CONVERTER ASSEMBLY AND METHOD FOR OPERATING A CONVERTER ASSEMBLY

Abstract

The invention relates to a converter assembly comprising at least two converters (7, 7ʹ) and a control unit (1) connected to the converters (7, 7ʹ), wherein the control unit (1) is designed, continuously or at discrete time intervals, to transmit to the converters (7, 7ʹ) their permissible electrical power range, in particular their minimum power value P.sub.min and/or their maximum power value P.sub.max, to determine the current power balance of the individual converters (7, 7ʹ) or to receive it from same, and to adjust the permissible electrical power range of the converters (7, 7ʹ) in such a way that the power balance of the entire converter assembly does not leave a predefined range. The invention also relates to a method for operating a converter assembly of this type.

Claims

1. Converter assembly comprising at least two converters and a control unit connected to the converters, wherein the control unit is designed, continuously or at discrete time intervals, to transmit to the converters their permissible electrical power range, in particular their minimum power value Pmin and/or their maximum power value Pmax, to determine the current power balance of the individual converters or to receive it from same, and to calculate the power balance of the entire converter assembly, and to adjust the permissible electrical power range of the converters in such a way that the power balance of the entire converter assembly does not leave a predefined range.

2. Converter assembly according to claim 1, wherein, in order to determine the current power balance of the converters, the control unit is connected to at least one voltage sensor to measure the input voltage of the converters and to current sensors to measure the input currents of the converters.

3. Converter assembly according to claim 1 , wherein the converters are supplied by a DC voltage intermediate circuit and the control unit is connected to a voltage sensor to measure the voltage VDC in the DC voltage intermediate circuit .

4. Converter assembly according to claim 1, wherein, in order to determine the current power balance of the converters, the control unit is connected to voltage sensors to measure the output voltage of the converters and to current sensors to measure the output currents of the converters .

5. Converter assembly according to claim 1, wherein the converters are connected to voltage sensors to measure their output voltage and to current sensors to measure their output currents, and are designed to transmit the measured values to the control unit.

6. Converter assembly according to claim 1 , wherein the control unit is designed to adjust the permissible electrical power range of the converters if the input voltage of the converters, in particular the voltage VDC of a DC voltage intermediate circuit supplying the converters, falls below a predetermined threshold value or exceeds a predetermined threshold value.

7. Converter assembly according to claim 1, wherein a discharge device connected to the control unit is provided to reduce the voltage in a DC voltage intermediate circuit, and the control unit is designed to activate the discharge device if the voltage in the DC voltage intermediate circuit exceeds a predetermined threshold value.

8. Converter assembly according to claim 1 , wherein the converters are designed as active front-end converters with bidirectional power flow.

9. Converter assembly according to claim 8, wherein the converters are used as machine converters in a drive test stand or as DC-DC converters in a battery test stand.

10. Converter assembly according to claim 1, wherein at least two of the converters are designed as line converters, in particular AC-DC converters, which supply separate sub-networks, preferably in the form of separate DC voltage intermediate circuits, from a central network, wherein the control unit is designed to adjust the permissible electrical power range of the converters in such a way that the power balance of the converters of the central network does not leave a predetermined range.

11. Converter assembly according to claim 10, wherein at least two further converters are arranged in at least one of the sub-networks, wherein the control unit is designed to adjust the permissible electrical power range of the converters in such a way that the power balance of the converters of each sub-network does not leave a predetermined range.

12. Method for operating a converter assembly with at least two converters and a control unit connected to the converters, comprising the following steps: a. transmitting, via the control unit (1), a permissible electrical power range to the converters, in particular a minimum power value Pmin and/or a maximum power value Pmax, b. receiving or calculating, via the control unit, the current power balance of the individual converters, c. calculating, via the control unit, the power balance of the entire converter assembly, and d. adapting, via the control unit, the permissible electrical power range of the converters in such a way that the power balance of the entire converter assembly does not leave a predetermined range.

13. Method according to claim 12, wherein, in order to calculate the current power balance of the converters, the control unit receives the input voltage of the converters from at least one voltage sensor and the input currents of the converters from current sensors.

