Rockwell Automation Technologies Incorporated

Allen-bradley Company, LLC

Rockwell Technologies, Inc.

Gary Leonard Skibinski

Lixiang Wei

Richard Lukaszewski

Zhijun Liu

Nickolay N Guskov

Zoran Vrankovic

Dongsheng Zhou

Russel J Kerkman

David Leggate

Gennadi Sizov

Craig R Winterhalter

Todd M Oestreich

Brian R Buchholz

David W Kirschnik

Rangarajan M Tallam

Ahmed Mohamed Sayed Ahmed

Brian Patrick Brown

David A Figie

Carlos Daniel Rodriguez-Valdez

Adam M Shea

Frederick Louis Hoadley

Walt A Maslowski

Russ J Kerkman

Yao Da

Nick Guskov

Jeffrey R Annis

Qiang Yin

David W Schlegel

Thomas Gilmore

Dennis Braun

Henrik B Nielsen

Jay M Erdman

Ahmet M Hava

Gary R Woltersdorf

James J Valasek

Bruce A Hachey

Peter K Meyer

William Jonn Sarver

William John Sarver

Steven J Krautkramer

John Wilkins

Jesus Mariscal

Rick Hoadley

James P Clavette

Naihu Li

Richard A Lukaszewski

Systems, methods and power converters are disclosed to provide regulated individual DC output signals to anode structures using a PWM inverter to generate a first AC signal, a sinewave filter to provide a filtered AC signal, a multiphase isolation transformer to provide a plurality of isolated AC signals, a multi-pulse diode bridge rectifier to provide a DC rectifier output signal, an output filter to provide a filtered DC rectifier output signal, and a blocking diode to provide the filtered DC rectifier output signal.

Adjustable AC/DC conversion topology to regulate an isolated DC load with low AC ripple

A line interface filter apparatus to couple a drive or group of drives to a shared multiphase AC bus, including individual phase circuits having an inductor coupled between a respective bus and drive phase lines, a tapped resistor coupled to the respective drive phase line, and a capacitor coupled between the resistor and a common connection of the capacitors of the individual phase circuits, where the capacitance of the capacitors is 5 to 15 times a per-phase equivalent capacitance of the drive or group of drives, and the resistance of the resistors is two times a damping ratio times a square root of a ratio of the filter inductance to the filter capacitance, where the damping ratio &#x3b6; is greater than or equal to 1.0 and less than or equal to 2.0.

Method and apparatus to mitigate DC bus over-voltages on common AC bus systems utilizing DC and AC drives

A motor drive that outputs a sinusoidal waveform utilizes power switching devices operable at high switching frequencies. The switching devices may be operated, for example, between twenty kilohertz and one megahertz. A first filter is included at the output of the motor drive which has a bandwidth selected to attenuate voltage components at the output which are at the switching frequency or multiples thereof such that the output voltage waveform is generally sinusoidal. Additional filtering is included within the motor drive to establish a circulation path for common mode currents within the motor drive. Further, a shield is provided adjacent to those components within the motor drive that may experience voltage or current waveforms at the switching frequency or multiples thereof to cause radiated emissions to establish eddy currents within the EMI shield rather than passing through the shield into the environment.

System and method for sinusoidal output and integrated EMC filtering in a motor drive

A method and line interface filter apparatus to couple a drive or group of drives to a shared multiphase AC bus, including individual phase circuits having an inductor coupled between a respective bus and drive phase lines, a resistor coupled to the respective drive phase line, and a capacitor coupled between the resistor and a common connection of the capacitors of the individual phase circuits, where the capacitance of the capacitors is 5 to 15 times a per-phase equivalent capacitance of the drive or group of drives, and the resistance of the resistors is two times a damping ratio times a square root of a ratio of the filter inductance to the filter capacitance, where the damping ratio is greater than or equal to 1.0 and less than or equal to 2.0.

A motor controller executing a current regulator and a modulation routine in separate update intervals provides an improved fundamental voltage waveform for a motor controlled by the motor controller. The current regulator is executed at a first periodic update rate and the modulation routine is executed at a second periodic update rate, where the frequency at which the modulation routine executes is at least twice the frequency at which the current regulator executes. Executing the current regulator and the modulation routines at different frequencies results in the current regulator generating a single voltage reference signal for multiple periods of the modulation routine. To reduce voltage ripple induced by decoupling execution of the current regulator and the modulation routine, the motor controller extrapolates the voltage reference generated by the current regulator into multiple voltage reference signals, where a unique voltage reference signal is provided for each period of the modulation routine.

