MULTI-PHASE ELECTRICAL TRANSFORMER AND POWER CONTROL APPARATUS
20230308034 · 2023-09-28
Assignee
Inventors
Cpc classification
H02M1/12
ELECTRICITY
International classification
H02M1/12
ELECTRICITY
Abstract
An electrical power control apparatus, including: a magnetic core having a plurality of phase limbs for respective phases of electric power, each of the phase limbs being interconnected to the other phase limbs at respective ends of the limb; primary windings around the respective phase limbs to receive input electrical energy in the form of input signals for the respective electrical phases and generate corresponding magnetic fluxes in the phase limbs; secondary windings around the respective phase limbs to generate output electrical energy in the form of output signals for respective electrical phases from magnetic fluxes in the phase limbs; and control windings around respective portions of the magnetic core to receive control signals for respective electrical phases to modify the magnetic fluxes in the respective phase limbs in order to modify the output signals generated from the secondary windings so that the output signals have one or more electrical attributes that satisfy respective predetermined criteria.
Claims
1. An electrical power control apparatus, including: a magnetic core having a plurality of phase limbs for respective phases of electric power, each of the phase limbs being interconnected to the other phase limbs at respective ends of the limb; primary windings around the respective phase limbs to receive input electrical energy in the form of input signals for the respective electrical phases and generate corresponding magnetic fluxes in the phase limbs; secondary windings around the respective phase limbs to generate output electrical energy in the form of output signals for respective electrical phases from magnetic fluxes in the phase limbs; and control windings around respective portions of the magnetic core to receive control signals for respective electrical phases to modify the magnetic fluxes in the respective phase limbs in order to modify the output signals generated from the secondary windings so that the output signals have one or more electrical attributes that satisfy respective predetermined criteria.
2. The electrical power control apparatus of claim 1, wherein each of the phase limbs is interconnected to the other phase limbs only at respective ends of the phase limb.
3. The electrical power control apparatus of claim 1, wherein the magnetic core further includes coupling limbs that interconnect the phase limbs, wherein each phase limb is connected to adjacent ones of the other phase limbs at a location of the phase limb between the ends of the phase limb.
4. The electrical power control apparatus of claim 1, wherein the limbs of the magnetic core have a square or rectangular cross-section.
5. The electrical power control apparatus of claim 1, wherein the limbs of the magnetic core have a circular cross-section.
6. The electrical power control apparatus of claim 1, wherein each of the control windings constitutes a portion of the corresponding secondary winding.
7. The electrical power control apparatus of claim 1, including one or more rectifier windings around respective portions of the magnetic core to generate electric power for the control windings.
8. The electrical power control apparatus of claim 3, wherein each of the rectifier windings constitutes a portion of the corresponding primary winding.
9. The electrical power control apparatus of claim 7, including one or more rectifier components coupled to the rectifier windings, wherein each rectifier component receives an AC input from the corresponding rectifier winding, rectifies the received signal and charges at least one corresponding capacitor, wherein the at least one corresponding capacitor provides the electric power for at least one of the control windings.
10. The electrical power control apparatus of claim 9, wherein each rectifier component is configured to correct the power factor of the corresponding electrical phase.
11. The electrical power control apparatus of claim 9, including one or more inverter components, each inverter component being coupled to the at least one corresponding capacitor and at least one of the corresponding control windings, and configured to generate the control signal for at least one of the control windings.
12. The electrical power control apparatus of claim 11, including a control component to control operation of the one or more inverter components.
13. The electrical power control apparatus of claim 1, including control components to generate, for each of the phases of electric power, the corresponding control signal that is applied to the corresponding control winding to dynamically control the magnetic flux through the corresponding phase limb and consequently the corresponding output signal at the corresponding secondary winding.
14. The electrical power control apparatus of claim 1, wherein the one or more electrical attributes are selected from AC voltage and harmonic content or harmonic distortion.
15. A multiphase electric power transformer, including: a magnetic core having a plurality of phase limbs for respective phases of electric power, each of the phase limbs being interconnected to the other phase limbs at respective ends of the limb; primary windings around the respective phase limbs to receive input electrical energy in the form of input signals for respective electrical phases and generate corresponding magnetic fluxes in the magnetic core; secondary windings around the respective phase limbs to generate output electrical energy in the form of output signals for respective electrical phases from magnetic fluxes in the magnetic core.
16. The multiphase electric power transformer of claim 15, wherein the limbs of the magnetic core have a square or rectangular cross-section.
17. The multiphase electric power transformer of claim 15, wherein the limbs of the magnetic core have a circular cross-section.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0044] Some embodiments of the present invention are hereinafter described, by way of example only, with reference to the accompanying drawings, wherein:
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DETAILED DESCRIPTION
[0066] International Patent Application No. PCT/AU2019/050246, entitled “An electrical power control apparatus and process” (referred to hereinafter as the “Faraday Exchanger application”), describes an electromagnetic apparatus or device, referred to in that application and herein as a “Faraday Exchanger”, that receives input electrical energy in the form of an AC input signal having some voltage waveform and root-mean-square (RMS) voltage amplitude, and converts that input electrical energy to output electrical energy in the form of an output signal having a desired or ‘target’ voltage waveform, and a desired or ‘target’ output RMS voltage. The input electrical energy typically varies over time (that is, its AC voltage waveform and/or its RMS voltage is time-dependent), and thus the apparatus operates to dynamically control the conversion so that the output electrical energy has the desired target voltage waveform and target RMS voltage independently of the input voltage waveform and RMS voltage, and dynamic variations of those input characteristics. The dynamic control is achieved by the dynamic control of magnetic flux coupling in a magnetic core.
