The present invention relates to forward power conversions from AC power or DC power to DC power and reverse power conversions from DC power to AC power, and relates to a soft switching power converter that is capable of performing reverse conversions with the use of a power supply of a DC link that is a high-frequency boost pulse voltage generated by a function of a magnetic energy recovering switch to recover the magnetic energy without loss in both current directions.
Various methods for converting DC to AC have been put into practical use. There has been a demand for smaller devices and higher efficiency. There is also a demand for a smaller number of components and simpler control operations. To reduce the sizes of components such as an insulating transformer, the switching frequency is made higher. As a result, the loss due to switching becomes larger. In a high-speed switching operation at a switching frequency higher than 10 kHz, the loss in voltage and current is much larger than the conduction loss of the semiconductor elements used for switching where the semiconductor elements are in a transient state between the on state and the off state.
While there is a demand for semiconductor elements appropriate for high-speed switching, a soft switching technique for making voltage or current, or both voltage and current to almost zero during an on/off operation of the semiconductor elements used for switching is an essential solution as a circuit technique.
Meanwhile, the inventor has suggested a circuit technique called a magnetic energy recovering switch that has already been granted (Japanese Patent No. 3,634,982, hereinafter referred to as “Patent Document 1”). The magnetic energy recovering switch includes a bridge circuit that is including four semiconductor elements that do not have a reverse blocking capability or are of a reverse-conduction type (hereinafter referred to as reverse-conduction semiconductor switches), and a capacitor that is connected between the DC terminals of the bridge circuit. The currents in both forward and backward directions can be turned on and off only by controlling the gates of the reverse-conduction semiconductor switches. Each two reverse-conduction semiconductor switches diagonally located in the bridge circuit is regarded as a pair. When at least one pair of reverse-conduction semiconductor switches are turned on or off at the same time, the capacitor absorbs the magnetic energy of the current, and the energy is released through the reverse-conduction semiconductor switches that are in the on state. In this manner, the current is recovered in the switch circuit.
An object of the present invention is to provide a power converter that turns switching operations of semiconductor elements used for all switching into soft switching operations, and is capable of boosting and lowering an output voltage. Another object of the present invention is to provide a reversible power converter that can be formed with a relatively small number of components and a simple control unit.
The present invention is a soft switching power converter that performs a conversion from AC power to DC power or a conversion from DC power to AC power through soft switching, and the object is achieved by the soft switching power converter including a boost pulse voltage generating unit 3 that uses an AC power supply or a DC power supply as an input power supply 1, and has the input power supply 1 input to AC input terminals a and b thereof via an AC inductor 2, the DC power supply reversing current polarity, a smoothing inductor 6 that is inserted in series between a DC output terminal c or d of the boost pulse voltage generating unit 3 and a DC power supply or a load 7, and smoothens and supplies a boost pulse voltage generated by the boost pulse voltage generating unit 3 to the DC power supply or the load 7, and a control unit 4 that controls the boost pulse voltage generating unit 3, the boost pulse voltage generating unit 3 including a bridge circuit formed with four reverse-conduction semiconductor switches S1, S2, S3, and S4, and a capacitor 31 that is connected between DC output terminals c and d of the bridge circuit, and recovers and stores magnetic energy of current at the time of current cutoff, the control unit 4 applying a control signal to gates so that at least one pair of the reverse-conduction semiconductor switches located on a diagonal of the bridge circuit are turned on and off at the same time, the control unit 4 setting an on/off period of the reverse-conduction semiconductor switches longer than a resonance period determined by a capacitance of the capacitor 31 and an inductance (Lac) of the AC inductor 2, a voltage of the capacitor 31 becoming zero through discharge in each cycle, a zero voltage being observed when the reverse-conduction semiconductor switches are turned off, a zero current being observed when the reverse-conduction semiconductor switches are turned on, the control unit 4 thereby realizing soft switching.
The object of the present invention is effectively achieved by the soft switching power converter further including a switching control unit 5 that is connected in parallel to the DC output terminals c and d of the boost pulse voltage generating unit 3, and performs on/off control alternately on voltages above and below a busbar based on a pulse width modulation (PWM) carrier signal synchronized with a generation period of the boost pulse voltage, the switching control unit 5 including one or a plurality of arms each connecting two semiconductor switches in series, the switching control unit 5 being controlled by the control unit 4.
