System and Method for Heating an Electrical Bus in an Electrical Cabinet for Cold Startup and Condensation/Frost Control
20200413492 ยท 2020-12-31
Inventors
Cpc classification
H05B3/0023
ELECTRICITY
H05B3/0014
ELECTRICITY
H05B3/0004
ELECTRICITY
F03D80/40
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F03D80/60
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y02E10/72
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
International classification
H05B1/02
ELECTRICITY
F03D80/40
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
A method for heating an electrical bus in an electrical cabinet containing at least one current conversion device includes determining a temperature inside of the electrical cabinet. The method also includes determining a temperature outside of the electrical cabinet. Further, the method includes applying heat to the electrical bus via conduction when the temperature outside of the electrical cabinet is below a predetermined temperature threshold or a difference between the temperature inside of the electrical cabinet and the temperature outside of the electrical cabinet is less than a desired temperature difference.
Claims
1. A method for heating an electrical bus in an electrical cabinet containing at least one current conversion device, the method comprising: determining a temperature inside of the electrical cabinet; determining a temperature outside of the electrical cabinet; and, applying heat to the electrical bus via conduction when the temperature outside of the electrical cabinet is below a predetermined temperature threshold or a difference between the temperature inside of the electrical cabinet and the temperature outside of the electrical cabinet is less than a desired temperature difference.
2. The method of claim 1, wherein the at least one current conversion device comprises at least one of a power converter or a power inverter.
3. The method of claim 1, wherein applying heat to the electrical bus via conduction further comprises coupling one or more heaters to the electrical bus.
4. The method of claim 3, wherein the one or more heaters comprise one or more power resistors.
5. The method of claim 4, further comprising placing a thermal interface material between the one or more power resistors and the electrical bus.
6. The method of claim 4, wherein the at least one current conversion device is a three-phase power system, the method further comprising coupling at least one of the one or more power resistors to each phase of the three-phase power system.
7. The method of claim 6, further comprising coupling a plurality of the power resistors connected in series to each phase of the three-phase power system.
8. The method of claim 6, further comprising determining ohmic values for each of the power resistors via computer-implemented numerical modeling based on one or more site parameters of the electrical cabinet, the ohmic values configured to achieve a desired heat flux for the electrical cabinet.
9. The method of claim 1, wherein the predetermined temperature threshold is 5 degrees Celsius.
10. The method of claim 1, wherein the at least one current conversion device comprises one or more components comprising at least one of an insulated-gate bipolar transistor (IGBT), an integrated gate commutated thyristor (IGCT), a gate commutated thyristor (GCT), a diode, or a metal oxide semiconductor field effect transistor (MOSFET), a power bridge, a capacitor, a resistor, an inductor, a transformer, a contactor, or a fuse.
11. An electrical power system, comprising: an electrical cabinet; at least one current conversion device housed within the electrical cabinet, the at least one current conversion device comprising a plurality of power semiconductor devices connected together via an electrical bus; one or more sensors for determining a temperature inside and of the electrical cabinet; one or more heaters to the electrical bus; and, a controller communicatively coupled to the one or more sensors and the one or more heaters, the controller configured for commanding the one or more heaters to apply heat to the electrical bus via conduction when the temperature outside of the electrical cabinet is below a predetermined temperature threshold or a difference between the temperature inside of the electrical cabinet and the temperature outside of the electrical cabinet is less than a desired temperature difference.
12. The electrical power system of claim 11, wherein the at least one current conversion device comprises at least one of a power converter or a power inverter.
13. The electrical power system of claim 11, wherein the one or more heaters comprise one or more power resistors.
14. The electrical power system of claim 11, wherein the one or more power resistors are constructed of nichrome wire.
15. The electrical power system of claim 13, wherein the at least one current conversion device comprises a single phase system or a three-phase power system, at least one of the one or more power resistors being coupled to each phase of the electrical power system.
16. The electrical power system of claim 15, wherein the one or more power resistors further comprise a plurality of the power resistors connected in series to each phase of the three-phase power system.
17. The electrical power system of claim 15, wherein the controller is further configured to determine ohmic values for each of the power resistors via computer-implemented numerical modeling based on one or more site parameters of the electrical cabinet, the ohmic values configured to achieve a desired heat flux for the electrical cabinet.