Voltage rotator for high switching frequency PWM inverter

A precharge system for precharging a DC bus circuit includes a first input, first and second circuit branches, and a controller, where the first circuit branch includes a first contactor between the first input and an AC to DC converter, the second circuit branch has: a disconnect switch coupled to the first input; a variable frequency drive (VFD) with an AC input coupled to the disconnect switch; an inductor coupled to an AC output of the VFD; and a second contactor coupled to the inductor. The precharge VFD provides precise control of the precharge operation such as charging time, current limiting, short-circuit and ground fault protection, monitoring DC Bus capacitance and verifies the health of the shared DC bus circuit through startup diagnostic. The controller opens the first contactor and closes the second contactor and the disconnect switch in a first mode to precharge the DC bus circuit using the VFD, and in a second mode, the controller closes the first contactor and opens the second contactor and the disconnect switch.

DC bus precharge system

A modulation routine in a motor drive under lightly loaded conditions which prevents DC bus voltage pump-up includes both active states and zero states. In a first zero state, each phase of the motor is connected to a negative rail of the DC bus, and in a second zero state, each phase of the motor is connected to a positive rail of the DC bus. When motor is lightly loaded or unloaded such that DC bus voltage pump-up may occur, the two zero states are utilized in an uneven manner. The specific division of the zero state between the first and second zero states may be selected in a manner that prevents the DC bus voltage pump-up from occurring.

Method and apparatus for mitigation of DC bus pump-up

Electroplating and painting systems, methods and power converters are disclosed to provide regulated individual DC output signals to anode structures distributed in a plating solution in a tank to promote formation of plating material on a workpiece using a PWM inverter to generate a first AC signal, a sinewave filter to provide a filtered AC signal, a multiphase isolation transformer to provide a plurality of isolated AC signals, a multi-pulse diode bridge rectifier to provide a DC rectifier output signal, an output filter to provide a filtered DC rectifier output signal, and a blocking diode to provide the filtered DC rectifier output signal to the corresponding tank anode structure.

Disclosed examples include enclosures with segregated or divided cooling paths and improved arc flash resistance. In one example, a TYPE 12, 50 DEGREE C. ambient common bus power conversion enclosure design provides enhanced arc flash protection & segregated cooling for high reliability of imbedded electronics. Example enclosures and systems can be used in association with AC/DC converters for motor drives or motor control centers, and/or for electroplating or painting systems with modular anode control (MAC) systems to implement an anodic DC electroplating for workpieces and other end use applications.

Arc flash resistant enclosure with segregated cooling

A thermal well temperature monitoring assembly with high dielectric strength capability is disclosed consisting of a low relative dielectric constant material in a continuous structure that does not have any air voids or pockets. The low relative dielectric constant structure of the thermal well has at least one internal cavity having an end region. A thermal sensor is at least partially located within the at least one internal cavity. The thermal sensor has one or more wires extending out of the end region of the internal cavity. A first low relative dielectric constant potting material encapsulates at least a portion of the thermal sensor within the internal cavity to remove air voids that decrease dielectric strength. A second low relative dielectric constant potting material fills at least a portion of the end region of the internal cavity to provide mechanical ruggedness and environmental sealing.

Thermal well for transformer and methods

A filter for reducing radiated emissions in switching power converters such as a motor drive is disclosed. The switching power converter modulates a DC voltage input to generate a desired AC voltage output. Capacitors are connected in parallel between each output phase and a common connection, which may be a ground connection. The magnitude and layout of the capacitors are selected to minimize current conducted by the capacitors. The capacitors may be surface mount technology located proximate to the switching devices or the capacitors may be incorporated in the circuit board on which the switching devices are mounted. The filter may be applied to any of the switching elements in a motor drive, such as the inverter section, an active rectifier section, or a switched mode power supply.

Method and apparatus for reducing radiated emissions in switching power converters

A method is provided for detection of a ground fault in a high resistance network in a voltage source power conversion circuit comprising a power converter that converts incoming AC power to DC power applied to a DC bus and an inverter that converts DC power from the DC bus to output AC power. The method includes detecting a midpoint-to-ground voltage between a low side of the DC bus and a ground potential and detecting the presence of a ground fault in a high resistance network based upon the detected midpoint-to-ground voltage.

System for detection of a ground fault in a high resistance ground network

The present techniques include methods and systems for detecting the grounding condition of an electrical system to automatically determine a suitable electrical drive configuration. The drive includes a test resistor which may be connected or disconnected from the drive to measure different drive voltages. The measured drive voltages are analyzed to determine a type of grounding configuration of the electrical system in which the drive is to be installed. Embodiments also include determining ground resistance condition such as a high resistance ground (HRG) fault or a ground resistance fault when the drive is in operation.

Ground scheme identification method

Growing community of inventors

Milwaukee, WI, United States of America

Gary Leonard Skibinski