Construction and operating method for a modular brake actuator

Abstract

The invention relates to a modular brake actuator (1) having submodules (2). In order to improve the modular brake actuator (1), the invention proposes that a first submodule group (21), a second submodule group (22) and a braking resistor (3) are arranged in a first series circuit (14) between two terminals (13) of the modular brake actuator (1), wherein the braking resistor (3) is arranged electrically between the first submodule group (21) and the second submodule group (22), wherein the first submodule group (21) and the second submodule group (22) each comprise at least one submodule (2), a further braking resistor (31) and a capacitor (7), wherein a second series circuit (15) comprising the further braking resistor (31) and the capacitor (7) is arranged electrically in parallel with at least one submodule (2) of the at least one submodule (2). The invention furthermore relates to a modular drive unit (10) comprising a modular multilevel power converter (11) and a modular brake actuator (1) of this kind, wherein the multilevel power converter (11) is connected to the modular brake actuator (1) on the DC voltage side. The invention further relates to an operating method for a modular brake actuator (1) of this kind or for a modular drive unit (10) of this kind, wherein a first AC voltage component (uBR,AC,1) is generated by the submodules (2) of the first submodule group (21) and a second AC voltage component (uBR,AC,2) is generated by the submodules (2) of the second submodule group (22), wherein the first AC voltage component (uBR,AC,1) and the second AC voltage component (uBR,AC,2) are in phase opposition to one another.

Description

[0001] Description

[0002] Design and operating procedure for a modular brake actuator

[0003] The invention relates to a modular braking unit, wherein a first submodule group and a braking resistor are arranged in series between two terminals of the modular braking unit, wherein the first submodule group has at least one submodule. The invention further relates to a modular drive unit comprising a modular multilevel power converter and such a modular braking unit. The invention further relates to an operating method for such a modular braking unit or for such a modular drive unit.

[0004] The modular multilevel power converter is known from DE 10 103 031 A1. This power converter, also known as M2C or MMC, has a converter topology that, thanks to its submodule design, is particularly suitable for medium- and high-voltage applications. The basic design of the multiphase converter comprises two converter arms per phase, each with a series connection of submodules. The two converter arms are connected to each other at the phase connection. The other side of the converter arms is connected to the DC side of the multilevel power converter. The AC side of the modular multilevel power converter is formed by one or more phase connections. In its basic design, the modular multilevel power converter can transmit energy bidirectionally between the DC and AC sides or temporarily store it to a certain extent.

[0005] To additionally enable targeted energy dissipation, the installation of a braking unit is advisable. A modular braking unit is known from WO 2007 / 023061 A2. The modular braking unit is typically connected to the DC side of the modular multilevel converter, for example, between a DC+ and a DC- connection.

[0006] The resistance of a brake actuator arrangement is often also referred to as a braking resistor, as it is suitable for converting electrical energy from an electrical machine, which is generated as a result of braking, into heat. The use of a braking actuator is not limited to the application of a braking electric drive. It does not necessarily have to be braking energy that is converted into heat. The braking actuator can, for example, also be used to stabilize a power grid by converting electrical energy from the power grid into heat. The term braking resistor was chosen to distinguish the resistor in which a given electrical energy or power is converted into heat or heat per unit of time from other resistors.

[0007] The term "power to be converted into heat" refers to the integral of the power over time being converted into heat. In other words, the amount of energy resulting from the power over time is converted into heat.

[0008] A series circuit is defined as a circuit of components through which the same current flows. A series circuit of partial impedances acts as a single two-terminal network with an impedance equal to the sum of the partial impedances.

[0009] The invention is based on the object of improving a modular brake actuator.

[0010] This object is achieved by a modular braking unit, wherein a first submodule group, a second submodule group and a braking resistor are arranged in a first series circuit between two terminals of the modular braking unit, wherein the braking resistor is electrically arranged between the first submodule group and the second submodule group, wherein the first submodule group and the second submodule group each have at least one submodule, a further braking resistor and a capacitor, wherein a second series circuit comprising the further braking resistor and the capacitor is arranged electrically parallel to at least one submodule of the at least one submodule. Furthermore, this object is achieved by a modular drive unit, wherein the drive unit has a modular multilevel power converter and such a modular braking unit, wherein the multilevel power converter is connected to the modular braking unit on the DC voltage side.This object is further achieved by an operating method for such a modular brake actuator or for such a modular drive unit, wherein a first alternating voltage component is generated by the submodules of the first submodule group and a second alternating voltage component is generated by the submodules of the second submodule group, wherein the first alternating voltage component and the second alternating voltage component are in antiphase with respect to one another.

