Electrical device, power supply system and method for manufacturing electrical device

Abstract

Embodiments of the present disclosure provide an electrical device, a power supply system having the electrical device, and a method for manufacturing the electrical device. The electrical device includes a detection circuit coupled to a generator and configured to detect the frequency of the generator. The electrical device also includes a controller coupled to the detection circuit and configured to receive a first signal indicating the detected frequency and adjust the frequency of the generator in response to determining that the detected frequency exceeds a predetermined frequency range. In this way, if the generator frequency exceeds a configured limit, active control of the rate of change of power to and from the generator can be achieved.

Description

Technical Field

[0001] Embodiments of the present disclosure generally relate to an electrical device, a power supply system having the electrical device, and a method of manufacturing the electrical device. Background Art

[0002] For high uptime sites, generators can often be used as a backup power source when there is a grid failure. Once the grid fails, the generator can be enabled to generate power to be supplied to the load. If the load is large enough, the frequency of the generator may change significantly.

[0003] Many typical loads, including commercial, industrial and data center loads, claim high sensitivity to frequency variations of no more than ±5%, however, for a 100% load step, a typical generator claims a 25% frequency variation. Therefore, if the generator momentarily takes over the entire load from the grid, the generator frequency variation may exceed what the load can tolerate.

[0004] Some auxiliary power sources are also used in power systems, such as uninterruptible power supplies (UPS), also known as battery backup, to provide backup power when your regular power source fails or the voltage drops to unacceptable levels. As an auxiliary power source, the UPS provides power to the load from an energy source (such as a battery) until the generator can start running and take over to power the load.

[0005] Also, a possible problem is that once the generator has started and is ready to take over the load from the UPS, the generator frequency may also have large frequency variations if the generator takes over the entire load instantaneously. Summary of the invention

[0006] Embodiments of the present disclosure provide an electrical device, a power supply system having the electrical device, and a method of manufacturing the electrical device.

[0007] In a first aspect, an electrical device is provided. The electrical device includes a detection circuit coupled to a generator and configured to detect a frequency of the generator. The electrical device also includes a controller coupled to the detection circuit and configured to receive a first signal indicating the detected frequency and adjust the frequency of the generator in response to determining that the detected frequency exceeds a predetermined frequency range.

[0008] By using the scheme of the first aspect, if the frequency of the generator exceeds the acceptable range, the frequency change of the generator can be monitored and adjusted by the electrical device. In this way, if the generator frequency exceeds the configured limit, active control of the rate of change of power to and from the generator can be achieved. The power supply associated with the generator is not intervened before the frequency limit is exceeded, and when the frequency limit is exceeded, the rate of change of power is changed to prevent the frequency limit from being exceeded.

[0009] In some embodiments, the detection circuit is further coupled to the load and configured to detect power consumed by the load, and wherein the controller is further configured to receive a second signal indicative of power consumed by the load and adjust the frequency of the generator by a frequency amount based on the second signal.

[0010] In some embodiments, the controller is further configured to adjust the frequency of the generator by adjusting a power level from the generator to the load based on the first signal and the second signal.

[0011] By measuring the power consumed by the load and the frequency of the generator, the controller can determine the amount of frequency or specific power level to be adjusted at the generator, which can result in more accurate and efficient regulation.

[0012] In some embodiments, the electrical device further comprises a rectifier coupled to the generator and the controller; an energy storage device coupled to the rectifier and the controller; and an inverter coupled to the energy storage device and the controller. The controller is configured to cause the rectifier, the energy storage device, and the inverter to adjust the power level from the generator to the load.

[0013] Therefore, in order to achieve automatic regulation of the frequency at the generator, the rectifier, inverter and energy storage device of the UPS 140 may also be employed to perform energy transmission and conversion, which are necessary components for this solution.

[0014] In some embodiments, the controller is further configured to, in response to determining that the detected frequency exceeds an upper threshold frequency of a predetermined frequency range, determine an amount of frequency to be adjusted based on the detected frequency and the upper threshold frequency; determine an amount of power to be loaded on the electrical device based on the frequency amount and the power consumed by the load; and deliver the power from the energy storage device to the generator by discharging the energy storage device.

