Inverter device
11695346 · 2023-07-04
Assignee
Inventors
Cpc classification
H02M7/537
ELECTRICITY
H05K7/20272
ELECTRICITY
International classification
H02M7/537
ELECTRICITY
H02M7/00
ELECTRICITY
Abstract
An inverter device intended to convert a DC voltage into three phases of a polyphase AC voltage with a predetermined frequency, the inverter device comprising three single-phase inverters, each of the three single-phase inverters being able to deliver one of the three phases.
Claims
1. An inverter device (DO) intended to convert a DC voltage into one phase of an AC voltage with a predetermined frequency, the inverter device (DO) comprising a single-phase inverter (O.sub.1, O.sub.2, O.sub.3) able to deliver the phase, the single-phase inverter comprising a toric output inductor, the inverter device comprising a support (S) radially surrounding a cooling channel (CA) extending longitudinally along an axis x and in which a cooling liquid is intended to flow along the axis x, the toric inductor being mounted on the support (S) so as to radially surround the cooling channel (CA) so as to be able to be cooled by the cooling liquid when this flows in the cooling channel (CA), wherein the inverter device (DO) is intended to convert a DC voltage into multiple phases of a polyphase AC voltage with a predetermined frequency, the inverter device comprising multiple single-phase inverters, each of the single-phase inverters being able to deliver one of the phases of the polyphase AC voltage, wherein toric output inductors are juxtaposed along the axis x, wherein the support (S) comprises a tubular support (SI) for switches surrounding the axis x and is radially defined by a first surface (S1) defining the cooling channel (CA) and by a second surface (S2) radially surrounding the first surface (S1), the power switches being arranged around the tubular support, bearing on the second surface (S2).
2. The inverter device (DO) according to claim 1, comprising electronic components mounted on the support around the cooling channel so as to be able to be cooled by the cooling liquid when this flows in the cooling channel (CA), the support (S) comprising a solid tubular support radially defining the cooling channel (CA).
3. The inverter device according to claim 1, wherein each of the single-phase inverters delivers one of the phases of the polyphase AC voltage in differential mode.
4. The inverter device (DO) according to claim 1, wherein the inverter device is intended to convert a DC voltage into three phases of a three-phase AC voltage with a predetermined frequency, comprising three single-phase inverters, each of the single-phase inverters being able to deliver one of the phases of the three-phase AC voltage.
5. The inverter device according to claim 1, comprising at least one toric output inductor mounted on the support (S) so as to radially surround the cooling channel (CA).
6. The inverter device (DO) according to claim 1, wherein the single-phase inverter comprises power switches mounted on the support (S) around the cooling channel so as to be able to be cooled by the cooling liquid when this flows in the cooling channel.
7. The inverter device (DO) according to claim 6, wherein the inverter device (DO) is intended to convert a DC voltage into multiple phases of a polyphase AC voltage with a predetermined frequency, the inverter device comprising multiple single-phase inverters, each of the single-phase inverters being able to deliver one of the phases of the polyphase AC voltage, and wherein the second surface (S2) has six planar faces distributed around the axis x, two of the power switches bearing on each of the planar faces.
8. The inverter device according to claim 1, wherein the inverter delivers the phase in differential mode.
9. A generator set (EG) intended to be mechanically coupled to a motor shaft (AR) of a motor of an aircraft and intended to deliver the phases of the polyphase AC voltage when the motor shaft is driven in rotation at a variable speed, the generator set (EG) comprising a generator (G) intended to engage with the shaft so as to generate an AC voltage with a fixed initial frequency, a rectifier intended to rectify the AC voltage and the inverter device (DO) according to claim 1.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) Other features, details and advantages of the invention will become apparent upon reading the description provided with reference to the appended drawings, which are given by way of example and in which, respectively:
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(9) From one figure to another, the same elements bear the same references.
DETAILED DESCRIPTION
(10) The invention relates to a generation system as shown schematically in
(11) The generator set EG is intended to mechanically engage with a motor shaft AR and to deliver three phases of a single-phase or polyphase AC voltage, for example a three-phase AC voltage, with a predetermined fixed frequency when the motor shaft AR is driven in rotation at a variable angular speed by a motor M arranged in the nacelle N.
