Patent Description:
Nowadays frequency converters have a key role in a control of electric engines, for example electric engines used in power plants which have to run <NUM> hours per day and <NUM> days per week. They allow, in particular, adjusting speed of controlled electric engines to actual needs of their users. Operation of electric engines with adjusted speed leads to energy savings in comparison to operation of the electric engines with nominal speed. That's why it is important for installations equipped with frequency converters to provide reliable and uninterrupted operation of said frequency converters. To fulfil mentioned requirements, a proper monitoring of frequency converters' components is essential since different kinds of frequency converters' components are designed to operate for different time periods. Moreover, different components have different modes of ageing. Among all the components used within said frequency converters, DC-link capacitors have the smallest resistance against an ageing process. Their ageing process depends on a number of factors like their temperature, ambient humidity, atmospheric pressure, vibrations, operating voltage, ripple current or charge-discharge cycles. For example, for electrolytic capacitors, which are the most commonly used capacitors in DC-links of frequency converters, the most crucial influences on a speed of their ageing process are ripple current and their temperature. The value of the ripple current affects the heat generated in the electrolytic capacitors. In turns, the temperature inside each electrolytic capacitor depends on ambient temperature and power, so indirectly on heat as well, dissipated inside such capacitor. Furthermore, said DC-link capacitors have parameter called Failure In Time (FIT) which relates to said ageing process. The FIT parameter is changing with time. The FIT parameter is following the bathtub curve, which comprises three periods: early failures when the FIT parameter is decreasing, random failures when the FIT parameter is constant, and wear out failures when the FIT parameter is increasing. In a new frequency converter DC-link capacitors are in random failures period. After using them for a time each of those capacitors enters a wear-out failure mode. The wear-out failure mode means that the electrical parameters of the capacitors gradually deteriorate and the capacitor fails. In said mode the FIT parameter is no longer valid what means that the capacitors will fail more often. At the same time said DC-link capacitors play a key role in ensuring uninterrupted and reliable operation of mentioned frequency converters so it is required to plan maintenance action and replacement of those capacitors more often than other components if necessary. Thereby, the biggest difficulty that arises in the case of frequency converters when trying to ensure their reliable operation is an estimation of time for DC-link capacitors replacement by new ones. A proper estimation allows for providing installations equipped with reliable operating frequency converters. Usually, frequency converters work uninterrupted till their failure so when such estimations are made they usually have a big margin for safety and changing condition of work.

From American patent <CIT> there is known a capacitor fault monitor for indicating a short circuit in a multi-section capacitor or a number of capacitors connected in series. Said capacitor fault monitor comprises a voltage divider, wherein the voltage divider comprises resistors connected in series. Said resistors are connected in parallel with said sections of the capacitor or the capacitors connected in series. The capacitor fault monitor is adopted to detect any voltage change across said capacitors to indicate a faulty capacitor. The object of the disclosed invention is to provide a simple relatively inexpensive and convenient means for determining a faulty capacitor in an electrical circuit. Another object of the invention is to detect short-circuit in a capacitor to prevent an explosion in the capacitor.

American patent application <CIT> discloses a fault detector for detecting faults in a DC capacitor circuit connected to the DC buses of an inverter circuit using semiconductor device for converting direct current into alternating current to suppress the voltage pulsation. The fault detector comprises a plurality of parallel-connected capacitor circuits each having a plurality of series-connected DC capacitors, and comparison means connected to the junctions of the series-connected DC capacitors to compare the respective potentials of the parallel-connected capacitor circuits and detects the short-circuit and time-ageing of the DC capacitors of the parallel-connected capacitor circuits rapidly on the basis of the output signal of the comparison means. The aim of the disclosed solution is to provide a fault detector capable of instantaneous detection of the anomalous condition of a DC capacitor circuit, such as an internal short-circuit, and capable of detection of the deterioration of the DC capacitors in performance, attributable to time ageing.

Furthermore, American patent <CIT> discloses a capacitor comprising a housing, a first plurality of capacitor sections in a first series within the housing, a second plurality of capacitor sections in a second series within the housing, a first electrode coupled to a first terminal of the first series and a first terminal of the second series, wherein the first electrode is electrically contactable outside the housing; and a second electrode coupled to a second terminal of the first series and a second terminal of the second series, wherein the second electrode is contactable outside the housing.