[0015] In some embodiments, the controller is further configured to, in response to determining that the detected frequency is lower than a lower threshold frequency of a predetermined frequency range, determine a frequency amount to be adjusted based on the detected frequency and the lower threshold; determine an amount of power to be unloaded by the electrical device based on the frequency amount and the power consumed by the load; and absorb power from the generator into the energy storage device by charging the energy storage device.

[0016] As mentioned above, the frequency value of the generator should be maintained within a predetermined range to avoid unacceptable frequency variations. In this way, by increasing or decreasing the load carried by the electrical equipment, the generator frequency can be brought back to the limit, thereby ensuring the safety of the generator and the load connected to the generator.

[0017] In some embodiments, the inverter is configured to convert a DC voltage from the energy storage device to an AC voltage during discharge of the energy storage device.

[0018] In some embodiments, the rectifier is configured to convert an AC voltage from the generator to a DC voltage during charging of the energy storage device.

[0019] In some embodiments, a generator is coupled between the electrical device and the load.

[0020] In some embodiments, the electrical device is coupled between the generator and the load.

[0021] In some embodiments, another load is coupled between the generator and the electrical device and is configured to be powered by at least one of the generator and the electrical device.

[0022] The electrical device can adjust the frequency of the generator in various power supply environments. Whether the generator is directly connected to the load or the electrical device is coupled between the generator and the load, the electrical device ensures that the frequency of the generator is adjusted to a predetermined range.

[0023] In some embodiments, the electrical device further includes a bypass element coupled to the controller, and the controller is further configured to bypass the electrical device in response to determining that the power consumed by the load is carried by the generator.

[0024] In some embodiments, the electrical device is a UPS.

[0025] In a second aspect, a power supply system is provided. The power supply system includes a load and a generator coupled to the load and configured to supply power to the load. The power supply system also includes an electrical device according to the first aspect coupled to the load and the generator.

[0026] In a third aspect, a method of manufacturing an electrical device is provided. The method includes providing a detection circuit coupled to a generator and configured to detect a frequency of the generator. The method also includes providing a controller coupled to the detection circuit and configured to receive a first signal indicating the detected frequency and adjust the frequency of the generator in response to determining that the detected frequency exceeds a predetermined frequency range.

[0027] It should be understood that the present disclosure is not intended to identify the key or essential features of the embodiments of the present disclosure, nor is it intended to be used to limit the scope of the present disclosure. Other features of the present disclosure will become readily understood through the following description. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] The above and other objects, features and advantages of the present disclosure will become more apparent through a more detailed description of example embodiments of the present disclosure in conjunction with the accompanying drawings, in which like reference numerals generally denote like components in example embodiments of the present disclosure.

[0029] Figure 1 A simplified block diagram of a power supply system having an electrical device according to an embodiment of the present disclosure is illustrated;

[0030] Figure 2A and Figure 2B Embodiments of a rectifier and an inverter of an electric device according to an embodiment of the present disclosure are shown.

[0031] Figure 3A-3C Different application scenarios for electrical devices according to embodiments of the present disclosure are shown;

[0032] Figure 4 An embodiment of a bypass element of an electrical device according to an embodiment of the present disclosure is shown; and

[0033] Figure 5 A flow chart illustrating a method of manufacturing an electric device according to an embodiment of the present disclosure is shown.

[0034] The same or similar reference numbers are used throughout the drawings to refer to the same or similar elements. DETAILED DESCRIPTION

[0035] The present disclosure will now be discussed with reference to several example embodiments. It should be understood that these embodiments are discussed only to enable those skilled in the art to better understand and thus implement the present disclosure, rather than to present any limitation on the scope of the subject matter.

[0036] As used herein, the term "including" and its variations should be interpreted as open terms meaning "including but not limited to." The term "based on" should be interpreted as "based at least in part on." The terms "one embodiment" and "embodiment" should be interpreted as "at least one embodiment." The term "another embodiment" should be interpreted as "at least one other embodiment." The terms "first," "second," etc. may refer to different or the same objects. Other definitions, whether explicit or implicit, may be included below. Unless the context clearly indicates otherwise, the definitions of terms are consistent throughout the description.

