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WO2021041597A1 - Alimentation électrique avec correction du facteur de puissance pour une utilisation avec un moteur de traction de câble - Google Patents

Alimentation électrique avec correction du facteur de puissance pour une utilisation avec un moteur de traction de câble Download PDF

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Publication number
WO2021041597A1
WO2021041597A1 PCT/US2020/048090 US2020048090W WO2021041597A1 WO 2021041597 A1 WO2021041597 A1 WO 2021041597A1 US 2020048090 W US2020048090 W US 2020048090W WO 2021041597 A1 WO2021041597 A1 WO 2021041597A1
Authority
WO
WIPO (PCT)
Prior art keywords
power
motor
power supply
mains
regulator
Prior art date
Application number
PCT/US2020/048090
Other languages
English (en)
Inventor
Eric N. LUK
Anthony J. BUSSAN
Original Assignee
Greenlee Tools, Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Greenlee Tools, Inc filed Critical Greenlee Tools, Inc
Publication of WO2021041597A1 publication Critical patent/WO2021041597A1/fr

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B66—HOISTING; LIFTING; HAULING
    • B66D—CAPSTANS; WINCHES; TACKLES, e.g. PULLEY BLOCKS; HOISTS
    • B66D1/00—Rope, cable, or chain winding mechanisms; Capstans
    • B66D1/28—Other constructional details
    • B66D1/40—Control devices
    • B66D1/48—Control devices automatic
    • B66D1/485—Control devices automatic electrical
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02P—CONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
    • H02P23/00—Arrangements or methods for the control of AC motors characterised by a control method other than vector control
    • H02P23/26—Power factor control [PFC]

