero crossing signal Zc in accordance with the power supply voltage Vs of the alternating-current power supply 100. The zero crossing signal Zc is, for example, a signal that outputs a “High” level when the power supply voltage Vs is of positive polarity and outputs a “Low” level when the power supply voltage Vs is of negative polarity. These levels may be reversed. A detection value of the power supply voltage Vs and the zero crossing signal Zc are input to the controller 12.
The converter 2 includes a rectifier 20 and a booster 22. The rectifier 20 includes four rectifier elements 20a connected in a bridge configuration. The rectifier 20 rectifies the power supply voltage Vs applied from the alternating-current power supply 100. The booster 22 is connected to output terminals of the rectifier 20. The booster 22 boosts a rectified voltage output from the rectifier 20 and applies the boosted voltage to the smoothing capacitor 4. In the example of
The booster 22 includes a reactor 22a, a rectifier element 22b, and a semiconductor switching element 22c. In the booster 22, the semiconductor switching element 22c turns on or off under control of a drive signal Gconv that is output from the controller 12. When the semiconductor switching element 22c is controlled to be turn-on, the rectified voltage is short-circuited via the reactor 22a. This operation is referred to as “power supply short-circuiting operation”. When the semiconductor switching element 22c is controlled to be turn-off, the rectified voltage is applied to the smoothing capacitor 4 via the reactor 22a and the rectifier element 22b. This operation refers to normal rectification operation. If the reactor 22a has stored energy at this time, the rectified voltage and a voltage generated across the reactor 22a add up and are applied to the smoothing capacitor 4.
The booster 22 boosts the rectified voltage by alternately repeating the power supply short-circuiting operation and the rectification operation. These operations are referred to as “boost operation”. The boost operation boosts a voltage between both ends of the smoothing capacitor 4 to a voltage higher than the power supply voltage Vs. Moreover, the boost operation improves a power factor of a power supply current that is a current flowing between the alternating-current power supply 100 and the converter 2. In other words, boost control that causes the booster 22 to perform the boost operation is performed in the first embodiment to boost the rectified voltage and improve the power factor of the power supply current. This control enables a waveform of the power supply current to approximate a sine wave.
The smoothing capacitor 4 is connected between output terminals of the converter 2. The smoothing capacitor 4 smooths the rectified voltage output from the converter 2 into a direct-current voltage including a ripple. Examples of the smoothing capacitor 4 include an electrolytic capacitor and a film capacitor, among others.
The voltage that is generated across the smoothing capacitor 4 has, rather than a full-wave rectified waveform of the alternating-current power supply 100, a waveform including a direct-current component with voltage ripple based on a frequency of the alternating-current power supply 100 superimposed but does not pulsate significantly. A main frequency component of this voltage ripple is a component that is double the frequency of the power supply voltage Vs when the alternating-current power supply 100 is the single-phase power supply or six times the frequency of the power supply voltage Vs when the alternating-current power supply 100 is the three-phase power supply. If the power input from the alternating-current power supply 100 and the power that is output from the inverter 3 do not change, amplitude of this voltage ripple is determined by capacitance of the smoothing capacitor 4. However, as stated above, the power converter according to the present disclosure avoids increased capacitance for a restrained increase in costs of the smoothing capacitor 4. Therefore, a certain degree of voltage ripple is generated in the smoothing capacitor 4. For example, the voltage across the smoothing capacitor 4 becomes the voltage that pulsates in a range such that the voltage ripple has a maximum value smaller than twice its minimum value.
The voltage detector 11 is provided across the smoothing capacitor 4. The voltage detector 11 detects a capacitor voltage Vdc that is the voltage across the smoothing capacitor 4. A detection value of the capacitor voltage Vdc is input to the controller 12.
