Energy Saving High Frequency Series Buck AC Voltage Regulator System

Abstract

An energy saving alternate current (AC) series voltage regulator comprises an AC high frequency (HF) series voltage buck power regulator, a bypass contactor (K1), a bidirectional AC semiconductor device (S1) connected in parallel with the bypass contactor and a control circuitry. Under the condition of an input AC mains voltage (Vin) drops below a specified and set optimum energy savings voltage or a lower selected voltage point, the control circuitry transitions both the slow bypass contactor and the fast bidirectional AC semiconductor device, then the AC high frequency (HF) series voltage buck power regulator are switched out to save the AC high frequency (HF) series voltage buck power regulator internal power electronics usage. Under this condition, the lower input AC mains voltage is directly delivered to an electrical load by the contactor bypass system, hence achieving more energy savings.

Claims

1. An energy saving alternating current (AC) series voltage regulator for regulating an AC output voltage from an AC output power source, comprising: an AC high frequency (HF) series voltage buck power regulator topology for bucking an AC input voltage of an AC input power source; a bypass contactor system; a bidirectional AC semiconductor device connected in parallel with the bypass contactor system; a control circuitry for receiving the AC input voltage, an AC reference voltage, the AC output voltage, and generating driving signals for the bypass contactor system and the bidirectional AC semiconductor device; wherein under a condition of the AC input voltage falling below a selected optimum energy savings set level, the control circuitry sensing the condition, generating driving signals to activate the bidirectional AC semiconductor device and to transition the bypass contactor system such that the bidirectional AC semiconductor device initially bypasses the AC HF series voltage buck power regulator topology, then the bypass contactor system contacts close and fully bypass the AC HF series voltage buck power regulator topology and the bidirectional AC semiconductor device.

2. The energy saving AC series voltage regulator of claim 1, wherein under the condition of that the AC input voltage falling below a selected optimum energy savings set level and after the bypass contactor system contacts are closed, the AC HF series voltage buck power regulator topology is disengaged with the AC input power source connected directly to the AC output power source.

3. The energy saving AC series voltage regulator of claim 1, wherein under a condition of high load surge or fault currents, the control circuitry sensing the condition, generating driving signals to activate the bidirectional AC semiconductor device and to transition the bypass contactor system such that the bidirectional AC semiconductor device initially bypasses the high load surge or fault currents away from electronics of the energy saving AC series voltage regulator, then the bypass contactor system contacts close and fully bypass the high load surge or fault currents away from electronics of the energy saving AC series voltage regulator and the bidirectional AC semiconductor device.

4. The energy saving AC series voltage regulator of claim 1, wherein the bypass contactor system comprising a normally closed (NC) bypass contactor.

5. The energy saving AC series voltage regulator of claim 1, wherein the AC HF series voltage buck power regulator topology comprises: a first and a second independently controllable AC bidirectional switches; and a first power inductor.

6. The energy saving AC series voltage regulator of claim 1, further comprising an input filter for eliminating HF switching energy from passing back into the AC input power source.

7. The energy saving AC series voltage regulator of claim 6, wherein the input filter comprising two capacitors and two inductors.

8. The energy saving AC series voltage regulator of claim 1, further comprising an output filter for averaging HF voltage ripple to create a smooth regulated voltage level for the AC output voltage.

9. The energy saving AC series voltage regulator of claim 8, wherein the output filter comprising two capacitors and two inductors.

10. The energy saving AC series voltage regulator of claim 1, further comprising a current transformer for generating an output current measurement signal to the control circuitry to achieve over-current protection.

11. The AC series voltage regulator of claim 5, wherein the switch driving signals for the AC bidirectional switches being pulse width modulation (PWM) control signals.

12. The energy saving AC series voltage regulator of claim 5, wherein each of AC bidirectional switches comprising one or more power semiconductor devices.