Definitions

  • Cable pulling is a commonly used technique in high-force rope pulling operations, such as wire conduit pulling, ship or oilfield use, whereby a pulling line is attached to an electrical cable or wire that is to be pulled through conduit or along a cable tray by a cable puller.
  • the conduit or cable tray may be any length and may contain any number of bends, turns, or other layout characteristics.
  • Cable pullers are known in the art.
  • the cable puller may, for example, be mounted to the floor or may be mounted on a wheeled carriage.
  • the pulling line is wound by an operator around a capstan rotatably mounted on a cable puller housing of the cable puller and tails off the capstan.
  • the capstan is powered by a cable puller motor mounted on the cable puller housing.
  • One end of the pulling line is connected to the object being pulled, while the other end of the pulling line is pulled by the cable puller.
  • the pulling line is wound by an operator around a capstan on the cable puller and the operator then pulls on the free, loose end of the pulling line.
  • the capstan is powered by the motor. As the motor turns the capstan, the friction of the pulling line on the capstan offloads most of the pulling force to the motor, requiring the operator to manually “tail” the free, loose end of the pulling line by applying a tailing force to the free, loose end of the pulling line to maintain friction of the pulling line on the capstan.
  • Most known cable puller motors are basic AC motors, which are coupled to the 120V AC mains power supply.
  • the only power control is typically an on-off switch.
  • a load on the capstan may become excessive, which may induce a motor stall condition.
  • the motor may draw excessive current sufficient to trip the mains circuit breaker. When this occurs, time is lost and work expense increases.
  • AC motors may be optimized by design for a particular fixed power factor because the rated speed (RPM) of the motor may be fixed and is not controllable.
  • RPM rated speed
  • Such design factors may include the number and dimension of windings, the core and rotor configuration, material composition, and the like.
  • adverse conditions such as stall conditions, cannot be easily handled.
  • PFC power factor correction
  • a power supply provides power for a cable puller motor, where the motor is operatively coupled to a cable puller assembly and is configured to drive a capstan that provides a pulling force on a pulling line wrapped around the capstan.
  • the power supply is operatively coupled to an AC mains source of power.
  • the power supply includes a bridge rectifier configured to rectify AC power provided by the AC mains and a chopper power controller configured to generate a pulse- width modulated (PWM) DC output power signal, based on received voltage and current signals.
  • PWM pulse- width modulated
  • Such signals may include a DC bus voltage signal, a reference voltage signal, a mains current signal, and a motor current signal.
  • a power factor pre-regulator is operatively coupled to a DC bus, where the power factor pre-regulator and the chopper power controller cooperate to maximize a power transfer from the AC mains to the motor.
  • a power supply provides power for a cable puller motor, where the motor is operatively coupled to a cable puller assembly and configured to drive a capstan that provides a pulling force on a pulling line wrapped around the capstan.
  • the power supply is operatively coupled to an AC mains source of power and includes a rectifier configured to rectify AC power provided by the AC mains, a chopper power controller configured to generate a pulse-width modulated (PWM) DC output power signal, based on received voltage and current signals, a power factor pre-regulator operatively coupled to a DC bus, where the power factor pre-regulator is configured to maximize a power transfer from the AC mains to the motor.
  • the power factor pre regulator includes a power factor controller configure to generate a PWM switching output signal that modulates current flow in an output capacitor of the DC bus.
  • a power supply provides power for a cable puller motor, where the motor is operatively coupled to a cable puller assembly and configured to drive a capstan that provides a pulling force on a pulling line wrapped around the capstan.
  • the power supply is operatively coupled to an AC mains source of power and includes a bridge rectifier configured to rectify AC power provided by the AC mains, a chopper power controller configured to generate a pulse-width modulated (PWM) DC output power signal based on a plurality of received voltage and current signals.
  • PWM pulse-width modulated
  • the chopper power controller is configured to control a plurality of semiconductor switches responsive to the PWM DC output power signal so as to turn on and off the semiconductor switches in a controlled sequence to provide a chopped DC power signal to the cable puller motor.
  • FIG. 1 is graph showing three AC waveforms.
  • FIG. 2 is a high-level electrical block diagram of a known power circuit for use in a cable puller machine.
  • FIG. 3 is a high-level electrical block diagram of one embodiment of a power supply arrangement for use in a cable puller machine.
  • FIG. 4 is a flowchart showing operation of a power controller in the power supply arrangement of FIG. 3, according to one embodiment.
  • FIG. 5 is a simplified schematic diagram of a rectifier circuit and DC bus of FIG. 3, according to one embodiment.
  • FIG. 6 is a simplified schematic pictorial diagram of the output power circuit of FIG. 3, according to one embodiment, showing a plurality of motor control switches.
  • FIG. 7 is a schematic diagram of power transistors used in the output power circuit shown in FIG. 6, according to one embodiment.
  • FIG. 8 is a simplified schematic diagram of an alternate embodiment of the output power circuit of FIG. 3, according to one embodiment.
  • FIG. 9 is a simplified schematic diagram of the power factor correction pre regulator of FIG. 3, according to one embodiment.
  • FIG. 1 is a graph showing three AC waveforms.
  • a first waveform 12 shows the input voltage provided by the mains 120-volt AC to a power supply of a cable puller machine (cable puller not shown).
  • the mains power is typically coupled to a 20-amp circuit breaker but may vary depending on the site.
  • the second waveform 14 shows a current spike drawn from the mains power, which may be caused by uncompensated rectification of the power supply to the cable puller machine. Such a current spikes may cause the mains circuit breaker to trip.
  • This current spike waveform 14 represents a high or excessive RMS current.
  • FIG. 2 is a high-level block diagram of a known motor power supply for a cable puller machine, which may control a DC motor, and which motor power supply may cause the current spikes show by waveform 14 of FIG. 1.
  • FIG. 3 is a high-level electrical block diagram of a cable puller power supply 300 according to one embodiment of the present invention.
  • An AC electrical source 310 such as the mains 120-volt AC power source, provides power for the power supply 300.
  • a rectifier circuit such as a full-wave bridge rectifier circuit 320, may be operatively coupled to the mains power 310.
  • the rectifier circuit 320 provides a rectified AC signal to a power factor correction (PFC) circuit or pre-regulator circuit 330.
  • PFC power factor correction
  • the output of the pre-regulator circuit 330 is provided to a DC bus circuit 340, which may include a plurality of fairly large capacitors configured “smooth” out the ripple in the rectified signal so as to approximate a DC voltage.