The inverter 3 is connected across the smoothing capacitor 4. The inverter 3: includes semiconductor switching elements Up, Un, Vp, Vn, Wp, and Wn connected in a three-phase bridge configuration. A reflux diode is connected across and in antiparallel with each of the semiconductor switching elements. In the inverter 3, the semiconductor switching elements Up to Wn turn on or off under control of drive signals Gup to Gwn that are output from the controller 12. The inverter 3: turns on or turns off the semiconductor switching elements Up to Wn; and converts the direct-current voltage, smoothed by the smoothing capacitor 4, into the alternating-current voltage for supplying to the motor 110.
A current detector 7 detects a converter current Iconv that is a current flowing in the converter 2. The converter current Iconv is also the current flowing between the rectifier 20 and the booster 22. A current detector 8 detects an inverter current Iinv that is a current flowing in the inverter 3. The inverter current Iinv is also the current flowing between the inverter 3 and the smoothing capacitor 4. The converter current Iconv and the inverter current Iinv are input to the controller 12.
The compressor 120 is the load that includes the motor 110. The load is, for example, included in an air conditioner. In the cases where the motor 110 serves as a motor that drives a compression mechanism, the motor 110 rotates according to the amplitude and the phase of the alternating-current voltage applied from the inverter 3, performing a compression operation.
The controller 12 includes a calculator 12a as a computing means. The calculator 12a is, for example, a microcomputer but may be another computing means referred to as a central processing unit (CPU), a microprocessor, a digital signal processor (DSP), or the like. The calculator 12a performs operation controls on the converter 2 and the inverter 3. The drive signals Gconv and Gup to Gwn that are output from the controller 12 are computed and generated by the single calculator 12a. In other words, control computations to control the operations of the converter 2 and the inverter 3 are performed by the single and common calculator 12a included in the controller 12.
The power converter 1 according to the first embodiment controls flow of an appropriate current into the motor 110 by having the semiconductor switching element 22c included in the booster 22 or the semiconductor switching elements Up to Wn included in the inverter 3 driven with appropriate timing. This control is performed on the basis of a detection value of the converter current Iconv that is detected by the current detector 7 and a detection value of the inverter current Iinv that is detected by the current detector 8.
A typical power converter includes a converter control system that controls a bus voltage to a desired value. The bus voltage is a voltage between the direct-current bus lines to which the smoothing capacitor 4 is connected. This type of converter control system performs the control on the basis of the detection value detected by the current detector 7. Moreover, in the typical power converter, and in the power converter of sensorless control having no position sensor or no speed sensor includes an inverter control system that controls speed of the motor 110. According to this type of inverter control system, the control is performed based on the detection value detected by the current detector 8, because the control is performed for causing an estimated speed value estimated in the control system to match a speed command value. In other words, the power converter 1 according to the first embodiment uses the detection values obtained from the existing current detectors 7 and 8 in controlling the converter 2 or the inverter 3.
The converter current Iconv is an example of a physical quantity representing an operation state of the converter 2, and the inverter current Iinv is an example of a physical quantity representing an operation state of the inverter 3. In the present description, in order to distinguish these two physical quantities from each other, the physical quantity representing the operation state of the converter 2 may be described as the “first physical quantity”, and the physical quantity representing the operation state of the inverter 3 may be described as the “second physical quantity”. It is to be noted that other physical quantities may be used instead of the above described physical quantities. Another example of the first physical quantity is power that is exchanged between the converter 2 and the smoothing capacitor 4. Another example of the second physical quantity is power that is exchanged between the smoothing capacitor 4 and the inverter 3
A description is provided next of configurations and operations of essential parts of the power converter 1 according to the first embodiment. A current that flows through the smoothing capacitor is hereinafter denoted by “Ic”.
First, when the semiconductor switching element 22c of the booster 22 does not conduct, a relation of the capacitor current Ic, the converter current Iconv, and the inverter current Iinv holds as expressed by Formula (1) below.
Ic=Iconv−Iinv (1)
In above Formula (1), the capacitor current Ic is defined as being of positive polarity in a direction of flow into a positive electrode of the smoothing capacitor 4, namely, in a charge current direction. The converter current Iconv is defined as being of positive polarity in a direction of current flow from the converter 2 into the smoothing capacitor 4. The inverter current Iinv is defined as being of positive polarity in a direction of current flow from the smoothing capacitor 4 into the inverter 3.
