Rectifier module

Abstract

The invention relates to a rectifier module (100) for converting a three-phase supply input voltage into a current-regulated and voltage-regulated DC output voltage, the rectifier module (100) comprising: a regulated supply rectifier (112) for generating a DC voltage, in particular a constant intermediate circuit voltage, from the three-phase supply input voltage; an inverter (113) for converting the DC voltage into a pulse width modulated AC voltage; a high-frequency transformer (124) for transmitting a pulse width modulated alternating voltage; a rectifier (126) for converting the pulse width modulated AC voltage into a DC output voltage; a control device (114); and a cooling device (136) for providing a flow of a cooling medium, the control supply rectifier (112) being connected on the input side to the supply connection (142) and on the output side to the inverter (113), the inverter (113) being connected on the input side to the control supply rectifier (112) and on the output side to the high-frequency transformer (124), wherein the high-frequency transformer (124) is connected on the input side to the inverter (113) and on the output side to the rectifier (126), and wherein the rectifier (126) is connected on the input side to the high-frequency transformer (124) and on the output side can be connected to an electrode, in particular an anode.

Description

Technical Field

[0001] The invention relates to a rectifier module for converting a three-phase power supply input voltage into a current-regulated and voltage-regulated direct current voltage. Background Art

[0002] It is known in practice that rectifier modules or switched-mode power supplies based on bipolar transistors with insulated gate electrodes (IGBTs) can generate a DC voltage for electrophoretic painting in painting plants. The internal clock frequency of the IGBTs is approximately 20 kHz, and in a 19" housing with a height of 6 height units (HE), a current of up to 100 A and a voltage of up to 450 V DC can be generated. The residual ripple of the DC output voltage is less than 1%. However, due to the nonlinear current consumption, significant harmonic currents and harmonic-current-related distortions of the AC input voltage occur. In addition, the efficiency of such switched-mode power supplies is only in the range of 90%, since losses occur through heat dissipation. Summary of the invention

[0003] An object of the present invention is to provide a rectifier module having reduced harmonic current radiation, improved power factor and minimized power loss.

[0004] According to the present invention, this object is achieved by a rectifier module having the features of the following technical solutions.

[0005] The rectifier module is used to convert the three-phase power input voltage into a current-regulated and voltage-regulated DC output voltage.

[0006] The rectifier module preferably includes:

[0007] a regulating mains rectifier for generating a DC voltage, in particular a constant intermediate circuit voltage, from a three-phase mains input voltage;

[0008] - an inverter for converting a DC voltage into a pulse-width modulated AC voltage;

[0009] - high-frequency transformer (HF transformer) for transmitting pulse-width modulated AC voltage;

[0010] - a rectifier for converting the pulse width modulated AC voltage into a DC output voltage;

[0011] - control means; and

[0012] - a cooling device for providing a flow of a cooling medium,

[0013] The regulating mains rectifier is connected to a mains connection on the input side and to an inverter on the output side, the inverter is connected to the regulating mains rectifier on the input side and to a high-frequency transformer on the output side, the high-frequency transformer is connected to the inverter on the input side and to the rectifier on the output side, the rectifier is connected to the high-frequency transformer on the input side and can be connected to an electrode, in particular an anode, on the output side.

[0014] The prerequisites here are, in particular, that the rectifier module has compact dimensions and the least possible weight, that a setting height of up to 2500 hm is feasible, that the module is no-load and short-circuit proof, that the residual ripple is low, and that a wide range of supply voltages can be applied. In addition, an output power of 32 kW can be achieved at a maximum voltage of 450 V and a maximum current intensity of 120 A. In addition, the module is preferably both current-regulated and voltage-regulated with high regulation accuracy. In addition, there is the possibility of Underwriters Laboratories certification (UL certification).

[0015] The invention is based on the basic idea of ​​using the technology of the active front end (AFE) for power supply rectification, in particular in order to achieve a high efficiency of a rectifier module, which is preferably used for electrophoretic painting of workpieces in a painting plant. This technology, also known under the name of "three-phase six-switch BOOST-type power factor correction", makes it possible to increase efficiency and reduce harmonic current radiation at similar costs compared to comparable embodiments of the prior art. In addition, the arrangement of the components of the rectifier module described below and the efficient cooling of selected components ensure that losses and interferences are reduced.

[0016] The term "current" in this specification and the attached technical solutions is understood as current in the electrical sense.

