The present invention relates to a smoothing circuit, an inverter, and a power supply apparatus.
AC power supplied to a heating coil used for induction heating is generally generated through a process of convening AC power of a commercial power supply into DC power through a converter and inversely converting the converted DC power into AC power of a desired frequency through an inverter. The inverter includes a plurality of power semiconductor devices, and the inverse conversion from DC power to AC power is performed by switching operations of the plurality of power semiconductor devices.
In a voltage-type inverter, DC power smoothed through a capacitor is supplied to power semiconductor devices. A first related art power conversion apparatus includes a first smoothing capacitor and a second smoothing capacitor having a smaller capacitance and high-frequency impedance than the first smoothing capacitor and disposed more adjacent to a semiconductor switching element than the first smoothing capacitor (see, e.g., to JP2004-254355A). A second related art power supply apparatus includes a plurality of capacitors arranged adjacent to a power semiconductor device, and the plurality of capacitors are connected in parallel to each other (see, e.g., JP2017-004593A).
A high-speed switching operation of the power semiconductor device rapidly changes a current flowing through the power semiconductor device, and the current change di/dt generates a surge voltage (L×di/dt) across the power semiconductor device through inductance L such as inductance of an electrical path between the power semiconductor device and a capacitor serving as a voltage source or internal inductance of the capacitor. An excessive surge voltage may destroy the power semiconductor device, and thus needs to be prevented. Since the current change di/dt is mainly decided by the characteristics of the power semiconductor device, the surge voltage can be prevented by reducing the inductance L.
As a method for reducing the inductance L, as in the first related art power conversion apparatus, for example, the capacitor may be disposed adjacent to the power semiconductor device. Accordingly, the inductance of the electrical path between the power semiconductor device and the capacitor can be reduced.
As another method for reducing the inductance L, as in the second related art power supply apparatus, the plurality of capacitors may be arranged adjacent to the power semiconductor device, and connected in parallel to each other. Accordingly, equivalent inductance corresponding to combined internal inductance of the plurality of capacitors can be reduced, and smaller capacitors can be disposed close to the power semiconductor device.
In order to effectively use the plurality of capacitors connected in parallel to each other, it is necessary to suppress a variation in current flowing through each of the capacitors. That is because a capacitor through which a relatively large amount of current flows is likely to be destroyed by heat generated therefrom. Furthermore, when a variation occurs in the current flowing through each of the capacitors connected in parallel to each other, internal inductance of a capacitor through which a relatively large amount of current flows becomes dominant in the combined internal inductance of the plurality of capacitors. As a result, the equivalent inductance corresponding to the combined internal inductance of the plurality of capacitors is not sufficiently reduced, and the preventing effect for a surge voltage may be degraded.
Illustrative aspects of the present invention provide a smoothing circuit capable of suppressing a surge voltage from occurring in an inverter, and uniformly distributing current to a plurality of capacitors provided in a smoothing circuit of a voltage-type power supply, thereby preventing damage due to heat generated in the respective capacitors.
According to an illustrative aspect of the invention, a smoothing circuit includes a plate-shaped circuit body having a positive-side output terminal and a negative-side output terminal, and a plurality of capacitors mounted on the circuit body and connected to each other in parallel between the positive-side output terminal and the negative-side output terminal, each capacitor having a positive terminal and a negative terminal. The circuit body includes, for each capacitor, a positive electrical path connecting the positive terminal of the capacitor and the positive-side output terminal to each other and a negative electrical path connecting the negative terminal of the capacitor and the negative-side output terminal to each other. With a sum of a length of the positive electrical path and a length of the negative electrical path being defined as a positive-negative electrical path length for each capacitor, a difference between a maximum positive-negative electrical path length and a minimum positive-negative electrical path length among the positive-negative electrical path lengths is equal to or smaller than 30% of the minimum positive-negative electrical path length.