[0011] Further advantageous embodiments of the invention are specified in the dependent claims. The invention is based, among other things, on the finding that the energy balance in the submodules and thus the stability of the modular braking unit can be achieved in a particularly simple manner. The essential structure comprises the first submodule group, the second submodule group and the braking resistor. The submodule groups each have at least one submodule. To expand the operating range with regard to the operating voltage of the braking unit, which when used with a power converter corresponds to the intermediate circuit voltage of the power converter, the respective submodule group can have a plurality of submodules, meaning at least two submodules. A parallel current path is arranged parallel to the submodule or to at least one of the submodules.Advantageously, the parallel current path is arranged parallel to the series connection of all submodules of the respective submodule group. The parallel current path is designed such that it has an additional braking resistor and can suppress the formation of a direct current in the parallel current path. A capacitor is advantageously used to suppress the direct current.

[0012] With the help of a DC voltage USM,DC,I / 2 applied across the two sub-module groups, a DC voltage UR can be generated across the braking resistor Ri, which generates a DC current i D c is generated by the modular brake actuator. This means

[0013] UsM,DC, 1 / 2 = U D — U R .

[0014] Advantageously, the DC voltage USM,DC,I / 2 can be divided equally between both sub-module groups, then the DC voltage USM.DC.I , USM,DC,2 across the respective sub-module groups is

[0015] The direct current ioc through the modular braking unit corresponds to the value that, multiplied by the intermediate circuit voltage or the voltage at the terminals of the modular braking unit, corresponds to the power to be converted into heat. The direct current i D c results in

[0016] ■ _ UR

[0017] 1dc ~ R1 Thus, the modular brake controller can be controlled or regulated in such a way that, depending on the power to be converted into heat, a direct current i D c is generated by the modular braking unit. Through this direct current ioc, the modular braking unit absorbs the power BS = UD ' ^DC -. The braking resistor Ri generates the power converted into heat. To achieve energy balance, the difference between the power PBS absorbed by the braking unit and the power PRI converted into heat in the braking resistor must be converted in the other resistors. This ensures that the capacitors of the submodules, also called submodule capacitors for ease of differentiation, maintain their charge over time and do not charge or discharge excessively. In other words, the energy balance ensures a stable operating point of the modular braking unit. The power P to be converted in the two other resistors R2a / b is therefore

[0018] This can, for example, be distributed equally between the two other resistors R2a, R 2bdistribute. The power in the other resistors is generated by an alternating voltage across the sub-module groups. Since the alternating voltage is part of the voltage across the sub-module groups, this is also referred to as the alternating voltage component. The same applies to the direct voltage across the sub-module groups, which is also referred to as the direct voltage component. Advantageously, the phase difference between the alternating voltage of the first sub-module group and the alternating voltage of the second sub-module group is 180°. In other words, the alternating voltage of the first sub-module group and the alternating voltage of the second sub-module group are in antiphase to one another. This ensures that no alternating current occurs at the terminals of the modular braking unit. Therefore, only the direct current ioc occurs at the braking unit, which does not cause any voltage fluctuations in the intermediate circuit.This allows the modular braking unit to be operated without harmonics loading the DC link. If the other resistors are selected with the same resistance value, the power dissipated in the other resistors is determined as follows.

[0019] The higher the frequency of the alternating component, the greater the alternating current through the resistors R2 due to the capacitor in the second series circuit. The current iR2 and thus the power PR2 can therefore be advantageously controlled using the frequency and / or additionally with the amplitude of the alternating voltage component. This control can be carried out, for example, depending on the level of the capacitor voltages of the submodules. In the case of energy equilibrium, the intermediate circuit voltage does not change on average. Thus, for example, with increasing capacitor voltages, the frequency and / or amplitude of the alternating voltage component can be increased, and with decreasing capacitor voltages, the frequency and / or amplitude of the alternating voltage component can be reduced. This allows a stable operating point to be achieved, for example, using a PI controller.This ensures that the energy absorbed by the submodules of the respective submodule group through the direct current is converted into heat via the additional resistance, so that on average over time (minus the electrical losses in the submodule) no energy is absorbed by the submodules.

[0020] The alternating voltage component can be any alternating signal such as a sine signal, square signal, triangular signal, trapezoidal signal, etc.

