Method and apparatus for bypassing Cascaded H-Bridge (CHB) power cells and power sub cell for multilevel inverter

• US 10,305,368 B2
• Filed: 01/22/2018
• Issued: 05/28/2019
• Est. Priority Date: 08/13/2012
• Status: Active Grant

• Current Assignee: Rockwell Automation Technologies Incorporated (Allen-Bradley Co., Inc.)
• Original Assignee: Rockwell Automation Technologies Incorporated (Allen-Bradley Co., Inc.)
• Inventors: Zargari, Navid R., Xiao, Yuan, Wei, Lixiang, Cheng, Zhongyuan
• Primary Examiner(s): Ahmed, Yusef A
• Application Number:
  US15/876,812
• Publication Number:
  US 20180145578A1
• Time in Patent Office: 491 Days
• CPC Class Codes: H02M 1/007 Plural converter units in cascade push-pull DC/DC converters with pre-regulator H02M3/3374; DC-AC converters following a DC-DC stage including a high frequency transformer H02M7/4807; DC-AC converters following a DC-DC conversion stage generating periodically varying voltages H02M7/4826
• CPC Class Codes: H02M 1/10 Arrangements incorporating converting means for enabling loads to be operated at will from different kinds of power supplies, e.g. from ac or dc
• CPC Class Codes: H02M 1/32 Means for protecting converters other than automatic disconnection
• CPC Class Codes: H02M 1/325 with means for allowing continuous operation despite a fault, i.e. fault tolerant converters
• CPC Class Codes: H02M 5/458 using semiconductor devices only
• CPC Class Codes: H02M 5/4585 having a rectifier with controlled elements
• CPC Class Codes: H02M 7/49 Combination of the output voltage waveforms of a plurality of converters

Abstract

Multilevel power converters, power cells and methods are presented for selectively bypassing a power stage of a multilevel inverter circuit, in which a single relay or contactor includes first and second normally closed output control contacts coupled between a given power cell switching circuit and the given power cell output, along with a normally open bypass contact coupled across the power stage output, with a local or central controller energizing the coil of the relay or contactor of a given cell to bypass that cell.

Claims

1. A power conversion system, comprising:

a plurality of power stages connected in series to form a multilevel inverter circuit for connection to a load, the power stages individually comprising;

a DC link capacitor coupled between first and second DC link nodes of a DC link circuit,

an output coupled with at least one other power stage in the multilevel inverter circuit,

a switching circuit including a plurality of switching devices to provide an output voltage signal having an amplitude of one of at least two discrete levels, and

a single relay or contactor including;

a coil,

a plurality of normally closed contacts operative in a first state to allow current to flow between the switching circuit and the output when the coil is deenergized, and operative in a second state to electrically isolate the switching circuit from the output when the coil is energized, and

a normally open contact coupled across the output to allow normal operation of the output in a first state when the coil is deenergized, and to bypass the output in a second state when the coil is energized; and

a controller configured to selectively energize the coil of at least one of the plurality of power stages to bypass the at least one power stage, and to provide switching control signals to operate the plurality of switching devices of the switching circuit of the individual power stages;

wherein the plurality of normally closed contacts of the single relay or contactor of the individual power stages includes;

a first normally closed contact coupled between a first internal node of the switching circuit and a first output terminal of the output, the first normally closed contact operative in a first state to electrically connect the first internal node to the first output terminal when the coil is deenergized, and operative in a second state to electrically disconnect the first internal node from the first output terminal when the coil is energized, and

a second normally closed contact coupled between a second internal node of the switching circuit and a second output terminal of the output, the second normally closed contact operative in a first state to electrically connect the second internal node to the second output terminal when the coil is deenergized, and operative in a second state to electrically disconnect the second internal node from the second output terminal when the coil is energized.

2. The power conversion system of claim 1, wherein the controller is a local controller.

3. The power conversion system of claim 1, wherein the controller comprises:

a local controller to provide the switching control signals to operate the switching devices of the switching circuit of the individual power stages; and

a second controller to selectively energize the coil of the at least one power stage to bypass the at least one power stage.

4. The power conversion system of claim 1, wherein the power conversion system is a multi-phase system comprising a plurality of multilevel inverter circuits individually including a corresponding plurality of the power stages connected in series to form a corresponding output phase of a multi-phase output of the power conversion system.

5. A power cell for use as a power stage in a multilevel inverter circuit, the power cell comprising:

a DC link capacitor coupled between first and second DC link nodes of a DC link circuit;

an output to be coupled with at least one other power stage in the multilevel inverter circuit;

a switching circuit including a plurality of switching devices to provide an output voltage signal having an amplitude of one of at least two discrete levels;

a single relay or contactor including;

a coil,

a plurality of normally closed contacts operative in a first state to allow current to flow between the switching circuit and the output when the coil is deenergized, and operative in a second state to electrically isolate the switching circuit from the output when the coil is energized, and

a normally open contact coupled across the output to allow normal operation of the output in a first state when the coil is deenergized, and to bypass the output in a second state when the coil is energized; and

a controller configured to selectively energize the coil to bypass the power stage, and to provide switching control signals to operate the plurality of switching devices of the switching circuit;

wherein the plurality of normally closed contacts of the single relay or contactor includes;

a first normally closed contact coupled between a first internal node of the switching circuit and a first output terminal of the output, the first normally closed contact operative in a first state to electrically connect the first internal node to the first output terminal when the coil is deenergized, and operative in a second state to electrically disconnect the first internal node from the first output terminal when the coil is energized; and

a second normally closed contact coupled between a second internal node of the switching circuit and a second output terminal of the output, the second normally closed contact operative in a first state to electrically connect the second internal node to the second output terminal when the coil is deenergized, and operative in a second state to electrically disconnect the second internal node from the second output terminal when the coil is energized.

6. A method for bypassing a power stage of a multilevel inverter circuit, the method comprising:

with a controller, energizing a coil of a single relay or contactor to electrically isolate a switching circuit of the power stage from an output of the power stage, and to bypass the output of the power stage; and

with the controller, providing switching control signals to operate switching devices of the switching circuit of the power stage;

wherein energizing the coil of the single relay or contactor opens a first normally closed contact coupled between a first internal node of the switching circuit and a first output terminal of the output to electrically disconnect the first internal node from the first output terminal;

wherein energizing the coil of the single relay or contactor opens a second normally closed contact coupled between a second internal node of the switching circuit and a second output terminal of the output to electrically disconnect the second internal node from the second output terminal; and

wherein energizing the coil of the single relay or contactor closes a normally open contact of the single relay or contactor to electrically connect the first output terminal to the second output terminal.