According to another illustrative aspect of the invention, a smoothing circuit includes a plate-shaped circuit body having a positive-side output terminal and a negative-side output terminal, and a plurality of capacitors mounted on the circuit body and connected to each other in parallel between the positive-side output terminal and the negative-side output terminal, each capacitor having a positive terminal and a negative terminal. The circuit body includes a positive solid pattern providing, for each capacitor, a positive electrical path connecting the positive terminal of the capacitor and the positive-side output terminal to each other, a negative solid pattern providing, for each capacitor, a negative electrical path connecting the negative terminal of the capacitor and the negative-side output terminal to each other, and an insulating layer interposed between the positive solid pattern and the negative solid pattern. With a middle point between the positive-side output terminal and the negative-side output terminal being defined as a base point and a distance from the base point to a middle point between the positive terminal and the negative terminal being defined as a distance to the capacitor for each capacitor, a difference between a maximum distance and a minimum distance among distances to the respective capacitors is equal to or smaller than 30% of the minimum distance.
According to another illustrative aspect of the invention, an inverter includes the smoothing circuit described above, and an inverter circuit connected to the positive-side output terminal and the negative-side output terminal of the smoothing circuit, and configured to convert DC power supplied from the smoothing circuit into AC power.
According to another illustrative aspect of the invention, a power supply apparatus includes the inverter described above, and a converter configured to convert AC power supplied from an AC power supply into DC power to supply the DC power to the smoothing circuit of the inverter.
Illustrative aspects of the present invention can provide a smoothing circuit capable of suppressing a surge voltage from occurring in an inverter, and can also provide an inverter and a power supply apparatus having improved protection for power semiconductor devices.
The power supply apparatus 1 includes a converter 3 configured to convert AC power supplied from an AC power supply 2 into DC power and an inverter 4 configured to convert the DC power output from the converter 3 into AC power.
The converter 3 may perform rectification using a diode bridge, for example, or perform rectification to vary an output voltage, using a semiconductor device such as a thyristor capable of controlling conduction based on an external signal.
As illustrated in
The upper arm (the power semiconductor device Q1) of the first leg QL1 and the lower arm (the power semiconductor device Q4) of the second leg QL2 are turned on in synchronization with each other, and the lower arm (the power semiconductor device Q2) of the first leg QL1 and the upper arm (the power semiconductor Q3) of the second leg QL2 are turned on in synchronization with each other. Furthermore, the upper arm of the first leg QL1 and the lower arm of the second leg QL2 and the lower arm of the first leg QL1 and the upper arm of the second leg QL2 are alternately turned on in cycles. Accordingly, AC power is generated from DC power, and outputted from a serial contact point between the upper arm and the lower arm of each of the first leg QL1 and the second leg QL2.
A load 5 including a heating coil is connected to an AC output of the inverter 4, and the AC power generated by the inverter 4 is supplied to the heating coil. Furthermore, a heating target is induction-heated by the heating coil. The heating target and the heating purpose are not specifically limited, and a heat treatment (e.g., quenching) for a steel material can be exemplified.
The power semiconductor device may include various types of power semiconductor devices capable of performing a switching operation, such as an insulated gate bipolar transistor (IGBT) and metal-oxide-semiconductor field-effect transistor (MOSFET), and silicon (Si) or silicon carbide (SiC) may be used as the semiconductor material.
The inverter circuit Inv may constitute first to third legs using six power semiconductor devices, and generate three-phase AC power. The inverter 4 may include a plurality of inverter circuits Inv. When the inverter 4 includes the plurality of inverter circuits Inv. AC powers generated by the respective inverter circuits Inv are combined, and the combined AC power is supplied to the load 5 from the inverter 4.
The inverter 4 further includes a smoothing circuit 7. The smoothing circuit 7 smoothes DC power containing a ripple, which is output from the converter 3, and supplies the smoothed DC power to the inverter circuit Inv.