[0021] For a sinusoidal curve of the alternating component with an amplitude of ÜSM,AC, the current has an amplitude of and thus the active power

[0022] The formula makes it clear that the power converted in the additional resistors can be controlled or regulated by the amplitude of the AC voltage and / or the frequency of the AC voltage component. Thus, the voltage across each sub-module group has a DC voltage component, the DC voltage of which causes the DC current through the modular braking unit and the braking resistor. Furthermore, the voltage across each sub-module group has an AC voltage component, the AC voltage of which causes an AC current across the sub-module groups through the additional resistors in the parallel current path of the second series circuit. The capacitor in series with the additional braking resistor prevents the DC voltage from affecting the current through the additional braking resistor.The current through the additional braking resistor can thus be controlled by the AC voltage, independently of the DC current and the power consumption of the modular braking unit. At the same time, the anti-phase nature of the AC voltage from the first and second submodule groups reliably prevents the formation of an AC current through the braking resistor and at the terminals of the modular braking unit. This allows the individual variables to be controlled separately. This allows the power through the individual resistors to be controlled and regulated independently of one another, allowing both the power to be converted into heat by the braking unit to be controlled and the operating point to be set stably. This results in a simple control structure for the modular braking unit, allowing the modular braking unit to operate stably. The power consumed by the braking unit is controlled or regulated using the DC component.The AC voltage component helps to balance the energy balance so that the modular brake controller can operate stably.

[0023] With the proposed design, the current absorbed by the modular braking unit is pure direct current. In other words, the current absorbed by the modular braking unit is free of harmonics, in particular free of harmonics at the frequency of the AC voltage component generated by the submodule groups. This reduces or eliminates the repercussions on the other components of the drive or power system that arise from the operation of a braking unit. For example, the design and / or operating method can reliably prevent unwanted fluctuations in the torque of a drive or unwanted energy oscillations in a power grid, regardless of the operating point.

[0024] For this purpose, it is particularly advantageous if the modular brake actuator comprises a control device configured to generate a first AC voltage component through the submodules of the first submodule group and a second AC voltage component through the submodules of the second submodule group, wherein the first AC voltage component and the second AC voltage component are in phase opposition to one another. Furthermore, it is advantageous if the control device is further configured to carry out an operating method according to one of the advantageous embodiments of the operating method of the invention.

[0025] A particularly advantageous feature of the proposed design is that there is no current path parallel to the braking resistor in the modular braking unit. This ensures that the entire current drawn by the braking unit, which is a direct current, flows through the braking resistor, causing a corresponding conversion of electrical energy into heat.

[0026] In an advantageous embodiment of the invention, the first submodule group and the second submodule group each have a plurality of submodules, wherein the submodules are arranged electrically in series. It has been shown that the arrangement of a plurality of submodules in the respective submodule group is also possible. In this case, not just one submodule generates a corresponding voltage with a DC voltage component and an AC voltage component across the respective submodule group, but a plurality of submodules. A plurality of submodules means at least two submodules that are arranged electrically in series. Due to the electrical arrangement in series, the voltages of the individual submodules are added together. These do not necessarily have to carry the same current.For example, these can be flowed through by different currents if only some of the submodules are arranged in parallel to the second series circuit consisting of a capacitor and another braking resistor or if the submodule group has several second series circuits.

[0027] The use of a variety of submodules makes it possible to adapt the modular braking unit to any voltage level. This makes the use of this modular braking unit particularly advantageous for medium-voltage and / or high-voltage applications. Furthermore, the use of a variety of submodules also makes it possible to increase the operating voltage and the power of the modular braking unit as required.

[0028] Since the submodule groups preferably generate the same DC voltage value and the same AC voltage amplitude to suppress an alternating current at the terminals of the modular braking unit, it has proven advantageous for the number of submodules in the first submodule group to be equal to the number of submodules in the second submodule group. In other words, the first submodule group has the same number of submodules as the second submodule group. This allows for good and high utilization of the submodules in the respective submodule groups to be achieved and ensured. The identical number of submodules in the first submodule group and the second submodule group makes it easy to generate both the same DC voltages and the AC voltages shifted by 180° to one another.

[0029] The number of submodules of the braking unit depends on the operating voltage of the modular braking unit, which corresponds to the intermediate circuit voltage of the converter to which the modular braking unit is connected on the DC side. In total, only enough submodules are required to generate the total intermediate circuit voltage. This number of submodules can then be distributed as desired between the two submodule groups. As described above, an even distribution of the submodules between the two submodule groups is advantageous with regard to the utilization of the submodules while preventing the formation of an alternating current at the terminals of the modular braking unit. Thus, the distribution of the submodules between two submodule assemblies does not require more submodules than a braking unit constructed from submodules as is known from the state of the art.

[0030] In a further advantageous embodiment of the invention, the second series circuit is arranged electrically in parallel with some of the submodules of the respective submodule group. For low values ​​of the additional braking resistor, in particular for resistance values ​​that are smaller than the braking resistor, only lower amplitudes are required for the AC voltage component, which can also be generated with a relatively small number of submodules. Thus, not all submodules of the submodule group have to be arranged in parallel with the second series circuit. This reduces the load, in particular on the capacitor of the second series circuit, caused by the DC voltage component that drops across this capacitor and according to which this capacitor must be designed.Because only a portion of the submodules of the respective submodule group are arranged in parallel with the second series circuit, the capacitor requirements are reduced without any negative impact on the control system. This makes the modular braking unit more cost-effective to implement.