[0037] Unless otherwise specified or limited, the terms "mounted," "connected," "supported," and "coupled," and variations thereof, are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Additionally, "connected" and "coupled" are not limited to physical or mechanical connections or couplings. In the following description, like reference numerals and labels are used to describe the same, similar, or corresponding parts in the drawings. Other definitions, whether explicit or implicit, may be included below.

[0038] As mentioned above, generators can often be used as backup power sources for high-uptime sites when the grid fails. Once the grid fails, the generator can be enabled to generate electricity to be supplied to the load. If the load is large enough, the frequency of the generator may change significantly.

[0039] Many typical loads, including commercial, industrial and data center loads, claim high sensitivity to frequency variations of no more than ±5%, however, for a 100% load step, a typical generator claims a 25% frequency variation. Therefore, if the generator momentarily takes over the entire load from the grid, the generator frequency variation may exceed what the load can tolerate.

[0040] Some auxiliary power sources are also used in power systems, such as uninterruptible power supplies (UPS), also known as battery backup, to provide backup power when your regular power source fails or the voltage drops to unacceptable levels. As an auxiliary power source, the UPS provides power to the load from an energy source (such as a battery) until the generator can start running and take over to power the load.

[0041] Also, a possible problem is that once the generator has started and is ready to take over the load from the UPS, the generator frequency may also have large frequency variations if the generator takes over the entire load instantaneously.

[0042] Several approaches have been proposed to manage generator frequency issues. For example, one approach is known as frequency independence. The most common type of UPS is the double conversion UPS, which allows the output (load) frequency to be independent of the input (generator) frequency, which can be referred to as "frequency independence" due to its double conversion implementation. Frequency independence allows the output frequency to remain constant while the input frequency can vary significantly.

[0043] However, not all UPS are frequency independent, so their output frequency is tied to the input frequency. Some configurations of generators and UPSs may allow some loads to be connected directly to the generator if the generator frequency is not allowed to exceed the frequency limitations of the loads.

[0044] Another common method is called generator walk-in. This method involves the UPS slowly handing over the load to the generator, rather than unloading it all at once, giving the generator time to pick up the load to minimize frequency changes.

[0045] The step-in functionality is usually implemented as a power ramp. If the ramp is too fast, the generator frequency may exceed the limit. If the ramp is too slow, the UPS will take unnecessarily longer to transfer power to the generator and there is a danger of depleting the battery storage. The ramps must be configured for different generator behaviors.

[0046] Therefore, the present disclosure proposes a method for controlling the generator frequency by using a UPS. By detecting the generator, the frequency at the generator can be adjusted to remain within an acceptable range. In this way, the safety and performance of the power supply system can be improved.

[0047] Figure 1 A simplified block diagram of a power supply system 100 having an electrical device 140 according to an embodiment of the present disclosure is illustrated.

[0048] like Figure 1 As shown in , the power supply system 100 may include a load 120 coupled to a power grid 110. Typically, the load 120 may be powered by the power grid 110. The power supply system 100 may also include a generator 130. The generator 130 is coupled to the load 120 and may be considered a backup power source for the load 120. As mentioned above, in the event of a power grid failure, the generator 130 may start running and generate electricity to take over the load.

[0049] The power supply system 100 may further include an electrical device 140, which may be referred to as a UPS 140 hereinafter. The UPS 140 includes a detection circuit 141, which may be coupled to the generator 130 to detect the frequency of the generator 130. The UPS 140 also includes a controller 142, which is coupled to the detection circuit 141. The detection circuit 141 may generate a signal indicating the detected frequency of the generator 130 and transmit the signal to the controller 142. If the controller 142 determines that the detected frequency is outside a predetermined frequency range, the controller 142 adjusts the frequency of the generator.

[0050] For example, if the controller 142 receives a signal indicating a detected frequency, the controller 142 may compare the detected frequency with a threshold frequency, which may be preconfigured or predetermined based on the properties of the generator. The threshold frequency may include an upper limit and a lower limit. If the detected frequency exceeds the upper limit or is below the lower limit, the controller 142 may be activated to adjust the frequency of the generator.

