Embodiments of the present disclosure relates generally to capacitors. More specifically, the present disclosure relates to discharging capacitors in an industrial automation drive or the like after power has been removed from the capacitor.
Industrial automation systems may employ various types of electronic devices such as an alternating current (AC) drive to provide a controllable AC voltage to various devices within the industrial automation system. The AC drive may receive AC voltage from an AC voltage source and convert the received AC voltage into direct current (DC) voltage using a rectifier. The AC drive may then convert the DC voltage into a controllable AC voltage using an inverter. In some cases, a regenerative AC drive may provide regenerated power back to a grid or to an AC voltage source from the inverter.
Unfortunately, a common problem with the use of the rectifier and the inverter in the AC drive or the regenerative AC drive includes the production of harmonic currents (i.e. currents that are usually integer multiples of the fundamental frequency), which may have a detrimental effect on the performance and reliability of other equipment coupled to the AC drive. These harmonic currents (harmonics) are typically caused by the switching of power conversion devices in the rectifier and the inverter of the AC drive. To attenuate these harmonics, inductor-capacitor-inductor (LCL) filters may be placed in series with the rectifier and the inverter such that the harmonics, due to the switching of power conversion devices in the rectifier and the inverter, may be reduced.
Generally, in order for the LCL filters to be effective, it is beneficial for the capacitors in the LCL filters to discharge fairly quickly. In conventional AC drives, the capacitors are discharged using bleed resistors. As such, the LCL filter may use additional wiring to incorporate the bleed resistors into its respective circuit. Moreover, the bleed resistors may produce a large amount of heat when the capacitors are discharging and when the AC drive operates under normal-operating conditions. As a result, the bleed resistors may be placed outside of an enclosure of the AC drive such that the heat dissipated by the bleed resistors do not adversely affect the components within the enclosure. Moreover, by using external bleed resistors, the AC drive may use a larger amount of space as compared to the AC drive alone. Accordingly, improved systems for discharging capacitors in an LCL filter or any other circuit are desirable.
In one embodiment, a self-discharging capacitor may include a capacitor and a resistor coupled in parallel to the capacitor. The self-discharging capacitor may also include a housing such that the capacitor and the resistor may be enclosed within the housing. The housing may also include a potting material that is thermally conductive and electrically non-conductive.
In another embodiment, a system may include an alternating current (AC) drive. The AC drive may include a rectifier that may convert AC voltage into direct current (DC) voltage, an inverter that may convert the DC voltage into a controllable AC voltage, and an inductor-capacitor-inductor (LCL) filter that may reduce harmonics generated by the rectifier, the inverter, or both. The LCL filter may include at least one capacitor-resistor assembly such that each capacitor-resistor assembly may include at least one capacitor and at least one resistor. Each respective capacitor may be coupled in parallel to a respective resistor, and each capacitor and resistor may be enclosed within a housing. The housing may include a potting material that is thermally conductive and electrically non-conductive.
In yet another embodiment, a method for manufacturing a three-phase self-discharging capacitor may include coupling a first resistor in parallel to a first capacitor, coupling a second resistor in parallel to a second capacitor, and coupling a third resistor in parallel to a third capacitor. The method may then include coupling the first capacitor, the second capacitor, and the third capacitor together, thereby creating a three-phase resistor-capacitor assembly. The three-phase resistor capacitor assembly may then be disposed into a housing. Afterwards, the method may include filling the housing with a potting material such that heat may dissipate evenly throughout the housing.
In yet another embodiment, a system may include a regenerative converter. The regenerative converter may include a rectifier that may convert AC voltage into direct current (DC) voltage and an inductor-capacitor-inductor (LCL) filter that may reduce harmonics generated by the rectifier. The LCL filter may also include at least one capacitor-resistor assembly, such that the at least one capacitor-resistor assembly may include at least one capacitor and at least one resistor. Here, each respective capacitor may be coupled in parallel to a respective resistor, such that each capacitor and each resistor may be enclosed within a housing. The housing may enclose a potting material that may be thermally conductive and electrically non-conductive.
