Soft switching three-level inverter

• US 5,684,688 A
• Filed: 06/24/1996
• Issued: 11/04/1997
• Est. Priority Date: 06/24/1996
• Status: Expired due to Term

• Current Assignee: Rockwell Automation Technologies Incorporated (Allen-Bradley Co., Inc.)
• Original Assignee: Reliance Electric Industrial Company
• Inventors: Aboumrad, Tony C., Rouaud, Didier G.
• Primary Examiner(s): NGUYEN, MATTHEW VAN
• Application Number:
  US08/668,885
• Time in Patent Office: 498 Days
• Field of Search: 363/17, 363/43, 363/97, 363/98, 363/131, 363/132
• US Class Current: 363/132
• CPC Class Codes: H02M 1/34 Snubber circuits
• CPC Class Codes: H02M 1/342 Active non-dissipative snubbers
• CPC Class Codes: H02M 7/487 Neutral point clamped inverters
• CPC Class Codes: Y02B 70/10 Technologies improving the efficiency by using switched-mode power supplies [SMPS], i.e. efficient power electronics conversion e.g. power factor correction or reduction of losses in power supplies or efficient standby modes

Abstract

A three-level NPC inverter topology including two auxiliary resonant commutation circuits which are controlled to clamp the voltage across each main inverter switch to zero voltage prior to altering the state of the switch in order to achieve soft switching of all main inverter switches while reducing output voltage harmonics and gradients.

Claims

1. A three-level neutral point clamped inverter leg for providing soft switching of power devices, the inverter leg comprising:

series coupled first, second, third, and fourth main switches connected between positive and negative rails of a DC supply, the first main switch connected between the positive rail and a first node, the second main switch connected between the first node and an output node, the third main switch connected between the output node and a second node, and the fourth main switch connected between the second node and the negative DC rail, the output node also connectable to a load for providing a load current, the DC supply including two DC sources arranged in series, a first DC source connected between the positive DC rail and a neutral node and the second DC source connected between the neutral node and the negative DC rail;

a current provider for providing a boost current source or boost current sink at either the first or second nodes;

first, second, third, and fourth diodes coupled in antiparallel relationship with the first, second, third, and fourth main switches respectively;

first and fourth capacitors coupled in parallel with the first and fourth main switches respectively; and

a first clamping diode and a first clamping capacitor connected between the first and neutral nodes and a second clamping diode and a second clamping capacitor connected between the neutral and second nodes, the first clamping diode arranged to pass current from the neutral node to the first node when forward biased and the second clamping diode arranged to pass current from the second node to the neutral node when forward biased.

2. The apparatus of claim 1 further including an output capacitor coupled between the output node and the neutral node.

3. The apparatus of claim 1 wherein the first and second DC sources are substantially identical.

4. The apparatus of claim 3 wherein the first DC source includes identical upper and lower first sources and the second DC source includes identical upper and lower second sources, all of the DC sources connected in series, the upper and lower first sources connected at a third node and the upper and lower second sources connected at a fourth node, the current provider includes first and second current sources, the first current source includes first and second antiparallel coupled auxiliary switches coupled in series with an upper inductor between the first and third nodes and the second current source includes third and fourth antiparallel coupled auxiliary switches coupled in series with a lower inductor between the second and fourth nodes.

5. The apparatus of claim 4 wherein the auxiliary switches are thyristors.

6. The apparatus of claim 1 further including a current sensor for sensing the load current and a threshold determiner for determining if the load current is sufficient to discharge capacitors in parallel with switches prior to turning the switches on.

7. The apparatus of claim 6 wherein, if the load current is insufficient to discharge capacitors in parallel with a switch prior to turning the switch on, the current provider provides a linearly increasing source or sink boost current at either the first or second nodes which has a magnitude that, in conjunction with the load current, is capable of discharging the capacitors that are in parallel with the switch prior to turning the switch on.

8. The apparatus of claim 1 further including a first resistor/capacitor snubber network across the second main switch and a second resistor/capacitor snubber network across the third main switch.

9. The apparatus of claim 1 further including a first resistor connected between the first node and the neutral node and a second resistor connected between the neutral node and the second node.

10. A method for controlling a three-level neutral point clamped inverter leg to provide soft switching of power devices, each inverter leg including a plurality of main switches and an output node which is connected to a load providing a line current thereat and a current means for providing a current source or sink, the leg also including at least one capacitor in parallel with each of the main switches, the inverter controlled so that turn-on delay periods are provided between each time one main switch is turned off and another main switch is turned on, the method comprising the steps of:

during each turn-on delay period, prior to turning on a main switch wherein the main switch to be turned on is a next-on switch;

(a) providing a discharge current including a boost current which, together with said line current, fully discharges all capacitors which are in parallel with said next-on switch so there is substantially zero potential across the next-on switch;

at the end of each turn-on delay period;

(b) turning on said next-on switch; and

(c) eliminating said source or sink current.