[0017] The terms "connectable" and "connected" in this specification and the attached technical solutions are understood to be both direct electrical connection and indirect electrical connection. In the case of indirect connection, it can be provided that other elements are arranged between two interconnected or interconnectable elements.

[0018] In this specification and the attached technical solutions, unless otherwise specified, the terms "component", "element" and "member" are used synonymously.

[0019] The rectifier module is connected to a source for a three-phase mains input voltage via a mains connection. The mains voltage or mains input voltage is preferably in the range of 380V to 460V at a mains frequency of 50Hz to 60Hz. The mains current intensity is preferably 50A at a mains voltage of 400V.

[0020] In the use of electrophoretic painting of workpieces, in particular vehicle bodies, the electrode forms the anode and the respective workpiece forms the associated cathode.

[0021] The regulating mains rectifier and the inverter can be designed as a common component or as separate components.

[0022] The regulating mains rectifier preferably converts the mains input voltage, which is preferably a three-phase AC voltage, into a DC voltage or an intermediate circuit voltage U z .

[0023] The inverter preferably converts the intermediate circuit voltage U z Converted into pulse width modulated AC voltage (PWM AC voltage).

[0024] The intermediate circuit voltage U z The generated PWM AC voltage is transmitted via an HF transformer, for example with a corresponding transformation ratio, from the primary circuit to the secondary circuit.

[0025] In order to make the HF transformer as compact and low-loss as possible, special ferrite cores and / or special high-frequency cables are used, the higher quality of the cables in the high-frequency range being due to the increase in the cross section that actively participates in the current flow.

[0026] At the same time, a galvanic separation is achieved via the HF transformer between the primary circuit applied to the input side of the HF transformer and the secondary circuit correspondingly applied to the output side of the HF transformer. In other words, the HF transformer galvanically separates the source of the mains input voltage from the electrode.

[0027] The rectifier, in particular the output rectifier, ensures rectification of the PWM AC voltage, in particular by bridge rectification, wherein the output rectification is realized by means of Schottky diodes based on silicon carbide (SiC).

[0028] The control device is preferably a central control card or a control board with a CANopen interface, for example a VSQ card, and comprises a digital signal processor (DSP) or is designed as such. The digital signal processor is preferably a microprocessor.

[0029] It may be advantageous if the regulating mains rectifier is an AFE or is designed as an AFE.

[0030] AFE is basically a circuit that generates a DC voltage from a three-phase AC voltage.

[0031] Although rectification with a conventional diode bridge has the disadvantage of drawing current from the power supply only in pulses, which results in high harmonics and harmonic current radiation, the power factor can be regulated and improved, even to a power factor of 1, by means of the AFE. In addition, the intermediate circuit voltage U zThe control is performed and thus a wide range input of the rectifier module for three-phase power supply can be achieved.

[0032] Current flow direction, power factor and intermediate circuit voltage U are achieved by vector control of switching transistors z The basic principle of this circuit connection is a step-up chopper or a boost converter (as a combination of an AFE throttle and a downstream transistor), whereby the intermediate circuit voltage U z Must always be above the maximum peak value of the wide range input.

[0033] The use of AFE technology makes it possible to keep the internal intermediate circuit voltage (DC link voltage) constant, which in conventional rectifier modules fluctuates according to fluctuations in the corresponding power supply voltage and its tolerance. As a result, the corresponding HF transformer and power supply wiring can be designed with less reserve, which achieves lower losses in the HF transformer and thus achieves a higher packaging density of the rectifier module and the accompanying smaller external dimensions.

[0034] Furthermore, by using AFE technology, mains reactive currents as produced by conventional rectifiers are largely eliminated and harmonic current emissions or total harmonic current distortion (THDi) are significantly reduced to less than 3%.

[0035] The constant intermediate circuit voltage U z Converted into a pulse width modulated (PWM) AC voltage.

[0036] It can also be provided that the cooling device is a fan for providing a cooling air flow, and that the fan leads to the high-frequency transformer and / or the rectifier for air cooling.

[0037] By means of a corresponding arrangement in the flow direction of the fan, cooling air is directed to or circulated through the HF transformer and / or the rectifier, thereby achieving effective cooling. By cooling one or both components, losses and disturbances caused by heat are reduced and the efficiency of the rectifier module is thus increased.

