Generalized discontinuous pulse width modulator

• US 6,023,417 A
• Filed: 02/20/1998
• Issued: 02/08/2000
• Est. Priority Date: 02/20/1998
• Status: Expired due to Term

• Current Assignee: Allen-Bradley Company (Rockwell Automation, Inc.)
• Original Assignee: Allen-Bradley Company LLC (Rockwell Automation, Inc.)
• Inventors: Hava, Ahmet M., Kerkman, Russel J.
• Primary Examiner(s): Wong, Peter S.
• Assistant Examiner(s): Patel, Rajnikant B.
• Application Number:
  US09/026,640
• Time in Patent Office: 718 Days
• Field of Search: 363/41, 363/42, 363/43, 363/98, 318/811, 318/599
• US Class Current: 363/41
• CPC Class Codes: H02M 1/0025 Arrangements for modifying reference values, feedback values or error values in the control loop of a converter
• CPC Class Codes: H02M 7/53875 with analogue control of three-phase output
• CPC Class Codes: H02P 6/085 in a bridge configuration

Abstract

A method and apparatus for selecting one of several different modulating signals for use with a system including a PWM controller and an inverter to generate low frequency alternating voltages on three motor supply lines, modulating signals selected as a function of a modulating index to minimize harmonic distortion in the alternating voltages, minimize switching losses, maximize overall system gain at high modulating index values and maximize the linear range of system operation.

Claims

1. An apparatus for use with a PWM controller and inverter, the controller comparing modulating signals to a carrier signal to generate firing signals for turning PWM inverter switches on and off thereby connecting each of first, second and third inverter output lines alternately between positive and negative DC buses and generating high frequency voltage pulses on each output line, the high frequency pulses on each line together generating low frequency alternating voltages, the positive DC bus having a DC bus voltage value, the apparatus for providing modulating signals which cause minimum harmonic distortion in the generated voltages, the controller providing three initial sinusoidal modulating signals, the apparatus comprising:

an identifier which receives at least one of the initial modulating signals and determines a modulating index;

a comparator which compares the modulating index to a threshold index, and

a selector which;

when the modulating index is less than the threshold index, provides a first signal set including first, second and third PWM signals corresponding to the first, second and third output lines, the first set having identical 120 degree phase shifted waveforms; and

when the modulating index is greater than the threshold index, provides a second signal set including first, second and third PWM signals corresponding to the first, second and third output lines, the second set having identical 120 degree phase shifted waveforms;

wherein, below the threshold index, the first set causes relatively less generated voltage harmonic distortion than the second set and, above the index, the second set causes relatively less generated voltage distortion than the first set.

2. The apparatus of claim 1 wherein the first set includes continuous PWM signals (CPWM).

3. The apparatus of claim 1 wherein the second set includes discontinuous PWM signals (DPWM).

4. The apparatus of claim 2 wherein the CPWM signals are sinusoidal PWM signals (SPWM).

5. The apparatus of claim 2 wherein the CPWM signals are space vector PWM signals (SVPWM).

6. The apparatus of claim 1 wherein the selector generates the second set by mathematically combining a zero sequence signal with each of three initial sinusoidal modulating waveforms, the zero sequence signal determined by mathematically combining at least one of the initial modulating signals with the DC bus voltage value.

7. The apparatus of claim 6 wherein the selector further includes:

a maximum magnitude determiner which receives the three initial sinusoidal modulating signals and identifies the modulating signal having the greatest magnitude as the maximum modulating signal;

a zero sequence resolver which identifies the sign of the maximum modulating signal as the zero sequence sign, subtracts the maximum modulating signal from the DC bus voltage value generating a zero sequence magnitude and multiplies the zero sequence magnitude by the zero sequence sign to generate a zero sequence signal; and

a signal modifier which mathematically combines the zero sequence signal and each of the three initial modulating signals generating the second set.

8. The apparatus of claim 7 wherein the modifier mathematically combines by adding the zero sequence signal to each of the three initial modulating signals.

9. The apparatus of claim 1 wherein the threshold index is essentially 0.65.

10. The apparatus of claim 1 wherein a switching loss occurs each time an inverter switch changes state from on to off or vice versa, the apparatus also for limiting switching losses and maximizing inverter gain, the comparator being a first comparator, the threshold index being a first index and the selector being a first selector, the apparatus further including a second comparator and a second selector and there also being a second threshold index, when the modulating index is greater than the first index, the second comparator comparing the modulating index to the second index and, wherein the second selector:

when the modulating index is less than the second index, provides a low loss signal set including first, second and third PWM signals having identical 120 degree phase shifted waveforms corresponding to the first, second and third output lines, respectively; and

when the modulating index is greater than the second index, provides a high gain signal set including first, second and third PWM signals having identical 120 degree phase shifted waveforms corresponding to the first, second and third inverter output lines, respectively;

wherein, below the second index, the low loss set is known to cause relatively less switching losses than the high gain set and, above the threshold index, the high gain set is know to cause relatively higher gain than the low loss set.