The capacitor comprises further a voltage unbalance detection circuit containing a voltage detector and a threshold circuit. The voltage detector is interposed between a node of the first series of the capacitor sections and a node of the second series of the capacitors in order to measure a voltage between the nodes of two parallel series constituting two parallel current paths. The voltage detector provides an output signal to the threshold circuit. The threshold circuit is configured to generate an unbalance detection signal at the unbalance detection output as a function of the voltage indicated by the voltage detector. The signal output is configured to transmit an output signal to outside the housing. The aim of the disclosed solution is an early detection or a pre-detection of an incipient capacitor failure without shutdown of the capacitor, unless a catastrophic failure, such as an explosion, of the capacitor is imminent. The further aim of the mentioned solution is to enable capacitors with early detected minor faults to continue operation until repairs are scheduled without unnecessary interruptions. Further prior art can be found in: <CIT> (<NUM>-<NUM>-<NUM>) and <CIT> (<NUM>-<NUM>-<NUM>).

Although the above-cited patent literature discloses solutions for detection of anomalous conditions of capacitors and even solutions for detection of deterioration of capacitors in use, none of these solutions provides an assessment of the reliability of DC-link circuit capacitors. Furthermore, none of these solutions provides the possibility of operating frequency converters with ageing DC-link circuit capacitors without replacing such capacitors until the scheduled service date of such devices leading as a consequence to their operation with a high risk of failure. Therefore, an object of the invention is to provide a method allowing assessment of the reliability of DC-link circuit capacitors and consequently prediction of duration of reliable operation of a frequency converter comprising such DC-link circuit capacitors, and further a method allowing operation of a frequency converter with ageing DC-link circuit capacitors without replacing such capacitors until the scheduled service date of such device synergistically leading to failure-free operation of such device and its higher reliability comparing to the solutions known from the prior art.

The object of the invention is a computer-implemented method for fixing an output power limit of a frequency converter comprising the following steps: determining voltage differences ΔUi between at least two DC-link circuit capacitors or at least two blocks of DC-link circuit capacitors for each of at least two different values of an output power Pout(i) of a frequency converter, thus providing at least two sets of the voltage differences ΔUi, where i = (<NUM>, <NUM>. , n), wherein the voltage differences ΔUi are determined during stable thermal conditions of the frequency converter; determining a percentile value for each set of the voltage differences ΔUi in order to eliminate the highest errors occurring during determination of voltage differences ΔUi, wherein the elimination of the highest errors is done through rejection of values of the voltage differences ΔUi which are higher than the value of determined percentile, where i = (<NUM>,<NUM>. ,n); determining characteristic ΔU = f(Pout) from the values of the percentile, determining a maximum allowable voltage difference ΔUmaxallow, where ΔUmaxallow = <MAT>, where Udc - a voltage of a DC-link circuit; fixing (<NUM>) a value of an output power limit Poutlimit of the frequency converter for the determined maximum allowable voltage difference ΔUmaxallow.

The application of the computer-implemented method for fixing an output power limit allows operation of the frequency converter with ageing DC link circuit capacitors without replacing such capacitors until the scheduled service date.

Preferably, the output power limit Poutlimit is fixed with a margin of an error factor Fme, wherein <NUM> < Fme <<NUM>.

Preferably, the margin of the error factor Fme is <NUM>.

The application of the margin of the error factor Fme, wherein <NUM> < Fme <<NUM>, in particular when the margin of the error factor Fme is <NUM> improves the safety of frequency converter operation at limited output power.

Preferably, in the step of determining voltage differences ΔUi, at least <NUM> samples of the voltage differences ΔUi are determined.

The determination of the at least <NUM> samples of the voltage differences ΔUi improves or even ensures operation of the frequency converter with ageing DC link circuit capacitors without replacing such capacitors until the scheduled service date.

Preferably, the percentile is of at least <NUM>th.

Preferably, the percentile is of <NUM>th.

The application of the percentile of <NUM>th further improves accuracy of fixing the output power limit Poutlimit.

Preferably, the DC link circuit capacitors are electrolytic capacitors.

Further, the object of the invention is a computer-implemented method for diagnosing conditions of DC-link capacitors comprising the following steps: comparing a value of an output power limit Poutlimit of a frequency converter comprising at least two DC-link capacitors or at least two blocks of DC-link capacitors with a value of a nominal power Pn of the frequency converter, wherein the value of the output power limit Poutlimit is fixed by the computer-implemented method for fixing an output power limit according to the invention; assessing conditions of the DC-link capacitors, wherein if the value of the nominal power Pn is higher than the fixed output power limit Poutlimit the frequency converter is used conditionally with the power Pi lower than the fixed output power limit Poutlimit without replacement of the at least two DC-link capacitors or at least two blocks of DC-link capacitors, where i = (<NUM>,<NUM>.

The application of the computer-implemented method for diagnosing conditions of DC-link circuit capacitors allows assessment of the reliability of the DC-link circuit capacitors and consequently prediction of duration of reliable operation of the frequency converter comprising the DC-link circuit capacitors.