11. The method of claim 10 wherein the leg includes series coupled first, second, third, and fourth main switches connected between positive and negative rails of a DC supply, the first main switch connected between the positive rail and a first node, the second main switch connected between the first node and the output node, the third main switch connected between the output node and a second node, and the fourth main switch connected between the second node and the negative DC rail, the DC supply including two DC sources arranged in series, a first DC source connected between the positive DC rail and a neutral node and the second DC source connected between the neutral node and the negative DC rail, each main switch having an antiparallel diode connected thereacross and the first and fourth main switches each having a capacitor coupled in parallel therewith, each leg including a first clamping diode and a first clamping capacitor connected between the first and neutral nodes and a second clamping diode and a second clamping capacitor connected between the neutral and second nodes, the first clamping diode arranged to pass current from the neutral node to the first node when forward biased and the second clamping diode arranged to pass current from the second node to the neutral node when forward biased, wherein the turn-on delay period begins when one of said main switches is turned off, the switch which is turned off being an off-switch, and the step of providing a discharge current includes the steps of, prior to turning off the off-switch, providing an increasing current that, when added to the line current, would discharge all capacitors in parallel with the next-on switch during the turn-on delay period, and allowing the current magnitude to increase until the magnitude is equal to the discharge current.

12. The method of claim 11 wherein the current means includes a first current source connected at the first node and a second current source connected at the second node and the step of providing a discharge current includes, when switching between the neutral node and the positive DC rail, providing the discharge current at the first node and, when switching between the neutral node and negative DC rail, providing the discharge current at the second node.

13. The method of claim 12 wherein the first current source includes first and second antiparallel coupled auxiliary switches coupled in series with an upper inductor at the first node and the second current source includes third and fourth antiparallel coupled auxiliary switches coupled in series with a lower inductor, and the step of providing the discharge current at the first node includes turning on either the first or the second auxiliary switches to place a potential across said upper inductor and the step of providing the discharge current at the second node includes turning on either the third or the fourth auxiliary switches placing a potential across said lower inductor.

14. The method of claim 13 wherein the step of providing the discharge current includes, when switching from the neutral node to the positive DC rail, turning on the second auxiliary switch to provide a current source at the first node, when switching from the positive DC rail to the neutral node, turning on the first auxiliary switch to provide a current sink at the first node, when switching from the neutral node to the negative DC rail, turning on the third auxiliary switch to provide a current sink at the second node, and when switching from the negative DC rail to the neutral node, turning on the fourth auxiliary switch to provide a current source to the second node.

15. The method of claim 14 wherein the converter includes a current sensor for each phase, each current sensor determining the sign of a corresponding load current, the step of providing the discharge current including the steps of:

determining the sign of the load current;

(a) when switching from the neutral node to the positive DC rail and the line current is positive, turning on the second auxiliary switch to apply a forcing potential across the upper inductor substantially equal to one-half the potential of one of the DC sources to provide a current at the first node, allowing the current in the upper inductor to increase to a first boost current level where the first boost current level is the sum of the line current and an auxiliary current wherein the auxiliary current is the current required to discharge the first capacitor during a turn on delay period;

(b) when switching from the positive DC rail to the neutral node and the line current is negative, turning on the first auxiliary switch to apply a forcing potential across the upper inductor substantially equal to one-half the potential of one of the DC sources to provide a current sink at the first node, allowing the current in the upper inductor to increase to a second boost current level where the second boost current level is the sum of the line current and an auxiliary current wherein the second boost current is the current required to discharge all capacitors in parallel with the third main switch;

(c) when switching from the neutral node to the negative DC rail and the line current is negative, turning on the third auxiliary switch to apply a forcing potential across the lower inductor substantially equal to one-half the potential of one of the DC sources to provide a current sink at the second node, allowing the current in the lower inductor to increase to a third boost current level where the third boost current level is the sum of the line current and an auxiliary current wherein the auxiliary current is the current required to discharge the fourth capacitor during a turn-on delay period; and

(d) when switching from the negative DC rail to the neutral node and the line current is positive, turning on the fourth auxiliary switch to apply a forcing potential across the lower inductor substantially equal to one-half the potential of one of the DC sources to provide a current at the second node, allowing the current in the lower inductor to increase to a fourth boost current level where the fourth boost current level is the sum of the line current and an auxiliary current wherein the auxiliary current is the current required to discharge all of the capacitors that are in parallel with the second main switch during a turn-on delay period.