13. The energy saving AC series voltage regulator of claim 12, wherein the power semiconductor devices being back-to-back unipolar MOSFET power semiconductor devices, silicon-controlled rectifiers (SCR)'s, gate turn off thyristor (GTO)'s connected as anti-parallel AC switches, TRIAC's, insulated-gate bipolar transistors (IGBT)'s, MOSFET transistors, or SCR's configured as AC switches.

14. The energy saving AC series voltage regulator of claim 1, wherein the bidirectional AC semiconductor device being a TRIAC or a rectifier bridge consist of four rectifiers with a unipolar semiconductor device configuration inserted in the bridge such as SCR, GTO, IGBT, MOSFET, back-to-back SCR's or TRIAC's.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Embodiments of the invention are described in more detail hereinafter with reference to the drawings, in which

[0010] FIG. 1 depicts a block diagram of a HF AC voltage regulator being employed in conjunction with a bypass contactor system in accordance to various embodiments of the present invention; and

[0011] FIG. 2 depicts a circuit diagram of an embodiment of a HF AC voltage regulator and a bypass contactor system in accordance to various embodiments of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0012] In the following description, methods, systems, and apparatuses for regulating an output AC voltage to a desired level regardless of the variation in an input AC voltage and the like are set forth as preferred examples. It will be apparent to those skilled in the art that modifications, including additions and/or substitutions may be made without departing from the scope and spirit of the invention. Specific details may be omitted so as not to obscure the invention; however, the disclosure is written to enable one skilled in the art to practice the teachings herein without undue experimentation.

[0013] In accordance to a preferred embodiment of the present invention, a HF AC voltage regulator is used in conjunction with a bypass contactor system as shown in FIG. 1. Since the size of any magnetics is largely inversely proportional to its operating frequency, the present invention was approached with this as a central design parameter. The primary goal of the present invention is to achieve an energy savings system using a HF AC voltage regulator that utilizes only high frequency (e.g. 1 kHz to 1000 kHz) magnetic structures that reduce significantly the size, weight and cost of these magnetic structures and incorporated into an energy savings system working in conjunction with a bypass contactor combined with a fast switching bidirectional AC semiconductor device connected in parallel with the contactor bypass contacts.

[0014] The energy saving HF AC voltage regulation system is designed to decrease and regulate the output AC voltage applied to the load to a set energy savings optimum AC voltage if under the condition of high AC input voltage above a set optimum energy savings specified output voltage. In a system where a full AVR is used, under the condition of low AC input voltage below an optimum energy savings voltage, energy will be spent internally to operate in increasing or boosting the input voltage. It would not save any energy by the load as it would increase or boost the low AC input voltage back to the higher set level. The present invention, under the condition of low AC input voltage level below the optimum selected output voltage level, provides a bypass contactor combined with fast bidirectional AC semiconductor device connected in parallel with the slower bypass contactor. Both the fast bidirectional AC semiconductor device and the bypass contactor are transitioned by the control electronics so that the fast bidirectional AC semiconductor device initially bypasses the HF AC voltage regulator, then the slower bypass contactor contacts close and fully bypasses the HF AC voltage regulator and including the bidirectional AC semiconductor device connected in parallel to the bypass contactor contacts. The electronic control switches out the HF AC voltage regulator such that the HF AC voltage regulator internal power electronics energy usage is saved. Further, the low AC mains input voltage is applied directly to the load, bypassing any voltage drop of the HF AC voltage regulator power electronics. This achieves additional energy savings with the low input AC mains voltage applied directly to the load.

[0015] There are two ways to regulate voltage on the AC mains. One is by series voltage regulation method, where the AC input and AC output are decoupled and just the differential voltage between the unregulated input AC voltage. The specified and fixed regulated output AC voltage is processed by the power electronics. The other is by shunt current regulation method, where the AC voltage is changed by injecting a specified current in shunt or parallel with the mains, and the level of that current is injected or absorbed by the power electronics interchanging energy with an internal storage device, such as a high voltage electrolytic capacitor. The shunt current regulation method, therefore, controls the AC mains line voltage by driving or absorbing a specified current into or from the mains line impedance or resistance.