In the example of
In the example of
The smoothing circuit 7 includes a plurality of capacitors connected in parallel to a DC output of the converter 3 and a DC input of the inverter circuit Inv. In the example of
The capacitor C1 has a capacitance component CC1, a resistance component RC1 and an inductance component LC1 therein. Furthermore, a resistance component RP1 and an inductance component LP1 are present in a positive electrical path between a positive terminal PC1 of the capacitor C1 and the positive-side output terminal P of the circuit body, and a resistance component RN1 and an inductance component LN1 are also present in a negative electrical path between a negative terminal NC1 of the capacitor C1 and the negative-side output terminal N of the circuit body.
Similarly, the capacitor C2 has a capacitance component CC2, a resistance component RC2 and an inductance component LC2 therein, a resistance component RP2 and an inductance component LP2 are present in a positive electrical path between a positive terminal PC2 of the capacitor C2 and the positive-side output terminal P of the circuit body, and a resistance component RN2 and an inductance component LN2 are present in a negative electrical path between a negative terminal NC2 of the capacitor C2 and the negative-side output terminal N of the circuit body.
Furthermore, the capacitor C3 also has a capacitance component CC3, a resistance component RC3 and an inductance component LC3 therein, a resistance component RP3 and an inductance component LP3 are present in a positive electrical path between a positive terminal PC3 of the capacitor C3 and the positive-side output terminal P of the circuit body, and a resistance component RN3 and an inductance component LN3 are present in a negative electrical path between a negative terminal NC3 of the capacitor C3 and the negative-side output terminal N of the circuit body.
Here, the current flowing through the capacitors C1, C2, C3 are related to the impedance between the positive-side output terminal P and the negative-side output terminal N, and high-frequency impedances Zi (i=1, 2, and 3) corresponding to the respective capacitors are expressed by the following equations.
Zi=√(Ri2+(ωLi)2)
Ri=R
Ci
+R
Pi
+R
Ni
Li=L
Ci
+L
Pi
+L
Ni
A variation in the high-frequency impedances Zi (i=1, 2, and 3) expressed by the above equation causes a variation in the currents flowing through the capacitors C1, C2, C3. The resistance component Ri typically has an extremely small value in the order of mΩ, and a dominant element deciding the high-frequency impedance Zi is considered as the inductance component Li. Therefore, when the inductance components Li are uniformized, it is possible to reduce a variation of the high-frequency impedances Zi, thereby preventing a variation in the currents flowing through the capacitors C1, C2, C3.
Furthermore, when the currents flowing through the capacitors C1, C2, C3 are uniformized, it is possible to reduce the entire equivalent inductance L of the smoothing circuit 7, obtained by combining the inductances Li containing the internal inductances LCi of the respective capacitors, thereby preventing a surge voltage L×di/dt generated across the power semiconductor devices Q1 to Q4.
The same capacitors are used as the capacitors C1, C2, C3, and the inductance components LCi (i=1, 2, and 3) of the capacitors C1, C2, C3 are equal to each other. Therefore, in order to uniformize the inductance components Li of the high-frequency impedances Zi, inductance LPNi (LPNi=LPi+LNi) corresponding to the sum of the inductance components LPi of the positive electrical paths and the inductance components LNi of the negative electrical paths in the capacitors C1, C2, C3 may be uniformized. Hereafter, the configuration of the smoothing circuit 7 for uniformizing the inductances LPNi of the positive and negative electrical paths in the respective capacitors will be described.
The circuit body 10 illustrated in
The metal plate 12 provided as a layer on the front surface of the insulating sheet 11 includes a positive-side output terminal P and three strip-shaped conductors P-P1, P-P2, P-P3 extending in a branched manner from the positive-side output terminal P. The three conductors P-P1, P-P2, P-P3 have terminals P1, P2, P3 provided at respective ends thereof (ends at the opposite side of the positive-side output terminal P) and connected to the positive terminals PC1, PC2, PC3 of the capacitors C1, C2, C3, respectively. The conductors P-P1, P-P2, P-P3 form the positive electrical paths for the capacitors C1, C2, C3.