[0051] Significant frequency changes may occur during transition periods during which, for example, the load may be taken over from the power source by the generator. Additionally, frequency changes may also occur if the load changes rapidly. By using the UPS to detect the frequency at the generator 130, the frequency change of the generator 130 may be adjusted by the UPS 140 if the frequency of the generator 130 exceeds an acceptable range. In this manner, active control of the rate of change of power to and from the generator 130 may be achieved if the generator frequency exceeds configured limits. The power source associated with the generator is not intervened until the frequency limit is exceeded, at which point the rate of change of power is altered to prevent the frequency limit from being exceeded.

[0052] In some embodiments, the detection circuit 141 of the UPS 140 may be further coupled to the load 120 and configured to detect power consumed by the load 120. The detection circuit 141 may generate another signal indicative of the power consumed by the load 120 and transmit the other signal to the controller 142.

[0053] If the controller 142 receives the second signal, the controller 142 may adjust the frequency of the generator 130 by a frequency amount based on the second signal. That is, the controller 142 may determine the frequency amount to be adjusted based on the power consumed by the load 120.

[0054] In some embodiments, controller 142 may further adjust the frequency of generator 130 by adjusting the power level from generator 130 to load 120 based on the first signal and the second signal.

[0055] By measuring the power consumed by the load and the frequency of the generator, the controller can determine the amount of frequency or specific power level to be adjusted at the generator, which can result in more accurate and efficient regulation.

[0056] In some embodiments, the UPS 140 may also include an energy storage device 143, which may be coupled to the controller 142. The controller 142 may also cause the energy storage device 143 to adjust the power level from the generator 130 to the load 120.

[0057] In some embodiments, if the controller 142 determines that the detected frequency exceeds an upper threshold frequency of a predetermined frequency range, the controller 142 may determine the frequency amount to be adjusted based on the detected frequency and the upper threshold frequency. The controller 142 may also determine the amount of power to be loaded by the UPS 140 based on the frequency amount and the power consumed by the load. The determined amount of power may then be transferred from the UPS 140 to the generator 130. During this process, the energy storage device 143 may be discharged to provide the determined amount of power.

[0058] In some embodiments, if the controller 142 determines that the detected frequency is lower than the lower threshold frequency of the predetermined frequency range, the controller 142 may determine the frequency amount to be adjusted based on the detected frequency and the lower threshold frequency. The controller 142 may also determine the amount of power to be unloaded by the electrical device based on the frequency amount and the power consumed by the load. The determined amount of power may then be absorbed from the generator 130 to the UPS 140. During this process, the energy storage device 143 may be charged by the absorbed power.

[0059] In some embodiments, the UPS 140 may also include power electronics 146 coupled to the energy storage device 143. The power electronics 146 may be configured to deliver power to the load 140. For example, the power electronics 146 may include any suitable power conversion elements.

[0060] As already mentioned above, the frequency value of the generator should be maintained within a predetermined range to avoid unacceptable frequency variations. In this way, by increasing or decreasing the load carried by the electrical equipment, the generator frequency can be brought back to the limit, thus ensuring the safety of the generator and the load connected to the generator.

[0061] The UPS 140 may also include other components, such as a rectifier or an inverter. Figure 2A and Figure 2B Embodiments of a rectifier and an inverter of an electric device according to an embodiment of the present disclosure are shown.

[0062] As shown, a rectifier 144 and an inverter 145 may be respectively coupled to the energy storage device 143. For example, the rectifier 144 may be configured to convert the AC voltage from the generator 130 into a DC voltage during the charging of the energy storage device 143. The inverter 145 may be configured to convert the DC voltage from the energy storage device 143 into an AC voltage during the discharging of the energy storage device 143.

[0063] In some embodiments, a rectifier 144 and an inverter 145 may also be coupled to the generator 130 to deliver power. The rectifier 144 and the inverter 145 may be coupled to the controller 142 to perform conversion based on commands received from the controller.