To extend a life of the smoothing capacitor 4, the capacitor current Ic should be reduced. This can be done by causing the converter current Iconv and the inverter current Iinv to equalize each other, as is obvious from above Formula (1). A description is hereinafter provided of a control technique that causes the converter current Iconv and the inverter current Iinv to equalize each other.
As mentioned above, in the first embodiment, the boost control is performed to boost the rectified voltage and improve the power factor of the power supply current. At this time, in the converter 2, the converter current Iconv, the bus voltage, a phase of the power supply voltage Vs, and another factor determine timing of the turning on and off of the semiconductor switching element 22c. Therefore, a control system illustrated
A description is provided of the operation of the converter current control system 60 illustrated in
As illustrated in
In a bus voltage control block 61, a current command value Is* is generated on the basis of a difference between a bus voltage command value Vdc* and the bus voltage Vdc. The bus voltage control block 61 can be configured using, for example, a proportional-integral (PI) controller. A power supply current command value Isin* is generated by multiplying the current command value Is* by an absolute value |sin θs| of a sinusoidal signal sin θs.
θs denotes the phase of the power supply voltage Vs. The phase θs can be determined by phase computation based on the zero crossing signal Zc obtained from the zero crossing detector 10. The phase computation can use a phase lock loop (PLL) process.
Attention is focused on a pulsation compensation block 62 illustrated in
Returning to
As described above, in the converter current control system 60 illustrated in
The preceding description has been for the control system in which the converter current Iconv is the control target. A description is provided next of the configuration and the operation of a control system in which the inverter current Iinv is a control target. FIG. is a diagram illustrating a configuration example of the inverter current control system 80 according to the first embodiment.
In the inverter current control system 80, as illustrated in
Explanations of characters used in
Attention is focused on a pulsation compensation block 82 illustrated in
In the configuration example of
Returning to
As described above, in the inverter current control system 80 illustrated in
While the converter 2 includes the booster 22 in the configuration example illustrated in
In the power converter 1A illustrated in
With the above-described power converter 1A, while switching control cannot be performed on the converter 2A, switching control of the inverter 3 is possible. Therefore, the use of the control technique of the inverter current control system 80 that is included in the above-described control technique according to the first embodiment can provide the above effect.
As described above, in the power converter according to the first embodiment, the controller is adapted to perform the control such that the first physical quantity representing the operation state of the converter is equal to the second physical quantity representing the operation state of the inverter. The present control technique is the technique that controls the first physical quantity, which corresponds to the converter current, and the second physical quantity, which corresponds to the inverter current, rather than using, as in Patent Literature 1, the capacitor current as a target value. Moreover, for the present control technique, the target value is not a fixed value but constantly changes, and as illustrated in
While the compressor has been described above as the example of the load, this is not limiting. The control technique described above is applicable to rotation control of a motor that drives a mechanism with period torque pulsations, not to mention the compressor.
In a second embodiment, a description is provided of timings of detections of the converter current Iconv and the inverter current Iinv.
However, at position A5 indicated by a broken line, the current flows through the detector only when the semiconductor switching element 22c is turned on. For this reason, the timing of the current detection and the timing of the turning on or off of the semiconductor switching element 22c need to be synchronized. In other words, the controller 12 according to the second embodiment needs to detect the converter current Iconv in accordance with timing of conduction or nonconduction of the semiconductor switching element 22c in the converter 2.
At each of positions B2 to B4 indicated by broken lines, the current similarly flows through the detector only when the semiconductor switching element Un, Vn, or Wn associating with the corresponding position is turned on. For this reason, the timing of the current detection and timing of turning on or off of the associating semiconductor switching element need to be synchronized. In other words, the controller 12 according to the second embodiment needs to detect the inverter current Iinv in accordance with timing of conduction or nonconduction of the semiconductor switching element Un, Vn, or Wn in the inverter 3.