Accordingly, the application of both disclosed methods leads to failure-free operation of the frequency converter and its higher reliability comparing to the solutions known from the prior art.

Preferably, the value of the output power limit Poutlimit of a frequency converter is periodically verified and/or updated.

Preferably, the DC-link circuit capacitors are electrolytic capacitors.

The application of electrolytic capacitors in each of the disclosed methods leads to reduction of production costs of frequency converters and at the same time provides an appropriate level of reliability of frequency converters.

The invention also relates to a system for carrying out the steps of the computer-implemented method for fixing an output power limit of a frequency converter according to the invention and/or the computer-implemented method for diagnosing conditions of DC-link capacitors according to the invention comprising at least one frequency converter, at least one monitoring apparatus and/or at least one server, wherein the at least one monitoring apparatus and/or the at least one server being configured to communicate with the at least one frequency converter, wherein the at least one monitoring apparatus and/or the at least one server being further configured to carry out the steps the computer-implemented method for fixing an output power limit of a frequency converter according to the invention and/or the computer-implemented method for diagnosing conditions of DC-link capacitors according to the invention.

For the purpose of the present invention, the term server also refers to cloud services.

Furthermore, a computer-readable medium storing computer-implemented instructions for performing all the steps of the computer-implemented method for fixing an output power limit of a frequency converter according to the invention and/or the computer-implemented method for diagnosing conditions of DC-link capacitors according to the invention on a frequency converter or monitoring apparatus and/or server.

The method for fixing an output power limit of a frequency converter according to the invention allows remote adjusting of an output power limit of a frequency converter.

The method for diagnosing conditions of DC-link circuit capacitors according to the invention allows to estimate actual conditions of such capacitors, i.e. their degree of deterioration and indicate if they need to be replaced such that maintenance actions may be planned ahead of severe problems associated not only with frequency converters but the whole installations comprising them.

The method for diagnosing conditions of DC-link circuit capacitors according to the invention allows to plan maintenance work of a frequency converter based on actual conditions of the capacitors, i.e. their degree of deterioration.

The method for diagnosing conditions of DC-link circuit capacitors according to the invention based on actual conditions of DC-link circuit capacitors allows to prepare a more detailed and accurate plan of maintenance work.

The method for diagnosing conditions of DC-link circuit capacitors according to the invention ensures remote assessment of the capacitor's conditions.

The method for diagnosing conditions of DC-link circuit capacitors according to the invention allows supplying to frequency converters users information on the actual condition of DC-link circuit capacitors.

The methods according to the invention ensure optimization of frequency converter operation and as a consequence optimization of frequency converter maintenance work leading to reduction of their maintenance costs.

The methods according to the invention allow prediction of duration of reliable operation of a frequency converter comprising such DC-link circuit capacitors.

The methods according to the invention allow to use electrolytic capacitors leading to reduction of production costs of frequency converters and at the same time providing an appropriate level of reliability of frequency converters.

The subject of the invention is shown in the embodiments in a drawing, in which:.

In a first step <NUM> of a computer-implemented method for fixing an output power limit of a frequency converter voltage differences ΔUi between two DC-link circuit capacitors C<NUM>, C<NUM> for each of five different values of an output power Pout(i) of a frequency converter, where i = (<NUM>, <NUM>. , n), are determined. As the example the following values are given: Pout(<NUM>) = <NUM> kW, Pout(<NUM>) = <NUM> kW, Pout(<NUM>) = <NUM> kW, Pout(<NUM>) = <NUM> kW, Pout(<NUM>) = <NUM> kW (<FIG>). The DC link circuit capacitors C<NUM>, C<NUM> are electrolytic capacitors. The application of electrolytic capacitors leads to reduction of production costs of the frequency converter and at the same time provides an appropriate level of reliability of the frequency converter. The voltage differences ΔUi are determined during stable thermal conditions of the frequency converter. The determination of the voltage differences ΔUi can be realized by measuring these values on the DC-link circuit capacitors C<NUM>, C<NUM>. Such determination leads to providing five sets of the voltage differences ΔUi. Next, in order to eliminate the highest errors occurring during the determination of the voltage differences ΔUi a value of <NUM>th percentile for each set of the voltage differences ΔUi is determined <NUM>. The elimination of the highest errors is done through rejection of values of the voltage differences ΔUi which are higher than the value of a determined percentile. In the next step <NUM> characteristic ΔU = f(Pout) from the values of the percentile is determined. After that, a maximum allowable voltage difference ΔUmaxallow is determined <NUM>, where <MAT> where
Udc - a voltage of a DC-link circuit.