[0016] In the present invention, as shown in FIG. 1, the HF AC voltage regulator can use either the shunt or series voltage regulation method as described above, but in accordance to the preferred embodiment of the present invention the HF AC series voltage regulation is the preferred method as it is more predictable since the series voltage regulation method is independent of line impedance.

[0017] In worldwide electrical systems, the point-of-use low voltage distributions are generally under either 110/120 VAC or 220/230/240 VAC, although most of the world is standardizing to nominal 120 VAC or 230 VAC systems for low voltage distribution voltages. Also there are standardized and legislated electrical system specifications, and especially distribution voltage levels and tolerances to be delivered to the switchboards of domestic and commercial premises. For example in the U.S.A., the standard distribution voltage for domestic and commercial premises is 120 VAC (specified by FERC/NERC), with voltage tolerances of maximum of +5% and minimum of 5%. In the higher voltage 230 VAC systems such as Australia (specified by AS60038), and the UK (specified by EN50160), the allowed voltages tolerances are specified as a maximum of +10% and a minimum of 6%. It is generally accepted in the industry that overvoltage levels can be higher. An overvoltage of +10% and an under-voltage of 10%, as the extreme limits are still acceptable. However, these extreme maximum voltages when applied to electronic equipment and appliances, especially electrical motors, that are designed to the nominal specified standard voltages such as 120 VAC in the USA and 230 VAC in Australia and UK, not only waste energy because of the additional higher working voltage, but also impede optimal performances. Motors and transformers can overheat, shorten working life times, and any equipment connected to the electrical system can be permanently damaged.

[0018] Therefore, in the U.S.A. for example, with the voltage range nominal 120 VAC, maximum voltage of +5% being 126 VAC, overvoltage of +10% being 132 VAC, minimum of 5% being 114 VAC, under-voltage of 10% being 108 VAC, it is generally accepted in the industry that the transmission and distribution operators in the U.S.A. will deliver the minimum voltage of 114 VAC to the premises switchboard, and allowing another 3.5% voltage drop estimated for a minimum of 110 VAC to the actual loads, such as appliances in domestic premises.

[0019] To deliver the specified range of voltages within the allowed voltage tolerances from the nominal voltage of 120 VAC to each domestic or commercial premise on a local power island distribution network, it requires a higher voltage at the input to the local power island distribution network because of the voltage drop that takes place serially along the physical wires of the distribution network due to the electrical resistance of the wires and system conductors. Thus, typically premises close to the sub-station of the distribution network local power island will see the higher maximum voltage ranges, and further along the local power island distribution network, the lower voltages in the range. In the U.S.A. for example, the voltage range can vary from 126 VAC or higher to 114 VAC or lower for a nominal 120 VAC local power island distribution network. Similarly, for the nominal 230 VAC countries, such as Australia and the UK, the voltage range can vary from 253 VAC or higher at the local power island substation to 216 VAC or lower along the distribution network for a nominal 230 VAC local power island distribution network.

[0020] There have been major investments made in the local power island distribution networks to minimize the tolerances of the delivered mains AC voltage to all domestic and commercial premises. But this has become more difficult due to the increasing usage and complex electronic loads being added into domestic and commercial premises, changing loads and power factors across the LV distribution network. In the U.S.A. for example, there is now more domestic and commercial electricity usage than industrial usage. With the recent disruptive advent of private domestic and commercial distributed energy generation (DEG), coupled with legislated Feed In Tariff (FIT) in many countries where any private domestic or commercial premise owner can purchase and install and generate their own electrical power (e.g. in the case of domestic photovoltaic (PV) installations), power can be impressed back onto the local power island distribution network, adding dramatically to the power system complexity and voltage range volatility, especially overvoltage.

[0021] Electrical and electronic equipment and appliances, especially electrical motors, are specifically design to operate at the nominal specified standard voltages, such as 120 VAC in the U.S.A., and other 120 VAC countries, and 230 VAC in Australia, UK, and other 230 VAC countries. Voltages over the nominal design standard voltages not only can damage the connected electrical and electronic equipment, but also cause the consumption of more energy than is necessary. Hence there is an optimum voltage in general that optimizes the performance and delivers the maximum energy savings.