[0031] In particular, if the second series circuit is arranged electrically in parallel to at least two submodules of the plurality of submodules, only a few additional braking resistors are required. If all submodules of a submodule group are arranged in parallel to the second series circuit, only one additional braking resistor is required per submodule group, i.e. a total of two additional braking resistors for the modular braking unit. These additional braking resistors, in particular if the modular braking resistor only comprises two additional braking resistors, can be arranged in close proximity to the braking resistor. This location can be designed for operation at high temperatures that arise in the vicinity of the braking resistor and the additional braking resistors during operation of the modular braking unit. Alternatively or additionally, it is also possible to provide the same cooling for the braking resistor and additional braking resistors, for example a shared cooling circuit.This allows the power loss to be transferred to a coolant in a particularly effective manner. The cooling circuit can thus be designed compactly. This simultaneously leads to a compact design and economical operation of the modular brake actuator.

[0032] In a further advantageous embodiment of the invention, the second series circuit is arranged electrically parallel to all submodules of the respective submodule group. This arrangement allows all submodules to contribute to generating the AC voltage component. Thus, all submodules can also transfer electrical energy to the additional braking resistor. This allows each submodule to transfer absorbed energy to the additional resistor, regardless of the operating point of the modular braking unit. This ensures the stability of all submodules within the modular braking unit in a simple manner.

[0033] In a further advantageous embodiment of the invention, the submodule groups each have a plurality of second series circuits, wherein the second series circuits are each arranged in parallel with at least one of the submodules. Due to this arrangement, the second series circuits have significantly lower requirements for the capacitor, in particular for the dielectric strength of the capacitor, and the additional braking resistor. The adaptability to any voltage level of an intermediate circuit results in increased requirements for the dielectric strength, in particular for the dielectric strength of the capacitor, if all submodules of a submodule group are arranged in parallel with the second series circuit. With increasing voltage, the cost of the capacitors increases disproportionately.To meet these requirements easily, the individual submodules or groups of submodules within the respective submodule groups are provided with the parallel arrangement of the second series circuit. Furthermore, the current through the individual second series circuits can be controlled or regulated independently of one another. This improves redundancy in the event of one or more submodules failing or a capacitor failing in one of the second series circuits. This increases availability. Since the modular braking unit often has a safety-relevant task associated with braking a drive system, the increased redundancy can significantly improve the safety of the entire drive and meet fail-safe requirements.

[0034] In a further advantageous embodiment of the invention, each submodule is arranged in parallel with one of the second series circuits. This design allows the second series circuit to be integrated into the submodule. This results in low heat generation for each individual resistor of the additional braking resistors, as this heat is distributed across the multitude of submodules. Due to the low heat generation, it is possible to connect the additional braking resistor to the submodule's cooling system. Thus, the additional resistors essentially contribute to the conversion of electrical energy into heat.

[0035] Furthermore, in the event of a fault, the entire submodule with the second series connection arranged in parallel can be easily replaced. This keeps maintenance times short and ensures the efficient use of the corresponding drive.

[0036] Furthermore, the submodule capacitor can be used for the second series circuit by adding the additional braking resistor to the submodule capacitor in such a way that the second series circuit consists of a capacitor and an additional braking resistor. The capacitor then serves, in accordance with the function of the submodule capacitor, both as an energy storage device for the submodule and as an element that prevents the generation of a direct current through the additional braking resistor.

[0037] In a further advantageous embodiment of the invention, at least one submodule of the respective submodule groups is designed as a full-bridge module. By designing at least one submodule as a full-bridge module, the control range of the braking actuator is increased. Thus, at least briefly, higher voltages than the intermediate circuit voltage of the power converter can be applied to the braking resistor. This enables at least temporary overload capacity of the modular braking actuator, whereby a power greater than the nominal power or rated power of the modular braking actuator can be converted into heat. Furthermore, the modular braking actuator is easier to control and regulate at the edge of its performance capability, particularly at maximum power, since a control reserve is created even if a voltage of zero is generated across the submodule groups by the submodules, i.e. the voltage of the intermediate circuit is applied across the braking resistor.This results, among other things, in better dynamic behavior of the modular brake actuator.