18. The electrical power system of claim 11, wherein the predetermined temperature threshold is set to represent a cold weather environment outside of the electrical cabinet, wherein the cold weather environment would cause failure of one or more components in the at least one current conversion device connected together via the electrical bus without applying the heat to the electrical bus due to operating the one or more components below a minimum operating temperature or condensation forming on the one or more components.
19. The electrical power system of claim 18, wherein the one or more components comprises at least one of an insulated-gate bipolar transistor (IGBT), an integrated gate commutated thyristor (IGCT), a gate commutated thyristor (GCT), a diode, or a metal oxide semiconductor field effect transistor (MOSFET).
20. The electrical power system of claim 11, wherein the electrical power system is a renewable energy power system, the renewable energy power system comprising at least one of a wind turbine power system, a solar power system, or an energy storage power system.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:
[0021]
[0022]
[0023]
[0024]
[0025]
[0026]
DETAILED DESCRIPTION
[0027] Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents
[0028] In general, the present disclosure is directed to systems and methods for heating the electrical bus work of a power converter cabinet by heat conduction via the use of power resistors with or without a thermal interface material therebetween designed to reduce the thermal resistance between the power resistor(s) and the electrical bus. Power resistors (which can be formed of nichrome, copper or any other suitable conductor, infinitely better than air) can be applied directly to the bus. Thus, the bus and the components attached thereto can be directly warmed without having to warm the surrounding air and structures. Thus, the method of the present disclosure is very efficient, in the total amount of energy required to achieve the component temperature rise, relative to the amount of space required and cost for air heaters, as well as in the ability of using the copper or aluminum bus work to distribute the heat to all extents and components, regardless of natural convection flow.
[0029] Referring now to the drawings,
[0030] Referring now to
[0031] In the embodiment of
[0032] As such, the stator bus 154 may provide an output multiphase power (e.g. three-phase power) from a stator of the DFIG 120, and the rotor bus 156 may provide an output multiphase power (e.g. three-phase power) from a rotor of the DFIG 120. The power converter 162 may also include a rotor side converter (RSC) 166 and a line side converter (LSC) 168. The DFIG 120 is coupled via the rotor bus 156 to the rotor side converter 166. Additionally, the RSC 166 is coupled to the LSC 168 via a DC link 136 across which is a DC link capacitor 138. The LSC 168 is, in turn, coupled to the line side bus 188.
[0033] The RSC 166 and the LSC 168 may be configured for normal operating mode in a three-phase, pulse width modulation (PWM) arrangement using insulated gate bipolar transistor (IGBT) switching elements, as will be discussed in more detail with respect to
[0034] In addition, the power converter 162 may be coupled to a controller 174 in order to control the operation of the rotor side converter 166 and the line side converter 168. In addition, the controller 174 may be communicatively coupled to the sensors 190, 192 and the heaters 193 described herein so as to control operation thereof. It should be noted that the converter controller 174 may be configured as an interface between the power converter 162 and a local wind turbine control system 176 and may include any number of control devices. In one embodiment, the controller 174 may be a digital controller that includes a processing device (e.g. microprocessor, microcontroller, etc.) executing computer-readable instructions stored in a computer-readable medium. The instructions when executed by the processing device may cause the processing device to perform operations, including providing control commands (e.g. switching frequency commands) to the power semiconductor devices of the power converter 162. Alternatively, the controller may be an analog controller or combinations of both digital and analog controllers.
[0035] In typical configurations, various line contactors and circuit breakers including, for example, a grid breaker 182 may also be included for isolating the various components as necessary for normal operation of the DFIG 120 during connection to and disconnection from a load, such as the electrical grid 184. For example, a system circuit breaker 178 may couple the system bus 160 to a transformer 180, which may be coupled to the electrical grid 184 via the grid breaker 182. In alternative embodiments, fuses may replace some or all of the circuit breakers.
[0036] In operation, alternating current power generated at the DFIG 120 by rotating the rotor 18 is provided to the electrical grid 184 via dual paths defined by the stator bus 154 and the rotor bus 156. On the rotor bus side 156, sinusoidal multi-phase (e.g. three-phase) alternating current (AC) power is provided to the power converter 162. The rotor side power converter 166 converts the AC power provided from the rotor bus 156 into direct current (DC) power and provides the DC power to the DC link 136. As is generally understood, power semiconductor devices (e.g. IGBTs) used in the bridge circuits of the rotor side power converter 166 may be modulated to convert the AC power provided from the rotor bus 156 into DC power suitable for the DC link 136.