(12) The motor is for example intended to drive the motor in rotation in a speed range ranging from 4500 rpm to 9000 rpm.
(13) The generator set EG comprises a generator G intended to mechanically engage with the motor shaft AR and able to deliver a polyphase AC voltage having the same predetermined RMS voltage regardless of the rotational speed of the motor shaft AR when the latter is driven in rotation by the motor M.
(14) The generation system comprises a control device CG for controlling the generator, configured so as to control the generator G such that the polyphase AC voltage delivered by the generator G has the predetermined RMS voltage regardless of the rotational speed of the motor shaft AR. The control device CG for controlling the generator comprises for example a power converter and a control unit for controlling the power converter. The control unit is configured so as to control the power converter such that it supplies electric power to the generator G so that this delivers the desired polyphase AC voltage at the predetermined RMS voltage, the frequency of which depends on the rotational speed of the shaft.
(15) The generator G is conventional to a person skilled in the art. It is for example a brushless wound-rotor synchronous generator. It then comprises a main electric machine, an exciter and a rotating rectifier bridge linking the main electric machine and the exciter.
(16) Advantageously, the generator G has three stages. It comprises an auxiliary brushless synchronous generator comprising a rotor, coupled to the common shaft, comprising permanent magnets and a stator comprising stator windings. As a variant, the generator G has two stages.
(17) The generator set EG also comprises a rectifier RG configured so as to deliver a substantially constant DC voltage UE when it is subjected, at input, to the single-phase or polyphase AC voltage generated by the generator G.
(18) Advantageously, the control device for controlling the generator is configured so as to control the generator such that it delivers a DC voltage of 540 V.
(19) The generator set EG also comprises an inverter device DO intended to transform the output voltage from the rectifier RG into one phase of a single-phase AC voltage or into multiple phases of a polyphase AC voltage, for example into three phases of a three-phase AC voltage, having a fixed predetermined frequency. The invention also relates to the inverter device DO.
(20) The phase or the phases, for example the three phases, are generated by the inverter device DO in differential mode.
(21) According to the invention, the inverter device DO comprises one or more independent inverters, for example three independent inverters O.sub.1, O.sub.2, O.sub.3, for example voltage inverters, each having an input connected to the output of the rectifier RG so as to be subjected to the DC voltage delivered at output of the rectifier RG. Each voltage inverter O.sub.1, O.sub.2, O.sub.3 is intended to deliver a single-phase voltage, corresponding to one of the phases of the polyphase, for example single-phase, AC voltage, or corresponding to the single-phase AC voltage, with a fixed frequency, based on the DC voltage delivered at output of the rectifier RG.
(22) The generator set EG comprises a control device CO for controlling the inverter device, configured so as to control the inverters O.sub.1, O.sub.2, O.sub.3, and more particularly controllable electronic switches of the inverters O.sub.1, O.sub.2, O.sub.3, such that each inverter O.sub.1, O.sub.2, O.sub.3 delivers one of the phases of the single-phase or polyphase, for example fixed-frequency three-phase, AC voltage and, in the case of a polyphase AC voltage, the inverters, for example the three inverters O.sub.1, O.sub.2, O.sub.3, deliver the phases of the polyphase AC voltage, for example the three phases of the three-phase voltage. This type of control is conventional to a person skilled in the art.
(23) The control device is for example configured such that each inverter supplies an AC voltage at 400 Hz with an RMS voltage of 300 V, the three AC voltages being phase-offset so as to form the phases of a three-phase AC voltage, based on the output DC voltage from the rectifier of 540 V.
(24) This configuration makes it possible to offer partial availability of the inverter device DO in the event of failure of one of the inverters if the device comprises multiple inverters.
(25) Moreover, the fact that the inverter device DO has multiple independent single-phase inverters, for example three independent single-phase inverters, allows good thermal and mechanical integration and easy mounting. Specifically, the power components of the various inverters may be separate from one another.
