Abstract:
Aspects of the invention are directed to systems and method for limiting losses in an uninterruptible power supply. In one aspect, the present invention provides an uninterruptible power supply (UPS) comprising an input to receive input power having an input voltage, an output to provide output power having an output voltage, a neutral line, an automatic voltage regulation (AVR) transformer coupled to the input and the output of the UPS and having an input, an output, a core and at least one switch controllably coupled to at least one of the core, the input and the output, and a means for isolating the core of the AVR transformer from the neutral line when the input voltage is substantially equal to a defined output voltage.

Description:
BACKGROUND OF INVENTION 
       [0001]    1. Field of Invention 
         [0002]    At least one embodiment of the invention relates generally to a method and system for providing uninterruptible, regulated power to critical and/or sensitive loads. More specifically, at least one embodiment of the invention relates to the reduction of losses in an uninterruptible power supply due to an automatic voltage regulation transformer. 
         [0003]    2. Discussion of Related Art 
         [0004]    The use of an uninterruptible power system (UPS) to provide power to a critical load is known. Known uninterruptible power systems include on-line UPS&#39;s, off-line UPS&#39;s, line interactive UPS&#39;s as well as others. On-line UPS&#39;s provide conditioned AC power as well as back-up AC power upon interruption of a primary source of AC power. Off-line UPS&#39;s typically do not provide conditioning of input AC power, but do provide back-up AC power upon interruption of the primary AC power source. Line interactive UPS&#39;s are similar to off-line and on-line UPS&#39;s in that they still switch to battery power when a blackout occurs; however, when a power line sag or swell occurs, at least one type of line interactive UPS activates a tap switching voltage regulation circuit to stabilize the output voltage continuously, without consuming battery power. This allows equipment connected to the UPS to continue to operate through extended power line sags or swells without draining the battery. The tap switching voltage regulation circuit often includes an automatic voltage regulation (AVR) transformer. 
       SUMMARY OF THE INVENTION 
       [0005]    In embodiments of the present invention, the problems associated with AVR transformer energy loss in a UPS are reduced by de-energizing the core of the transformer and preventing losses due to the AVR transformer when the AVR is not performing a regulation function. 
         [0006]    In one aspect, the present invention features an uninterruptible power supply (UPS). The UPS may include an input to receive input power having an input voltage, an output to provide output power, a neutral line, and an automatic voltage regulation (AVR) transformer coupled to the input and the output of the UPS, the AVR transformer having an input, an output, a core, and at least one switch controllably coupled to at least one of the core, the input and the output. The UPS further comprises a bypass switch configured to selectively couple the core of the AVR transformer to the neutral line, and a controller configured to control the at least one switch of the AVR transformer and the bypass switch, wherein the controller is configured to control the bypass switch to isolate the core of the AVR transformer from the neutral line in a first mode of operation and to couple the core of the AVR transformer to the neutral line in a second mode of operation. 
         [0007]    According to one or more aspects of the invention, the controller is configured to, in the first mode of operation, couple the at least one switch of the AVR transformer to the core and to at least one of the AVR transformer input and the AVR transformer output in a configuration to provide an output voltage of the AVR transformer that is equal to an input voltage of the AVR transformer. 
         [0008]    According to one or more aspects of the invention, the UPS further comprises a DC voltage source and an inverter coupled to the DC voltage source, wherein the inverter is coupled to the input of the AVR transformer and is configured to provide regulated AC power to the AVR transformer. Also, according to one or more aspects of the invention, the DC voltage source includes a battery. 
         [0009]    According to one or more aspects of the invention, the controller is configured to, in the second mode of operation, couple the at least one switch of the AVR transformer to the core and to at least one of the AVR transformer input and the AVR transformer output in a configuration to provide an output voltage of the AVR transformer that is greater than an input voltage of the AVR transformer by a first ratio. 
         [0010]    According to one or more aspects of the invention, the controller is configured, in a third mode of operation, to control the bypass switch to couple the core of the AVR transformer to the neutral line and wherein the controller is further configured to couple the at least one switch of the AVR transformer to the core and to at least one of the AVR transformer input and the AVR transformer output in a configuration to provide an output voltage of the AVR transformer that is greater than the input voltage of the AVR transformer by a second ratio which is larger than the first ratio. Also, according to one or more aspects of the invention, the second ratio may be twice the first ratio. 