[0064] Therefore, in order to achieve automatic adjustment of the frequency at the generator, the rectifier, inverter and energy storage device of the UPS 140 may also be employed to perform energy transmission and conversion, which are necessary components for this solution.

[0065] The frequency adjustment method at the UPS 140 and the generator may be used in various application scenarios. Figure 3A-3C Different application scenarios for electrical devices according to embodiments of the present disclosure are shown.

[0066] For example, in Figure 3A The generator 130 is coupled to the output of the UPS and directly coupled to the load 120, while Figure 3B The generator 130 is coupled to the input of the UPS 140 and the UPS is directly coupled to Figure 3B The load in 120. Figure 3C In the embodiment, another load 150 is also coupled to the generator 130. In the case where the load is directly coupled to the generator, such as Figure 3B and Figure 3C As shown in , the generator frequency cannot be allowed to exceed the frequency limit of the load. According to the active control of the UPS disclosed in the present invention, the frequency of the generator can be prevented from reaching an unacceptable frequency value regardless of the type of UPS. For example, the UPS cannot be implemented as a double conversion UPS.

[0067] Therefore, the UPS according to the present disclosure can adjust the frequency of the generator in various power supply environments. Whether the generator is directly connected to the load or the electrical device is coupled between the generator and the load, the electrical device ensures that the frequency of the generator is adjusted to a predetermined range.

[0068] Figure 4 An embodiment of a bypass element of an electrical device according to an embodiment of the present disclosure is shown. As shown, UPS 140 may also include a bypass element 170. Bypass element 170 may be coupled to a controller (not shown). If the power consumed by the load has been completely taken over by the generator, the controller may bypass UPS 140.

[0069] In this solution, the UPS is used to actively control the rate of change of power to and from the generator if the generator frequency exceeds the configured limits. It is advantageous to intervene only when the frequency limits are exceeded, at which point the rate of change of power is changed to prevent exceeding the frequency limits. Meaning this way, the UPS delivers power to and from the generator as quickly as the generator can handle, provided it does not exceed the frequency limits.

[0070] Furthermore, by automatically varying the rate of change of power, the system does not need to be calibrated for different generator behaviors. Since the generator frequency never exceeds the configurable limits, the UPS can be frequency dependent and loads connected directly to the generator are safe.

[0071] The present disclosure also provides a power supply system having a UPS 140. The power supply system may be Figure 1 and Figure 3A-3C Any of the power supply systems 100 shown in, but not limited to, those.

[0072] Furthermore, it should be understood that the controller 142 may be integrated in the UPS 140, such as a chip embedded in the UPS 140. The controller 142 may be implemented as any individual device, element, or component separate from the UPS 140.

[0073] Furthermore, the present disclosure also provides a method for manufacturing a UPS. Figure 5 A flow chart illustrating a method of manufacturing an electric device according to an embodiment of the present disclosure is shown.

[0074] At 610, a detection circuit is provided coupled to the generator and configured to detect a frequency of the generator. At 620, a controller is provided, coupled to the detection circuit and configured to receive a first signal indicative of the detected frequency and to adjust the frequency of the generator in response to determining that the detected frequency is outside a predetermined frequency range.

[0075] In the solution of the present disclosure, the UPS can measure the generator voltage frequency and the load power. The UPS is configured to support any load step (increase or decrease) so that the load increase and decrease will discharge or charge the energy storage device respectively. In a ramped or filtered manner, the UPS transfers the load to the generator, thereby achieving zero charging or zero discharging of its energy storage. However, if the generator voltage frequency reaches the configured upper or lower frequency limit, the UPS maintains the current power set point. If the generator voltage frequency exceeds the configured frequency limit, the UPS increases or decreases its load to bring the generator frequency back to the limit.

[0076] It should be understood that the above detailed embodiments of the present disclosure are only used to illustrate or explain the principles of the present disclosure, and are not used to limit the present disclosure. Therefore, any modification, equivalent substitution and improvement, etc., without departing from the spirit and scope of the present disclosure, should be included in the protection scope of the present disclosure. At the same time, the attached claims of the present disclosure are intended to cover all variations and modifications that fall within the scope and boundaries of the claims or the equivalents of the scope and boundaries.