[0038] The fan preferably also enables heat energy, which is generated, for example, at a regulated power rectifier and / or inverter and preferably transferred by means of one or more heat sinks into the cooling air flow, to be transported from the cooling air flow mentioned above out of the rectifier module via the rear side of the housing.

[0039] It is also conceivable to use water cooling instead of a fan, the cooling medium water of the water cooling absorbing and dissipating the heat of the HF transformer and / or the rectifier by means of a corresponding installation.

[0040] The HF transformer and / or the rectifier can be directly accessible for cooling. However, it is also conceivable that these components are mounted on a cooling body, essentially access the cooling body and promote corresponding cooling.

[0041] It is particularly advantageous if the HF transformer is shielded at least with respect to the regulated mains rectifier, the inverter and the control device.

[0042] Shielding the HF transformer with respect to the aforementioned components prevents the efficiency of the rectifier module from being reduced due to electromagnetic disturbances.

[0043] Preferably, the lead or connection length between the inverter and the input-side or primary-side connection of the HF transformer is as short as possible, whereby in particular losses and interferences are avoided or at least reduced.

[0044] It can be advantageous if the rectifier module comprises an input filter device which can be connected to a power supply connection on the input side and to a regulated power supply rectifier on the output side, and which is configured such that it transmits current and / or voltage measurement values ​​of the three-phase power supply input voltage to the control device.

[0045] The input filter device is constructed as an LCL filter or includes an LCL filter, through which the high-frequency interference signals of the switching transistors of the power rectifier and / or inverter are filtered on the one hand so that they do not reach the power supply network or the input power line. On the other hand, the input filter device prevents the high-frequency signals of the AC power distribution source, that is, the power supply, from intruding into the rectifier module as interference.

[0046] It may be particularly advantageous if the rectifier module comprises an output filter device which is connected to the rectifier on the input side and can be connected to the electrode on the output side and is configured such that it transmits current and / or voltage measurement values ​​of the DC output voltage to the control device.

[0047] The electrodes can be connected via a DC voltage output of the rectifier module, to which the output filter device is connected on the output side and which has, in particular, four positive leads and one negative lead.

[0048] The internal switching frequency of the AFE and / or the inverter can preferably be suppressed or at least filtered or smoothed by the output filter.

[0049] Preferably, a blocking diode or an isolation diode is arranged or connected between the output side of the rectifier in the negative lead of the output circuit or the secondary circuit and the input side of the output filter device so as to suppress the reverse current generated in the cathode dipping equipment due to the large number of rectifier modules connected in parallel.

[0050] In order to provide and transmit the current and / or voltage measurement values ​​of the DC output voltage to the control device, the output filter device preferably includes an output measurement card (Messkarte), which has a shunt (Shunt) on each positive lead of the output circuit, and the corresponding measurement value is intercepted at the shunt.

[0051] It may be advantageous if the rectifier module has a data interface, by means of which data can be exchanged between a control device of the rectifier module and an external network.

[0052] It is particularly advantageous if the data interface comprises a Profinet / CANopen gateway or is designed as a Profinet / CANopen gateway.

[0053] However, it is also conceivable that the data interface comprises an Ethernet IP interface or is designed as an Ethernet IP interface.

[0054] It should be understood that a gateway can be an interface and vice versa.

[0055] It should also be understood that the Ethernet IP / CANopen interface may be referred to simply as the Ethernet IP interface.

[0056] The data interface enables in particular external activation of the rectifier module and simultaneously serves to monitor the rectifier module, for example to protect the rectifier module from overload, which can occur if, due to special events, the rectifier module is to be operated outside permissible limit values.

[0057] In order to protect the rectifier modules, it is important to react accordingly quickly to possible external disruptive influences, such as grid faults or grid fluctuations, in order to ensure safe and constant operation while maintaining all technical properties.

[0058] The Profinet / CANopen gateway can also be used to make information about the rectifier modules available to the higher-level control unit.

[0059] The Profinet / CANopen gateway is responsible in particular for the conversion between the Profinet real-time interface of the data interface and the internal CANopen communication of the rectifier module or its control unit or a corresponding protocol.

[0060] In addition, the rectifier module is also ready for application within the framework of Industry 4.0 due to this data interface.

[0061] It is also conceivable that the control device controls and / or regulates the mains rectifier and / or the inverter and / or the cooling device, in particular by means of pulse width modulation.