14. Method according to claim 12 , wherein the control unit receives the voltage VDC of a DC voltage intermediate circuit from a voltage sensor.

15. Method according to claim 12 , wherein the control unit receives the output voltages of the converters from voltage sensors and the output currents of the converters from current sensors.

16. Method according to claim 12 , wherein the converters are connected to voltage sensors to measure their output voltage and to current sensors to measure their output currents, and transmit the measured values to the control unit.

17. Method according to claim 12 , wherein the control unit adjusts the permissible electrical power range of the converters if the input voltage of the converters, in particular the voltage VDC of a DC voltage intermediate circuit supplying the converters, falls below a predetermined threshold value or exceeds a predetermined threshold value.

18. Method according to claim 12 wherein the control unit activates a , discharge device connected to the control unit to reduce the voltage in a DC voltage intermediate circuit if the voltage in the DC voltage intermediate circuit exceeds a predetermined threshold value.

19. Method according to claim 12 , wherein the control unit, adjusts the permissible electrical power range of the converters of a central network in such a way that the power balance of the converters of the central network does not leave a predetermined range, and adjusts the permissible electrical power range of the converters of at least one sub-network in such a way that the power balance of the converters of each sub-network does not leave a predetermined range.

20. Computer-readable storage medium comprising computer-readable instructions that cause an electronic control unit , for example a computer, a microcontroller or a microprocessor, to carry out a method according to claim 12.

Description

[0032] Further features according to the invention arise from the claims, the figures and the following description of the figures. The invention is explained below on the basis of non -exclusive exemplary embodiments.

[0033] FIG. 1 shows a schematic block diagram of the topology of a converter assembly according to the invention in a test stand for drives;

[0034] FIG. 2 shows a schematic block diagram of the topology of a converter assembly according to the invention in a test stand for batteries (so-called battery cycler);

[0035] FIGS. 3a-3b show schematic block diagrams of the topologies of converter assemblies according to the invention in a hierarchical network structure with two sub-networks.

[0036] FIG. 1 shows a schematic block diagram of the topology of an exemplary embodiment of a converter assembly according to the invention in a test stand for drives. The test stand includes a line converter that converts a central network 14 (multiphase AC line voltage) available at the test stand into a DC voltage of around 820 V. This DC voltage is referred to as intermediate circuit voltage (DC link) and is available at the test stand to supply the device under test. The line converter is a DC voltage converter (AC-DC converter) in the form of a switched active front-end bridge rectifier.

[0037] In this exemplary embodiment, the test stand is designed for testing the electrical and mechanical components of a drive device under test 13 with a drive unit 11, for example an electric motor, and a transmission 12. The drive which is to be tested may be the drive of a motor vehicle, in particular an electric vehicle or a hybrid vehicle. In this exemplary embodiment, two electrical machines 16, 16' (load machines, so-called dynamometers) are provided which are coupled to the shaft of the drive device under test 13. These electrical machines 16, 16' are supplied by two converters 7, 7' (machine converters) which convert the intermediate circuit DC voltage V.sub.DC into an AC voltage. The converters 7, 7' are designed as AC voltage converters (DC-AC converters), for example as switched active front-end bridge inverters.

[0038] In addition to the mechanical drive train of the drive 13, the electric drive unit 11 of the drive device under test 13 is also tested in this exemplary embodiment. For this purpose, the test stand includes a further bidirectional converter 7ʺ which is connected to the intermediate circuit 9 and provides the drive unit 11 with a variable AC voltage. Depending on the operating state, the drive unit 11 consumes power or supplies power to the intermediate circuit.

[0039] Current sensors 6, 6ʹ, 6ʺ are arranged in the DC voltage input lines of the converter 7, 7ʹ, 7ʺ, and a voltage sensor 5 is arranged in the DC voltage intermediate circuit 9. These sensors continuously supply measured values of the voltage in the intermediate circuit 9 and the input currents of the converters 7, 7ʹ, 7ʺ to a control unit 1 via a data bus 10. In this exemplary embodiment, the converter assembly includes the three converters 7, 7ʹ, 7ʺ, but not the line converter.