[0037] In addition, the LSC 168 converts the DC power on the DC link 136 into AC output power suitable for the electrical grid 184. In particular, power semiconductor devices (e.g. IGBTs) used in bridge circuits of the LSC 168 can be modulated to convert the DC power on the DC link 136 into AC power on the line side bus 188. The AC power from the power converter 162 can be combined with the power from the stator of DFIG 120 to provide multi-phase power (e.g. three-phase power) having a frequency maintained substantially at the frequency of the electrical grid 184 (e.g. 50 Hz or 60 Hz). In certain instances, as mentioned, for an individual DFIG wind turbine power system 100, the reactive power may be supplied primarily by the RSC 166, via the generator 120 and the LSC 168.
[0038] Additionally, various circuit breakers and switches, such as grid breaker 182, system breaker 178, stator sync switch 158, converter breaker 186, and line contactor 172 may be included in the wind turbine power system 100 to connect or disconnect corresponding buses, for example, when current flow is excessive and may damage components of the wind turbine power system 100 or for other operational considerations. Additional protection components may also be included in the wind turbine power system 100.
[0039] Moreover, the power converter 162 may receive control signals from, for instance, the local control system 176 (also referred to herein as a turbine controller) via the converter controller 174. The control signals may be based, among other things, on sensed states or operating characteristics of the wind turbine power system 100. Typically, the control signals provide for control of the operation of the power converter 162. For example, feedback in the form of a sensed speed of the DFIG 120 may be used to control the conversion of the output power from the rotor bus 156 to maintain a proper and balanced multi-phase (e.g. three-phase) power supply. Other feedback from other sensors may also be used by the controller 174 or control system 176 to control the power converter 162, including, for example, stator and rotor bus voltages and current feedbacks. Using the various forms of feedback information, switching control signals (e.g. gate timing commands for IGBTs), stator synchronizing control signals, and circuit breaker signals may be generated.
[0040] The power converter 162 also compensates or adjusts the frequency of the three-phase power from the rotor for changes, for example, in the wind speed at the hub 20 and the blades 22. Therefore, mechanical and electrical rotor frequencies are decoupled and the electrical stator and rotor frequency matching is facilitated substantially independently of the mechanical rotor speed.
[0041] Under some states, the bi-directional characteristics of the power converter 162, and specifically, the bi-directional characteristics of the LSC 168 and RSC 166, facilitate feeding back at least some of the generated electrical power into generator rotor 120. More specifically, electrical power may be transmitted from the stator bus 154 to the line side bus 188 and subsequently through the line contactor 172 and into the power converter 162, specifically the LSC 168 which acts as a rectifier and rectifies the sinusoidal, three-phase AC power to DC power. The DC power is transmitted into the DC link 136. The capacitor 138 facilitates mitigating DC link voltage amplitude variations by facilitating mitigation of a DC ripple sometimes associated with three-phase AC rectification.
[0042] The DC power is subsequently transmitted to the RSC 166 that converts the DC electrical power to a three-phase, sinusoidal AC electrical power by adjusting voltages, currents, and frequencies. This conversion is monitored and controlled via the converter controller 174. The converted AC power is transmitted from the RSC 166 via the rotor bus 156 to the generator rotor. In this manner, generator reactive power control is facilitated by controlling rotor current and voltage.
[0043] Referring now to
[0044] Each bridge circuit may generally include a plurality of power semiconductor devices 194, 195 (e.g. IGBTs, IGCTs, GCTs, diodes, and/or MOSFETs) coupled in series with one another via an electrical bus (e.g. buses 156, 188). For instance, as shown in
[0045] As is generally understood, the line side converter 168 and the rotor side converter 166 may be controlled, for instance, by providing control commands, using a suitable driver circuit, to the gates of the IGBTs. For example, the converter controller 174 may provide suitable gate timing commands to the gates of the IGBTs of the bridge circuits. The control commands may control the switching frequency of the IGBTs to provide a desired output. It should be appreciated by those of ordinary skill in the art that, as an alternative to IGBTs, the power convertor 162 may include any other suitable power semiconductor devices, such as, IGCTs, GCTs, diodes, and/or MOSFETs.