  • a chopper power controller 350 may receive the following signal inputs: A) a mains current signal 351, which may be measured at a node between the inductor L and the rectifier as seen in FIG. 9, B) a DC bus voltage output signal 354 from the DC bus 340, C) a first voltage reference signal 355 Vrefi, which may be any stable precision regulated reference voltage, and D) a motor output current signal 374 indicative of the motor current.
  • the chopper power controller 350 Based on the above-described four inputs, the chopper power controller 350, in turn, generates a pulse-width modulated (PWM) DC power signal 356 to an output power circuit 360 in the form of a variable duty-cycle rectangular waveform. This may also be referred to as a chopped DC power signal.
  • PWM pulse-width modulated
  • the ratio of the on to off portions of the rectangular power waveform determine the power delivered to the motor 370 per unit time.
  • the output power circuit 360 provides a switch arrangement that provides switching power in accordance with the PWM DC power signal 356 provided by the power controller 350, and where the output of the solid-state switches of the output power circuit 360 drives a DC motor or load 370. Examples of the output power circuit 360 may be shown in FIGS. 6-8.
  • the output power circuit 360 also provides a feedback motor current signal 374 to the chopper power controller 350 representative of the current drawn by the motor 370. Any suitable current monitoring method may be used, including a shunt resistor, Hall devices, and the like.
  • the power supply 300 having such pre-regulator circuit 330 is able to maximize the amount of power drawn from the AC source or mains power 310 while drawing a minimum RMS current from the mains, thereby maximizing the effective power available to the motor 370. This reduces or eliminates the chance of tripping the mains circuit breaker during the pulling operation.
  • the use of a pre-regulator circuit 330 also allows a wide range of source voltages and output voltages for use with various motors.
  • the chopper power controller 350 When a maximum power limit is met, meaning the maximum power is being drawn from the mains power 310, the chopper power controller 350 reduces the PWM DC power signal 356 ratiometrically (by modulation of the duty cycle) as motor current increases so as to maintain the mains power 310 maximum power draw without overload.
  • the pre-regulator circuit 330 thus allows a maximum power transfer from the mains power 310 while using the lowest RMS current possible.
  • the above power regulation process is further described in the flowchart of FIG. 4, which shows various steps that the power controller 350 may take.
  • the chopper power controller 350 senses or measures the motor load via the motor output current signal 374, and also measures the voltage supplied to the motor via the DC bus voltage output signal 354, as shown in step 410. The power consumption is then calculated per step 414 using the motor output current signal 374, the DC bus voltage output signal 354, and the PWM DC power signal 356 is generated accordingly.
  • step 416) If the calculated power consumption is greater than a maximum or predetermined amount (step 416) as shown by the “YES” arrow 418, the motor speed is reduced by appropriate further modulation of the PWM DC power signal 356, as shown in step 420.
  • step 428 determines if the motor speed or motor voltage is at a maximum level, and if it is, as shown by the “YES” arrow 430, control branches to step 420 so that the motor speed is reduced by appropriate further modulation of the PWM DC power signal 356.
  • a step 440 increases the motor speed or motor voltage by appropriate further modulation of the PWM DC power signal 356.
  • the above steps repeat, as shown by the branch back to step 410 so as to provide continuous real-time control of the motor 370.
  • FIG. 5 is a simplified schematic diagram of the rectifier circuit 320 of FIG. 3.
  • Other rectifier configurations are possible. For purposes of illustration, a full-wave bridge rectifier circuit is shown. Further, for purposes of clarity, only one DC bus capacitor of the DC bus 340 is shown, which may be an electrolytic capacitor or bank of capacitors.
  • FIG. 6 is a simplified schematic diagram of the output power circuit 360, which illustrates how power is turned on and turned off to the motor 370 under control of the PWM DC power signal 356 provided by the chopper power controller 350.
  • the PWM DC power signal 356 controls each of the solid-state switches (SI, S2, S3, S4) so as to energize and deenergize the motor during the corresponding ON time. The amount of time that a particular pair of switches is closed or ON determines the average power provided to the motor 370, and hence motor speed.
  • the switches may be transistors or any semiconductor switch, such as power transistors in the form of FETs (field effect transistors), IGBTs (insulated-gate bipolar transistors), and the like.
  • the output power circuit 360 can control the motor 370 in a forward and in a reverse direction. To operate the motor 370 in a first direction, switches SI and S4 are closed and power is thus applied, while switches S3 and S3 remain open. To operate the motor 370 in the opposite direction, switches S2 and S3 are closed and power is thus applied, while switches SI and S4 remain open. Half of the switches may be omitted if the motor 370 is to be operated only in one direction.
  • FIG. 7 is a schematic diagram of power transistors used to implement the switches shown in FIG. 6.
  • each switch may be implemented using power transistors.
  • the power transistor representing switch SI may be connected in a high-side arrangement where, for example, the source is connected to V+ and the drain is connected to one side of the motor 370, while the other side of the motor is connected to ground.
  • the power transistor representing switch SI may be connected in a low-side arrangement where, for example, one side of the motor is connected to V+ and the other side of the motor is connected to the source, while the drain is connected to ground.
  • FIG. 8 is a simplified schematic diagram of an alternate embodiment of the output power circuit 360.
  • This circuit includes six transistor switches used to control a three-phase AC induction motor 802 or alternatively, a brushless DC motor, depending on the application and rated power requirements.
  • FIG. 9 is a schematic diagram of the pre-regulator circuit 330 of FIG. 3, according to one embodiment.
  • FIG. 9 illustrates the AC source or mains power 310, the rectifier circuit 320, the load or motor 370, the DC bus or smoothing capacitors 340, and a PFC controller 900.
  • the pre-regulator circuit 330 which is shown as a box in FIG. 3, may be formed in part by inductor L, diode D PfC , and power factor correction transistor or switch 902 having a bypass diode DB as shown in FIG. 9.
  • the PFC controller 900 of FIG. 9 may operate in boost mode and provides the PWM switching output signal 956 based on a plurality of inputs.
  • the PFC controller 900 of FIG. 9 is not to be confused with the chopper power controller 350 of FIG. 3, although some input signals are common to both components.
  • Inputs to the PFC controller 900 may include: a. Vdc (354 DC bus voltage output signal, also shown in FIG. 3) b. Vref2 (960 stable regulated second reference voltage) c. Vac (952 measured at node between rectifier and inductor) d. I (L) (972, current through inductor L)
  • duty cycle of the PWM DC power signal 356 provided by the power controller 350 in FIG. 3 is maintained to be ratiometric to the input voltage waveform, and thus provides a good power factor due to the ratiometric characteristic.
  • the duty cycle is then scaled relative to the DC bus voltage to provide regulation.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Rectifiers (AREA)