[0040] The control unit 1 is connected to the converters 7, 7ʹ, 7ʺ and to a discharging device 8, likewise via the data bus 10. These connections are used to specify for the converters a permissible power range and, optionally, a power setpoint P.sub.soll, or to activate the discharge device 8 to reduce the voltage in the intermediate circuit 9.

[0041] In this exemplary embodiment, the control unit 1 is designed as an electronic microcontroller with a central data processing unit (CPU) 2, for example an ARM microprocessor or an ASIC. The data processing unit 2 is connected to a storage unit 3 and an interface unit 4 via a data bus. The storage unit 3 can be any machine-readable data memory, for example a non-volatile semiconductor memory or volatile semiconductor memory, ROM, EPROM, EEPROM, RAM, SRAM, flash memory and the like.

[0042] The interface unit 4 can be based on industry standards such as USB, FireWire, Ethernet, USART, I2Sand the like. Wireless network protocols can also be provided, such as Wi-Fi, Bluetooth and the like. Embodiments of suitable control units are part of the general expertise of the skilled person, so that not every component of the control unit 1 needs to be explained in detail.

[0043] During operation, the control unit 1 continuously measures the voltage in the intermediate circuit 9 and the currents of the converters 7, 7ʹ, 7ʺ, and provides the converters 7, 7ʹ, 7ʺ in each case with power setpoints and their permissible power ranges. If the DC voltage measured by the DC voltage sensor 5 falls below a predetermined threshold value, or if this DC voltage exceeds a predetermined threshold value, then the control unit 1 adapts the permissible power range in such a way that the voltage drop or voltage rise is counteracted. This ensures that the voltage in the intermediate circuit 9 always remains within a certain bandwidth, so that the line converter is only moderately loaded.

[0044] Ideally, the control unit 1 adapts the power flows of the converters 7, 7ʹ, 7ʺ in such a way that the line converter is only required to the cover the power loss. This can be achieved if at least one of the converters 7, 7ʹ, 7ʺ supplies power to the intermediate circuit 9, and at least one of the converters 7, 7ʹ, 7ʺ draws power from the intermediate circuit 9. The control unit 1 may be designed to actively induce such “back-to-back” operating states, even if this involves modifying predefined test models. This makes it possible to achieve a particularly compact dimensioning of the line converter.

[0045] FIG. 2 shows a schematic block diagram of the topology of another exemplary embodiment of a test stand for batteries according to the invention (so-called battery cycler). In this exemplary embodiment, four active front-end converters 7, 7ʹ, 7ʺ, 7ʺʹ controlled by the control unit 1 are provided which are each designed as switched DC/DC converters and which charge or discharge a battery 15, 15ʹ, 15ʺ, 15ʺʹ. In this exemplary embodiment, the converter assembly includes the four converters 7, 7ʹ, 7ʺ, 7ʹʺ, but not the line converter which generates the intermediate circuit voltage.

[0046] The functionality of the control unit 1 is similar to the exemplary embodiment according to FIG. 1. The control unit 1 adapts the permissible power ranges of the converters 7, 7ʹ, 7ʺ, 7ʹʺ in such a way that the sum of the powers of the converters lies below a predetermined threshold value.

[0047] In the event that the voltage in the intermediate circuit 9 exceeds a predetermined threshold value, the control unit 1 activates a discharge unit 8, for example a heating resistor, in order to relieve the intermediate circuit. In the event that the voltage in the intermediate circuit 9 falls below a different threshold value, the control unit 1 reduces the power ranges of individual or all converters, so that the voltage in the intermediate circuit 9 recovers again.

[0048] Instead of the individual batteries 15, 15ʹ, 15ʺ, 15ʺʹ, in exemplary embodiments which are not shown, separate battery cells or battery modules (combinations of battery cells) can also be tested.