[0022] Referring to FIG. 1. In this example, the optimum energy savings voltage on the output of the HF AC voltage regulator is selected to be the nominal mains voltage 5% to achieve normal equipment performance and maximize energy savings. Thus, energy savings set voltage can be 114 VAC for nominal 120 VAC systems, and 220 VAC for nominal 230 VAC systems, or other lower energy saving voltages could be selected, and this is just an example to clearly show the concept and other energy savings optimization voltages can be obviously specified for the output of the HF AC voltage regulator. For example, in the present invention only the HF AC voltage regulator needed working in conjunction with a series bypass contactor, and the output voltage of the HF AC voltage regulator is set at energy saving level of 114 VAC for nominal 120 VAC systems, and set at energy saving level of 220 VAC for 230 VAC systems, so under the conditions of extreme or overvoltage the HF AC AVR voltage regulator keeps the output voltage to the load at the selected set energy savings optimizing voltages.

[0023] Under the condition of that the input AC mains voltage falling below the energy savings set voltage (e.g. 114 VAC for nominal 120 VAC systems and 220 VAC for nominal 230 VAC systems), if a full AVR is used, then the full AVR will not only be using internal power to increase or boost the low input mains AC voltage, it will not save as much energy as the present invention. In accordance to various embodiments of the present invention, when the control electronics sense the input AC mains voltage falling below the energy savings set voltage, the control electronics, a bypass contactor system is activated, and switch off the HF AC voltage regulator power electronics are switched off, saving internal power electronics energy consumption. Under this condition, the low main AC input voltage is applied directly to the load, minimizing the voltage drop and power electronics usage of the HF AC voltage regulator that stayed connected in the circuit. As shown in FIG. 1, additional energy savings is achieved by the low input mains AC voltage being applied directly to the load through the bypass contactor system.

[0024] Still referring to FIG. 1. Although HF AC voltage regulation can be achieved either by shunt or series method, the series method is used in the preferred embodiments of the present invention. In accordance to various embodiments of the present invention, any HF AC voltage regulator can be used in parallel with a bypass contactor system to create an energy savings high frequency AC voltage regulation system.

[0025] Referring to FIG. 2. Some of the preferred embodiments of the HF AC voltage regulator include, but not limited to, the topologies of HF AC series buck voltage regulators as disclosed in U.S. Non-provisional Patent Application No. 14/525,230 and U.S. Non-provisional Patent Application No. 14/565,444. Described in the '230 patent application and shown herein again in FIG. 2 is a HF series AC buck voltage regulator with bidirectional AC switches Q1 and Q2. In addition, HF filter components are added to suppress and filter the HF (e.g. 1 kHz1,000 kHz) switching frequency on the input and output. Filter inductors L1 and L2 with filter bypass capacitors C1 and C2 on the input; and filter inductors L4 and L5 with filter bypass capacitors C3 and C4 on the output. Capacitors C2 and C3 are optional depending on the components used and the operating frequency. Inductor L3 is a power inductor that is designed to operate at HF (e.g. 1 kHz to 1,000 kHz).

[0026] The AC switching devices Q1 and Q2 switch at HF (e.g. 1 kHz to 1,000 kHz) under electronic control either through analogue or mixed analogue or digital circuitry, but typically digital control circuitry with DSP or microprocessor signal processing. The outputs from the control electronics drive the AC semiconductor devices with HF (e.g. 1 kHz to 1,000 kHz) modulated PWM modulation, and at each HF point along the LF mains AC voltage input, typically at 50 Hz or 60 Hz, the control electronics generates a specific pulse of width wide enough to drive the AC switches Q1 and Q2 to generate a negative differential voltage in combination with power inductor L3, hence bucking and regulating the output voltage at each point along the input AC voltage to the desired value set by the internal control reference.