[0046] It should be appreciated that the converter controller 174 and turbine controller 176 may each correspond to any suitable computing device and/or any combination of computing devices. For instance, as shown in
[0047] Additionally, the controller(s) 174, 176 may also include a communications module 185 to facilitate communications between the controller(s) 174, 176 and the various components of the power system 100, e.g. any of the components of
[0048] It should be appreciated that sensors (e.g. sensors 190, 192) may be communicatively coupled to the communications module 185 using any suitable means. For example, as shown in
[0049] As used herein, the term processor refers not only to integrated circuits referred to in the art as being included in a computer, but also refers to a controller, a microcontroller, a microcomputer, a programmable logic controller (PLC), an application specific integrated circuit, and other programmable circuits. The processor(s) 181 is also configured to compute advanced control algorithms and communicate to a variety of Ethernet or serial-based protocols (Modbus, OPC, CAN, etc.).
[0050] Additionally, the memory device(s) 183 may generally comprise memory element(s) including, but not limited to, computer readable medium (e.g., random access memory (RAM)), computer readable non-volatile medium (e.g., a flash memory), a floppy disk, a compact disc-read only memory (CD-ROM), a magneto-optical disk (MOD), a digital versatile disc (DVD) and/or other suitable memory elements. Such memory device(s) 183 may generally be configured to store suitable computer-readable instructions that, when implemented by the processor(s) 181, configure the controller(s) 174, 176 to perform the various functions as described herein.
[0051] Referring to
[0052] Referring now to
[0053] As shown at (202), the method 200 includes determining a temperature inside of the electrical cabinet 177. As shown at (204), the method 200 also includes determining a temperature outside of the electrical cabinet 177. For example, as shown in
[0054] Referring still to
[0055] For example, in one embodiment, the controller 174 is configured to command the heaters 193 to apply heat to the electrical bus(es) 156, 188 via conduction when the temperature outside of the electrical cabinet 177 is below a predetermined temperature threshold or a difference between the temperature inside of the electrical cabinet 177 and the temperature outside of the electrical cabinet 177 is less than a desired temperature difference.
[0056] In additional embodiments, the predetermined temperature threshold may be set to ensure there is no frost or liquid water present, thereby reducing the effectiveness of engineered insulation. In addition, the predetermined temperature threshold may be set to maintain a temperature rise over the incoming cooling air to ensure condensation does not form on the surfaces of the electrical components. Moreover, the predetermined temperature threshold may be set to ensure the electrical components stay at a temperature that is within their rated operating temperature range. In other words, frost or liquid water would normally cause failure of one or more components (such as the various power semiconductor devices 194, 195) in the current conversion device(s) 175 connected together via the electrical bus(es) 156, 188 without applying the heat directly to the bus(es) 156, 188. For example, in one instance, the power semiconductor devices 194, 195 may fail due to operating the devices 194, 195 below a minimum operating temperature. Alternatively, the power semiconductor devices 194, 195 may short out due to condensation forming thereon, i.e. if the cabinet and the surrounding environment are at or around freezing temperatures. Therefore, as an example, in an embodiment, the predetermined temperature threshold may be set to 10 degrees Celsius ( C.), more preferably 5 C., still more preferably 0 C. Even at mild temperatures, a small temperature rise is also important to maintain between the inside of the cabinet 177 and outside of the cabinet 177, otherwise, condensation may also form and short out the components therein.
[0057] In another embodiment, the method 200 may also include determining ohmic values for each of the power resistors 196 via computer-implemented numerical modeling (such as finite element analysis), e.g. based on one or more site parameters of the electrical cabinet 177. In such embodiments, the ohmic values are configured to achieve a desired heat flux for the electrical cabinet 177.
[0058] Various aspects and embodiments of the present invention are defined by the following numbered clauses:
[0059] Clause 1. A method for heating an electrical bus in an electrical cabinet containing at least one current conversion device, the method comprising:
[0060] determining a temperature inside of the electrical cabinet;
[0061] determining a temperature outside of the electrical cabinet; and,
[0062] applying heat to the electrical bus via conduction when the temperature outside of the electrical cabinet is below a predetermined temperature threshold or a difference between the temperature inside of the electrical cabinet and the temperature outside of the electrical cabinet is less than a desired temperature difference.