[0049] FIGS. 3a-3b show schematic block diagrams of the topologies of converter assemblies according to the invention in a hierarchical network structure with two sub-networks. In FIG. 3a, two sub-networks 17, 17ʹ are provided which are supplied by a central network 14 (3-phase AC network) via converters 7, 7ʹ. In this exemplary embodiment, the converters 7,7ʹ are line converters, i.e. rectifiers which each supply a DC voltage intermediate circuit 9, 9ʹ. Voltage sensors 5, 5ʹ are arranged in the DC voltage intermediate circuits 9, 9ʹ which supply their measured values to a control unit 1 via the data bus 10. Furthermore, current sensors 6, 6ʹ are arranged in the DC lines of the converters 7, 7ʹ which also supply their measured values to a control unit 1 via the data bus 10. The DC voltage intermediate circuits 9, 9ʹ supply two converters for testing batteries 15 in the first sub-network 17, and in the second sub-network 17ʹ supply a converter for operating an electrical machine 16 for testing a drive device under test 13. However, these converters are not connected to the control unit 1.

[0050] The control unit 1 ensures a measured balance between the two sub-networks 17, 17ʹ by continuously transmitting permissible power ranges to the converters 7, 7ʹ via the data bus 10. If necessary, the control unit 1 can also activate one of the two discharge devices 8, 8ʹ to reduce the voltage in the intermediate circuits 9, 9ʹ. However, an active influencing of the powers of the converters in the sub-networks does not take place in this exemplary embodiment.

[0051] FIG. 3b shows a direct further development of the exemplary embodiment according to FIG. 3a. In this exemplary embodiment, the two converter 7ʺ, 7ʹʺ of the sub-network 17, which test the batteries 15, are also connected to the control unit 1 via the data bus 10.

[0052] Thus, the control unit 1 can not only balance the power of the sub-networks 17, 17ʹ with respect to the central network 14 but also, within the sub-network 17, supply the two converters 7ʺ, 7ʺʹ with permissible power ranges in such a way that the power balance in the sub-network 17 remains within a predetermined range. Such a design is particularly advantageous in practice, since it allows the operation of various test systems on a common central network 14.

[0053] In other exemplary embodiments, not shown, not the control unit, but each converter itself is connected to internal or external voltage sensors to measure their output voltage and to internal or external current sensors to measure their output currents. The converter transmits these measured values for current and voltage to the control unit, or calculates its current power balance itself and transmits this to the control unit. Naturally, exemplary embodiments are also envisaged in which some of the controlled converters determine their power balance themselves, and others do not determine their power balance themselves; instead, the control unit is responsible for determining the power balance of these converters. In this respect, the invention is not limited to the exemplary embodiments described above.

[0054] However, the invention is not limited to the present exemplary embodiments, but includes all converter assemblies and methods for operating converter assemblies within the framework of the following claims.

[0055] Terms used herein such as converter, line converter or machine converter should not be interpreted too narrowly. A converter according to the invention, be it a machine converter or a line converter, can be understood as any controlled electrical and/or electronic circuit that converts one DC voltage into another DC voltage or AC voltage, or converts an AC voltage into another AC voltage or DC voltage. Such a circuit may for example, but not exclusively, be a direct converter, a matrix converter, an AC voltage converter, a DC voltage converter, a switched bridge inverter, a switched bridge rectifier or the like. The concrete realisation of the converter in terms of circuitry is not critical. Converters provided according to the invention can also feature internal galvanic isolation and can be intended for high electrical powers, for example powers in the region of 100 kW at a DC voltage of 850 V or 300 kVA alternating current power.

[0056] List of reference signs [0057] 1 control unit [0058] 2 data processing unit [0059] 3 storage unit [0060] 4 interface unit [0061] 5, 5ʹ voltage sensor [0062] 6, 6ʹ, 6ʺ, 6ʺʹ current sensor [0063] 7, 7ʹ, 7ʺ, 7ʺʹ converter [0064] 8, 8ʹ discharge device [0065] 9, 9ʹ DC voltage intermediate circuit [0066] 10 data bus [0067] 11 drive unit [0068] 12 transmission [0069] 13 drive device under test [0070] 14 central network [0071] 15, 15ʹ, 15ʺ, 15ʹʺ battery [0072] 16, 16ʹ electrical machine [0073] 17, 17ʹ sub-network