Claims

1. An electrical device (140), comprising: a detection circuit (141) coupled to the generator (130) and configured to detect a frequency of the generator (130); and a controller (142) coupled to the detection circuit (141) and configured to receive a first signal indicative of a detected frequency and to adjust the frequency of the generator (130) in response to determining that the detected frequency is outside a predetermined frequency range; an energy storage device (143), the energy storage device (143) being coupled to the controller (142); The controller (142) is further configured to: in response to determining that the detected frequency exceeds an upper threshold frequency of the predetermined frequency range, determining an amount by which the frequency is to be adjusted based on the detected frequency and the upper threshold frequency; determining an amount of power to be loaded by the electrical device (140) based on the frequency amount and the power consumed by the load (120); as well as The electrical charge is delivered from the energy storage device (143) to the generator (130) by discharging the energy storage device (143).

2. The electrical device (140) of claim 1, wherein the detection circuit (141) is further coupled to a load (120) and is configured to detect power consumed by the load (120), and wherein the controller (142) is further configured to receive a second signal indicative of the power consumed by the load (120) and to adjust the frequency of the generator (130) by a frequency amount based on the second signal.

3. The electrical device (140) of claim 2, wherein the controller (142) is further configured to adjust the frequency of the generator (130) by adjusting a power level from the generator (130) to the load (120) based on the first signal and the second signal.

4. The electrical device (140) according to claim 3, further comprising: a rectifier (144) coupled to the generator (130) and the controller (142); The energy storage device (143) is also coupled to the rectifier (144); and an inverter (145) coupled to the energy storage device (143) and the controller (142); The controller (142) is configured to cause the rectifier (144), the energy storage device (143), and the inverter (145) to adjust the power level from the generator (130) to the load (120).

5. The electrical device (140) according to claim 4, wherein the controller (142) is further configured to: in response to determining that the detected frequency is below a lower threshold frequency of the predetermined frequency range, determining the amount by which the frequency is to be adjusted based on the detected frequency and the lower threshold frequency; determining an amount of power to be unloaded by the electrical device (140) based on the frequency amount and the power consumed by the load (120); as well as The amount of electricity from the generator (120) is absorbed into the energy storage device (143) by charging the energy storage device (143).

6. The electrical device (140) according to claim 4, wherein the inverter (145) is configured to convert a DC voltage from the energy storage device (143) into an AC voltage during the discharge of the energy storage device (143).

7. The electrical device (140) of claim 5, wherein the rectifier (144) is configured to convert an AC voltage from the generator (120) into a DC voltage during the charging of the energy storage device (143).

8. The electrical device (140) of claim 2, wherein the generator (130) is coupled between the electrical device (140) and the load (120).

9. The electrical device (140) of claim 2, wherein the electrical device (140) is coupled between the generator (130) and the load (120).

10. The electrical device (140) according to claim 9, wherein another load (150) is coupled between the generator (130) and the electrical device (140) and is configured to be powered by at least one of the generator (130) and the electrical device (140).

11. The electrical device (140) of claim 2, wherein the electrical device (140) further comprises a bypass element (170) coupled to the controller (142) and the controller (142) is further configured to bypass the electrical device (140) in response to determining that the power consumed by the load (120) is carried by a generator.

12. The electrical device (140) according to any one of claims 1 to 11, wherein the electrical device (140) is an uninterruptible power supply (UPS).

13. A power supply system (100), comprising: load(120); a generator (130) coupled to the load (120) and configured to supply power to the load (120); as well as The electrical device (140) according to any one of claims 1 to 12, wherein the electrical device (140) is coupled to the generator (130) and the load (120).

14. A method for manufacturing an electrical device (140) according to any one of claims 1 to 12, comprising: providing a detection circuit (141) coupled to the generator (130) and configured to detect the frequency of the generator (130); and A controller (142) is provided, the controller (142) being coupled to the detection circuit (143) and configured to receive a first signal indicative of a detected frequency and to adjust the frequency of the generator (130) in response to determining that the detected frequency is outside a predetermined frequency range.

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