The metal plate 13 provided as a layer on the back surface of the insulating sheet 11 includes a negative-side output terminal N and three strip-shaped conductors N-N1, N-N2, N-N3 extending in a branched manner from the negative-side output terminal N. The three conductors N-N1, N-N2, N-N3 have terminals N1, N2, N3 provided at respective ends thereof (ends at the opposite side of the negative-side output terminal N) and connected to the negative terminals NC1 to NC3 of the capacitors C1, C2, C3, respectively. The conductors N-N1, N-N2, N-N3 form the negative electrical paths for the capacitors C1, C2, C3.
The strip-shaped conductors P-P1, P-P2, P-P3, N-N1, N-N2, N-N3 have substantially the same width.
In the example of
The length lnP1 of the strip-shaped conductor P-P1 is the length of the positive electrical path for the capacitor C1, the length lnN1 of the strip-shaped conductor N-N1 is the length of the negative electrical path for the capacitor C1, and the sum of the lengths lnP1, and lnN1 is defined as a positive-negative electrical path length lnPN1 for the capacitor C1 (lnPN1=lnPi+lnNi). Similarly, the length lnP2 of the strip-shaped conductor P-P2 is the length of the positive electrical path for the capacitor C2, the length lnN2 of the strip-shaped conductor N-N2 is the length of the negative electrical path for the capacitor C2, and the sum of the lengths lnP2 and lnN2 is defined as a positive-negative electrical path length lnPN2 for the capacitor C2 (lnPN2=lnP3+lnN2). The length lnP3 of the strip-shaped conductor P-P3 is the length of the positive electrical path for the capacitor C3, the length lnN3 of the strip-shaped conductor N-N3 is the length of the negative electrical path for the capacitor C3, and the sum of the lengths lnP3 and lnN3 is defined as a positive-negative electrical path length lnPN3 for the capacitor C3 (lnPN3=lnP3+lnN3).
Since the strip-shaped conductors P-P1, P-P2, P-P3, N-N1, N-N2, N-N3 have substantially the same width, the positive-negative electrical path lengths lnPN1, lnPN2, lnPN3 for the respective capacitors C1, C2, C3 correspond to the inductances LPN1 to LPN3 of the positive-negative electrical paths for the capacitors C1, C2, C3. Therefore, when the positive-negative electrical path lengths lnPN1, lnPN2, lnPN3 are uniformized, the inductances LPN1 to LPN3 of the positive-negative electrical paths for the capacitors C1, C2, C3 are uniformized. Moreover, when the inductances LPN1 to LPN3 of the positive-negative electrical paths for the capacitors C1, C2, C3 are uniformized, a variation in currents flowing through the capacitors C1, C2, C3 is prevented. As a result, a surge voltage is prevented since the inductances from the capacitors C1, C2, C3 to the power semiconductor devices Q1 to Q4 are extremely low.
In order to suppress a variation in the currents flowing through the capacitors C1, C2, C3, the difference Δln may be reduced, where Δln is the difference between the maximum positive-negative electrical path length lnmax and the minimum positive-negative electrical path length lnmin (Δln=lnmax−lnmin) among the positive-negative electrical path lengths lnPN1, lnPN2, lnPN3 for the capacitors C1, C2, C3. It is preferable that the difference Δln be as small as possible. Considering that the difference Δln is equal to or greater than 50% of lnmin in related art smoothing circuits including a plurality of capacitors, the difference Δln may be designed to be, for example, equal to or smaller than 30% of lnmin (Δln≤0.3×lnmin).
In the example illustrated in
The metal plate layer on the front surface of the insulating sheet includes a positive-side output terminal P and terminals P1, P2, P3 to which the positive terminals PC1, PC2, PC3 of the capacitors C1, C2, C3 are connected. The positive-side output terminal P is provided approximately at the center of the circuit body 20, and the terminals P1, P2, P3 are arranged around the positive-side output terminal P. Since current flows along the shortest path of a homogeneous conductor, a straight line P-P1 connecting the positive-side output terminal P and the terminal P1 becomes the positive electrical path for the capacitor C1. Similarly, a straight line P-P2 connecting the positive-side output terminal P and the terminal P2 becomes the positive electrical path for the capacitor C2, and a straight line P-P3 connecting the positive-side output terminal P and the terminal P3 becomes the positive electrical path for the capacitor C3.