Abstract

Alimentation électrique pour un moteur de traction de câble fournissant une alimentation à un moteur couplé de manière fonctionnelle à un ensemble de traction de câble, le moteur étant conçu pour entraîner un cabestan qui fournit une force de traction sur une ligne de traction enroulée autour du cabestan. L'alimentation électrique est couplée de manière fonctionnelle à une source d'alimentation secteur CA et comprend un redresseur configuré pour redresser une puissance CA fournie par le réseau CA et un contrôleur de puissance hacheur configuré pour générer un signal d'alimentation de sortie CC PCM. L'invention concerne également un pré-régulateur de facteur de puissance couplé de manière fonctionnelle à un bus CC et configuré pour maximiser un transfert de puissance de la source de secteur CA au moteur.
PCT/US2020/048090 2019-08-30 2020-08-27 Alimentation électrique avec correction du facteur de puissance pour une utilisation avec un moteur de traction de câble WO2021041597A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US201962893859P 2019-08-30 2019-08-30
US62/893,859 2019-08-30

Publications (1)

Publication Number Publication Date
WO2021041597A1 true WO2021041597A1 (fr) 2021-03-04

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Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5464193A (en) * 1994-01-19 1995-11-07 Wrate; Leonard A. Multi-functional wire and cable pulling apparatus
US5585708A (en) * 1991-02-22 1996-12-17 Kenetech Windpower, Inc. Four quadrant motor controller minimizing distortion index
US20100076612A1 (en) * 2008-09-22 2010-03-25 Siemens Energy & Automation, Inc. Systems, Devices, and/or methods for Managing Drive Power
US20120092913A1 (en) * 2009-04-20 2012-04-19 Eaton Industries Company Pfc booster circuit
US20180287522A1 (en) * 2017-03-29 2018-10-04 Qm Power, Inc. Multispeed Alternating Current Motor

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5585708A (en) * 1991-02-22 1996-12-17 Kenetech Windpower, Inc. Four quadrant motor controller minimizing distortion index
US5464193A (en) * 1994-01-19 1995-11-07 Wrate; Leonard A. Multi-functional wire and cable pulling apparatus
US20100076612A1 (en) * 2008-09-22 2010-03-25 Siemens Energy & Automation, Inc. Systems, Devices, and/or methods for Managing Drive Power
US20120092913A1 (en) * 2009-04-20 2012-04-19 Eaton Industries Company Pfc booster circuit
US20180287522A1 (en) * 2017-03-29 2018-10-04 Qm Power, Inc. Multispeed Alternating Current Motor

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