Hybrid topology for multilevel power conversion

• US 6,005,788 A
• Filed: 02/12/1999
• Issued: 12/21/1999
• Est. Priority Date: 02/13/1998
• Status: Expired due to Term

• Current Assignee: National Science Foundation (Government of the United States of America)
• Original Assignee: Wisconsin Alumni Research Foundation (University of Wisconsin System)
• Inventors: Manjrekar, Madhav D., Lipo, Thomas A.
• Primary Examiner(s): NGUYEN, MATTHEW VAN
• Application Number:
  US09/249,643
• Time in Patent Office: 312 Days
• Field of Search: 363/65, 363/71, 363/95, 363/97, 363/131, 363/132
• US Class Current: 363/71
• CPC Class Codes: B60L 15/007 Physical arrangements or structures of drive train converters specially adapted for the propulsion motors of electric vehicles
• CPC Class Codes: H02M 1/0054 Transistor switching losses periodically suspending operation of switching converter in low power mode H02M1/0035
• CPC Class Codes: H02M 7/4835 comprising two or more cells, each including a switchable capacitor, the capacitors having a nominal charge voltage which corresponds to a given fraction of the input voltage, and the capacitors being selectively connected in series to determine the instantaneous output voltage
• CPC Class Codes: H02M 7/49 Combination of the output voltage waveforms of a plurality of converters
• CPC Class Codes: H02M 7/501 sinusoidal output voltages being obtained by the combination of several pulse-voltages having different amplitude and width
• CPC Class Codes: Y02T 10/64 Electric machine technologies in electromobility

Abstract

The present invention provides a multilevel electric power converter including a plurality of DC voltage sources providing different DC source voltage levels. The DC source voltage levels are preferably multiples of each other and may vary in a binary fashion or in a geometric progression with a factor of three to provide a large number of output voltage levels for a given number of inverter levels. The multilevel inverter is preferably implemented as a series connected set of H-bridge inverters, with each H-bridge inverter having an independent DC voltage source providing the desired DC source voltage level. A hybrid modulation strategy may be employed whereby the lowest voltage level inverter is modulated at a high frequency, e.g., by pulse width modulation, and higher voltage level inverters in the multilevel inverter are modulated to provide a low frequency stepped waveform. The combined high frequency pulse width modulated and low frequency stepped waveform has good spectral quality. A high voltage high quality waveform may be generated in this manner by taking advantage of the high voltage blocking capability of switching devices, such as GTO thyristors, in the high voltage inverters in the multilevel inverter, and the high frequency switching characteristics of switching devices, such as IGBTs, in the lowest voltage level inverter in the multilevel inverter. A multilevel inverter in accordance with the present invention may be employed in a single-phase or multi-phase applications.

Claims

1. A multilevel electric power converter, comprising:

(a) a plurality of DC voltage sources providing DC source voltage levels, wherein a DC source voltage level provided by a one of the plurality of DC voltage sources is different from a DC source voltage level provided by another of the plurality of DC voltage sources;

(b) inverter switching devices connected to the DC voltage sources to form a plurality of inverters connected in series to an output of the power converter; and

(c) controller means for controlling the inverter switching devices to synthesize a multilevel inverter output voltage signal at the output of the power converter by selectively combining the DC source voltage levels provided by the DC voltage sources.

2. The multilevel electric power converter of claim 1 wherein the DC source voltage level provided by the one of the plurality of DC voltage sources is a multiple of the DC source voltage level provided by the other of the plurality of DC voltage sources.

3. The multilevel electric power converter of claim 2 wherein the DC source voltage level provided by the one of the plurality of DC voltage sources is approximately twice the DC source voltage level provided by the other of the plurality of DC voltage sources.

4. The multilevel electric power converter of claim 3 wherein the DC source voltage levels provided by the plurality of DC voltage sources vary in a binary fashion.

5. The multilevel electric power converter of claim 2 wherein the DC source voltage level provided by the one of the plurality of DC voltage sources is approximately three times the DC source voltage level provided by the other of the plurality of DC voltage sources.

6. The multilevel electric power converter of claim 5 wherein the DC source voltage levels provided by the plurality DC voltage sources vary in a geometric progression with a factor of three.

7. The multilevel electric power converter of claim 1 wherein the plurality of DC voltage sources includes more than two DC voltage sources providing more than two different DC source voltage levels.

8. The multilevel electric power converter of claim 1 wherein the inverter switching devices are connected to form an H-bridge inverter across each of the plurality of DC voltage sources, wherein the H-bridge inverters connected across each of the plurality of DC voltage sources are connected together in series across the output of the power converter.

9. The multilevel electric power converter of claim 8 wherein the controller means includes means for controlling the inverter switching devices in at least one of the H-bridge inverters to generate a pulse width modulated inverter output signal and means for controlling the inverter switching devices in another of the H-bridge inverters to generate a stepped waveform inverter output signal which is combined with the pulse width modulated inverter output signal to form the multilevel inverter output voltage signal.

10. The multilevel electric power converter of claim 9 wherein the controller means includes means for controlling the inverter switching devices in an H-bridge inverter connected across a DC voltage source of the plurality of DC voltage sources providing a lowest DC source voltage level to generate a pulse width modulated inverter output signal from the H-bridge inverter connected across a DC voltage source of the plurality of DC voltage sources providing a lowest DC source voltage level.

11. The multilevel electric power converter of claim 10 wherein the DC source voltage level of the DC voltage source of the plurality of DC voltage sources providing the lowest DC source voltage is V, and wherein the DC source voltage levels provided by the others of the plurality of DC voltage sources are 2*3^n-2 V for n=2 to the number of DC voltage sources in the multilevel electric power converter.