Further, the object of the present invention is achieved by the soft switching power converter, wherein, when power to be supplied to the load 7 is DC, the number of the arms is one, and the boost pulse voltage is lowered and supplied to the load by turning on and off the semiconductor switches, when the power to be supplied to the load 7 is single-phase AC, the number of the arms is two, and control is performed by turning on and off the semiconductor switches, to generate a low-frequency single-phase AC voltage, when the power to be supplied to the load 7 is three-phase AC, the number of the arms is three, and control is performed by turning on and off the semiconductor switches, to generate a three-phase AC voltage, and when the power to be supplied to the load 7 is N-phase AC, the number of the arms is N, and control is performed by turning on and off the semiconductor switches, to generate an N-phase AC voltage.
Further, the object of the present invention is effectively achieved by the soft switching power converter, wherein, when the input power supply 1 is DC, the control unit 4 turns on and off only one pair of the reverse-conduction semiconductor switches (a pair of S1 and S3, or a pair of S2 and s4) located on a diagonal of the bridge circuit, while maintaining the other pair of the reverse-conduction semiconductor switches in an off state, to thereby control the reverse-conduction semiconductor switches to operate as diodes.
Further, the object of the present invention is effectively achieved by the soft switching power converter, wherein, the boost pulse voltage generating unit 3 includes: a half-bridge circuit that is formed with two series-connected reverse-conduction semiconductor switches S2 and S3 of the reverse-conduction semiconductor switches and two series-connected diodes, and two of the capacitors 31 that are respectively connected in parallel to the two series-connected diodes.
Further, the object of the present invention is effectively achieved by the soft switching power converter, wherein, when the input power supply 1 is a three-phase AC power supply, the boost pulse voltage generating unit 3 includes a three-phase full-wave bridge circuit that is formed with six of the reverse-conduction semiconductor switches in the form of three legs, each leg being formed with two series-connected reverse-conduction semiconductor switches of the reverse-conduction semiconductor switches, and a circuit that is connected between DC terminals of the three-phase full-wave bridge circuit, and has a first capacitor and a first diode that are connected in parallel, the parallel-connected first capacitor and the first diode being connected in series to a second capacitor and a second diode that are connected in parallel so that the first diode and the second diode are orientated in a forward direction, a midpoint of the series connection being connected to a neutral point of the three-phase AC power supply, and the reverse-conduction semiconductor switches of a direction of a three-phase AC current are selected from the legs each connecting two of the reverse-conduction semiconductor switches, and all the selected reverse-conduction semiconductor switches are turned on or off at the same time, to generate the boost pulse voltage between the DC terminals of the three-phase full-wave bridge circuit, a three-phase AC power conversion being thereby performed.
Further, the object of the present invention is effectively achieved by the soft switching power converter, wherein thyristors are used as the semiconductor switches of the switching control unit 51.
Further, the object of the present invention is effectively achieved by the soft switching power converter, wherein, instead of the smoothing inductor 6, a diode is used as a unit for smoothing the boost pulse voltage.
Further, the object of the present invention is effectively achieved by the soft switching power converter, wherein, when power MOSFETs each having a parasitic diode built therein are used as the four reverse-conduction semiconductor switches S1, S2, S3, and S4, a synchronization signal is transmitted at the time of reverse conduction of the reverse-conduction semiconductor switches, to reduce conduction loss.
Further, the object of the present invention is effectively achieved by the soft switching power converter, wherein, based on an input voltage or an input current of the boost pulse voltage generating unit 3, a voltage and a current of a DC output or an AC output switched through the pulse width modulation, and a voltage of the capacitor 31, the control unit 4 determines an on/off time ratio of the gate signal and a switching period, and performs on/off control on the reverse-conduction semiconductor switches.
Further, the object of the present invention is achieved by the soft switching power converter, wherein the arms of the switching control unit 5 are replaced with four series-connected semiconductor switches.
Further, the object of the present invention is effectively achieved by the soft switching power converter, wherein, when the input power supply 1 is three-phase AC, and the power to be supplied to the load 7 is three-phase AC, the reverse-conduction semiconductor switches are used as the semiconductor switches of the switching control unit 5.
In a soft switching power converter according to the present invention, a near-zero voltage is observed when the semiconductor elements used for all the switching are turned off, and a near-zero current is observed when the semiconductor elements are turned on. Accordingly, there is no switching loss, and high-speed operations can be properly performed. Thus, high-frequency operations can be realized, and the power converter can be made smaller in size. Also, this power converter has the excellent advantage that it is capable of performing reverse power conversions from DC power to AC power, unlike a conventional power converter that performs forward power conversions from AC power to DC power through diode bridge inputs.
Preferred embodiments of the present invention will be described with reference to the accompanying drawings. In the drawings, like components, members, and processes are denoted by like reference numerals, and the same description will not be repeated. The embodiments do not restrict the present invention but are merely examples, and all the features and the combinations of the features described in the following embodiments are not necessarily essential in the present invention.