(26) The control device CO advantageously comprises one or more individual control devices, for example three individual control devices, each individual control device being configured so as to control just one of the inverters. The control device is then configured so as to synchronize the commands from the three individual control devices. The synchronization is for example performed using an “open collector” priority bus formed of multiple, for example three, logic signals. In the case of three inverters, the three inverters generate three synchronization signals with a predetermined frequency that are phase-offset by 120°. These signals are pooled via this logic bus: the 1st of the inverters that toggles to the low state synchronizes the other two inverters.
(27) The generation system advantageously comprises a transformer T configured so as to create galvanic isolation between the inverter device DO and a distribution network DL for the polyphase, for example three-phase, voltage on board the aircraft.
(28) The transformer T is advantageously configured so as to generate phases having an RMS voltage with a predetermined distribution different from that of the phases delivered by the inverters. The inverter device DO is for example configured so as to deliver an AC voltage at 400 Hz having an RMS voltage of 115 V or 230 V.
(29) The transformer T is advantageously configured so as to transform the phases delivered by the inverters in differential mode into a common-mode polyphase voltage, for example a common-mode three-phase voltage (three phases and neutral).
(30) In the advantageous embodiment in
(31) The transformer T and the control device CG for controlling the generator are housed in a volume defined by the body of the aircraft on which the nacelle N is mounted.
(32) In the remainder of the description, the invention is described in the case of an inverter device comprising three inverters, but it obviously also applies to the case in which the inverter device comprises one inverter or multiple inverters. Notably, the circuit diagram, the insertion of the inverter device into the circuit diagram, the structure and the layout of the elements of each of the inverters may notably be applied to the case of an inverter device comprising a single inverter or multiple inverters in a number other than three.
(33)
(34) Each inverter O.sub.1, O.sub.2, O.sub.3 comprises power components.
(35) Each inverter Oi comprises an input filter comprising two input capacitors C.sub.ij (where j=1 to 2) connected in parallel between the input terminals E.sub.i1 and E.sub.i2 of the inverter O.sub.i under consideration. The capacitors C.sub.ij have a low impedance, making it possible to achieve a fixed voltage at the output of the input filter. The value of the output voltage of the input filter does not vary as a function of a variation in the inrush current.
(36) Each voltage inverter O.sub.i (where i=1 to 3) furthermore comprises four power switches T.sub.ik (where k=1 to 4) connected in the form of an H-bridge at the output of the input filter C.sub.ij (where j=1 to 2).
(37) Each switch T.sub.ik comprises for example a transistor TR connected in parallel with a diode D. The transistor is for example an insulated-gate bipolar transistor or IGBT, for example a PNP IGBT.
(38) The H-bridge of each inverter O.sub.i comprises two branches B.sub.i1 and B.sub.i2 each comprising two switches that are connected in series.
(39) Each voltage inverter O.sub.i comprises a first LC output filter comprising an output inductor Lf.sub.i and an output capacitor Cf.sub.i that are connected in series between the two centre taps of the two branches B.sub.i1 and B.sub.i2 of the H-bridge. This LC filter is a low-frequency filter for achieving a sinusoidal voltage having an average value of zero volts. The function of the output inductor Lf.sub.i is that of smoothing the voltage so as to achieve a sinusoidal voltage at output of the inverter O.sub.i, and the function of the output capacitor Cf.sub.i is that of eliminating any voltage offset so as to achieve an output voltage having an average value of zero.
(40) To this end, the resonant frequency of the LC filter is very low in comparison with the cutoff frequency of the power switches.
(41) Each inverter O.sub.i also comprises a current sensor CT.sub.i for measuring the output current of the inverter O.sub.i.
(42) The control device CO for controlling the inverter device uses the measurement of the output current delivered by the current sensors CT.sub.i of the inverters O.sub.i to control the power switches so as to limit the output current in the event of overload.
(43) Advantageously, each inverter O.sub.i comprises a second low-pass output filter HF.sub.i connected to the terminals of the output capacitor Cf.sub.i of the inverter O.sub.i. The second output filter HF.sub.i is configured so as to filter the high-frequency stray signals generated in particular at the cutoff frequency of the switches and at frequencies of its harmonics.
(44) This low-pass filter is for example a series LC filter having a resonant frequency of the order of the cutoff frequency.
(45) The output voltage U.sub.i of each inverter O.sub.i is the voltage measured at the output of the low-pass filter HF.sub.i.