These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
Embodiments of the present disclosure are generally directed towards a self-discharging capacitor assembly that may be used in an alternating current (AC) drive or in series with any power converting devices. In one embodiment, a resistor may be coupled across or in parallel with a capacitor such that stored energy in the capacitor may be dissipated via the resistor. The resistor-capacitor assembly may then be placed within a housing and the empty space in the housing may be filled with a thermally conductive but electrically non-conductive material (i.e., potting material). As a result, the thermally conductive properties of the material may dissipate the heat evenly through out the potting material without substantially increasing the ambient temperature outside the housing.
By way of introduction,
In either case, the LCL filter 12 may include inductors 18 and capacitors 20. Each capacitor 20 may be coupled in parallel with a resistor 22. The resistor 22 may discharge the capacitor 20 when no power is available at the capacitor 20. As mentioned above, in conventional discharging circuits, the resistors 22 may include bleed resistors that may have high impedance values. These bleed resistors are traditionally located outside an enclosure of the AC drive 10 due to the amount of heat generated by the resistors when the capacitors 20 are discharging. Moreover, since bleed resistors are often assembled as a series of resistors, the bleed resistor assembly in traditional systems may encompass a large amount of space in the industrial automation system, where space is generally limited.
Such deficiencies in traditional systems are now recognized and addressed by present embodiments. Indeed, in one embodiment, the capacitors 20 and the resistors 22 of
Keeping the circuit of
Referring now to
Generally, the resistor 22 may be selected such that it loses a small amount of power (i.e., watts) or heat and maintains a similar temperature as the capacitor 20. The amount of power loss may be represented by Equation 1 below:
W=V
2
/R (1)
where W is the number of watts lost, V is the voltage across the capacitor 20 and/or the resistor 22 and R is the impedance value of the resistor 22. Keeping this in mind, the impedance value of the resistor 22 may be determined by first determining a maximum change in temperature (ΔTgoal) and then calculating a resistance value based on a voltage applied across the capacitor 20 and the resistor 22 and Equation 1 above. For instance, the maximum change in temperature (ΔTgoal) for the capacitor 22 may be determined according to Equation 2 below:
ΔTgoal=ΔTmax
where ΔTmax
Watts Lost=ΔTgoal×(W/°C.) (3)
where (W/° C.) is the expected watts lost per degree Celsius as specified by the manufacturer of the resistor 22 or the like. Using the voltage being applied across the capacitor 20 and the resistor 22 and the expected number of watts lost, the impedance value of the resistor 22 may be determined based on Equation 4 below:
R=V
2/Watts Lost (4)
Generally, the impedance of the resistor 22 may be relatively large such that the number of watts lost by the resistor may be minimized. In one embodiment, the resistor 22 may be a wirewound resistor that may have a large impedance value (e.g., 150 kΩ). By using a large impedance resistor, the resistor 22 may experience a relatively low amount of power (i.e., watts) or heat loss when the capacitor 20 discharges.
In addition to having a large impedance value, the resistor 22 may include a large surface area that may be used to dissipate the watts or heat generated by the resistor 22 when the capacitor 20 discharges. This large surface area may provide a large area for the heat generated by the resistor 22 to dissipate, thereby minimizing the difference between the temperature of the resistor 22 and the temperature of the capacitor 20. Since the resistor 22 may be selected such that it experiences a small amount of power (i.e., watts) or heat loss, the temperature of the resistor 22 should be similar to the temperature of the capacitor 20. In other words, the resistor 22 may be selected such that the difference (ΔT) between the temperature of the resistor 22 and the temperature of the capacitor 20 may be minimized. As such, the impedance of the resistor 22 may also be determined using a desired difference (ΔT) between the temperature of the resistor 22 and the temperature of the capacitor 20 and Equations 3-4 above. By using the resistor 22 that has a low temperature difference ΔT, the heat dissipated by the resistor 22 may not damage the film of the capacitor 20. That is, the low temperature difference ΔT may prevent localized damage to the film of the capacitor 20.
In lieu of using a wirewound resistor, the resistor 22 may also be a plastic film or thin film resistor. In one embodiment, the plastic film or thin film resistor may be interleaved with or wrapped around the capacitor 20. In any case, as mentioned above, the plastic film or thin film resistor may be selected such that it has a high impedance value and a large surface area such that the resistor loses a small amount of power (i.e., watts) or heat and maintains a similar temperature as the capacitor 20.