The present invention has a principal component that is the magnetic energy regeneration switch (hereinafter referred to as “MERS”) disclosed in Patent Document 1.
The MERS includes a bridge circuit formed with four reverse-conduction semiconductor switches and a capacitor connected between the DC terminals of the bridge circuit.
Forward and backward currents can be switched on or off only by performing gate control on the reverse-conduction semiconductor switches. With each two reverse-conduction semiconductor switches diagonally located in the bridge circuit being a pair, at least one of the two pairs of reverse-conduction semiconductor switches are turned on or off at the same time. As a result, the capacitor absorbs the magnetic energy from the current when the reverse-conduction semiconductor switches are turned off, and discharges the magnetic energy through the reverse-conduction semiconductor switches that are in the on state. In this manner, the single-phase full-bridge MERS as a switch circuit recovers the magnetic energy.
When two reverse-conduction semiconductor switches diagonally located in the bridge circuit in the MERS are turned on or off at the same time, a DC pulse voltage is generated at the capacitor, and the magnetic energy is accumulated as charge energy. The capacitor discharges charges in series with the power source. Further, more energy is generated from the power source. Accordingly, the voltage of the capacitor and the power supply current grow at each pulse. If there is no loss due to electric resistance, the capacitor voltage and the power supply current grow unlimitedly. In the switching operations of the reverse-conduction semiconductor switches at this point, a near-zero voltage is observed when the reverse-conduction semiconductor switches are turned off, and a near-zero current is observed when the reverse-conduction semiconductor switches are turned on. In this manner, so-called zero-voltage zero-current switching (soft switching) is performed.
Since a DC pulse voltage appears between both ends of the capacitor, the voltage is smoothened by a smoothing inductor to obtain a DC output. In this manner, DC or AC power can be converted to DC power. Further, it is possible to convert DC or AC power to a single-phase AC voltage or three-phase AC voltage with low-speed switches that switch in synchronization with the near-zero state of the voltage of the DC pulse voltage. Moreover, switches that are PWM-controlled may be used for switching, to obtain waveforms similar to fundamental waves (sine waves).
The operation to be performed by the single-phase full-bridge MERS to generate a boost pulse voltage is now described, with reference to the accompanying drawings.
In the following description with reference to the drawings, the paths through which the DC pulse voltage and the current flow between the DC terminals c and d when the reverse-conduction semiconductor switches S1 and S3 are turned on or off at the same time will be mainly described.
1) When the reverse-conduction semiconductor switches S1 and S3 are turned on where the capacitor C does not have a voltage, the current from the DC power supply flows through the following paths, and a parallel conduction state is formed: b—the parasitic diode of the reverse-conduction semiconductor switch S2-c—the reverse-conduction semiconductor switch S1-a; and b—the reverse-conduction semiconductor switch S3-d—the parasitic diode of the reverse-conduction semiconductor switch S4-a, as indicated by the arrows in
2) When the reverse-conduction semiconductor switches S1 and S3 are turned off at the same time while a current is flowing from the power supply to an AC inductor Lac, the current from the DC power supply flows through the following path: b—the parasitic diode of the reverse-conduction semiconductor switch S2-c—the capacitor C-d—the parasitic diode of the reverse-conduction semiconductor switch S4-a, as shown in
3) When the voltage of the capacitor C is made higher by the charging from the power supply, the capacitor C and the AC inductor Lac resonate, and the magnetic energy of the AC inductor Lac is transferred to the capacitor C. At this point, the current stops flowing.
Accordingly, even when the flowing current is cut off by turning off the reverse-conduction semiconductor switches S1 and S3 at the same time, a voltage is not immediately generated at the capacitor C, and the voltage becomes gradually higher while the capacitor C is charged. The increase rate of the voltage of the capacitor C is determined by a resonance period calculated from the capacitance of the capacitor C and the inductance of the AC inductor Lac. As long as the increase rate of the capacitor voltage is sufficiently lower than the switching on-and-off rate of the reverse-conduction semiconductor switches, it is safe to say that a near-zero voltage is realized when the reverse-conduction semiconductor switches S1 and S3 are turned off.
The voltage between both ends of the capacitor C appears between the DC terminals c and d, and a DC pulse voltage is generated in synchronization with the switching on and off of the gates of the reverse-conduction semiconductor switches. In a case where there is no load resistance as in
4) When the reverse-conduction semiconductor switches S1 and S3 are again turned on, a current does not flow in the path extending through the parasitic diodes of the reverse-conduction semiconductor switches S2 and S4, as shown in
5) After the capacitor C completely discharged, and the voltage between both ends of the capacitor C becomes almost zero, the current from the DC power supply again flows through the following paths, and a parallel conduction state is formed: b—the parasitic diode of the reverse-conduction semiconductor switch S2-c—the reverse-conduction semiconductor switch S1-a; and b—the reverse-conduction semiconductor switch S3-d—the parasitic diode of the reverse-conduction semiconductor switch S4-a, as shown in
Next, the operation to be performed by the MERS to generate a boost pulse voltage is described through a computer simulation.