[0038] In a further advantageous embodiment of the invention, at least some of the submodules are designed as unipolar submodules, in particular as half-bridge modules or double half-bridge modules. The parallel arrangement of the second series circuit allows energy introduced into the submodules by the direct current to be easily released again without requiring a reversal of the voltage at the submodules. Such a reversal of the polarity can be achieved, for example, using bipolar submodules. However, due to the higher number of semiconductors, the bipolar submodules are more expensive than the unipolar submodules. However, the second series circuit eliminates the need to change the voltage direction at the submodules.This means that the submodules can be designed as unipolar submodules, for example as half-bridge modules or double half-bridge modules, especially if these are parts of the parallel circuit with the second series circuit consisting of a capacitor and another braking resistor.

[0039] In a further advantageous embodiment of the invention, the multilevel power converter is connected to an electrical machine on the AC voltage side, wherein the control device is configured to convert electrical energy from a braking operation of the electrical machine at least partially into heat by means of the modular braking unit. An electrical machine generates electrical energy during a braking operation. If the grid-side power converter is not designed for feeding electrical energy back into the power grid or the grid is not capable of absorbing it, the electrical energy can be converted into heat without wear using the modular braking unit. This ensures the safe operation of the modular drive unit, in particular regardless of the operating state of the power grid. In addition, the electrical machine can be highly dynamic, i.e.with rapid load changes, since the proposed modular brake actuator can ensure a sufficiently fast response.

[0040] In a further advantageous embodiment of the invention, the multilevel converter is connected to a power grid on the AC side, wherein the control device is configured to convert electrical energy into heat, in particular to improve the stability of the power grid. This makes the multilevel converter particularly suitable for energy transmission and distribution tasks. For example, such a multilevel converter can be used to connect a remote energy source, such as an offshore wind farm, to a feed-in point on the mainland. Should the power grid at the feed-in point be temporarily unable to absorb the energy, the braking controller can convert electrical energy into heat.This prevents the wind farm from being shut down and then requiring a costly restart, for example, in the event of a short-term fault that would limit its capacity. This increases the stability of both the power grid and the energy-generating wind farm.

[0041] When two power supply networks are coupled, the braking controller can also be used to compensate for an unbalanced power balance between the power supply networks and thus contribute to stable operation of both power supply networks.

[0042] In a further advantageous embodiment of the invention, the frequency and / or amplitude of the AC voltage components depends on the voltage of the submodules. The voltage across the individual submodules leads to the voltage applied across the submodules of the respective submodule group. In other words, it is particularly advantageous if the frequency and / or amplitude of the AC voltage components depends on the voltage applied across the submodules of the respective submodule group. An unbalanced energy balance can be detected based on the voltage of the submodules, which results from the voltage of the submodule capacitors. If the submodules consume electrical energy on average, which can be observed by a voltage increase across the capacitor, an increase in the amplitude of the AC voltage component and / or an increase in the frequency of the AC voltage component counteracts this increase.For example, using a PI controller, the amplitude and / or frequency of the AC voltage component can be specified or varied depending on the submodule voltage.

[0043] In a further advantageous embodiment of the invention, the amplitude of the AC voltage components is smaller than a DC voltage component generated by the submodules of one of the submodule groups. If the amplitude of the AC voltage component is smaller than the DC voltage, only unipolar submodules are required to generate this voltage, since the polarity of the voltage is not reversed. The parallel current path of the second series circuit enables a balanced energy balance to be achieved for all operating points, even when using unipolar submodules. If even more control reserve is required in the event that the amplitude corresponds to the DC voltage component, this can be achieved by increasing the frequency. Especially in the range of high power levels of the braking unit, only a small amount of power needs to be dissipated via the additional braking resistor due to the low voltage drop across the submodules.This is also possible using small amplitudes, possibly supported by increasing the frequency of the alternating voltage component.

[0044] The invention is described and explained in more detail below with reference to the exemplary embodiments shown in the figures. They show:

[0045] FIG 1 , FIG 2 Designs of a modular brake actuator,

[0046] FIG 3 to FIG 6 embodiments of the submodule,

[0047] FIG 7 Time courses of current and voltage,

[0048] FIG 8 to FIG 10 embodiments of the modular drive unit.

[0049] FIG. 1 shows an embodiment of the modular braking unit 1. This modular braking unit 1 has, between its two terminals 13, a first series circuit 14 comprising a first submodule group 21, a second submodule group 22, and a braking resistor 3, wherein the braking resistor is arranged between the first submodule group 21 and the second submodule group 22, i.e., centrally in this first series circuit 14. The modular braking unit 1 is configured to be connected at its terminals 13 to an intermediate circuit 9 of a power converter, in particular a modular multilevel power converter 11.