(46) A description will now be given of the mechanical and thermal architecture of the inverter device DO according to the invention.
(47)
(48) The inverter device DO comprises a support S radially surrounding a channel CA extending along an axis x, and in which a cooling liquid is intended to flow along the axis x.
(49) The cooling liquid is intended to flow in the cooling circuit CR in the form of a closed loop. This cooling circuit CR comprises the cooling channel CA, a pump PP and a heat exchanger ET.
(50) The support S advantageously comprises an output connector C.sub.g intended to convey a cooling liquid, for example oil or water, going from a cooling channel CA to the heat exchanger ET, intended to cool the cooling liquid, and then to the pump PP configured so as to channel the cooling liquid to an input connector C.sub.d of the support S, in the direction of the arrows in
(51) Advantageously, some electronic components, notably power components of the inverter device DO, are mounted on the support S around the cooling channel CA such that these power components are able to be cooled by the cooling liquid when this flows in the cooling channel CA.
(52) The cooling channel CA advantageously extends longitudinally along the axis x.
(53) This assembly is compact and easy to implement. It allows mounting in the nacelle N, thereby making it possible to reduce the mass of the assembly.
(54) This mounting allows the power components mounted around the cooling channel CA to be cooled with the same cooling liquid as that used to cool the electric machine of the generator.
(55) The fact that the cooling channel CA extends linearly is beneficial for the integration of the inverter device DO.
(56) Advantageously, some electronic components Lf.sub.i, T.sub.ik of each of the three inverters O.sub.i are mounted on the support S around the cooling channel CA such that these power components are able to be cooled by the cooling liquid when this flows in the cooling channel CA. This makes it possible to mount the components of the three inverters on the nacelle and to cool the components of the three inverters by way of the same cooling loop.
(57) These components advantageously comprise the output inductors Lf.sub.i and the power switches T.sub.ik. Specifically, these are the components of the inverters that dissipate the most heat.
(58) To this end, the support S comprises a support SB for inductors, on which the output inductors Lf.sub.i are mounted, and a support SI for switches, on which the power switches T.sub.ik are mounted.
(59) These supports are attached to one another.
(60) Advantageously, the electronic components Lf.sub.i, T.sub.ik mounted on the support S are intended to be mounted on the nacelle via the support S. This allows easy mounting of the three inverters on the nacelle.
(61) Advantageously, each of these electronic components Lf.sub.i, T.sub.ik bears on a radial surface of a solid tubular body SB.sub.i, SI having a tubular shape radially defining the cooling channel CA. Radial surface of the tubular body is understood to mean a surface radially defining the tubular body.
(62) As will be seen in the remainder of the text, each of this or these tubular body or bodies SB.sub.i, SI is advantageously radially defined by an inner surface defining the cooling channel CA and by an outer surface completely radially surrounding the inner surface. This makes it possible to achieve a good exchange of heat between each component bearing on the tubular body and the cooling liquid flowing in the cooling channel CA radially defined by the tubular body SB.sub.i, SI.
(63) Advantageously, each of this or these tubular body or bodies is made of metal. Metals have the advantage of being good thermal conductors.
(64) The metal body is for example made of aluminium, having the advantage of being lightweight, or made of steel.
(65)
(66) The individual inductor support SB.sub.1 defines a cylindrical inner volume V.sub.1 corresponding to an axial portion of the cooling channel CA.
(67) The individual support comprises a tubular base section EB.sub.1 with an axis x and a plate P.sub.1 extending in a transverse plane perpendicular to the axis x. The plate P.sub.1 is adjacent to the tubular base section EB.sub.1 along the axis x.
(68) The plate P.sub.1 adjacent to the tubular base section EB.sub.1 is in the shape of a disc comprising an aperture having a diameter substantially identical to that of the inner diameter of the tubular base section EB.sub.1.
(69) The tubular base section EB.sub.1 and the plate P.sub.1 surround and radially define the individual portion of the cooling channel CA.
(70) The individual support SB.sub.1 is advantageously provided with first cooling fins A1 extending within the inner volume V.sub.1.
(71) For example, the first fins A1 are produced in the form of plates extending radially within the cooling channel CA, and more particularly within the volume V.sub.1.