16. The method of claim 15 wherein each current sensor can also determine the magnitude of a corresponding load current and the converter provides positive and negative threshold current levels, the negative threshold current being the magnitude of current required to discharge the first capacitor during a turn-on delay period and the positive threshold current being the magnitude of current required to discharge the fourth capacitor during a turn-on delay period, and the step of providing the discharge current further including the steps of:

determining the magnitude of the load current;

(a) when switching from the neutral node to the positive DC rail with a negative line current which is less than the negative threshold current, turning on the second auxiliary switch to apply a forcing potential across the upper inductor substantially equal to one-half the potential of one of the DC sources to provide a current at the first node, allowing the current in the upper inductor to increase until the sum of the upper conductor current and the line current is sufficient to discharge the first capacitor during a delay period;

(b) when switching from the positive DC rail to the neutral node with a positive line current which is less than the positive threshold current, turning on the first auxiliary switch to apply a forcing potential across the upper inductor substantially equal to one-half the potential of one of the DC sources to provide a current sink at the first node, allowing the current in the upper inductor to increase until the sum of the upper inductor current and the line current is sufficient to discharge all of the capacitors that are in parallel with the third main switch during a delay period;

(c) when switching from the neutral node to the negative DC rail and the line current is positive and less than the positive threshold current, turning on the third auxiliary switch to apply a forcing potential across the lower inductor substantially equal to one-half the potential of one of the DC sources to provide a current sink at the second node, allowing the current in the lower inductor to increase until the sum of the lower inductor current and the line current is sufficient to discharge the fourth capacitor during a delay period; and

(d) when switching from the negative DC rail to the neutral node and the line current is negative and greater than the negative threshold current, turning on the fourth auxiliary switch to apply a forcing potential across the lower inductor substantially equal to one-half the potential of one of the DC sources to provide a current at the second node, allowing the current in the lower inductor to increase until the sum of the lower inductor current and the line current is sufficient to discharge all of the capacitors in parallel with the second main switch during a delay period.

17. The method of claim 16 wherein the step of providing the discharge current further including the steps of, under all other circumstances, providing zero discharge current.

18. The method of claim 13 wherein the auxiliary switches are thyristors and the step of eliminating said auxiliary current includes the step of allowing the currents through said series coupled inductors to resonate to zero.

19. The method of claim 11 wherein the step of providing the increasing current until the current magnitude equals the discharge current includes the step of providing a linearly increasing current for a period calculated to generate the desired discharge current.

20. An n-level neutral point clamped inverter leg for providing soft switching of power devices where n is greater than two, the inverter leg comprising:

a DC supply providing n different potential rails including a zero potential rail, and at least one maximum positive potential rail and one maximum negative potential rail;

a plurality of series coupled switches connected between the maximum positive and negative potential rails, the switches arranged in (n-1) pairs, switches in each pair connected at intraswitch nodes and adjacent switch pairs connected at interswitch nodes, a first switch connected to the maximum positive potential rail and a (2n-2) switch connected to the maximum negative potential rail, each of the interswitch nodes uniquely connected to a different one of said potential rails, one of the interswitch nodes connected to an output line which is connectable to a load;

a plurality of capacitors, at least one of said capacitors arranged in parallel with each of said switches;

a plurality of diodes, a different one of said diodes coupled in antiparallel relationship with each of said switches;

a current provider for providing a discharging current source or sink at any of the intraswitch nodes; and

a controller for controlling the current provider and the switches;

whereby, the controller controls the switches and the current provider so that, prior to changing the state of a switch, the current provider provides a current source or a current sink to at least one of said intraswitch nodes to discharge all capacitors in parallel with said switch so that at least one diode in parallel with said switch clamps zero voltage across said switch.

21. The inverter leg of claim 20 wherein the switch pairs include (n-1)/2 pairs connected in series between the maximum positive potential rail and the output line and (n-1)/2 pairs connected in series between the maximum negative potential rail and the output line.

22. The inverter leg of claim 21 wherein the maximum negative and maximum positive potential rails have substantially identical magnitudes.

23. The inverter leg of claim 22 wherein the potential rails include identical numbers of positive and negative potential rails and, for each positive potential rail there is a negative potential rail that has a substantially identical magnitude.

24. The inverter leg of claim 23 wherein the current provider includes (n-1) auxiliary circuits, one circuit connected to each of the intraswitch nodes, each auxiliary circuit capable of providing either a current sink or a current source.

25. The inverter leg of claim 24 wherein each auxiliary circuit includes first and second antiparallel coupled auxiliary switches coupled in series with an inductor, the auxiliary circuit connected between an intraswitch node and one of said DC potential rails.