[0050] The submodule groups 21, 22 each have at least one submodule 2. If there is more than one submodule 2, there is a plurality of submodules 2. A plurality of submodules 2 means at least two submodules 2. These submodules 2 or some of these submodules 2 are arranged electrically in series, for example to increase the operating voltage of the modular braking actuator 1. A second series circuit 15 is arranged in parallel to the at least one submodule 2, to the submodules 2 arranged electrically in series, or to some of the submodules 2 arranged electrically in series. The second series circuit 15 has a capacitor 7 and a further braking resistor 31. The capacitor 7 prevents the formation of a direct current through the further braking resistor 31. With the help of voltages USMI, USM2 generated across the submodules 2, a voltage can be generated across the braking resistor 3.Since the active power is absorbed by the modular braking unit 1 via a direct current, a direct voltage of USMI = USM.DC and USM2 = USM,DC,2 is generated across the respective submodule groups. This also creates a direct voltage of UR = UR across the braking resistor, which leads to a direct current ioc through the braking resistor 3. The voltage U. S MI , U S In addition to the DC component of USM.DC and UsM,DC,2, an AC component is also superimposed on M2. This AC component causes an AC current i R2 by the further braking resistor 31. Thus, the direct current i D c the control or regulation of the power consumption of the modular brake unit 1 and the alternating current i R2through the second series circuit 15 in order to establish energy equilibrium within the modular braking unit 1, so that no energy is absorbed or released within the sub-modules 2 on average over time. If the energy stored in the sub-modules 2 remains the same on average over time, the modular braking unit 1 can be operated stably at the corresponding operating point over time. The formation of an alternating current through the braking resistor 3 is avoided by the alternating voltage components of the two sub-module groups 21, 22 being aligned in antiphase to one another. This means that at a constant intermediate circuit voltage UD, no alternating voltage drops across the braking resistor 3 that could cause an alternating current. This also means that no alternating current appears to the outside, i.e. at the connections 13 of the modular braking unit 1.This means that the modular brake controller 1 can be operated on a power converter with particularly low reaction, since no harmonics are generated.

[0051] FIG. 2 shows an alternative embodiment of the modular braking unit 1. In this case, each submodule 2 has a parallel second series circuit 15 comprising capacitor 7 and a further braking resistor 31. Furthermore, any combination of the exemplary embodiments according to FIG. 1 and FIG. 2 is possible, in which only some of the submodules 2 are arranged in parallel with a second series circuit 15 and another part of the submodules 2 is arranged in parallel with another second series circuit 15.

[0052] Figures 3 to 6 show exemplary embodiments of submodules 2. All known submodules 2, in particular the submodules 2 of Figures 3 to 6, are suitable for the modular brake actuator 1. To avoid repetition, reference is made to the description of Figures 1 and 2 and to the reference numerals introduced therein.

[0053] The illustrated embodiments of submodule 2 comprise at least two semiconductor switches 24. By switching operations of the semiconductor switches 24, an output voltage Usub can be generated at the terminals of submodule 2. A control module 16 transmits the control signals to the semiconductor switches 24 of submodule 2. The control module 16 is preferably arranged outside of submodule 2 and is therefore not part of submodule 2. Alternatively, it is possible to equip each submodule 2 with its own control module 16. However, it has proven advantageous to control all submodules 2 of the modular braking actuator 1 with one control module 16. In addition, the control module 16 can then perform the calculations required for the control and regulation of the voltages and currents.In particular, the control module 16 can also be part of a control device with which the DC components and AC components in the voltage across the submodule groups 21, 22 are generated.

[0054] FIG 3 shows a half-bridge module. This has two semiconductor switches 24 and a sub-module capacitor 25. The voltage Uc.sub is applied to the sub-module capacitor 25. By switching operations of the semiconductor switches 24, the output voltage U S ub of zero or Uc.sub are generated at the terminals of submodule 2. A control module 16 controls the semiconductor switches 24 so that the desired voltage is applied between the submodule terminals 26. Since the polarity of the output voltage does not change, such a submodule 2 is also referred to as a unipolar submodule.

[0055] FIG. 4 shows another embodiment of a half-bridge module. If the second series circuit 15 is arranged electrically parallel only to this submodule 2, a submodule capacitor 25 can be omitted. In this case, the capacitor 7 of the second series circuit 15 can assume the function of the energy storage in the submodule 2, which is otherwise fulfilled by a submodule capacitor 25. Such an expansion is also possible for the submodules 2 described below by replacing the submodule capacitor 25 with the second series circuit 15 comprising capacitor 7 and an additional braking resistor 31.

[0056] A control module 16 controls the semiconductor switches 24 so that the desired voltage is applied between the submodule terminals 26. Since the polarity of the output voltage does not change in this embodiment, such a submodule 2 is also referred to as a unipolar submodule.