Finally, a value of an output power limit Poutlimit of the frequency converter for the determined maximum allowable voltage difference ΔUmaxallow is fixed <NUM> with a margin of an error factor Fme of <NUM>. The application of the disclosed method allows operation of the frequency converter with ageing DC link circuit capacitors without replacing such capacitors until the scheduled service date. In turn, the application of the margin of the error factor Fme, wherein <NUM> < Fme <<NUM>, in particular when the margin of the error factor Fme is <NUM>, improves the safety of frequency converter operation at limited output power. Moreover, the application of the percentile of <NUM>th further improves accuracy of fixing the output power limit Poutlimit. Furthermore, in the step of determining <NUM> voltage differences ΔUi, <NUM> samples of the voltage differences ΔUi are determined. The determination of <NUM> samples of the voltage differences ΔUi improves or even ensures operation of the frequency converter with ageing DC link circuit capacitors without replacing such capacitors until the scheduled service date.

In a first step <NUM> of a computer-implemented method for diagnosing conditions of DC-link capacitors a value of an output power limit Poutlimit of a frequency converter is compared <NUM> with a value of a nominal power Pn of the frequency converter. The value of the output power limit Poutlimit is fixed by the computer-implemented method for fixing an output power limit of a frequency converter. In the final step <NUM> conditions of the DC-link capacitors C<NUM>, C<NUM> are assessed, wherein if the value of the nominal power Pn of the frequency converter is higher than the fixed output power limit Poutlimit the frequency converter is used conditionally with the power Pi lower than the fixed output power limit Poutlimit without replacement of the DC-link capacitors C<NUM>, C<NUM> , where i = (<NUM>,<NUM>. Furthermore, the value of the output power limit Poutlimit of the frequency converter is periodically verified and updated as the rate of change of output power limit Poutlimit increases as the used capacitors age. As a result the change of the output power limit Poutlimit will be faster for older capacitors. It should be noted here that these steps are important because capacitors do not age linearly.

A system <NUM> for carrying out the steps of the computer-implemented method for fixing an output power limit of a frequency converter according to the invention and/or the computer-implemented method for diagnosing conditions of DC-link capacitors according to the invention comprises a frequency converter <NUM> and a monitoring apparatus <NUM> being configured to communicate with the frequency converter <NUM>. The monitoring apparatus <NUM> is further configured to carry out the steps of the computer-implemented method for fixing an output power limit of a frequency converter according to the invention and/or the computer-implemented method for diagnosing conditions of DC-link capacitors according to the invention. In another embodiment the system <NUM> comprises a server <NUM> instead of the monitoring apparatus <NUM>. The server <NUM> is configured then to communicate with the frequency converter <NUM>. The server <NUM> is further configured to carry out the steps of the computer-implemented method for fixing an output power limit of a frequency converter according to the invention and/or the computer-implemented method for diagnosing conditions of DC-link capacitors according to the invention. In yet another embodiment the system <NUM> comprises both the monitoring apparatus <NUM> and the server <NUM>. In such embodiment the monitoring apparatus <NUM> and the server <NUM> are configured to communicate with the frequency converter <NUM> and both the monitoring apparatus <NUM> and the server <NUM> are configured to carry out the steps of the computer-implemented method for fixing an output power limit of a frequency converter according to the invention and/or the computer-implemented method for diagnosing conditions of DC-link capacitors according to the invention.

Claim 1:
A computer-implemented method for fixing an output power limit of a frequency converter comprising the following steps:
- determining (<NUM>) voltage differences ΔUi between at least two DC-link circuit (C<NUM>, C<NUM>) capacitors or at least two blocks of DC-link circuit capacitors for each of at least two different values of an output power Pout(i) of a frequency converter, thus providing at least two sets of the voltage differences ΔUi, where i = (<NUM>, <NUM> ..., n), wherein the voltage differences ΔUi are determined during stable thermal conditions of the frequency converter;
- determining (<NUM>) a percentile value for each set of the voltage differences ΔUi in order to eliminate the highest errors occurring during determination of voltage differences ΔUi, wherein the elimination of the highest errors is done through rejection of values of the voltage differences ΔUi which are higher than the value of a determined percentile, where i = (<NUM>,<NUM>...,n);
- determining (<NUM>) characteristic ΔU = f(Pout) from the values of the determined percentile,
- determining (<NUM>) a maximum allowable voltage difference ΔUmaxallow, where <MAT> where
Udc - a voltage of a DC-link circuit
- fixing (<NUM>) a value of an output power limit Poutlimit of the frequency converter for the determined maximum allowable voltage difference ΔUmaxallow.