[0027] For example, if the control is switching at a design frequency of 25,000Hz, then every 40 microseconds the amplitude of the input mains LF voltage, typically at 50 Hz or 60 Hz, is bucked and decreased at that point, against the set internal voltage reference. Thus, every 40 microseconds the circuit bucks the input AC voltage to adjust and regulate the desired set output AC voltage.

[0028] The input filter comprises capacitors C1 and C2, and filter inductors L1 and L2. The output filter comprises capacitors C3 and C4, and filter inductors L4 and L5. Alternatively, various combinations of HF filter elements can be used to filter and bypass the HF switching frequencies of the AC bidirectional semiconductor switches, switching at HF, such as in this example, at 25,000Hz.

[0029] The circuitries and description thereof disclosed herein are simplified for clarity and various other circuit configurations and devices can be used in applying the principles of the present invention. For instance, the bidirectional AC switches are semiconductor devices and can comprise of various circuit configurations, but these switches are still acting as AC bidirectional semiconductor switches as used commonly in the industry. Such Bidirectional AC semiconductor switches, for example, but not limited to, can be a rectifier bridge comprising of four rectifiers with a unipolar semiconductor device configuration inserted in the bridge such as SCR, GTO, IGBT, MOSFET, or any other semiconductor device used for the same effect with PWM drive control that can create a controlled bidirectional AC semiconductor switch device. Also, other semiconductor AC switch configurations and devices used in the industry with or without rectifiers such as back-to-back or anti-parallel-SCR's, GTO, IGBT, RB-IGBT, MOSFET, any other back-to-back or anti-parallel bidirectional AC semiconductor devices or configurations, or any other similar new semiconductor devices in the future, such as, but not limited to, GaN, SiC are some of the alternative embodiments of the present invention.

[0030] Still referring to FIG. 2. The HF series buck AC voltage regulator that utilizes HF (e.g. 1 KHz-1,000 KHz) power inductor L3 in combination with AC bidirectional semiconductor switches Q1 and Q2, which are driven by an electronic control circuit, creates a novel topology that can decrease the input AC voltage and regulate the AC output voltage to a set desired optimum energy savings level. Furthermore, this HF series buck AC voltage regulator only has to process the differential power across the buck inductor (power inductor L3) to decrease the input to a regulated output AC voltage. This configuration has a much less power consumption in relative to the total output power. The buck inductor only has to handle the power required to adjust the differential input AC voltage to reduce the output AC voltage to the desired optimum energy savings set level.

[0031] Under the condition of that the mains AC input voltage falling below the selected optimum energy savings set level, the control electronics senses the input AC mains voltage, transitions the bypass contactor K1 as well as the bidirectional AC semiconductor device S1 connected in parallel with the bypass contactor K1, then disengages the series buck AC voltage regulator power electronics. The fast bidirectional AC semiconductor device S1 initially bypasses the HF series buck AC voltage regulator, then the slower bypass contactor K1 contacts close and fully bypass the HF AC voltage regulator and including the bidirectional AC semiconductor device S1 connected in parallel with the bypass contactor K1.

[0032] Firstly, the electronic control switches out the HF AC voltage regulator, which saves the HF AC voltage regulator internal power electronics energy usage. Secondly, the low AC mains input voltage is applied directly to the load, bypassing any voltage drop of the HF AC voltage regulator power electronics to achieve additional energy savings.

[0033] The bidirectional AC semiconductor device S1 shown in FIG. 2 is a TRIAC. However, the bidirectional AC semiconductor device can also be a rectifier bridge consist of four rectifiers with a unipolar semiconductor device configuration inserted in the bridge such as SCR, GTO, IGBT, MOSFET, back-to-back SCR's or TRIAC's; or any other bidirectional AC semiconductor device used for the same effect with drive control that can create a controlled bidirectional AC semiconductor switch device connected in parallel with the bypass contactor K1. Depending on the circuitry and application, any ordinarily skilled person in the art can design either zero voltage switching or any other controlled timing, and galvanic isolated or non-isolated switching of the bidirectional AC semiconductor device. Other semiconductor AC switch configurations and devices used in the industry such as back to back SCR's, GTO, IGBT, MOSFET, any other back to back bidirectional AC devices, or any other similar devices and switched by isolated or non-isolated means are various embodiments of the present invention.