The metal plate layer on the back surface of the insulating sheet includes a negative-side output terminal N and terminals N1, N2, N3 to which the negative terminals NC1 to NC3 of the capacitors C1, C2, C3 are connected. The negative-side output terminal N is provided approximately at the center of the circuit body 20 and provided adjacent to the positive-side output terminal. The terminals N1. N2, N3 are arranged around the negative-side output terminal N. The terminal N1 is provided adjacent to the terminal P1, the terminal N2 is provided adjacent to the terminal P2, and the terminal N3 is provided adjacent to the terminal P3. Like the positive electrical path, a straight line N-N1 connecting the negative-side output terminal N and the terminal N1 becomes the negative electrical path for the capacitor C1, a straight line N-N2 connecting the negative-side output terminal N and the terminal N2 becomes the negative electrical path for the capacitor C2, and a straight line N-N3 connecting the negative-side output terminal N and the terminal N3 becomes the negative electrical path for the capacitor C3.
The length lnP1 of the straight line P-P1 is the length of the positive electrical path for the capacitor C1, the length lnN1 of the straight line N-N1 is the length of the negative electrical path for the capacitor C1, and the sum of the lengths lnP1 and lnN1 is defined as a positive-negative electrical path length lnPN1 for the capacitor C1 (lnPN1=lnP1+lnN1). Similarly, the length lnP2 of the straight line P-P2 is the length of the positive electrical path for the capacitor C2, the length lnN2 of the straight line N-N2 is the length of the negative electrical path for the capacitor C2, and the sum of the lengths lnP2 and lnN2 is defined as a positive-negative electrical path length lnPN2 for the capacitor C2 (lnPN2=lnP2+lnN2). The length lnP3 of the straight line P-P3 is the length of the positive electrical path for the capacitor C3, the length lnN3 of the straight line N-N3 is the length of the negative electrical path length for the capacitor C3, and the sum of the lengths lnP3 and lnN3 is defined as a positive-negative electrical path length lnPN3 for the capacitor C3 (lnPN3=lnP3+lnN3).
The positive-negative electrical path lengths lnPN1, lnPN2, lnPN3 for the respective capacitors C1, C2, C3 correspond to the inductances LPN1 to LPN3 of the positive-negative electrical paths for the capacitors C1, C2, C3, as in the above-described circuit body 10. Therefore, it is possible to suppress a variation in currents flowing through the capacitors C1, C2, C3 by designing the difference Δln to be equal to or smaller than 30% of lnmin, where Δln is the difference between the maximum positive-negative electrical path length lnmax and the minimum positive-negative electrical path length lnmin (Δln=lnmax−lnmin) among the positive-negative electrical path lengths lnPN1, lnPN2, lnPN3 for the respective capacitors C1, C2, C3.
The positive-negative electrical path lengths lnPN1, lnPN2, lnPN3 for the capacitors C1, C2, C3 can be replaced with distances from the positive-side output terminal P and the negative-side output terminal N to the capacitors C1, C2, C3.
Here, the middle point MP1-N1 between the terminal P1 (the positive terminal PC1) and the terminal N1 (the negative terminal NC1) is defined as the position of the capacitor C1. Similarly, the middle point MP2-N2 between the terminal P2 (the positive terminal PC2) and the terminal N2 (the negative terminal NC2) is defined as the position of the capacitor C2, and the middle point MP3-N3 between the terminal P3 (the positive terminal PC3) and the terminal N3 (the negative terminal NC3) is defined as the position of the capacitor C3. With the middle point MP-N between the positive-side output terminal P and the negative-side output terminal N being the base point, a distance to the middle point MP1-N1 is defined as a distance d1 to the capacitor C1, a distance to the middle point MP2-N2 is defined as a distance d2 of the capacitor C2, and a distance to the middle point MP3-N3 is defined as a distance d3 of the capacitor C3. It is possible to suppress a variation in the currents flowing through the capacitors C1, C2, C3 by designing the difference Δd to be equal to or smaller than 30% of dmin, where Δd is the difference between the maximum distance dmax and the minimum distance dmin (Δd=dmax−dmin) among the distances d1 to d3 to the capacitors C1, C2, C3.