         [0011]    According to one or more aspects of the invention, the controller is configured, in a fourth mode of operation, to control the bypass switch to couple the core of the AVR transformer to the neutral line and wherein the controller is further configured to couple the at least one switch of the AVR transformer to the core and to at least one of the AVR transformer input and the AVR transformer output in a configuration to provide an output voltage of the AVR transformer that is less than the input voltage of the AVR transformer by a third ratio. According to one or more aspects of the invention, the third ratio may be 1.15:1. Also, according to one or more aspects of the invention, the bypass switch is an electromagnetic switch. In addition, according to one or more aspects of the invention, the electromagnetic switch is a relay. According to one or more aspects of the invention, the relay is a single pole double throw relay or a single pole single throw relay. 
         [0012]    In another aspect, the present invention features a method of providing stable power in an uninterruptible power supply (UPS) having an automatic voltage regulation (AVR) transformer, an input to received input power having an input voltage, an output to provide output power having an output voltage, and a neutral line, the AVR transformer having an input, an output and a core selectively coupled to the neutral line, the method comprising determining whether the input voltage to the UPS is within a specified tolerance, if the input voltage to the UPS satisfies a first condition, isolate the core of the AVR transformer from the neutral line and if the input voltage of the UPS satisfies a second condition, couple the core of the AVR transformer to the neutral line. 
         [0013]    According to one or more aspects of the method, the method further comprises the act of configuring the AVR transformer to boost the output voltage of the UPS if the input voltage of the UPS is less than a specified tolerance and configuring the AVR transformer to reduce the output voltage of the UPS if the input voltage of the UPS is greater than a specified tolerance. 
         [0014]    According to one or more aspects of the method; the act of isolating comprises an act of decoupling the core of the AVR transformer from the neutral line. 
         [0015]    According to one or more aspects of the method, the method further includes at least one switch controllably coupled to at least one of the core, the input of the AVR transformer and the output of the AVR transformer, and a bypass switch configured to selectively couple the core of the AVR transformer to the neutral line, wherein the act of isolating further comprises the act of coupling the at least one switch to the core and one half cycle later, controlling the bypass switch to decouple the core from the neutral line, wherein the act of coupling the core to the neutral line further comprises the act of controlling the bypass switch to couple the core to the neutral line and one half cycle later, coupling the at least one switch to the core. 
         [0016]    In another aspect, the present invention features a UPS. The UPS having an input to receive input power having an input voltage, an output to provide output power having an output voltage, a neutral line, and an AVR transformer coupled to the input and the output of the UPS and having an input, an output, a core and at least one switch controllably coupled to at least one of the core, the input and the output. The UPS further comprises a means for isolating the core of the AVR transformer from the neutral line when the input voltage is substantially equal to a defined output voltage. 
         [0017]    According to one or more aspects of the invention, the at least one switch is selectively coupled, in a first mode of operation, to the core in a configuration to provide an output voltage of the AVR transformer that is equal to an input voltage of the AVR transformer. 
         [0018]    According to one or more aspects of the invention, the UPS further comprises a DC voltage source coupled to an inverter and wherein the inverter is coupled to the AVR transformer and is configured to provide regulated AC power to the AVR transformer. Also, according to one or more aspects of the invention, the DC voltage source includes a battery. 
         [0019]    According to one or more aspects of the invention, in a second mode of operation, the core of the AVR transformer is coupled to the neutral line and the at least one switch is selectively coupled to the core in a configuration that results in the output voltage of the AVR transformer being greater than the input voltage of the AVR transformer by a first ratio. 
         [0020]    According to one or more aspects of the invention, in a third mode of operation, the core of the AVR transformer is coupled to the neutral line and the at least one switch is selectively coupled to the core in a configuration that results in the output voltage of the AVR transformer to be greater than the input voltage of the AVR transformer by a second ratio which is larger than the first ratio. Also, according to one or more aspects of the invention, the second ratio is twice the first ratio. 
         [0021]    According to one or more aspects of the invention, in a fourth mode of operation, the core of the AVR transformer is coupled to the neutral line and the at least one switch is selectively coupled to the core in a configuration that results in the output voltage of the AVR transformer being smaller than the input voltage of the AVR transformer. 
     
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         [0022]    The accompanying drawings are not intended to be drawn to scale, in the drawings, each identical or nearly identical component that is illustrated in various figures is represented by a like numeral. For purposes of clarity, not every component may be labeled in every drawing. In the drawings: 
           [0023]      FIG. 1  is a block diagram of a line interactive uninterruptible power supply including an automatic voltage regulation transformer. 
           [0024]      FIG. 2  is a schematic view of an automatic voltage regulation transformer included in a UPS in accordance with the present invention. 
           [0025]      FIG. 3  is a schematic view of an automatic voltage regulation transformer in the inverter mode in accordance with the present invention. 
           [0026]      FIG. 4  is a schematic view of an automatic voltage regulation transformer in the pass through mode in accordance with the present invention. 
           [0027]      FIG. 5  is a schematic view of an automatic voltage regulation transformer in the boost mode in accordance with the present invention. 
           [0028]      FIG. 6  is a schematic view of an automatic voltage regulation transformer in the double boost mode in accordance with the present invention. 
           [0029]      FIG. 7  is a schematic view of an automatic voltage regulation transformer in the trim mode in accordance with the present invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0030]    Embodiments of the invention are not limited to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings. Embodiments of the invention are capable of being practiced or of being carried out in various ways. Also, the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having,” “containing”, “involving”, and variations thereof herein, is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. 
         [0031]    A drawback of utilizing an AVR transformer to stabilize a voltage at the output of a UPS is that an AVR transformer consumes energy even when not regulating the output voltage, which leads to energy losses in the transformer. In at least some embodiments of the present invention, the problems associated with AVR transformer energy loss in a UPS are eliminated by de-energizing the core of the transformer and preventing losses due to the AVR transformer when the AVR is not regulating the output voltage. 
         [0032]    One embodiment of an uninterruptible power supply in accordance with the present invention will now be described with reference to  FIG. 1  which shows a block diagram of a line interactive uninterruptible power supply (UPS)  10  for providing AC power to a load. The UPS includes an input  12  to receive AC power from an AC power source, an output  14  that provides AC power to at least one controlled outlet  13 , a DC voltage source  11  coupled to a DC to DC converter  15 , an inverter  18  operatively coupled to the DC to DC converter  15  to receive DC power and to provide AC power, a transfer relay  16  selectively coupled to the UPS input  12  and the inverter  18 , a UPS controller  17 , an external communication control circuit  19  for communicating with external devices, an EMI/Surge filter  21 , and an automatic voltage regulation (AVR) transformer  20  coupled to a bypass relay  34 , the transfer relay  16  and at least one AVR relay  43 . The DC voltage source  11  includes a battery  22 , at least one backup battery pack  23 , a battery charger  25  and a logic supply  35 . The UPS controller  17  is coupled to a current sense circuit  37 , a voltage sense circuit  39 , a line sense circuit  41 , a switch relay control  45  and at least one controllable relay  47 . 
         [0033]    With reference to  FIG. 2 , which shows a schematic view of the automatic voltage regulation transformer, the AVR transformer  20  includes an input  24 , an output  30 , a core  32  including a top portion  49 , a middle portion  51  and a bottom portion  53 , a first AVR relay  26  selectively coupled between the input  24  and either the top portion  49  of the core  32  or a first tap  27  coupled to the bottom portion  53  of the core  32 , a second AVR relay  28  selectively coupled between the output  30  and either the top portion  49  of the core  32  or a second tap  29  coupled to the middle portion  51  of the core  32 , and a bypass relay  34  for decoupling the AVR transformer core  32  from a neutral line  36 . The first AVR relay  26 , the second AVR relay  28  and the bypass relay  34  may be single pole double throw (SPDT) relays. The bypass relay  34  may also be a single pole single throw (SPST) relay. A metal oxide varistor may also be coupled across the bypass relay  34  to absorb energy when the bypass relay  34  is opened. 
         [0034]    The operation of the UPS  10  will now be described with reference to  FIGS. 1-7 . With reference to  FIGS. 1-2 , the UPS controller  17  monitors the status of the UPS  10  by reading the outputs of the voltage sense circuit  39 , the current sense circuit  37  and the line sense circuit  41 . In monitoring the outputs, the UPS controller may determine whether the input voltage to the UPS  10  is in a normal or abnormal condition. The input voltage is in an abnormal condition if the input voltage at the input  12  of the UPS  10  is in a blackout, sag, or swell condition. Irrespective of the input voltage, the UPS controller  17  operates the UPS  10  and the AVR transformer  20  so that the voltage at the output  30  is within predetermined values, i.e. a nominal value plus or minus a given threshold. 
         [0035]    For example, with reference to  FIGS. 1 and 3 , if the input voltage at the input  12  of the UPS  10  fails (blackout), the UPS controller  17  activates the transfer relay  16  to couple the AVR transformer  20  to the inverter  18  to receive voltage from the DC voltage source  11  instead of the input  12 . DC power from the DC voltage source  11  is regulated by the DC to DC converter  15 , which is controlled by the UPS controller  17 . The regulated DC power from the DC/DC converter  15  is converted to AC power by the inverter  18  and output to the transfer relay  16  and AVR transformer  20 . With reference to  FIG. 3 , which shows operation in inverter mode, the UPS controller  17  adjusts the AVR relays  26 ,  28  to an inverter mode in which the AVR transformer  20  is not required to perform an output voltage regulation function. The AVR transformer is not required to perform an output voltage regulation function because the DC voltage from the DC voltage source  11  is already regulated by the DC/DC converter  15  and DC/AC converter  18 . In the pass through mode, the first AVR relay  26  is set in a second position  48  and the second AVR relay  28  is set in a second position  44  with both AVR relays  26 ,  28  coupled to the top portion  49  of the core  32  so that the taps  27 ,  29  are de-energized and the voltage at the output  30  of the AVR transformer  20  is equal to the voltage at the input  24  of the AVR transformer  20 . Also, in the inverter mode, the bypass relay  34  is opened to decouple the core  32  of the AVR transformer from a neutral line  36  to eliminate any potential losses due to the AVR transformer  20 . The UPS controller also operates a set of controllable relays  47 , through a switch relay control  45 , which determine which controlled outlets  13  will be connected to the output  14 . 
         [0036]    In another example, with reference to  FIGS. 1 and 4 , if the input voltage at the input  12  of the UPS  10  is at a normal level and AVR transformer regulation is not required, the transfer relay  16  couples the AVR transformer  20  to the input of the UPS  10  and the UPS controller  17  adjusts the AVR relays  26 ,  28  to a pass through mode in which the AVR transformer  20  is not required to perform an output voltage regulation function. In the pass through mode, the first AVR relay  26  is set in a second position  48  and the second AVR  28  is set in a second position  44  with AVR relays  26 ,  28  coupled to the top portion  49  of the core  32 , so that the taps  27 ,  29  are de-energized and the voltage at the output  30  of the AVR transformer  20  is equal to the voltage at the input  24  of the AVR transformer  20 . Also, in the pass through mode, the bypass relay  34  is opened to decouple the core  32  of the AVR transformer from a neutral line  36  to eliminate any potential losses due to the AVR transformer  20 . 
         [0037]    If the input voltage is in a sag or swell condition, the transfer relay  16  couples the AVR transformer  20  to the input of the UPS  10  and the UPS controller  17  adjusts the AVR relays  26 ,  28 , consequently activating or deactivating the corresponding taps  27 ,  29  to provide a stabilized voltage at the output  30  of the AVR transformer. 
         [0038]    For example, with reference to  FIG. 5 , if the input voltage at the input  12  of the UPS  10  is in a sag condition and the output voltage needs to be increased, the UPS controller  17  adjusts the AVR relays  26 ,  28  to a boost mode. In the boost mode, the first AVR relay  26  of the AVR transformer  20 , is set in a first position  38 , coupled to the bottom portion  53  of the core  32 , so that the first tap  27  is energized and the second AVR relay  28  of the AVR transformer  20  is set in a first position  40 , coupled to the middle portion  51  of the core  32 , so that the second tap  29  is energized, allowing the electrical current  42  at the input  24  of the AVR transformer  20  to flow from the bottom portion  53  of the core  32  to the middle portion  51  of the core in a first direction, resulting in the voltage at the output  30  of the AVR transformer  20  being greater than the voltage at the input  24  of the AVR transformer  20 . The increase of voltage between the output  30  and input  24  due to the AVR transformer  20  is directly correlated to the turn ratio of the core  32  of the AVR transformer  20  which varies depending on where the core  32  is tapped (determined by the first and second AVR relays  26 ,  28  and corresponding taps  27 ,  29  of the AVR transformer  20 ). For example, in the boost mode, the voltage at the output of the AVR transformer may be increased, in relation to the voltage at the input of the AVR transformer, by a first ratio. The first ratio may be 1:1.15. 
         [0039]    With reference to  FIG. 6 , if the output voltage needs to be increased by a greater ratio, the second AVR relay  28  of the AVR transformer  20 , can be put in a second position  44 , coupled to the top portion  49  of the core  32 , so that the second tap  29  is de-energized, allowing the current  46  to flow through a larger portion of the core  32 , from the bottom portion  53  to the top portion  49 , in the first direction, effectively increasing the turn ratio of the AVR transformer, and resulting in a larger voltage at the output  30 . For example, in the boost mode, the voltage at the output of the AVR transformer may be increased by a second ratio which is greater than the first ratio. In one embodiment, the second ratio may be double the value of the first ratio. The second ratio may be 1:1.3. 
         [0040]    In another example, with reference to  FIG. 7 , if the input voltage at the input  12  of the UPS  10  is in an swell condition and the output voltage needs to be reduced, the transfer relay  16  couples the AVR transformer  20  to the input of the UPS  10  and the UPS controller  17  adjusts the AVR relays  26 ,  28  to a trim mode. In the trim mode, the first AVR relay  26  of the AVR transformer  20 , is set in a second position  48 , coupled to the top portion  49  of the core  32 , so that the first tap  27  is de-energized, and the second AVR relay  28  of the AVR transformer  20 , is set in a first position  40 , coupled to the middle portion  51  of the core  32 , so that the second tap  29  is energized, allowing the electrical current  50  at the input  24  of the AVR transformer  20  to flow through a section of the core  52  of the AVR transformer, from the top portion  49  to the middle portion  51 , in a second direction, which results in the voltage at the output  30  of the AVR transformer  20  being lower than the voltage at the input  24  of the AVR transformer  20 . The decrease of voltage between the output  30  and input  24  due to the AVR transformer  20  is directly correlated to the turn ratio of the core  32  of the AVR transformer  20 . For example, in the trim mode, the voltage at the output of the AVR transformer may be decreased, in relation to the voltage at the input of the AVR transformer, by a ratio. The ratio may be 1.15:1. 
         [0041]    When the AVR transformer core is transitioned from an energized to de-energized state or from a de-energized state to an energized state, it is beneficial in at least one embodiment to operate the AVR relays of the AVR transformer and the bypass relay in such a way to minimize any loss of volt-seconds or imbalance in the UPS. For example, in at least one embodiment the UPS controller  17  engages the bypass relay as close to the zero crossing of the AC voltage waveform as possible to minimize any loss of volt-seconds. Additionally, in at least one embodiment the UPS controllers  17  engages the bypass relays and the AVR relays exactly 180 degree apart to minimize any loss of volt-seconds or imbalance. For example, when the AVR transformer core is transitioned from a de-energized to an energized state, the bypass relay may be engaged first, followed by the AVR relays exactly one half cycle later. In another example, when the AVR transformer is transitioned from an energized to a de-energized state, the AVR relays may be engaged first, followed by the bypass relay exactly one half cycle later. 
         [0042]    One advantage to at least one embodiment of the present invention described above is that the problems usually associated with AVR transformer energy loss in a UPS are reduced by de-energizing the core of the transformer and preventing losses due to the AVR transformer when the AVR is not performing a regulation function. By de-energizing the core, electric current is prevented from flowing in the core, which results in the elimination of any tare loss due to the AVR transformer when the ACR transformer is not performing a regulation function. 
         [0043]    Embodiments of the invention are described above in conjunction with a line interactive UPS. The methods and systems described herein can also be used with other types of uninterruptible power supplies and in a variety of power supply systems and voltage regulation systems. 
         [0044]    As described above, the systems and methods of embodiments of the invention utilize a plurality of different switches. The switches could be implemented in a variety of different ways such as, but not limited to, SPDT relays, SPST relays, transistors or other types of switches. 
         [0045]    In at least one embodiment, the DC voltage supply  11  includes extra battery packs  23  to provide extra DC storage capacity, a battery charger for converting AC voltage from the input  12  into DC voltage to charge the battery  22  and backup battery packs  23 , and a logic supply  21  for providing regulated DC voltages. In other embodiments, other backup power sources may be used including AC and DC generators. 
         [0046]    In at least one embodiment the UPS controller  17  is connected to an external communication control circuit  19  to communicate with external devices. 
         [0047]    In at least one embodiment the input  12  is connected to an EMI/Surge filter  21  to provide EMI and surge protection to the UPS  10 . 
         [0048]    In at least one embodiment, the controllable relays  47  are not included in the UPS and the controlled outlets  13  are not controlled outlets but are standard outlets. 
         [0049]    As described above, the systems and methods of embodiments of the invention utilize a UPS controller. The UPS controller could be implemented in a variety of different ways such as, but not limited to, a microprocessor, logic circuit, computer or other type of electronic controller. 
         [0050]    Having thus described several aspects of at least one embodiment of this invention, it is to be appreciated various alterations, modifications, and improvements will readily occur to those skilled in the art. Such alterations, modifications, and improvements are intended to be part of this disclosure, and are intended to be within the spirit and scope of the invention. Accordingly, the foregoing description and drawings are by way of example only.