[0034] Still referring to FIG. 2. A series current limiting resistor R1 is connected in series with the bidirectional AC semiconductor device S1 if necessary to limit the current going through the bidirectional AC semiconductor device S1. The series current limiting resistor R1 may, however, be omitted depending upon the specification and sizing of the bidirectional AC semiconductor device, bypass contactor contacts rating, and the designed surge currents. When the bypass contactor K1 contacts are opened or closed under the control electronics, the fast bidirectional AC semiconductor device S1 is also activated along with the slower contactor transition. On closing the bypass contactor K1 contacts, the electronics including the bidirectional AC semiconductor device S1 are completely bypassed. Upon opening, the bypass contactor K1 contacts are protected by the bidirectional AC semiconductor device S1 that continues to carry the bypass current until the bypass contactor K1 contacts are fully open, thus protecting the contactor contacts from current interruption.

[0035] Under the condition of high current surges, either from load surges or fault load currents, the bypass contactor K1 in combination with the bidirectional AC semiconductor device S1 bypass these high current surges by the control electronics detecting the current surge, activating the fast bidirectional AC semiconductor device and closing the bypass contactor contacts. Also, both the bypass contactor K1, and the bidirectional semiconductor device S1 are specified and sized to take the high surge currents, before the slower contactor contacts close to safely bypass the surge current from the electronics including the bidirectional AC semiconductor device. Once the surge has passed, or if it continues safely through the bypass contactor K1 closed contacts and triggers an external standard back up breaker, the control electronics detects the normal power and initiates a startup routine to return the unit to normal operation.

[0036] It will be obvious to any ordinarily skilled person in the art that a bidirectional AC semiconductor device can be used without an electromechanical bypass contactor. However, any bidirectional AC semiconductor device always has a much higher power dissipation with passing currents than the metal-metal contacts of an electromechanical bypass contactor. It is an alternative embodiment of the present invention to use only bidirectional AC semiconductor devices in place of the combination of S1 and K1 shown in FIG. 2.

[0037] It is to be noted that the bypass contactor K1 shown in FIG. 2. can be a normally close (NC) or normally open (NO) contacts, depending upon the desired application. In the present invention, the preferred embodiment for the contactor contacts of the bypass contactor K1 are normally closed (NC) and the electronics control can open and close the contactor contacts by energizing (contacts open) or de-energizing (contact closed). The reason for the use of NC contacts is that since the bypass contactor K1 is a bypass contactor, and if the input power fails, or the unit electronics fail, the contactor will then be deactivated, and the bypass contact will be closed. Firstly for input power failure or interruption, the unit and its power electronics are fully bypassed, and when input power resumes the contactor bypass will already be in place due to the NC contactor bypass contacts, and the control electronics, after a specified time period by the control electronics, can initiate a start-up routine to return the unit to normal operation.

[0038] The embodiments disclosed herein may be implemented using general purpose or specialized computing devices, computer processors, microcontrollers, or electronic circuitries including but not limited to digital signal processors (DSP), application specific integrated circuits (ASIC), field programmable gate arrays (FPGA), and other programmable logic devices configured or programmed according to the teachings of the present disclosure. Computer instructions or software codes running in the general purpose or specialized computing devices, computer processors, or programmable logic devices can readily be prepared by practitioners skilled in the software or electronic art based on the teachings of the present disclosure.

[0039] The foregoing description of the present invention has been provided for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many modifications and variations will be apparent to the practitioner skilled in the art.

[0040] The embodiments were chosen and described in order to best explain the principles of the invention and its practical application, thereby enabling others skilled in the art to understand the invention for various embodiments and with various modifications that are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the following claims and their equivalence.