11. The apparatus of claim 10 wherein the selector generates each second signal set by mathematically combining a zero sequence signal with each of the initial modulating signals, the selector including a zero sequence identifier for identifying the high gain zero sequence signal, the identifier including:

a maximum magnitude determiner which receives the three initial sinusoidal modulating signals and identifies the modulating signal having the greatest magnitude as the maximum modulating signal; and

a zero sequence resolver which identifies the sign of the maximum modulating signal as the high gain zero sequence sign and mathematically combines the maximum modulating signal, the DC voltage and the zero sequence sign to generate the high gain zero sequence signal.

12. The apparatus of claim 11 wherein the resolver mathematically combines by subtracting the maximum modulating signal from the DC voltage value to generate a high gain zero sequence magnitude signal and multiplies the high gain zero sequence magnitude signal by the zero sequence sign.

13. The apparatus of claim 10 wherein the selector generates each second signal set by mathematically combining a zero sequence signal with each of the initial modulating signals, the selector including a zero sequence identifier fo identifying the low loss zero sequence signal, the identifier including:

a phase shifter receiving each of the first, second and third initial modulating signals and generating first second and third phase shifted signals by phase shifting the initial signals by a specified phase angle;

a maximum magnitude determiner receiving each of the phase shifted signals and identifying the instantaneous maximum phase shifted signal; and

a zero sequence resolver which correlates one of the initial modulating signals with the maximum phase shifted signal, the correlated initial modulating signal being a correlated signal, determines the instantaneous sign of the correlated signal as the low loss zero sequence sign, and mathematically combines the correlated signal, the DC bus voltage and the low loss zero sequence sign to generate the low loss zero sequence signal.

14. The apparatus of claim 13 wherein the resolver mathematically combines by subtracting the correlated signal from the DC voltage value to generate a low loss zero sequence magnitude signal and multiplying the low loss zero sequence magnitude signal by the low loss zero sequence sign.

15. The apparatus of claim 13 wherein the specified phase angle is 30 degrees.

16. The apparatus of claim 10 wherein the first threshold index is substantially 0.65 and the second threshold index is substantially 0.91.

17. The apparatus of claim 10 wherein the controller provides at least one current signal indicating the phase of a current associated with a first of the initial modulating signals, to generate the low loss zero sequence signal, the apparatus further including:

a phase angle determiner using the current signal and the first initial modulating signal to identify the phase angle between the current signal and first initial modulating signal;

a phase shifter receiving each of the first, second and third initial modulating signals and generating first second and third phase shifted signals by phase shifting the initial signals by the phase angle;

a maximum magnitude determiner receiving each of the phase shifted signals and identifying the instantaneous maximum phase shifted signal; and

a zero sequence resolver which correlates one of the initial modulating signals with the maximum phase shifted signal, the correlated initial modulating signal being a correlated signal, determines the instantaneous sign of the correlated signal as the low loss zero sequence sign, and mathematically combines the correlated signal, the DC bus voltage and the low loss zero sequence sign to generate the low loss zero sequence signal.

18. The apparatus of claim 17 wherein the resolver mathematically combines subtracting the correlated signal from the DC bus voltage value to generate a low loss zero sequence magnitude signal and multiplying the low loss zero sequence signal by the low loss zero sequence sign.

24. The method of claim 7 wherein the step of mathematically combining the zero sequence signal with each of the three initial modulating signals includes adding the zero sequence signal to each of the three initial modulating signals.

29. The method of claim 10 wherein the step of providing a low loss signal set includes identifying a low loss zero sequence signal and mathematically combining each of the initial modulating signals with the low loss zero sequence signal and the step of identifying a high gain zero sequence signal includes the steps of:

phase shifting the initial signals by a specified phase angle to generate first, second and third phase shifted signals;

identifying the instantaneous maximum phase shifted signal;

correlating one of the initial modulating signals with the maximum phase shifted signal, the correlated initial modulating signal being a correlated signal;

determining the instantaneous sign of the correlated signal as the low loss zero sequence sign; and

mathematically combining the correlated signal, the DC bus voltage and the low loss zero sequence sign to generate the low loss zero sequence signal.

30. The method of claim 29 wherein the step of mathematically combining the correlated signal, the DC bus voltage and the low loss zero sequence sign includes the steps of:

subtracting the correlated signal from the DC voltage value to generate a low loss zero sequence magnitude signal; and

multiplying the low loss zero sequence magnitude signal by the low loss zero sequence sign.