[0067] Additionally and simultaneously, the output electrical energy of the Faraday Exchanger has a power factor determined by the downstream load drawing power from the Exchanger. The Faraday Exchanger determines that power factor on its output, and provides a unity power factor on its input, such that (the input of) the Exchanger appears as an ideal (i.e., purely resistive) load.
[0068] The Faraday Exchanger is thus able to provide voltage waveform and RMS voltage conversion while simultaneously providing power factor correction. The use of high-speed electromagnetic path modulation instead of the electronic circuit switching used in prior art power electronics devices enables the Faraday Exchanger to deliver improved efficiency and performance (while also electrically isolating the upstream and downstream components).
[0069] The Faraday Exchanger is particularly useful when multiple instances of the exchanger are distributed throughout an electric power distribution network to maintain a stable and clean sinusoidal AC waveform with reduced harmonic content and improved power factor throughout the network, particularly when unpredictable and highly variable renewable energy sources such as solar and wind power generators are distributed throughout the network. By dynamically storing and releasing energy to compensate for such variations throughout the network, the overall stability of the network can be maintained. The control of power factor reduces energy losses, and thus improves the power carrying capacity and productivity of the network. The reduction of harmonics increases the efficiency and security of the network. By being able to adjust output voltage in real time depending on grid frequency and rate of change of grid frequency, a change in demand of loads connected to the exchanger is created. Faraday Exchangers can hence support the grid frequency and Rate of Change of Frequency (“RoCoF”) protection within the parameters of grid operation by producing suitable demand response from the loads connected to the exchanger output.
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[0071] When applied to three-phase power, a three-phase (“3P”) Faraday Exchanger includes three of the magnetic cores described above in parallel, one for each phase, with a single control component configured to dynamically control and coordinate the operation of all three magnetic cores, as illustrated schematically in
[0072] Although the three-phase Faraday Exchanger has been demonstrated to be extremely capable at maintaining a stable and clean supply of electric power in the face of unpredictable and highly variable injected power, there is nevertheless room for improvement. In particular, the magnetic cores are heavy and rather costly.
[0073] In order to alleviate these difficulties, the inventors have developed a multi-phase magnetically coupled core that forms the basis of a new form of multi-phase Faraday Exchanger. For example, in the case of three-phase power, a three-phase Faraday Exchanger need include only one magnetic core, namely a three-phase magnetically coupled core as described herein, rather than the three separate magnetic cores described in the Faraday Exchanger application. The use of only one magnetic core not only provides substantial cost and weight savings, but also reduces iron losses, and enables the transfer of energy between phases to occur entirely in the magnetic domain. As described below, a magnetically coupled multi-phase core also provides other performance benefits.
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[0075] Primary and secondary windings for each phase are arranged around the corresponding peripheral vertical limbs interconnecting the central layer with the top and bottom layers of the magnetic core. The rectifier and control windings for each phase are wound around the corresponding horizontal limb of the central Y-shaped layer of the magnetic core.
[0076] A particular advantage of the multi-phase magnetic cores described herein is the significant reduction in the total volume of core material required, relative to using multiple separate magnetic cores for respective electrical phases. This factor alone provides a significant reduction in volume, mass, and cost of a three-phase Faraday Exchanger. Additionally, magnetic modelling of this core configuration reveals that the magnetic flux flows effectively cancel each other in the central vertical limbs interconnecting the central layer to the top and bottom layers of the magnetic core, as illustrated schematically in
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[0078] In this embodiment, the primary, secondary, and rectifier windings for each phase are wound concentrically in a stacked arrangement around the corresponding vertical limbs interconnecting the corresponding vertex of the central layer with the respective vertices of the top and bottom layers. That is, for each vertical limb the corresponding rectifier windings are wound directly onto the corresponding vertical limb, the corresponding secondary windings are wound over the rectifier windings, and the corresponding primary windings are wound over the secondary windings. The control windings for each phase are wound around a corresponding horizontal limb of the central layer.
[0079] The three-phase magnetic cores of
[0080] As shown in
[0081] Returning to the square form embodiment illustrated in
[0082] The three-phase magnetic core configurations described herein support considerable flexibility in the arrangement of windings around the various limbs of the magnetic core. For example,
[0083] The electromagnetic performance of the three-phase magnetic cores described herein can be simulated using an electromagnetic stimulator platform, in this instance Altair Flux3D, as described at https://www.altair.com/flux/. The simulations described below were generated for a signal frequency of 50 Hz at time steps of 300 μs (i.e., 60 steps per cycle), for a 10 kVA core with the following parameters: [0084] Primary voltage peak value 166V; [0085] Primary turns: 117; [0086] Secondary turns: 65; [0087] Rectifier turns: 10; [0088] Inverter turns: 10; [0089] core material: thyssenkrupp Powercore® M400-50A non-grain oriented (NGO) electrical steel.