In order to suppress a variation in the currents flowing through the capacitors C1, C2, C3, it is preferable that the difference Δd be as small as possible. Thus, in the example of
(LP1≈LP2≈LP3≈LN1≈LN2≈LN3),
and the inductances LPN1 to LPN3 corresponding to the sums of the inductance components of the positive electrical paths and the inductance components of the negative electrical paths also become nearly equal to each other
(LPN1≈LPN2≈LPN3).
In the example of
(LP1≈LP2≈LP3),
the inductance components LN1, LN2, LN3 of the negative electrical paths in the capacitors C1, C2, C3 are nearly equal to each other
(LN1≈LN2≈LN3),
and the inductances LPN1 to LPN3 corresponding to the sums of the inductance components of the positive electrical paths and the inductance components of the negative electrical paths also become nearly zero
(LPN1≈LPN2≈LPN3).
So far, it is been described that three capacitors C1, C2, C3 are mounted on the circuit body of the smoothing circuit 7. However, the number of capacitors is not limited thereto, as long as a plurality of capacitors are provided. For example, the number of capacitors may be two, four or more.
As described above, according to an illustrative aspect of the present invention, a smoothing circuit includes a plate-shaped circuit body having a positive-side output terminal and a negative-side output terminal, and a plurality of capacitors mounted on the circuit body and connected to each other in parallel between the positive-side output terminal and the negative-side output terminal, each capacitor having a positive terminal and a negative terminal. The circuit body includes, for each capacitor, a positive electrical path connecting the positive terminal of the capacitor and the positive-side output terminal to each other and a negative electrical path connecting the negative terminal of the capacitor and the negative-side output terminal to each other. With the sum of the length of the positive electrical path and the length of the negative electrical path being defined as the positive-negative electrical path length for each capacitor, the difference between the maximum positive-negative electrical path length and the minimum positive-negative electrical path length among the positive-negative electrical path lengths is equal to or smaller than 30% of the minimum positive-negative electrical path length.
According to another illustrative aspect of the present invention, the circuit body may include a positive solid pattern providing the positive electrical paths for the respective capacitors, a negative solid pattern providing the negative electrical paths for the respective capacitors, and
an insulating layer interposed between the positive solid pattern and the negative solid pattern, and with the middle point between the positive-side output terminal and the negative-side output terminal being defined as a base point and the distance from the base point to the middle point between the positive terminal and the negative terminal being defined as a distance to the capacitor for each capacitor, the difference between the maximum distance and the minimum distance among the distances to the respective capacitors is equal to or smaller than 30% of the minimum distance.
The middle point between the positive terminal and the negative terminal of each capacitor may be arranged on a circle centered on the base point.
The positive terminal and the negative terminal of each capacitor may be arranged on another circle centered on the base point.
The positive terminals of the plurality of capacitors may be arranged on a first circle centered on the base point, and the negative terminals of the plurality of capacitors may be arranged on a second circle centered on the base point, the second circle being different from the first circle.
An inverter may include the smoothing circuit and an inverter circuit connected to the positive-side output terminal and the negative-side output terminal of the smoothing circuit. The inverter is configured to convert DC power supplied from the smoothing circuit to AC power.
A power supply apparatus may include the inverter and a converter configured to convert DC power supplied from the AC power supply into DC power and to supply the converted DC power to the smoothing circuit of the inverter.
This application claims priority to Japanese Patent Application No. 2017-212184 filed on Nov. 1, 2017, the entire content of which is incorporated herein by reference.
Number | Date | Country | Kind |
---|---|---|---|
2017-212184 | Nov 2017 | JP | national |
Filing Document | Filing Date | Country | Kind |
---|---|---|---|
PCT/JP2018/036912 | 10/2/2018 | WO | 00 |