[0062] It may be advantageous if the control device is designed to monitor the temperature at one or more locations of the rectifier module, in particular the temperature of the cooling device, the regulating power rectifier, the inverter and the high-frequency transformer.

[0063] It may be advantageous if the control device and / or the data interface is connected to a DC power supply connection.

[0064] It may also be provided that the regulating mains rectifier and / or the inverter comprises one or more SiC-based metal oxide semiconductor field effect transistors (MOSFETs).

[0065] This reduces the switching losses compared to conventional MOSFETs and compared to bipolar transistors with insulated gate electrodes (IGBT technology) and, in combination with other measures, allows efficiencies of up to 97% to be achieved.

[0066] In another embodiment of the present invention, it can be provided that the switching frequency of the power rectifier and / or the inverter is set to at least 40 kHz.

[0067] Losses are further reduced by increasing the switching frequency to 40 kHz to trigger PWM via the control device, which helps to achieve improved overall efficiency.

[0068] In another embodiment of the invention, it can be provided that the rectifier module comprises an internal power supply unit for generating and providing an internal auxiliary voltage for the control device, which is connected to the power connection on the input side and to the control device on the output side.

[0069] The internal power supply unit is preferably connected to the power supply connection via an input filter device on the input side. The input filter device accordingly feeds the power supply voltage into the internal power supply unit.

[0070] In another embodiment of the present invention, it may be provided that the efficiency of the rectifier module is as high as 97% and / or the power factor of the rectifier module is 0.99 to 1.0 in the range of 20% to 100% output power. BRIEF DESCRIPTION OF THE DRAWINGS

[0071] Further features and / or advantages of the invention are the subject matter of the drawings and the following description of exemplary embodiments.

[0072] In the attached picture:

[0073] Figure 1 A schematic diagram of a rectifier module according to the present invention is shown;

[0074] Figure 2 Shows Figure 1 A schematic top view of the front side of a rectifier module according to the present invention; and

[0075] Figure 3 Shows Figure 1 Schematic circuit diagram of components of a rectifier module according to the present invention.

[0076] Identical or functionally equivalent elements are provided with the same reference symbols in all figures. DETAILED DESCRIPTION

[0077] Figure 1 The illustrated embodiment of a rectifier module, which is designated as a whole by 100 , serves to convert a three-phase mains input voltage into a current-regulated and voltage-regulated DC voltage.

[0078] exist Figure 3 , a schematic circuit diagram of the components of the rectifier module 100 is additionally shown, which particularly highlights the connections between the components.

[0079] The rectifier module 100 includes a housing 102 in which other components are accommodated, wherein the housing 102 preferably has a width of 445 mm, a height of 177 mm, and a depth of 540 mm.

[0080] The rectifier module 100 preferably has a maximum overall weight of 27 kg.

[0081] The housing 102 is divided into a first sub-area 106 and a second sub-area 108 by the shielding member 104. Figure 2 The front side 109 shown in more detail in Figure 1 Middle finger pointing down.

[0082] The shield 104 preferably comprises at least one heat sink, via which thermal energy can be transferred from one subregion to another subregion, in particular from the first subregion 106 to the second subregion 108 .

[0083] The rectifier module 100 further includes an input filter device 110 , an active front end converter (AFE converter) 111 , a control device 114 , an internal power supply unit 116 and a data interface 118 , wherein these components are arranged in the first sub-region 106 of the housing 102 .

[0084] Figure 1 The AFE converter 111 in FIG. 1 is shown as a component in which a regulating power rectifier 112 and an inverter 113 configured as an AFE are combined, and Figure 3 The illustration in shows the two components in a functionally separated manner.

[0085] The AFE converter 111 includes one or more metal oxide semiconductor field effect transistors (MOSFETs) based on silicon carbide (SiC). These SiC MOSFETs are preferably arranged on or mounted on at least one cooling body of the shield 104 in such a way that the heat energy generated at the AFE converter 111 during operation of the rectifier module 100 is transferred from the first sub-region 106 to the second sub-region 108.

[0086] The data interface 118 is designed as a Profinet / CANopen gateway 120 or comprises a Profinet / CANopen gateway 120 .

[0087] The control device 114 is configured as a VSQ card 122 or includes a VSQ card 122 .