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[0091] Similarly,
[0092] Windings
[0093] In addition to the advantages resulting from the new multi-phase magnetic core configurations, the inventors have also devised improvements to the core windings. In particular, inventors have determined that is not necessary for the rectifier and control windings to be physically separate to the primary and secondary windings and to be wound around horizontal limbs of the core. In particular, as shown in
[0094] On the primary side, the relevant equations are as follows:
[0095] and on the secondary side:
[0096] This provides a significant reduction in the amount of copper wire required, reducing copper wire energy losses, and significantly reducing the size, weight and cost of the core. Moreover, this allows the central horizontal limbs to be entirely omitted, enabling new and simplified rectilinear and spherical core configurations as shown in
[0097] To demonstrate the performance of these three magnetic core configurations, the primary current, secondary voltage, and secondary current in each configuration was simulated as described above, and the results are shown in
TABLE-US-00001 TABLE 1 Material Analysis: NGO vs GOES @50 Hz Cogent M470-50A Cogent M095-27P Square P_I S_V Saturation P_I S_V Saturation Form −mm Target: 21A Target: 86v 1.5T Target: 21A Target: 86.6v 1.9T 60 Out of shape 82.6 to 85.1 Large area Out of shape 83.0 to 84.9 Large area −57.6 −56.0 86 Imbalanced .sup. 84 to 85.6 4 corners Imbalanced 84.3 to 85.8 4 corners .sup. −27.1A −24.8 90 Imbalanced 84.9 to 85.9 3 corners Imbalanced 85.0 to 86.0 3 corners −26.2 −Phase A 100 Imbalanced 85.2 to 85.8 3 corners Imbalanced 85.5 to 86.3 3 corners −24.3 −Phase A 110 Imbalanced 85.3 to 86.2 2 corners Imbalanced 85.9 to 86.5 2 corners −23.1 −Phase A 120 Imbalanced 85.6 to 86.2 2 corners Imbalanced 86.1 to 86.6 No saturation −22.5 −light −22.6
TABLE-US-00002 TABLE 2 Material Analysis: Geometry matter interactions Demi Torus Cogent M470-50A Cogent M095-27P @50 Hz P_I S_V Saturation P_I S_V Saturation mm Target: 21A Target: 86v 1.5T Target: 21A Target: 86.6 1.9T 60 Imbalanced Fully balanced Conjunction edge Imbalanced Fully balanced No saturation −46.8 −48 70 Imbalanced Fully balanced Conjunction edge Fully balanced Fully balanced No saturation −46.8 80 Fully balanced Fully balanced No saturation Fully balanced Fully balanced No saturation 86 Fully balanced Fully balanced No saturation Fully balanced Fully balanced No saturation
TABLE-US-00003 TABLE 3 Material analysis: Negative return to scale Primary Core Current length Target Secondary Core Material mm 21A Voltage Saturation Square M470- 60 × × Heavy Form YY 50A NGO 86 27.6 √ Medium 120 √ √ Light M095- 60 × × Heavy 27P GO 86 24.8 √ Medium 120 √ √ No saturation Demi M470- 60 × √ Light Torus 50A NGO 70 × √ Light Form YY 80 √ √ No saturation M095- 60 × √ Light 27P GO 70 √ √ No saturation
Saturation Definitions
[0098] Heavy: Large area around corner and limb; Medium: Area around 3-4 corners;
[0099] Light: Area around 1-2 corners
TABLE-US-00004 TABLE 4 Materials Conclusion: Demi Torus outstanding Core geometry designed to optimize matter radiation interactions delivers 3 times better result Core Core Diameter volume Core Form Material mm m.sup.3 Square Cogent M470-50A 120 0.024 YY NGO Cogent M095-27P 86 0.011 GO Demi Torus Cogent M470-50A 80 0.012 YY NGO Cogent M095-27P 70 0.008 GO
[0100] A transformer with the demi-torus magnetic core provides far superior performance, and with substantially lower mass and volume relative to the other configurations described herein. For example, a 500 kVA transformer can be made from a demi-torus core with a core volume of 0.087 m.sup.3 and weighing 666 kg. When used as the core of a three-phase Faraday Exchanger, the total weight of the core and windings is 984 kg. When used as the magnetic core of a conventional three-phase transformer, the total weight of the core and windings is 1250 kg.
[0101] Although embodiments of the present invention have been described above in the context of three-phase electric power, it should be understood that other embodiments of the invention may support multi-phase or polyphase electric power in which the number of phases is greater than three and the phase difference between respective phases is less than 120°. For example, the number of phases may be 5, 6, 7 or even greater.
[0102] Many modifications will be apparent to those skilled in the art without departing from the scope of the present invention.