[0063] Clause 2. The method of Clause 1, wherein the at least one current conversion device comprises at least one of a power converter or a power inverter.
[0064] Clause 3. The method of any of the preceding clauses, wherein applying heat to the electrical bus via conduction further comprises coupling one or more heaters to the electrical bus.
[0065] Clause 4. The method of Clause 3, wherein the one or more heaters comprise one or more power resistors.
[0066] Clause 5. The method of Clause 4, further comprising placing a thermal interface material between the one or more power resistors and the electrical bus.
[0067] Clause 6. The method of Clause 4, wherein the at least one current conversion device is a three-phase power system, the method further comprising coupling at least one of the one or more power resistors to each phase of the three-phase power system.
[0068] Clause 7. The method of Clause 6, further comprising coupling a plurality of the power resistors connected in series to each phase of the three-phase power system.
[0069] Clause 8. The method of Clause 6, further comprising determining ohmic values for each of the power resistors via computer-implemented numerical modeling based on one or more site parameters of the electrical cabinet, the ohmic values configured to achieve a desired heat flux for the electrical cabinet.
[0070] Clause 9. The method of any of the preceding clauses, wherein the predetermined temperature threshold is 5 degrees Celsius.
[0071] Clause 10. The method of any of the preceding clauses, wherein the at least one current conversion device comprises one or more components comprising at least one of an insulated-gate bipolar transistor (IGBT), an integrated gate commutated thyristor (IGCT), a gate commutated thyristor (GCT), a diode, or a metal oxide semiconductor field effect transistor (MOSFET), a power bridge, a capacitor, a resistor, an inductor, a transformer, a contactor, or a fuse.
[0072] Clause 11. An electrical power system, comprising:
[0073] an electrical cabinet;
[0074] at least one current conversion device housed within the electrical cabinet, the at least one current conversion device comprising a plurality of power semiconductor devices connected together via an electrical bus;
[0075] one or more sensors for determining a temperature inside and of the electrical cabinet;
[0076] one or more heaters to the electrical bus; and,
[0077] a controller communicatively coupled to the one or more sensors and the one or more heaters, the controller configured for commanding the one or more heaters to apply heat to the electrical bus via conduction when the temperature outside of the electrical cabinet is below a predetermined temperature threshold or a difference between the temperature inside of the electrical cabinet and the temperature outside of the electrical cabinet is less than a desired temperature difference.
[0078] Clause 12. The electrical power system of Clause 11, wherein the at least one current conversion device comprises at least one of a power converter or a power inverter.
[0079] Clause 13. The electrical power system of Clauses 11-12, wherein the one or more heaters comprise one or more power resistors.
[0080] Clause 14. The electrical power system of Clauses 11-13, wherein the one or more power resistors are constructed of nichrome wire.
[0081] Clause 15. The electrical power system of Clause 13, wherein the at least one current conversion device is a three-phase power system, at least one of the one or more power resistors being coupled to each phase of the three-phase power system.
[0082] Clause 16. The electrical power system of Clause 15, wherein the one or more power resistors further comprise a plurality of the power resistors connected in series to each phase of the three-phase power system.
[0083] Clause 17. The electrical power system of Clause 15, wherein the controller is further configured to determine ohmic values for each of the power resistors via computer-implemented numerical modeling based on one or more site parameters of the electrical cabinet, the ohmic values configured to achieve a desired heat flux for the electrical cabinet.
[0084] Clause 18. The electrical power system of Clauses 11-17, wherein the predetermined temperature threshold is set to represent a cold weather environment outside of the electrical cabinet, wherein the cold weather environment would cause failure of one or more components in the at least one current conversion device connected together via the electrical bus without applying the heat to the electrical bus due to operating the one or more components below a minimum operating temperature or condensation forming on the one or more components.
[0085] Clause 19. The electrical power system of Clause 18, wherein the one or more components comprises at least one of an insulated-gate bipolar transistor (IGBT), an integrated gate commutated thyristor (IGCT), a gate commutated thyristor (GCT), a diode, or a metal oxide semiconductor field effect transistor (MOSFET).
[0086] Clause 20. The electrical power system of Clauses 11-19, wherein the electrical power system is a renewable energy power system, the renewable energy power system comprising at least one of a wind turbine power system, a solar power system, or an energy storage power system.
[0087] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.