12. A multilevel electric power converter, comprising:

(a) a first inverter including a first DC voltage source providing a first DC source voltage level and first inverter switching devices connected across the first DC voltage source and responsive to first inverter switching device control signals;

(b) a second inverter connected in series with the first inverter and including a second DC voltage source providing a second DC source voltage level and second inverter switching devices connected across the second DC voltage source and responsive to second inverter switching device control signals;

(c) an output of the electric power converter connected to the first and second inverters; and

(d) controller means for providing the first inverter switching device control signals and second inverter switching device control signals to control the first and second inverters to synthesize an AC voltage waveform on the output of the electric power converter, wherein the first inverter switching device control signals are provided at a frequency much higher than a fundamental frequency of the AC voltage waveform on the output of the electric power converter, and wherein the second inverter switching device control signals are provided to control the second inverter to produce a stepped waveform output signal.

13. The multilevel electric power converter of claim 12 wherein the first and second inverters are H-bridge inverters wherein the inverter switching devices are connected across the DC voltage sources in an H-bridge configuration.

14. The multilevel electric power converter of claim 12 wherein the first inverter switching devices are transistor based switching devices and the second inverter switching devices are high voltage blocking thyristor based switching devices.

15. The multilevel electric power converter of claim 12 wherein the first DC source voltage level is different from the second DC source voltage level.

16. The multilevel electric power converter of claim 15 wherein the second DC source voltage level is a multiple of the first DC source voltage level.

17. The multilevel electric power converter of claim 16 wherein the second DC source voltage level is twice the first DC source voltage level.

18. The multilevel electric power converter of claim 12 comprising at least one additional inverter including an additional DC voltage source providing an additional DC source voltage level and additional inverter switching devices connected across the additional DC voltage source and responsive to additional inverter switching device control signals, connected in series with the first and second inverters, and wherein the controller means includes additionally means for providing the additional inverter switching device control signals to control the additional inverter to produce a stepped waveform output signal in combination with the output of the second inverter.

19. The multilevel electric power converter of claim 18 wherein the second and additional DC source voltage levels are multiples of the first DC source voltage level.

20. The multilevel electric power converter of claim 19 wherein the first DC source voltage level is V, and wherein the DC source voltage levels provided by the second and additional DC voltage sources are 2*3^n-2 V for n=2 to the number of DC voltage sources in the multilevel electric power converter.

21. The multilevel electric power converter of claim 12 wherein the first inverter switching device control signals are pulse width modulated signals.

22. A method for providing a multilevel electric power converter output voltage signal, comprising the steps of:

(a) providing a plurality of DC voltage sources having DC source voltage levels, wherein a DC source voltage level provided by a one of the plurality of DC voltage sources is different from a DC source voltage level provided by another of the plurality of DC voltage sources; and

(b) synthesizing a multilevel electric power converter output voltage signal having a peak voltage level higher than a largest of the plurality of DC source voltage levels by selectively combining the DC source voltage levels provided by the DC voltage sources.

23. The method of claim 22 wherein the DC source voltage level provided by the one of the plurality of DC voltage sources is a multiple of the DC source voltage level provided by the other of the plurality of DC voltage sources.

24. The method of claim 23 wherein the DC source voltage level provided by the one of the plurality of DC voltage sources is approximately twice the DC source voltage level provided by the other of the plurality of DC voltage sources.

25. The method of claim 24 wherein DC source voltage levels provided by the plurality of DC voltage sources vary in a binary fashion.

26. The method of claim 23 wherein the DC source voltage level provided by the one of the plurality of DC voltage sources is approximately three times the DC source voltage level provided by the other of the plurality of DC voltage sources.

27. The method of claim 26 wherein the DC source voltage levels provided by the plurality of DC voltage sources vary in a geometric progression with a factor of three.

28. The method of claim 22 wherein the plurality of DC voltage sources includes more than two DC voltage sources providing more than two different DC source voltage levels.

29. The method of claim 22 including the step of providing inverter switching devices connected to form an H-bridge inverter across each of the plurality of DC voltage sources, wherein the H-bridge inverters connected across each of the plurality of DC voltage sources are connected together in series, and wherein the step of synthesizing the multilevel electric power converter output voltage signal includes the steps of controlling the inverter switching devices in at least one of the H-bridge inverters to generate a pulse width modulated inverter output signal and controlling the inverter switching devices in another of the H-bridge inverters to generate a stepped waveform inverter output signal which is combined with the pulse width modulated waveform inverter output signal which is combined with the pulse width modulated inverter output signal to form the multilevel electric power converter output voltage signal.

30. A method for controlling a multilevel electric power converter to synthesize an AC voltage waveform on an output thereof, wherein the electric power converter includes a first inverter having a first DC voltage source providing a first DC source voltage level and first inverter switching devices connected across the first DC voltage source and responsive to first inverter switching device control signals, a second inverter connected in series with the first inverter and having a second DC voltage source providing a second DC source voltage level and second inverter switching devices connected across the second DC voltage source and responsive to second inverter switching device control signals, wherein the output of the electric power converter is connected to the first and second inverters, comprising the steps of:

(a) providing the first inverter switching device control signals at a frequency much higher than a fundamental frequency of the AC voltage waveform on the output of the electric power converter to produce a high frequency inverter output signal; and

(b) providing the second inverter switching device control signals to control the second inverter to produce a stepped waveform output signal which is combined with the high frequency inverter output signal to produce the AC voltage waveform on the output of the electric power converter.

31. The multilevel electric power converter of claim 30 wherein the step of providing the first inverter switching device control signals includes the step of providing pulse width modulated control signals.