[0088] Furthermore, a high-frequency transformer (HF transformer) 124 , one or more AFE chokes 125 , a rectifier 126 , an output filter device 128 , an isolation diode 130 , and an output measurement card 132 are arranged in the second sub-region 108 of the housing 102 , wherein the HF transformer 124 can be separated from the remaining components of the second sub-region 108 by a fence 134 .

[0089] Furthermore, a cooling device 136 , in particular a fan 138 , which generates a cooling air flow 140 and makes it available within the housing 102 or conveys it into the housing 102 is arranged on the front side at the second partial region 108 .

[0090] The cooling air flow 140 basically circulates around or is directed to the HF transformer 124 and the rectifier 126 for air cooling.

[0091] Accordingly, the fence 134 does not extend over the entire height of the housing 102 at least on the side opposite the front side 109 of the housing 102 , so that the cooling air flow can also flow around the rectifier 126 or lead to the rectifier.

[0092] Before discussing the various connections of the components in more detail below, it should be understood that Figure 1 In the figure, those leads or connections that appear to be led out of the housing 102 or are guided outside along the housing 102 are shown outside the housing 102 only for illustration reasons, that is, all connections should actually extend inside the housing 102.

[0093] Furthermore, the term “connection” is further understood to mean an electrically conductive connection through which an electric current flows or by means of which an electric voltage can be applied, wherein the connection comprises one or more conductors or leads.

[0094] The rectifier module 100 is connected to a source for a three-phase mains input voltage via a mains connection 142 .

[0095] A power connection 142 arranged on the front side 109 of the housing 102 is connected to the input filter device 110 via a connection 144 , so that the HF component of the input voltage can initially be reduced in order to meet the requirements for permissible interference.

[0096] The input filter device 110 prevents HF signals generated in the rectifier module 100 from reaching the input leads, and prevents HF components of the mains input voltage from reaching the circuits of the rectifier module 100 as interference.

[0097] On the one hand, internal power supply unit 116 is fed by input filter device 110 via connection 146 , which in turn supplies an internal auxiliary voltage to control device 114 via connection 148 .

[0098] On the other hand, the filtered power supply input voltage is supplied from the input filter device 110 to the AFE converter 111 via the connection unit 150 .

[0099] Furthermore, input filter device 110 provides current measurement values ​​to control device 114 via connection 152 and voltage measurement values ​​via connection 154 .

[0100] Furthermore, a DC supply connection 156 , which is also arranged on the front side 109 of the housing 102 , supplies power to the control device 114 via a connection 155 and supplies a DC voltage to the data interface 118 via a connection 157 .

[0101] The data interface 118 furthermore has a connection 158 which is likewise arranged on the front side 109 of the housing 102 and via which the data interface 118 can be connected, for example, to a Profinet network for data exchange.

[0102] The AFE converter 111 is connected via a connection 160 to the HF transformer 124 , which in turn is connected via a connection 162 to the rectifier 126 .

[0103] For the connection 164 between the rectifier 126 and the output filter device 128 , an isolation diode 130 is arranged or inserted in the negative lead 166 , which suppresses a negative reverse current through the rectifier diode in the event of an externally occurring reverse voltage.

[0104] The output filter device 128 is also connected to the output measurement card 132 having four shunts via the connection part 168, and is also connected to the DC voltage output part 172 having four positive leads and one negative lead via the connection part 170, and one or more electrodes, especially one or more anodes, are connected to the DC voltage output part.

[0105] The DC voltage output 172 is likewise arranged on the front side 109 of the housing 102 .

[0106] The output measurement card 132 supplies the control device with current measurement values ​​via the connection 174 and with voltage values ​​via the connection 176 , or transmits these values ​​via the connections 174 , 176 .

[0107] Furthermore, a cooling device connection 178 is arranged on the front side 109 of the housing 102 , which connection 178 supplies the cooling device 136 with electric current via a connection 180 .

[0108] The temperature measurement values ​​from one or more measuring points in the rectifier module 100 are also transmitted or forwarded to the control device 114 via one or more connections 182. The measuring points are particularly preferably located at the AFE converter 111, the HF transformer 124 and the cooling device 136.

[0109] The control device 114 controls and / or regulates the AFE converter 111 by means of a PWM signal via a control and / or regulating connection 184 and controls and / or regulates the cooling device 136 via a control and / or regulating connection 186 .

[0110] Furthermore, data is exchanged between control device 114 and data interface 118 via CAN bus 188 .