Referring back to the method 40, after the resistor 22 is coupled across the capacitor 20, at block 44, the resulting resistor-capacitor assembly may be placed inside the housing 32. The housing 32 may be cylindrically shaped, but it should be noted that the housing 32 may be shaped as a square, rectangle, or the like. The housing 32 may be a flame retardant thermoplastic case. In one embodiment, the housing 32 may be larger than the resistor-capacitor assembly such that the housing 32 may include some amount empty space that may be filled using a potting material as described below.
At block 46, the empty space of the housing 32 may be filled with a potting material or compound that may be thermally conductive and electrically insulative (i.e., non-conducting). In one embodiment, the potting material may be a thermally conductive urethane or epoxy that wicks excess heat away from the resistor-capacitor assembly. As such, the potting material may be a gel-based material, an oil-based material, or the like. In any case, the thermally conductive potting material may ensure that heat dissipated by the resistor 22 may be distributed evenly inside the self-discharging capacitor assembly 24. Further, the thermally conductive potting material may enable the self-discharging capacitor assembly 24 to have a uniform temperature across the housing 32.
Common perception by capacitor manufacturers is that integrating a resistor into a capacitor housing is undesirable because the capacitor will be overheated, thereby reducing the life of the capacitor. However, it is now recognized that by distributing the dissipated heat evenly inside the self-discharging capacitor assembly 24, the heat dissipated by the resistor 22 when the capacitor 20 discharges may not provide a direct heat source on the capacitor 20. Moreover, since the resistor 22 may be designed such that a small amount of watts are lost over a large amount of surface area and dissipated evenly via the thermally conductive potting material, the temperature of the self-discharging capacitor assembly 24 may not substantially contribute to the ambient temperature of the AC drive. In other words, the difference in temperature between the self-discharging capacitor assembly 24 and the ambient temperature may not be substantial (e.g., less than 10° C.). In certain embodiments, the resistor 22 may be selected such that the number of watts lost by the resistor 22 may not cause the temperature inside the housing 32 to exceed a temperature rating, as specified by a manufacturer or the like, for the capacitor 20.
After the empty space of the housing 32 is filled with the potting material at block 46, the resulting self-discharging capacitor assembly 24 may be considered to be a single-phase self-discharging capacitor assembly 24 since only one resistor-capacitor assembly is present in the housing 32. However, it should be noted that a multi-phase self-discharging capacitor assembly 24 may be manufactured using the same method 40 described above by assembling additional resistor-capacitor assemblies and coupling one end of each assembled resistor-capacitor assembly together (i.e., at the common node 30) at block 42. The method 40 may then continue at block 44 by placing each of the assembled resistor-capacitor assemblies into the same housing 32. Then, at block 46, the empty space within the housing 32 may be filled with the potting material as described above.
Generally, the AC drive 10 of
In essence, the electrical connections between each capacitor 20 and each resistor 22 are prepared during the manufacturing of the three-phase self-discharging capacitor assembly 24 described above with reference to
Since the thermally conductive and electrically insulative potting material 62 may evenly distribute the heat generated from the resistors 22 throughout the housing 32, the placement of the resistors 22 should not be limited to being close to the center of the housing 32 or adjacent to the capacitors 20. Instead, the resistors 22 may be placed in any space within the housing 32 that is not occupied by the capacitor 20. For example,
As mentioned above, the three-phase self-discharging capacitor assembly 24 may also be manufactured for other multi-phase systems or a single-phase system as well. For example,
Referring now to
Although each capacitor assembly 24 (i.e., single-phase and multi-phase) described above has been described with respect to the LCL filter 12 in the AC drive 10, it should be noted that each capacitor-resistor assembly 24 described above may be used in a wide variety of electrical devices, such as a regenerative converter bus supply, a power rectifier, an inverter, and the like, and is not limited to being used in LCL filters that are part of an AC drive. For example, a regenerative converter may include an LCL filter 12 in series with a rectifier 14, such that the LCL filter 12 may reduce harmonics produced by the rectifier 14. Here, like the AC drive 10, the LCL filter 12 may employ the capacitor-resistor assembly 24 described above to avoid using bleed resistors and the like.
Moreover, although the capacitor-resistor assemblies depicted in
While only certain features of the invention have been illustrated and described herein, many modifications and changes will occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention.