«2 United States Patent Hammond et al. (54) MULTIPHASE POWER SUPPLY WITH SERIES CONNECTED POWER CELLS WITH. FAILED CELL BYPAS' (75) Inventors: Peter W. Hammond, Westmoreland County; Mare F. Aiello, Allegheny County, both of PA (US) (73) Assignee: Robieon Corporation, New Keasington, PA (US) (1) Notice: Subject 10 aay disclaimer, the term of this patent is extended or adjusted under 35 USC 154(b) by 0 days Appl. No. O9/413,563 Filed: Oct. 6, 1999 Related US. Application Data (62) Division of application No. 09)082,885, filed on May 21, 1998, now Pat No. 5,985,909, G1) In. ch HO1H 33/32; HO1H 900, HOLH 83/00 us. cl 307/125; 320/122; 320/120; 200/43. 16; 204290; 200/318; 200/323; 307/144 (58) Field of Search 20/1 R, 43.16, 200/290, 318, 323; 307/125, 142, 144, 54, 71; 320/126, 1 (56) References Cited S. PATENT DOCUMENTS 9/1971 Beck ors ste \ 8 sid | “1 |TRIP-AELEASE | J —7 een) l 315 ir aif oes 3,600,507 303/56 316~ 'US006222284B1 00 Patent No: US 6,222,284 BL (45) Date of Patent: Apr. 24, 2001 4939.25 BOTT Fletcher ta 369/70 445025 4/1979 Nagano ot al 363156 4303877 * 12/1981 Meinbold 3206 4A26511 1/1984 Espelage eta 36971 44698°738 10/1987 Miler et 26365 51008797 41991. Patel eta 36337 SD73848 121991 Steigerwald et al 36305 1/1993. Tokiwa et al. 36365 611994. Malik 3680 $1997 Hammond 36371 5.708.576 1/1998 Jones et al 26305 57710304 + 1/1998. Pascual et al 3206 5.744936 * 4/1998 Kawakami 3201120 53814970 * 911998. Schmiah sn0/122 SS0.136 * 12/1998 Kancko 320/122 5808239 * 4/1999 Kava 307/125 5052815 * 91999 Rovllard ta. 320/122 FOREIGN PATENT DOCUMENTS. 452m 11970 GP) * cited by examiner Primary Examiner—osie Ballato Assistant Examiner—Rios Roberto (74) Auorney, Agent, or Firm—Buebsa 67) ABSTRACT. sn Ingersoll, PC. A igh output level is maintained in power supplies having, ‘multiple cells in each leg. Failed cells in any leg are bypassed to provide a current path through the respective leg. Allof the uafailed cells sre utilized while maintaining equal magnitude between phases and a halance phase reli tionship in the line-to-ine output voltage. The invention ‘may be utilized in conjunction with a peak voltage reduction circuit, and a by-pass switch, 5 Claims, 14 Drawing ee 322) a [ca [ [esU.S. Patent Apr. 24, 2001 Sheet 1 of 14 US 6,222,284 BL N L-2 Tr CELL cy At 4 CELL £ By CELL coy Cy cé CELL 30 Ag INPUT ctw ee TRANSFORMER | HL : Cp £ 9 CELL 1 Ag 10 CELL Q E loo, . a ca CELL C3 & 2 CELL Ag 13 CELL By 14 CELL C4 76 CELL As. 5 CELL Bs a7 CELL Cg a 1B Cc FIG. ta 2-{uoroF]U.S. Patent Apr. 24, 2001 Sheet 2 of 14 US 6,222,284 BL 65 86 67 LOCAL FIBEROPTIC MASTER CONTROLLER|—| MODULATOR MODULATION CONTROL LINK CONTROLLER FIG. 1b +——+ 1 84 Thee 788 94 » ie Eq ‘a [GAIN a . ° + LKa | —{X 82 ny x B [GAIN : 7 “Ls T ~—{(z 83 Vc [GAIN | “GS Eg Ko = 92 85 87 89 95: "FIG. 11U.S. Patent Apr. 24, 2001 Sheet 3 of 14 US 6,222,284 BL PWM MODULATOR POWER WITH PHASE-SHIFT CELLS MA, on MAy ot MAg ea MAg ie MAg ol MB, aa Ow MB, = MASTER | _ vB" a CONTROLLER] yo. MBg By MB, a MBs esi MC, fea MCy ica MC3 Cs MC, Es FIG. 1c cs cat LL FIBER OPTICSUS 6,222,284 BI Sheet 4 of 14 Apr. 24, 2001 U.S, Patent ONISI s STVNINY3L ANdLNO 1130 x UL PL ‘Old SHOLSISNVUL S3IW3S SNVAW SSVdAd SIVNHALT (41) 3AIUG V NI $1130 G3L0SNNOO {| -SalUaS TWH3IASS dO 3NO SV 3SN HOS HYALYAANOOD YSMOd 69 SS¥dAd LOVLNOO G30VOT-ONIYdS ¥ ONISN SNV3W SSVdAg SLVNYSLTV (1) s STVNINYSL 4NdLno AOAC asvaiau-didL| AIC W NI ST140 GALOSNNOO “SHIMSS WWHAASS 110 40 3NO SW 3SN HOd f° AI HSLHSANOO HAMOd u J 69 ssvaag ONIHAS SYOS TATIVEYd-LLNV DNISN SNWA SSVdA FLYNT (2!) x SNUG V NI STWNIWUSL $1130 GSLOSNNOO LndLno “S3IH3S TVH3A3S 730 4O 3NO Sv 3SN HOd : | uaLHSIANOO WaMOd 69 SS¥dAa WOLOVINOO OLLANOWWN ¥ ONISN SNVSIN SSVAAG SLVNYELIV (1) a SAH V NI STWNINHAL $7130 G3L03NNOO indino /-.--- C) -S3IdaS Tvu3ASS 7130 40 3NO Sv 3SN YOd jd Y3LHSANOO Y3MOd U J 69 SSVdAdU.S. Patent Apr. 24, 2001 Sheet 5 of 14 US 6,222,284 BL 4160 VOLTS MAX (LINE-TO-LINE) UNBALANCED AFTER LOSS OF A4 AND AS. VvCBU.S. Patent Apr. 24, 2001 Sheet 6 of 14 US 6,222,284 BL Ce BALANCE RESTORED AFTER LOSS OF A4 AND AS BY INHIBITING B4, B5, C4, AND C5 MAXIMUM VOLTAGE = 2494 (60%) BALANCE RESTORED AFTER LOSS OF A4 AND AS BY ADJUSTING ANGLES MAXIMUM VOLTAGE = 3542 (85%)U.S. Patent Apr. 24, 2001 Sheet 7 of 14 US 6,222,284 BL 78% OF FULL VOLTAGE IS AVAILABLE BALANCE RESTORED TO SYSTEM WITH 5 CELLS PER PHASE AFTER LOSS OF 1 CELL IN PHASE B AND 2 CELLS IN PHASE C 51% OF FULL VOLTAGE 1S AVAILABLE BALANCE RESTORED TO SYSTEM WITH 5 CELLS PER PHASE AFTER LOSS OF 1 CELL IN PHASE B AND 2 CELLS IN PHASE CUS 6,222,284 BI Sheet 8 of 14 Apr. 24, 2001 U.S, Patent YOLVINGOW WMd OLLNO. SGNVWWOO Q39Nd3d-AWad xd Wa Tav uOrd 9 Old WNWININ NINN |_ 103738 T “On CIN WA | ak WAWIXVN 103148 NI SANVWWOO SOVIIOA WAIOSNNISUS 6,222,284 BI Sheet 9 of 14 Apr. 24, 2001 U.S, Patent YOLYINGOW Wad OL. LNO. SCNVWWOO 390Nd3"-yW3d Z Old JOULNOO SS¥dA@ MAN JH INSW3TdMI OSTV OL GAIJIGOW ‘9 “914 JO GOHLAW NOLLONGaY-yvad WAWININ NiWn |_LOw13as 2 LLL Oa TON | NWO [OA NI ne EN) SGNVWWOO “aa 28M | Niva [aN ( FOVLIOA - 7valosnnis + 4 wy wat < LF Lave 8 ea WAWIXvW woon xwwn|_Loa7asUS 6,222,284 BI Sheet 10 of 14 Apr. 24, 2001 U.S, Patent Pe ‘Old (L=0> GNY ‘I=@) ‘I=v») GaSSvdAa uv ST190 ON NSHM ‘2 "DId WOH .€N = «4 98 ‘Old (L=0> CNY ‘1=8) ‘I=V>) Gassvdad SHV S710 ON N3HM ‘2 O14 WOH (NINN ONY X¥WN NINN (43d HO) .€N 28 ‘Old (L=0> GNY '|=@> ‘I=W») GASSWdAd SUV STIAO ON N3HM ‘291d WOS Z/(NIWN + XVINN) = WOON 138) \OHAZ (dau HOS) .8N XV ee Old (1-3 CNV ‘1=@> ‘L=vo!) GASS¥dAd SUV STISO ON NaHM ‘Z’9ld WOU SONVINNOO SO¥IOA TVaIOSNNISUS 6,222,284 BI Sheet 11 of 14 Apr. 24, 2001 U.S, Patent ST130 N3HM P6 ‘Old (L=Oo GNW ‘29'l=@) ‘L=V») GaSSvdAd Suv Sa ONY @ STI30 NSHM ‘2 “Old WOU «aN = 23 96 ‘Old (L=Oo CNY ‘29°L=@ ‘L=W) GASSWdA JUV SB CNV 72 Old WOH Z(NINN + XN) =WOON STISON3HM‘2" (\=0 GNv ‘29°I=@ 96 ‘Old (1=0» ONY ‘29"1=@) ‘l=v») GaSSvdAg Su S@ CNY 7@ S130 N3HM ‘2 Old WOH (NINN ONY XY fey 0) 2 (434 WO) .€n yau xn ®6 ‘Old =V)) GASSVdA SUV SA ONY 7d 4 WOWS SANVWNOO J9VIIOA TVGIOSNNISUS 6,222,284 BI Sheet 12 of 14 Apr. 24, 2001 U.S, Patent POL Old (L=0 ONY ‘1-8 'S=¥¥) GASSWdAG SHV S¥ ONY Pv ‘ev ‘ev STIZ0 NAHM ‘2914 WOUS .€N = «V3 (=m CNY 90k ‘Old “|=@y ‘S=Vy) GASSWdAd SHV SV ONY PY ‘ey ‘2¥ STISO N3HM‘Z"DI4 WOHS (NINN ONY XV a (434 WS)" “wn 201 ‘Ola (1-0) GNY ‘I= 'S=V¥) GASSWdA SHV SV CNY PV ‘ev ‘ev STI30 N3HM ‘2 “91d WO ZNINN + X¥NN) = WOON XV (434 YO) “wn NIWA (434 UO) AS wn Xv ouaz $1130 N3HM FOL ‘Old (OM CNY ‘1=) ‘S=¥») GASSWdAG SHY SV ONY PV ‘ev ‘ZV 'L"DId WOKS SONVWWOD SOVIIOA TYGIOSNINISUS 6,222,284 BI Sheet 13 of 14 Apr. 24, 2001 U.S, Patent YOLVINGON WMd OLLNO SGNVWWOO @30nds¥-MVAd 602: ol ‘Old WNINININ nnn | L9373S Joe ggg 8027 i = om |. “On | Nive [-OS coz YSTIOWLNOO HOLO3AWOUS | a SaNvWWOO “ai | NIvO SOVLIOA WOIOSANIS roe, aaoNviva wy WW | NIV + WAWIXYAN Xenn| toss | 5 (on'et'v») XvN=xeWY Loe: woon XOUDLZ az?U.S. Patent Apr. 24, 2001 Sheet 14 of 14 US 6,222,284 BL 301 e 303 304. ELECTRICALLY ACTIVATED SOLENOID VALVE OUTPUT 307 A PLASTIC AIR TUBE at (306 r { ) PRESSURIZED AIR PISTON ‘SOURCE a FIG. 13 316 NORMAL 313 SOURCE OUTPUT 312 ALTERNATE N SOURCE cau L | TRIP-RELEASE DEVICE a] 310 FIG. 14 N wr] \c 321. NG 322 \_++-\--323 CELL Al CELL A2 CELL AZ FIG. 15US 6,222,284 BI 1 ‘MULTIPHASE POWER SUPPLY WITH SERIES CONNECTED POWER CELLS WITH FAILED CELL BYPASS ‘This application isa divisional application of US. patent application Ser. No. 09/082,888, fled’ May 21, 1998, now US. Pat. No, 5,986,000 which is hereby incorporated herein by reference. BACKGROUND OF THE INVENTION I. Field of the Invention ‘This invention relates to a drive and specifically a drive and a method for operating a variable drive such as a variable-speed motor drive system, I. Description of Prior Art Variable-output drives traditionally are used in industry to provide variable electtic power to AC motors. These same drives can be used in other applications not related speci cally to motors but where a variable-output vollage oF Frequency is desired. Typical drives have an AC input power sousce and some type of conversion apparatus, usualy using, solid-state deviees, for converting the fixed AC input voliage ino a variable-oltage andlor variable-fequency output One suet type of drive is described in U.S. Pat, No. 5,625,545, which is incomporated herein by reference. That patent describes a power supply used a8 a drive which Utilizes. a number of power cells arranged to produce a three-phase AC output. Such multiple power cells in series ‘can be ulilized to provide higher voltage outputs than would be available with only a single cell. However, should a given cell in a series arrangement fail during operation, that ‘current path ean become open-cireuited, rendering the entire rive inoperable. In many applications, especially industcal applications utilizing variable-speed drives itis desirable to ‘continue to operate ia a reduced mode when a single cell, Fails. One method to do sue a reduced operation isto short ‘out the damaged or failed cell. This can thea result in an ‘unbalanced output, in that the leg having the shorted cell must operate at less than full voltage. Such operation can create imbalanced Line conditions and be damaging to load elements, Therefore, when a cell fails in a series fatangement, itis usually desirable to permit operation at a reluced voltage or speed by shuating out an equal number of cells in each ofthe other legs. While the output from such a drive having shunted cells in each leg is reduced, it does permit the drive to operate at reduced voltage or speed, (Often times such reduced operation is highly desirable so that the process being controlled by the drive ean continue ‘until itis convenient to shut down for repairs. In addition, it may be desirable to operate the drive at a reduced-voltage condition so a8 to maintain a desired minimum level of production. Typically, when a drive having multiple con- Yerters arranged in series has a failure, the output voltage and power available is reduced proportional to the ratio of the number of unfailed cells in a given leg divided by the number of total cells in such leg. AS an example, if one of | ‘the cells in the aforesaid patent, such as power cell A, were to fail, typically powercells A, B, and C, would be shunted by appropriate bypass circuitry. Such cireitry is shown ia FIG. 9 of the US. Pat. No. 5,625,545 patent. When oper- ting under such bypass condition, the output of the three- phase drive at references 22, 25 and 24 is proportionally reduced by one-third. In such an operating condition, the ‘output voltage available to the motor would only be 66% of the full voltage. In such a condition, the motor would only beable to each approximately two-thirds of its rated speed, 10 3s ra 2 In many applications being able to reach even 66% of rated speed in a failed cell mode is desirable. However, it still ropresenis a substantial reduction i the output speed and power available from the drive. When multiple power ells bor converters are used in series, the total power delivered 10 the load is usually supplied generally equally by all the power cells. Thus in the example above when one of nine cls fails, 8% of rated power should sill be available. By shunting out or bypassing two operational power cells such asB, and C, inthe example, these power cells can no longer ‘contibutet the output power available to the load. It would be very desirable, then, to optimize the output voltage and power avilable to the load during a failed cell condition, ‘The invention provides for an apparatus and a method that permits operation during a failed mode at a power output that utilizes all of the cells or eonverters that are operational SUMMARY OF THE INVENTION The invention is directed to a method of operating a multiphase power supply that bas a plurality of cells or converters connected in series in each ofa plurality of legs ‘This esuls in each leg having 3 leg voltage equal tothe sum of connected cells in such Te, In addition the power supply has lineto-line vollage output between the terminal eds cof each pais of legs. This invention applies to loads that are not connected to the common Teg junction, but only to the «nd poinis of the legs, so that oniy te line-to-line output voltage appears on the load. During a failed covdition in ‘which aay one or number of cells have Failed in any of the legs, the lne-toline voltage output is maximized. This is done by detecting failed cells in any’of the leys and fonming ‘scurcent path around such aed eel by an elecisieal bypass ‘As a rest no voltage component fom the Failed eell is included within the leg in which it previously was con- nected. The outputs ofthe unailed cells are conirolled so as to maximize the line-oline volige in the output of the power supply 50 that theic magnitudes are generally equal. By so regulating thie outputs, the line-t-line phase volt- ages ofthe output of the power supply can be balanced. la 4 three-phase output supply without failed cells, balanced voltage 18 maintained by having a 120° phase relationship between the leg output voltages. The Tineo-line. phase balance can be restored by adjusting the leg-o-leg phase relationship between the respective legs when failed cells fave detected. Circuitry is provided to implement a method for reducing the peak voltage demands between legs. Voli age command sigaals can be generated to provide peak Voltage reduction, and such signals can be. modified 1 ompensate forthe detection of failed cells. The modics- tion ean be a gain contol using »gsin which is proportional to the ratio ofthe total number of cells i the le (eluding failed cells) divided by the number of active cells (aot bypassed) inthe ey. The vention is particularly adapted to pulse width modulated serial converters in each leg. The result alanced line-tolie output from the power supply and full ulization ofeach wafailed cell i the system, DESCRIPTION OF THE DRAWINGS FIG, 1a is s diagram showing the power eieuity of an embodiment having five power cells in each leg of a three-phase dive, FIG, 1b is a diagrammatic representation showing the converter circuitry of an embodiment of one cell such 3s those showa ia FIG. La FIG. Le is diagrammatic representation of an embod- ‘ment of eoatolsigoal scheme that could be used to control 4 fivesellper-leg drive such as shown in FIG, LaUS 6,222,284 BI 3 FIG. 1d shows four alternative embodiments of a cell bypass. FIG. 2 isa voltage diagram of a typical array of five cells ‘connected in series in each leg of a three-phase output FIG. 3 isa diagrammatic representation of voltage in an array similar to that shown in FIG. 2 but having two failed cells out of leg A. FIG. 4 Prior An) isa voltage diagram showing a prior at method of operating with two failed cells in leg A and to cells removed from each of leg B and C. FIG. 8a isa voltage diagram of an array operating without two failed eels in leg A but utilizing all five cells in legs BB and C. FIG. $6 is a voltage diagram of an array operating after the loss of one cell in phase B and two cells in phase C. FIG, Seis a voltage diagram of an array operating alter the loss of two cells in phase B and three cells in phase C. FIG, 6 shows a diagram of prior art conteol function to reduce the peak voltage commands to a three-phase supply. HIG, 7 shows a block diagram of a control function to reduce peak vollage and to optimize the output voltage during operation With failed converter cells. FIGS. 8a, , cand d are diagrams showing conto! signal ‘waveforms under various operating conditions. FIGS. 94, b, ¢ and d are signal waveforms of some ‘embodiments, FIGS. 10a, b, ¢ and d are control waveforms of some cembosiments, FIG. 11 is a circuit diagram of an embodiment of FIG. 7. FIG. 12 shows a block diagram of « second improved control function to reduce peak voltage and optimize the ‘output vollage during operation with failed converter cells. FIG, 13 isa diagram of a pneumatically operated transfer ich FIG, I4 is transfer switch using a spring-loaded contact. HIG. 18 is a diagram of a 3.cell arrangement using ansfer switches, DESCRIPTION OF SOME EMBODIMENTS. FIG, La shows a power citeuit diagram for an AC drive, ‘This is atypical arrangement in which the invention ean be ulilized, however, other drives and power supplies can also ulilize the apparatus and method of this invention. A three~ ‘hase incoming line 1 feeds into @ power transformer 2. As shown, power transformer 2 may be of any configuration, and in’ some preferred embodiments will be the multiple ‘winding three-phase isolation transformer as shown in US, Pat, No. 5,625,545. Such a transformer may have a primary ‘winding which issta or mesh connected, which iseneagized from the three-phase incoming line 1. The tansformer may then energize a number of single or multi-phase secondary ‘windings. In presently preferred embodiments, there will be. § a umber of secondary windings each corresponding to a respective converter or power cell in the drive. It is also preferred thatthe windings be preselected to certain degrees ff electrical phase such as taught in the aforementioned patent, In some applications other transformer configura. tons will be utilized, and in certain applications an incomis isolation transformer need not be ulized at all. AS shown i FIG. La, the incoming transformer or other AC posser supply feeds individual power converters. In FIG. La, 15 power cells or converters sre utilized. In this citcuit arrangement, there are thee legs inthe output lin, each having five power converters. Leg A has converters A, through As. Leg B. 10 3s 0 ra 4 contains power converters B, through Bs, and leg C contains, power converters C, through C. The voltage available in Any leg isthe result of the sum ofthe individual power cells in that leg, such that leg A bas an output voltage which isthe sum of power converters A, through Ay, Similarly, leg B has fan ouput voltage which i the sum of ils converters, B, through Bg, and leg C has an output voltage which is the Summ ‘of the five converters arranged in series C, through C,. The drive feeds three-phase power to 4 motce 20, which may be any Joad but in the diagram shown would commonly be an induction motor. This application is understood to produce a variable-speet! AC drive. As such, it may control process motors, fans, pumps or other equipment. It is usually desi able to maintain a variable-speed operation, either during an initial stat-up of a process run, As such, the vollage avai able to the motor at terminals A, B and Cis varied by control ‘of the drive. The motor 20 sees a voltage between terminals ‘ACB as the sum of the vollages of the individual power ‘converters in leg And leg B. AS a result, the motor voltage available at terminals A-B equals the sum ofthe power cells (AprAstAstAeAc-B,-B.-B,-B,-B,). Respective other ‘motor terminal voltages are also the Summation of the voltages in the connections between their respective texmi- nals, AS such, the vollage between terminals B and C ‘comprises the sum of the power cells (B,+B+B,+B,+B,— C)-CeHC,-C,-C,). Ina like manner the voltage: from terminal C to A comprises the sum of the converter voltages, (CA CAC AC AC AmAaw Ag AywAs). Each Teg of the drive as shown is connected in a star having a common or ‘neutral point N, which is aot connected to the load, in this cease motor 20, The output voltage component from each leg ‘comprises the sum of the power cells inthe respective leg {rom the neutral to the motor terminal. Output voltage in leg ‘Ais measured between terminal A and N, the neutral point of the converter arrangement. It includes the sum of the voltages on converters Ay through As. As can be seen if ‘converter cell A, was to fail, the available voltage to the load, in this case motor 20, would be decreased in the voltage measuced from A to N, as one cel has been removed {rom that leg. If «drive i to be operated under this mode wherein one of the cells has failed such as, for example, cell ‘Ag, that cell can be shorted or bypassed. To balance the ‘output, typically another cell in each of the other respective legs would also be bypassed. As an example, should cell A, {ail it is common practice to bypass cells A, B, and CAS 4 eaull, the output voltages available to the motor terminals ‘A, Band C would remain balanced. However, the available ‘output voltage and ouiput power would be redueed, because the mumber of active power cells being ulized in the circuitry has been reduced. However, in practicing the present invention, should cell A, fail, it can be bypassed and cells B, and C, can remain operational such thal the output, voltage and power can be maintained at higher maximum evel FIG. 16 shows a typical power cell or converter such as Avs, Bus and C, 5, as shown in FIG. La. However, itis 0 be understood that other power cells or power converters can be utilized in practicing this inveation, The power cell and control shown ia FIG, 1b is similar to that shown in U.S. Pat No. 5,625,545. However, the master controller provides for control ofthe individual power cell ia a manner that permits high output operation during a failed mode. Power cell $0, as shown, is a power converter which converts the three phase incoming power into a DC component through utili zation of a rectifier composed of diodes $1,-81, and '52,-82., The output ofthis rectifier is then directed across capacitors 58, and 53,, which can provide storage and