More specifically,
1. Vdcin: the voltage of the DC power supply 10 V
2. L: the inductance of the AC inductor Lac 1 mH
3. C: the capacitance of the capacitor 10 micro-F
4. f: the on/off frequency of the gates of the reverse-conduction semiconductor switches S1 and S3, 1 kHz (T: period—1 millisecond)
5. R: the DC resistance of the AC inductor Lac 0.5 Ω.
As described in the description of the above computer simulation, the MERS can generate a current pulse at an AC terminal and a voltage pulse at a DC terminal. Here, the reverse-conduction semiconductor switches realize zero-voltage zero-current switching, regardless of the size of current. In a switching operation without loss, the capacitor voltage and the flowing power supply current grow until the input from the power supply become balanced with the loss at the electric resistance.
Further, the capacitor voltage Vc is now described in greater detail with the use of formulas.
Where L indicates the inductance of the AC inductor Lac, I indicates the current, C indicates the capacitance of the capacitor C, and Vc indicates the voltage of the capacitor C, the magnetic energy of the AC inductor Lac and the electrostatic energy of the capacitor are transduced mutually without loss. Therefore, the following formula (1) is satisfied:
C·Vc
2/2=L·I2/2 (1)
Accordingly, the relationship between the capacitor voltage Vc and the current I is satisfied by the following equation (2):
Vc={√(L/C)}I (2)
Since the final value of the steady current Is is determined by the DC resistance R of the AC inductor Lac, the following equation (3) is satisfied:
Is=V/R (3)
Accordingly, the following equation (4) is also satisfied:
Vc=(Z/R)V, provided Z=√(L/C) (4)
As is apparent from the above equation (4), the capacitor voltage Vc is multiplied by the value equivalent to the ratio between the surge impedance Z of the power supply voltage and the DC resistance R of the AC inductor Lac.
With Ts indicating the time required before the capacitor voltage Vc settles in a steady state, Ts is calculated by adding up the pulse-off times of the time constants of L and R. Accordingly, Ts approximates the value obtained by dividing the time constant (L/R) by the on/off ratio (Duty), which is expressed by the following equation (5):
Is≈(L/R)/Duty (5)
The circuit constants of
The boost pulse voltage generating unit 3 includes a bridge circuit formed with four reverse-conduction semiconductor switches S1, S2, S3, and S4, and a capacitor 31 that is connected between the DC output terminals c and d of the bridge circuit, and recovers and stores the magnetic energy of current.
The control unit 4 applies control signals to the gates, so that at least one pair of reverse-conduction semiconductor switches located on a diagonal of the bridge circuit are turned on and off at the same time. The control unit 4 also makes the on/off periods of the reverse-conduction semiconductor switches longer than the resonance period determined by the capacitance C of the capacitor 31 and the inductance Lac of the AC inductor 2. With this arrangement, the voltage of the capacitor 31 becomes almost zero, releasing in each half cycle. As a result, a near-zero voltage is observed when the reverse-conduction semiconductor switches are turned off, and a near-zero current is observed when the reverse-conduction semiconductor switches are turned on. In this manner, soft switching is realized.
The capacitor 31 of the power converter according to the present invention simply stores the magnetic energy of the AC inductor 2. How to use the capacitor 31 is completely different from how to use the capacitor of a conventional voltage-type inverter. In a conventional voltage-inverter, the capacitor is used as a voltage source, and therefore, constantly holds voltage. After a current is cut off, voltage is simultaneously generated at the semiconductor elements to be used for switching. As a result, hard switching is performed.
The capacitor 31 of the power converter according to the present invention sets the pulse periods of the gates of the reverse-conduction semiconductor switches, so that the voltage of the capacitor 31 is reduced to a near-zero voltage in each half cycle. The capacitor 31 characteristically resonates with the AC inductor 2.
The capacitance C of the capacitor 31 is a capacitance that is determined by the resonant frequency with respect to the inductance Lac of the AC inductor 2. As a result, the capacitance C of the capacitor 31 can be made much smaller than the capacitance of the voltage-source capacitor of a conventional voltage-type inverter.