(72)
(73) The first output inductor Lf.sub.1 is toric and comprises a toric magnetic circuit CM.sub.1 and a winding B.sub.1 formed around the toric magnetic circuit CM.sub.1. The winding B.sub.1 is a winding of an electrically conductive wire, for example made of copper, formed around the toric magnetic circuit CM.sub.1. As may be seen in
(74) The first output inductor Lf.sub.1 radially surrounds the channel CA, and more particularly the tubular base section EB.sub.1.
(75) Advantageously, each toric output inductor completely radially surrounds the cooling channel CA.
(76) More generally, at least one output inductor is toric and radially surrounds the cooling channel CA, and more particularly the tubular base portion.
(77) The toric power inductor Lf.sub.1 forms a crown that surrounds the axis x and the cooling channel CA.
(78) The tubular base portion EB.sub.1 is solid.
(79) Advantageously, the power inductor Lf.sub.1 bears radially on the tubular base portion EB.sub.1.
(80) The power inductor Lf.sub.i may be in direct or indirect physical contact with the tubular base portion EB.sub.i.
(81) This layout of the power inductors is particularly compact and allows effective cooling of the power inductors by way of a liquid flowing in the cooling channel CA.
(82) Advantageously, as shown in
(83) More generally, multiple toric output inductors are advantageously arranged adjacently along the axis.
(84) The volumes defined by the various individual supports SB.sub.i are then adjacent along the axis x.
(85) As may be seen in
(86) The support S also comprises an end plate P.sub.g contiguous with the tubular base portion EB.sub.1 of the first individual support SB.sub.1.
(87) Each power inductor Lf.sub.1, respectively Lf.sub.2, respectively Lf.sub.3 is axially interposed between two plates P.sub.g, P.sub.1, respectively P.sub.1, P.sub.2, respectively P.sub.2, P.sub.3, so as to be kept at an axial position that is substantially fixed with respect to the support S.
(88) Advantageously, each power inductor Lf.sub.1, respectively Lf.sub.2, respectively Lf.sub.3 is axially separated from each of the two plates P.sub.g, P.sub.1; respectively P.sub.1, P.sub.2; respectively P.sub.2, P.sub.3 between which it is interposed by a thermal interface I.
(89) Advantageously, each thermal interface I is joined to one of the toric output inductors and to a plate P.sub.g. The thermal interfaces I are electrically insulating and promote the exchange of heat between the toric output inductor and the cooling channel CA via the plates P.sub.i, P.sub.g.
(90) The thermal interface I, joined to one of the toric output inductors and to a plate P.sub.g, P.sub.i, has for example the shape of a slat having a central aperture surrounding one of the base portions. It may be formed of an electrically insulating material having a high heat transfer coefficient, for example a polymer, such as for example Kapton or polypropylene. As a variant, the thermal interface I has multiple layers. It comprises for example layers of the same electrically insulating material separated by a state change material that changes state when a threshold temperature is exceeded, such that the thickness of the thermal interface decreases when the temperature exceeds this threshold temperature. This allows the thermal interface to take up the axial expansion of a power inductor when the temperature increases, and therefore makes it possible to limit low-temperature vibrations.
(91) Preferably, as shown in
(92) To this end, the support SI for power switches is adjacent to the support SB for inductors along the axis x.
(93)
(94) The support SI for power switches is tubular and solid. The tubular support SI surrounds the axis x and is radially defined by a first surface S1 defining the volume VI, which is an axial portion of the cooling channel CA, and by a second surface S2, radially surrounding the first surface S1 and to which the power switches T.sub.ik are fixed.
(95) Advantageously, the second surface S2 comprises at least one planar face SP.sub.m (m=1 to 6).
(96) In the advantageous embodiment in
(97) The planar faces SP.sub.m extend longitudinally along the axis x.
(98) The support SI for power switches is advantageously provided with second cooling fins A2 projecting from the first surface S1, so as to extend within the cooling channel CA.
(99) For example, the second fins A2 are produced in the form of plates extending radially within the cooling channel CA.
(100)
(101) Advantageously, the set of power switches T.sub.ik is arranged radially around the support SI for switches, bearing on the surface S2.