[0057] FIG 5 shows a so-called double half-bridge module. This double half-bridge module has four semiconductor switches 24 and two sub-module capacitors 25. The voltage Uci.sub and Uc2,sub are respectively applied to the sub-module capacitors 25. By switching operations of the semiconductor switches, the output voltage U Sub from zero, from one of the capacitor voltages Uci .sub, Uc2,sub or from the sum of the capacitor voltages Uci ,sub, Uc2,sub at the submodule terminals 26 of submodule 2. A control module 16, not shown here, can control the semiconductor switches 24 such that the desired voltage is applied between the submodule terminals 26. This submodule 2 is also a unipolar submodule. FIG. 6 shows a so-called full-bridge module. This full-bridge module has four semiconductor switches and a submodule capacitor 25. The voltage Uc.sub is applied to the submodule capacitor 25. By switching actions of the semiconductor switches 24, the output voltage Usub from zero, the positive or the negative capacitor voltage ±Uc,sub of the submodule capacitor can be generated at the submodule terminals 26 of submodule 2.A control module 16 (not shown here) can control the semiconductor switches 24 such that the desired voltage is applied between the submodule terminals 26. Since this submodule 2 can generate voltages of different polarity, this type of submodule 2 is also referred to as a bipolar submodule.

[0058] FIG 7 shows the time course of the voltages u related to the intermediate circuit voltage UD, which are generated by the submodule groups 21, 22. The two submodule groups 21, 22 together generate the voltage USM,DC,I / 2, which is preferably distributed equally between the respective submodule groups 21, 22, so that each of the submodule groups 21, 22 has a DC component of An alternating voltage component is superimposed on both direct voltage components, whereby the alternating voltage components are aligned in phase opposition, ie with a phase shift of 180°, so that they do not generate a voltage drop across the braking resistor 3. These alternating components can take on any desired time characteristic, such as a sinusoidal, rectangular, triangular, trapezoidal, etc. FIG. 7 shows a sinusoidal time characteristic with a respective amplitude of Ü S M,AC-

[0059] FIG 8 shows a modular drive unit 10 with a modular multilevel power converter 11 and a modular braking unit 1. These are connected to one another via the intermediate circuit 9, to which the intermediate circuit voltage UD is applied. In other words, the modular multilevel power converter 11 is connected on the DC voltage side to the terminals 13 of the modular braking unit 1. To avoid repetition, reference is made to the description of FIGS. 1 to 6 and to the reference numerals introduced there. The modular braking unit 1 has the first series circuit 14 of the first submodule group 21, the second submodule group 22 and the braking resistor 3. The submodule groups 21, 22 each have at least one submodule 2 and the second series circuit 15 comprising a capacitor 7 and a further braking resistor 31, which are not explicitly shown for reasons of clarity. In this regard, reference is made to the embodiments of FIGS. 1 and 2.The modular multilevel power converter 11 can, but not necessarily, have the same submodules 2 as the submodule groups 21, 22 of the modular braking unit 1. The series connection of the submodules of the modular multilevel power converter 11 preferably also has an inductance 8, which improves the control behavior of the modular multilevel power converter 11. The connections L1, L2, L3 represent the AC voltage side connections or, in short, the AC voltage side of the modular multilevel power converter 11. In this exemplary embodiment, the modular multilevel power converter 11 is designed as a three-phase device. Alternatively, a single-phase version with a neutral conductor or any desired number of phases is possible by arranging a corresponding number of phase modules in the modular multilevel power converter 11.

[0060] FIG. 9 shows another embodiment of the modular drive unit 10. The modular multilevel power converter 11 is connected to a power grid 6 on the AC side. Alternatively, it can be connected to any energy source or energy storage device.

[0061] In the embodiment of FIG 10, the modular drive unit 10 has two modular multilevel power converters 11 and a modular braking unit 1, which are electrically connected to one another at the intermediate circuit 9. A first of the two modular multilevel power converters 11 is connected to an electrical machine 5 on its AC voltage side. A second of the two modular multilevel power converters 11, i.e. a further modular multilevel power converter 11, is connected to a power supply network 6 on its AC voltage side. The electrical machine 5 can be supplied, i.e. fed, with electrical energy from the power supply network 6. Feeding energy back from the electrical machine 5 into the power supply network 6, for example during a braking process, is also possible with the modular drive unit 10.If the power supply network 6 is temporarily or permanently unable to absorb the energy, the electrical energy generated by the electric machine 5 can be advantageously converted into heat without wear by means of the modular brake actuator 1. A mechanical brake subject to wear can be dispensed with in this embodiment. List of reference symbols.