The voltage of the capacitor 31 oscillates in synchronization with the pulse period of the gate signals of the reverse-conduction semiconductor switches, to recover the magnetic energy. The voltage of the capacitor 31 is boosted from the power supply, and a DC boost pulse voltage having a near-zero voltage period appears between the DC output terminals c and d.
The switching control unit 5 has one or more arms each connecting two semiconductor switches in series. In synchronization with the generation period of the boost pulse voltage, the switching control unit 5 alternately turns on and off the voltages above and below the busbar, based on a pulse-width-modulation (PWM) carrier signal.
In a case where the power to be supplied to the load 7 is DC power, only one arm is used, and a DC voltage is lowered and supplied to the load 7 by turning on and off the semiconductor switches.
In a case where the power to be supplied to the load 7 is single-phase AC power, two arms are used, and a low-frequency single-phase AC voltage is generated by controlling the switching on and off of the semiconductor switches.
In a case where the power to be supplied to the load 7 is three-phase AC power voltage, three arms are used, and a three-phase AC voltage is generated by controlling the switching on and off of the semiconductor switches.
In a case where the power to be supplied to the load 7 is N-phase AC power, N arms are used, and a N-phase AC voltage can be generated by controlling the switching on and off of the semiconductor switches.
In the following Embodiments, the N-phase AC is indicated by three-phase AC. The L filter and the C filter that are provided on the side of the AC input terminal and on the side of the DC output terminal, respectively, are designed to eliminate signals of unnecessary frequencies, and obtain power of desired frequencies.
A soft switching power converter according to Embodiment 1 of the present invention is now described.
More specifically, in
In
In a case where power MOSFETs containing parasitic diodes are used as the reverse-conduction semiconductor switches of
More specifically,
More specifically,
1. Reverse-conduction semiconductor switches S1, S2, S3, and S4 (the semiconductor elements used being IGBTs and diodes connected in inverse-parallel to the IGBTs, with the conduction loss of each element being not considered)
2. Lac: AC inductor 0.6 mH
3. Ldc: smoothing inductor 5 mH
4. Load: DC load 144 S2.
5. Cdc: smoothing capacitor 2000 micro-F
6. AC power supply: 50 Hz, 200 Vrms
7. Capacitor: 0.1 micro-F
Other than the above, filter circuits (C filter of 2 micro-F, L filter of 100 micro-H) are added to the AC side. An output DC voltage of 350 V is obtained from the input AC voltage of 200 Vrms.
In the soft switching power converter according to Embodiment 1 of the present invention, on the other hand, AC is not rectified by a diode bridge. Instead, AC can be input directly to the soft switching power converter, and an AC-to-DC conversion can be performed. A high-frequency pulse link generated by utilizing the function of the MERS to generate a boost pulse voltage is used to perform an AC-to-boost DC conversion with a PFC function. The generation of a boost pulse voltage by the MERS causes no loss. A zero voltage is observed when the semiconductor elements used for the switching are turned off, and a zero current is observed when the semiconductor elements are turned on. Accordingly, soft switching is performed. Thus, it is possible to obtain a smaller-size device that has no switching loss, is appropriate for high-speed switching operations, and can cope with higher frequencies. Further, it is possible to perform a reverse conversion from DC to AC, which cannot be performed with a conventional diode bridge input.
A soft switching power converter according to Embodiment 2 of the present invention is now described.
More specifically, the Embodiment illustrated in
A soft switching power converter according to Embodiment 3 of the present invention is now described.
More specifically,
A soft switching power converter according to Embodiment 4 of the present invention is now described.
More specifically,
A soft switching power converter according to Embodiment 5 of the present invention is now described.
More specifically,
The switching frequency of the reverse-conduction semiconductor switches of
A soft switching power converter according to Embodiment 6 of the present invention is now described.
More specifically,
In
As can be seen from
A soft switching power converter according to Embodiment 7 of the present invention is now described.
More specifically,
A soft switching power converter according to Embodiment 8 of the present invention is now described.
More specifically, in the Embodiment illustrated in
As shown in
A soft switching power converter according to Embodiment 9 of the present invention is now described.
More specifically,
As a conventional art, there is an AC-to-AC direct conversion circuit that is called a matrix converter (hereinafter referred to as MC). This circuit does not include a voltage source capacitor, but requires an AC switch that has a blocking capability in both forward and backward directions. In a case where an input and an output are three-phase AC, the number of semiconductor elements to be used is nine, but the structures of the semiconductor elements to be used are complicated, resulting in a cost increase.
On the other hand, the conversion circuit of
Number | Date | Country | Kind |
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2007-320000 | Dec 2007 | JP | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/JP2008/072716 | 12/8/2008 | WO | 00 | 6/10/2010 |