[0111] If further from Figure 2 It can be seen that the status LED 190 is arranged at the front side 109 of the housing 102, which is preferably triggered by the control device 114 and notifies the user of the status or operating status of the rectifier module 100 through visual effects, wherein different luminous colors in particular make it possible to distinguish different operating conditions.

[0112] Supplemented by Figure 1 and Figure 2 , in the following text, according to Figure 3 In particular, the step of converting the voltage from the power supply connection 142 to the DC voltage output 172 will be described.

[0113] The three-phase power input voltage is fed into the rectifier module 100 via the power connector 142 , that is, a three-phase current or a three-phase alternating current is applied at the power connector 142 .

[0114] It is then first filtered in an input filter device 110 which is connected on the input side to the mains connection 142 and on the output side to the AFE converter 111 or the regulated mains rectifier 112 in order to filter out, in particular, HF components of the mains input voltage.

[0115] In a regulating mains rectifier 112 designed as an AFE, which is connected to an input filter device 110 on the input side and to an inverter 113 on the output side, the filtered mains input voltage is then actively rectified with a sinusoidal mains current consumption, thereby providing a constant intermediate circuit voltage.

[0116] Next, the intermediate circuit voltage is converted into a PWM AC voltage in the inverter 113, which is connected to the regulating power rectifier 112 on the input side and to the HF transformer 124 on the output side. The PWM AC voltage is then transmitted to the secondary circuit, i.e., the output circuit, in the HF transformer 124 according to the transformation ratio selected from the primary circuit applied to the input side of the HF transformer 124, which is connected to the inverter 113 on the input side and to the rectifier 126 on the output side.

[0117] The HF transformer electrically separates the source of the mains input voltage from the electrodes.

[0118] The transmitted PWM AC voltage is further rectified in the rectifier 126, which is connected to the HF transformer 124 on the input side and to the output filter device 128 on the output side, so that after filtering or smoothing in the output filter device 128, the DC voltage can be cut off at the DC voltage output part 172, which is connected to the rectifier 126 on the input side and to the DC voltage output part 172 on the output side.

[0119] In terms of more comprehensive control and / or regulation, the control device 114 can also be supplied with measured values ​​relating to the intermediate circuit voltage via the connection 192, which is derived or tapped off at the output side of the regulated mains rectifier 112. Furthermore, current measured values ​​of the PWM AC voltage in the primary circuit can be tapped off at the output side of the inverter 113 or at the input side of the HF transformer 124 via the connection 194 and provided to the control device 114.

[0120] Description of Reference Numerals

[0121] 100 Rectifier Module

[0122] 102 Housing

[0123] 104 Shielding

[0124] 106 First sub-area

[0125] 108 Second sub-area

[0126] 109 front

[0127] 110 Input filter

[0128] 111 AFE Converter

[0129] 112 Regulating the power rectifier

[0130] 113 Inverter

[0131] 114 Control Device

[0132] 116 Internal power supply unit

[0133] 118 Data Interface

[0134] 120Profinet / CANopen Gateway

[0135] 122VSQ Card

[0136] 124 High frequency transformer (HF transformer)