(102) Advantageously, the set of power switches T.sub.ik comprises power switches distributed radially around the support SI for power switches. This allows good cooling of the various power switches T.sub.ik.
(103) Advantageously, the power switches T.sub.ik bear on various planar faces SP.sub.m of the second surface S2 or on the various planar faces of the second surface S2. This makes it possible to guarantee effective cooling of the power switch by joining a planar face of the power switch or of a support on which the power switch is mounted to one of the planar axial support SI faces.
(104) In the non-limiting embodiment in the figures, the inverter device DO comprises power modules M.sub.m. Each power module M.sub.m comprises a substantially planar base SO.sub.m (m=1 to 6) and two power switches T.sub.ik.
(105) At least one planar face of each switch T.sub.ik is joined to a planar surface of one of the bases SO.sub.m that itself bears on one of the planar faces SP.sub.m so as to have a large heat exchange surface between the switch and the support SI, thereby promoting cooling of the switch by the cooling liquid flowing in the channel CA.
(106) Each module M.sub.m advantageously comprises a cover CAP.sub.m. The two switches of the module M.sub.m are interposed between the cover CAP.sub.m and the base of the module SO.sub.m.
(107) In the advantageous embodiment in the figures, two power switches bear on each of the six planar faces of the second surface S2.
(108) In other words, each power module M.sub.m bears on one of the planar faces SP.sub.m of the second surface S2.
(109) Advantageously, as may be seen in
(110) Each power module M.sub.m extends longitudinally along the axis x, and the two power switches of the power module are adjacent along the axis x. Only the switches T.sub.32 and T.sub.34 are therefore not visible in
(111) Therefore, in the specific embodiment in the figures, the power switches are distributed radially around the channel CA and axially along the channel CA.
(112) As a variant, the power switches are distributed only axially around the axis x. This promotes the uniformity of the cooling of each of the switches.
(113) More generally, the second surface S2 comprises at least one planar face and at least one power switch is fixed to the planar face. The number of planar faces of the second surface able to be seen in the figures is not limiting. It is possible for example to contemplate a second surface having an overall shape of a polygon having a number of sides other than six in the plane perpendicular to the axis x.
(114) It is possible for example to contemplate a second surface having an overall shape of a dodecagon, so as to have twelve planar faces. It is then possible to place a switch bearing on each of the faces. As a variant, it is possible to contemplate a second surface having an overall shape of a triangle, so as to have three planar faces. It is then possible to place four switches bearing on each of the faces.
(115) In general, the second surface S2 advantageously comprises various planar faces distributed around the axis x. Some power switches bear on at least one subset of these planar faces.
(116) The number of power modules and the number of power switches per power module are not limiting. It is possible to contemplate multiple intermediate supports per power switch or else one or more than two switches per intermediate support.
(117) Advantageously, all of the electronic components of the inverter device DO are mounted on the support S and arranged around the cooling channel CA in a cylindrical volume shown in dashed lines in
(118) The cylindrical volume is axially defined by the plate P.sub.g and by another end plate P.sub.d perpendicular to the axis x.
(119) Advantageously, the control device CO for controlling the inverter device is advantageously integrated into this cylindrical volume.
(120) In the non-limiting embodiment in
(121) The electronic components other than the switches and the toric output inductors may be arranged radially around the tubular end support ST and/or around the power switches. This makes it possible to limit the diameter of the cylindrical volume taken up by the components of the inverter device.
(122) As a variant, the components of the inverter device DO other than the output switches and the output inductors may be arranged radially around the tubular end support ST and/or around the switches and/or around the output inductors.
(123) The support S may be a single-piece component or be an assembly of components that are assembled in a sealtight manner so as to avoid liquid from flowing from the cooling channel to the electronic components.
(124) The inverter device DO advantageously comprises a housing enclosing the electronic components of the inverter device in a sealtight manner. I
(125) The housing comprises for example a tubular cover connected to the end plates P.sub.g and P.sub.d in a sealtight manner.
(126) The cooling channel surrounds the axis x.
(127) Advantageously, the cooling channel CA is rotationally symmetrical about the axis x.
(128) Advantageously, at least one of the tubular supports is rotationally symmetrical about the axis x.