The power converter 1B illustrated in
In
In the typical power converter, detectors are disposed at positions appropriate to a use. The use of the technique according to the second embodiment enables the acquisition of the converter current Iconv and the inverter current Iinv with the appropriate timing, regardless of the positions where the detectors are disposed. Therefore, additional costs for a circuit are suppressed.
In cases where the semiconductor switching elements 22c and 24 are used to realize boost control or power factor improvement as in the power converters 1 and 1B illustrated in
Therefore, as illustrated in
Provided the filter 40 is a filter that sufficiently attenuates the high frequency noise synchronous with the switching cycle of the semiconductor switching element 22c or 24, its configurations do not matter. The filter 40 may be configured with a filter circuit that, as an analog circuit, performs filter processing on a signal received from a detector. Instead of being configured this way, the filter 40 may be configured to perform, on the signal that the calculator 12a receives from the detector, filter processing as a digital circuit inside the calculator 12a, that is to say, filter processing as digital processing. The filter 40 may be configured with a low-pass filter or with a notch filter that cancels high frequency components in a specific frequency band.
The above contents are conceivable not only for the converter current Iconv as the control target, but also for the inverter current Iinv as the target value in the control. Therefore, the high frequency noise removal processing is performed even on the inverter current Iinv. Specifically, as illustrated in
While the above description has been made for the processing within the pulsation compensation block 62 illustrated in each of
As described above, the power converter according to the third embodiment includes the filter circuit adapted to perform the filter processing on the first and second physical quantities, and the controller is adapted to control at least one of the converter or the inverter on the basis of outputs of the filter circuit. Thus, an enhanced capacitor current reducing effect is possible, since accurate control of the converter current and the inverter current is enabled.
According to the power converter of the third embodiment, the controller is adapted: to perform the filter processing on detection values of the first and second physical quantities; and to control at least one of the converter or the inverter on the basis of outputs reflecting the filter processing. Thus, an enhanced capacitor current reducing effect is possible, since accurate control of the converter current and the inverter current is enabled.
The refrigeration cycle applied equipment 900 has a compressor 120 with a built-in motor 110 of the first embodiment, a four-way valve 902, an indoor heat exchanger 906, an expansion valve 908, and an outdoor heat exchanger 910 connected via refrigerant piping 912.
The compressor 120 internally includes a compression mechanism 904 that compresses a refrigerant and the motor 110 that runs the compression mechanism 904.
The refrigeration cycle applied equipment 900 is capable of operating for heating or cooling through switching operation of the four-way valve 902. The compression mechanism 904 is driven by the motor 110 that is controlled at variable speed.
In the heating operation, as indicated by solid line arrows, the refrigerant is pressurized and discharged by the compression mechanism 904 and returns to the compression mechanism 904 through the four-way valve 902, the indoor heat exchanger 906, the expansion valve 908, the outdoor heat exchanger 910, and the four-way valve 902.
In the cooling operation, as indicated by dashed line arrows, the refrigerant is pressurized and discharged by the compression mechanism 904 and returns to the compression mechanism 904 through the four-way valve 902, the outdoor heat exchanger 910, the expansion valve 908, the indoor heat exchanger 906, and the four-way valve 902.
In the heating operation, the indoor heat exchanger 906 acts as a condenser to release heat, and the outdoor heat exchanger 910 acts as an evaporator to absorb heat. In the cooling operation, the outdoor heat exchanger 910 acts as a condenser to release heat, and the indoor heat exchanger 906 acts as an evaporator to absorb heat. The expansion valve 908 depressurizes and expands the refrigerant.
The described refrigeration cycle applied equipment 900 according to the fourth embodiment includes the power converter 1 described in the first embodiment; however, this is not limiting. The power converter 1A illustrated in
The above configurations illustrated in the embodiments are illustrative, can be combined with other techniques that are publicly known, and can be partly omitted or changed without departing from the gist.
This application is a U.S. national stage application of International Patent Application No. PCT/JP2021/000197 filed on Jan. 6, 2021, the disclosure of which is incorporated herein by reference.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2021/000197 | 1/6/2021 | WO |