[0137] 125 AFE choke

[0138] 126 Rectifier

[0139] 128 Output filter

[0140] 130 Isolation diode

[0141] 132 Output measurement card

[0142] 134 Fence

[0143] 136 Cooling device

[0144] 138 Ventilator

[0145] 140 Cooling air flow

[0146] 142 Power connector

[0147] 144 Connection

[0148] 146 Connection

[0149] 148 Connection

[0150] 150 Connection

[0151] 152 Connection

[0152] 154 Connection

[0153] 155 Connection

[0154] 156 DC power supply connector

[0155] 157 Connection

[0156] 158 Connector

[0157] 160 Connection

[0158] 162 Connection

[0159] 164 Connection

[0160] 166 Negative lead

[0161] 168 Connection

[0162] 170 Connection

[0163] 172 DC voltage output section

[0164] 174 Connection

[0165] 176 Connection

[0166] 178 Cooling device connector

[0167] 180 Connection

[0168] 182 connection

[0169] 184 Control and / or regulation connection

[0170] 186 Control and / or regulation connection

[0171] 188CAN bus

[0172] 190 Status LED

[0173] 192 Connection

[0174] 194 Connection

Claims

1. A rectifier module (100) for converting a three-phase power supply input voltage into a current-regulated and voltage-regulated DC output voltage, wherein the rectifier module (100) comprises: - a regulating mains rectifier (112) for generating a DC voltage, in particular a constant intermediate circuit voltage, from a three-phase mains input voltage; - an inverter (113) for converting the DC voltage into a pulse width modulated AC voltage; - a high frequency transformer (124) for transmitting the pulse width modulated AC voltage; - a rectifier (126) for converting the pulse width modulated AC voltage into a DC output voltage; - a control device (114); and - a cooling device (136) for providing a flow of a cooling medium, The regulating mains rectifier (112) is connected to a mains connection (142) on the input side and to the inverter (113) on the output side, The inverter (113) is connected to the regulated power rectifier (112) on the input side and to the high-frequency transformer (124) on the output side. The high-frequency transformer (124) is connected to the inverter (113) on the input side and to the rectifier (126) on the output side. The rectifier (126) is connected to the high-frequency transformer (124) on the input side and can be connected to an electrode, in particular an anode, on the output side.

2. The rectifier module (100) according to claim 1, characterized in that: The regulating mains rectifier (112) is an active front end or is configured as an active front end.

3. The rectifier module (100) according to claim 1 or 2, characterized in that: The cooling device (136) is a ventilator (138) for providing a cooling air flow (140), and the ventilator (138) is directed to the high-frequency transformer (124) and / or the rectifier (126) for air cooling.

4. The rectifier module (100) according to any one of claims 1 to 3, characterized in that: The high frequency transformer (124) is shielded at least relative to the regulated power rectifier (112), the inverter (113) and the control device (114).

5. The rectifier module (100) according to any one of claims 1 to 4, characterized in that: The rectifier module (100) comprises an input filter device (110), in particular an LCL filter device, which can be connected to the power supply connection (142) on the input side and to the regulating power rectifier (112) on the output side, and the input filter device is configured so that the input filter device transmits current and / or voltage measurement values ​​of the three-phase power supply input voltage to the control device (114).

6. The rectifier module (100) according to any one of claims 1 to 5, characterized in that: The rectifier module (100) comprises an output filter device (128), which is connected to the rectifier on the input side and can be connected to the electrode on the output side, and is configured so that it transmits current and / or voltage measurement values ​​of the DC output voltage to the control device (114).

7. The rectifier module (100) according to any one of claims 1 to 6, characterized in that: The rectifier module (100) has a data interface (118), by means of which data can be exchanged between the control device (114) of the rectifier module (100) and an external network.

8. The rectifier module (100) according to claim 7, characterized in that: The data interface (118) comprises a Profinet / CANopen gateway (120) or an Ethernet IP interface, or is designed as a Profinet / CANopen gateway (120) or an Ethernet IP interface.

9. The rectifier module (100) according to any one of claims 1 to 8, characterized in that: The control device (114) controls and / or regulates the regulated power rectifier (112) and / or the inverter (113) and / or the cooling device (136), in particular by means of pulse width modulation (PWM).

10. The rectifier module (100) according to any one of claims 1 to 9, characterized in that: The control device (114) is designed to monitor the temperature at one or more locations of the rectifier module (100), in particular the temperature of the cooling device (136), the regulating power rectifier (112), the inverter (113) and the high-frequency transformer (124).

11. The rectifier module (100) according to any one of claims 7 to 10, characterized in that: The control device (114) and / or the data interface (118) are connected to a DC power supply connection (156).

12. The rectifier module (100) according to any one of claims 1 to 11, characterized in that: The regulated power rectifier (112) and / or the inverter (113) include one or more silicon carbide (SiC) based metal oxide semiconductor field effect transistors (MOSFETs).

13. The rectifier module (100) according to any one of claims 1 to 12, characterized in that: The switching frequency of the regulated power rectifier (112) and / or the inverter (113) is at least 40 kHz.

14. The rectifier module (100) according to any one of claims 1 to 12, characterized in that: The rectifier module (100) comprises an internal power supply unit (116) for generating and providing an internal auxiliary voltage for the control device (114), wherein the internal power supply unit is connected to the power connection on the input side and to the control device (114) on the output side.

15. The rectifier module (100) according to any one of claims 1 to 14, characterized in that: The efficiency of the rectifier module (100) is as high as 97% and / or the power factor of the rectifier module (100) is 0.99 to 1.0 in the range of 20% to 100% output power.

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