31. The method of claim 29 wherein the specified phase angle is 30 degrees.

19. A method for use with a PWM controller and inverter, the controller comparing modulating signals to a carrier signal to generate firing signals for turning PWM inverter switches on and off thereby connecting each of first, second and third inverter output lines alternately between positive and negative DC buses and generating high frequency voltage pulses on each output line, the high frequency pulses on each line together generating low frequency alternating voltages, the controller providing thee initial sinusoidal modulating signals and the DC bus having a DC bus voltage value, the method for providing modulating signals which cause minimum harmonic distortion in the generated voltages, the method comprising the steps of:

determining a modulating index using at least one of the initial modulating signals;

comparing the modulating index to a threshold index; and

when the modulating index is less than the threshold index, providing a first signal set including first, second and third PWM signals corresponding to the first, second and third output lines, the first set having identical 120 degree phase shifted waveforms; and

when the modulating index is greater than the threshold index, providing a second signal set including first, second and third PWM signals corresponding to the first, second and third output lines, the second set having identical 120 degree phase shifted waveforms; and

wherein, the first set is known to cause relatively less harmonic distortion than the second set when the modulating index is less than the threshold index and the second set is known to cause relatively less harmonic distortion than the first set when the modulating index is greater than the threshold index.

20. The method of claim 19 wherein the step of providing the first signal set includes providing continuous PWM signals (CPWM).

21. The method of claim 19 wherein the step of providing the second signal set includes providing discontinuous PWM signals (DPWM).

22. The method of claim 21 also including the step of identifying the second set, the step of identifying further including the steps of:

mathematically combining the at least one of the initial modulating signals with a peak carrier signal to generate a zero sequence signal; and

mathematically combining the zero sequence signal with each of the three initial modulating signals to generate the second set.

23. The method of claim 22 wherein the step of identifying the second set includes the step of identifying the zero sequence signal and the step of identifying the zero sequence signal further includes the steps of:

identifying the modulating signal having the greatest magnitude as the maximum modulating signal;

identifying the sign of the maximum modulating signal as the zero sequence sign;

subtracting the maximum modulating signal from the DC bus voltage value generating a zero sequence magnitude; and

multiplying the zero sequence magnitude by the zero sequence sign to generate a zero sequence signal.

25. The method of claim 19 wherein the threshold index is essentially 0.65.

26. The method of claim 19 wherein a switching loss occurs each time an inverter switch changes state from on to off or vice versa, the method also for limiting switching losses and maximizing inverter gain, the threshold index being a first threshold index, the method further including the steps of:

when the modulating index exceeds the first threshold index, comparing the modulating index to a second threshold index;

when the modulating index is less than the second threshold index, providing a low loss signal set including first, second and third PWM signals having identical 120 degree phase shifted waveforms corresponding to the first, second and third output lines, respectively; and

when the modulating index is greater than the second index, providing a high gain signal set including first, second and third PWM signals having identical 120 degree phase shifted waveforms corresponding to the first, second and third inverter output lines, respectively;

wherein, below the second threshold index, the low loss set is known to cause relatively less switching losses than the high gain set and, above the second threshold index, the high gain set is known to cause relatively higher gain than the low loss set.

27. The method of claim 26 wherein the step of providing a high gain signal set includes identifying a high gain zero sequence signal and mathematically combining each of the initial modulating signals with the high gain zero sequence signal and the step of identifying a high gain zero sequence signal includes the steps of:

identifying the initial modulating signal having the greatest instantaneous magnitude as the maximum modulating signal;

identifying the sign of the maximum modulating signal as the high gain zero sequence sign; and

mathematically combining the maximum modulating signal, the DC voltage and the zero sequence sign to generate the high gain zero sequence signal.

28. The method of claim 27 wherein the step of mathematically combines the maximum modulating signal, the DC voltage signal and the zero sequence sign includes the steps of:

subtracting the maximum modulating signal from the DC voltage value to generate a high gain zero sequence magnitude signal; and

multiplying the high gain zero sequence magnitude signal by the zero sequence sign.

32. The method of claim 26 wherein the first threshold index is substantially 0.65 and the second threshold index is substantially 0.91.

33. The method of claim 26 wherein the controller provides at least one current signal indicating the phase of a current associated with a first of the initial modulating signals, to generate the low loss zero sequence signal, the method further including the steps of:

using the current signal and the first initial modulating signal to identify the phase angle between the current signal and first initial modulating signal;

generating first second and third phase shifted signals by phase shifting the initial signals by the phase angle;

identifying the instantaneous maximum phase shifted signal;

correlating one of the initial modulating signals with the maximum phase shifted signal, the correlated initial modulating signal being a correlated signal;

determining the instantaneous sign of the correlated signal as the low loss zero sequence sign; and

mathematically combining the correlated signal, the DC bus voltage and the low loss zero sequence sign to generate the low loss zero sequence signal.

34. The method of claim 33 wherein the step of mathematically combining the correlated signal, the DC bus voltage and the low loss zero sequence sign includes the steps of:

subtracting the correlated signal from the DC bus voltage value to generate a low loss zero sequence magnitude signal; and

multiplying the low loss zero sequence signal by the low loss zero sequence sign.