[0062] 1 Modular brake actuator

[0063] 2 Submodul

[0064] 3 Braking resistor

[0065] 5 electric machine

[0066] 6 Energy supply network

[0067] 7 Capacitor

[0068] 8 Inductance

[0069] 9 intermediate circuit

[0070] 10 Modular drive unit

[0071] 11 multilevel power converters

[0072] 13 connections of the brake actuator (1)

[0073] 14 first series connection

[0074] 15 second series connection

[0075] 16 Control module

[0076] 21 first submodule group

[0077] 22 second submodule group

[0078] 24 semiconductor switches

[0079] 25 Submodule capacitor

[0080] 26 submodule connections

[0081] 31 additional braking resistor

Claims

Patent claims 1. Modular brake actuator (1), wherein a first sub-module group (21), a second sub-module group (22) and a braking resistor (3) are arranged in a first series circuit (14) between two terminals (13) of the modular brake actuator (1), wherein the braking resistor (3) is arranged electrically between the first sub-module group (21) and the second sub-module group (22), wherein the first sub-module group (21) and the second sub-module group (22) each have at least one sub-module (2), a further braking resistor (31) and a capacitor (7), wherein a second series circuit (15) comprising the further braking resistor (31) and the capacitor (7) is arranged electrically parallel to at least one sub-module (2) of the at least one sub-module (2).

2. Modular brake actuator (1) according to claim 1, wherein the first sub-module group (21) and the second sub-module group (22) each have a plurality of sub-modules (2), wherein the sub-modules (2) are arranged electrically in series.

3. Modular brake actuator (1) according to claim 2, wherein the second series circuit (15) is arranged electrically parallel to a part of the submodules (2) of the respective submodule group (21, 22), in particular electrically parallel to at least two submodules (2) of the plurality of submodules (2).

4. Modular brake actuator (1) according to claim 2, wherein the second series circuit (15) is arranged electrically parallel to all submodules (2) of the respective submodule group (21, 22).

5. Modular brake actuator (1) according to one of claims 2 to 4, wherein the sub-module groups (21, 22) each have a plurality of second series circuits (15), wherein the second series circuits (15) are each arranged in parallel to at least one of the sub-modules (2).

6. Modular brake actuator (1) according to claim 5, wherein each submodule (2) is arranged in parallel to one of the second series circuits (12).

7. Modular brake actuator (1) according to one of claims 1 to 6, wherein at least one submodule (2) of the respective submodule groups (21, 22) is designed as a full-bridge module.

8. Modular brake actuator (1) according to one of claims 2 to 7, wherein at least some of the submodules (2) are designed as unipolar submodules, in particular as half-bridge modules or double half-bridge modules.

9. Modular drive unit (10), comprising a modular multilevel power converter (11) and a modular braking unit (1) according to one of claims 1 to 8, wherein the multilevel power converter (11) is connected to the modular braking unit (1) on the DC voltage side.

10. Modular drive unit (10) according to claim 9, wherein the multilevel power converter (11) is connected on the AC voltage side to an electrical machine (5), wherein the control device (4) is configured to convert electrical energy from a braking operation of the electrical machine (5) at least partially into heat by the modular braking controller (1).

11. Modular drive unit (10) according to one of claims 9 or 10, wherein the multilevel power converter (11) or a further multilevel power converter is connected on the AC voltage side to a power supply network (6), wherein the control device (4) is designed to convert electrical energy into heat, in particular to improve the stability of the power supply network (6).

12. Operating method for a modular brake actuator (1) according to one of claims 1 to 8 or for a modular drive unit (10) according to one of claims 9 to 11, wherein a first alternating voltage component (UBR,AC,I) is generated by the submodules (2) of the first submodule group (21) and a second alternating voltage component (UBR,AC,2) is generated by the submodules (2) of the second submodule group (22), wherein the first alternating voltage component (UBR,AC,I) and the second alternating voltage component (UBR,AC,2) are in antiphase to one another.

13. Operating method according to claim 12, wherein the frequency (f) and / or the amplitude (ü) of the alternating voltage components (UBR,AC,I , UBR,AC,2) is dependent on the voltage of the submodules (2), in particular dependent on the voltage applied across the submodules (2) of the respective submodule group (21, 22).

14. Operating method according to one of claims 12 or 13, wherein the amplitude (ü) of the alternating voltage components (UBR,AC,I , UBR,AC,2) is in each case smaller than a direct voltage component (U B R,DC,I , U B R,DC,2)- 15. Operating method according to one of claims 12 to 14, wherein the frequency (f) and / or the amplitude (ü) of the alternating voltage components (U B R,AC,I , U BR,AC,2) is dimensioned such that the electrical energy absorbed by the modular braking unit (1) is completely converted into heat by the braking resistor (3) and the further braking resistor (31).

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