Power cell bypass method and apparatus for multilevel inverter

• US 9,787,213 B2
• Filed: 12/22/2015
• Issued: 10/10/2017
• Est. Priority Date: 03/18/2013
• Status: Active Grant

• Current Assignee: Rockwell Automation Technologies Incorporated (Allen-Bradley Co., Inc.)
• Original Assignee: Rockwell Automation Technologies Incorporated (Allen-Bradley Co., Inc.)
• Inventors: Wei, Lixiang, Xiao, Yuan, Lu, Haihui, Weber, Douglas B.
• Primary Examiner(s): Dole, Timothy J
• Assistant Examiner(s): Kyaw, Htet Z
• Application Number:
  US14/978,571
• Publication Number:
  US 20160111967A1
• Time in Patent Office: 658 Days
• Field of Search: 363 43
• 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 7/49 Combination of the output voltage waveforms of a plurality of converters

Abstract

Multilevel inverters, power cells and bypass methods are presented in which a power cell switching circuit is selectively disconnected from the power cell output, and a bypass which is closed to connect first and second cell output terminals to selectively bypass a power stage of a multilevel inverter, with an optional AC input switch to selectively disconnect the AC input from the power cell switching circuit during bypass.

Claims

1. A power conversion system, comprising:

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

a switching circuit including a plurality of switching devices coupled between a DC link circuit and an output, the switching circuit operative according to a plurality of switching control signals to provide an output voltage having an amplitude of one of at least two discrete levels at the output,

a first output control switch coupled between a first node of the switching circuit and a first output terminal, the first output control switch operative in a first state to allow current to flow between the switching circuit and the output, and in a second state to prevent current from flowing between the switching circuit and the output,

a second output control switch coupled between a second node of the switching circuit and a second output terminal, the second output control switch operative in a first state to allow current to flow between the switching circuit and the output, and in a second state to prevent current from flowing between the switching circuit and the output, and

a bypass switch coupled across the output of the switching circuit, the bypass switch operative in a conductive state to bypass the output of the switching circuit; and

a controller operative to selectively bypass at least one power stage by placing the first and second output control switches in the respective second states and by placing the bypass switch in the conductive state.

2. The power conversion system of claim 1, wherein the controller is operative to selectively place the first and second output control switches in the second state before placing the bypass switch in the conductive state.

3. The power conversion system of claim 2, further comprising an input switch coupled between an AC input and the switching circuit of the at least one power stage, the input switch being operative in a first state to allow current to flow between the AC input and the switching circuit and a second state to prevent current from flowing between the AC input and the switching circuit, wherein the controller is operative to bypass the at least one power stage by placing the first and second output control switches in the respective second states, by placing the bypass switch in the conductive state, and by placing the input switch in the second state.

4. The power conversion system of claim 3, wherein the controller is operative to selectively place the first and second output control switches in the second state before placing the input switch in the second state.

5. The power conversion system of claim 4, wherein the controller is operative to place the input switch in the second state before placing the bypass switch in the conductive state.

6. The power conversion system of claim 5, wherein the switching circuit includes four switching devices connected in an H-bridge configuration between the DC link circuit and the output, and wherein the controller is operative to provide the switching control signals to the four switching devices of the switching circuit to provide the output voltage having an amplitude of one of at least two discrete levels at the output.

7. The power conversion system of claim 2, wherein the switching circuit includes four switching devices connected in an H-bridge configuration between the DC link circuit and the output, and wherein the controller is operative to provide the switching control signals to the four switching devices of the switching circuit to provide the output voltage having an amplitude of one of at least two discrete levels at the output.

8. The power conversion system of claim 1, further comprising an input switch coupled between an AC input and the switching circuit of the at least one power stage, the input switch being operative in a first state to allow current to flow between the AC input and the switching circuit and a second state to prevent current from flowing between the AC input and the switching circuit, wherein the controller is operative to bypass the at least one power stage by placing the first and second output control switches in the respective second states, by placing the bypass switch in the conductive state, and by placing the input switch in the second state.

9. The power conversion system of claim 8, wherein the controller is operative to selectively place the first and second output control switches in the second state before placing the input switch in the second state.

10. The power conversion system of claim 8, wherein the switching circuit includes four switching devices connected in an H-bridge configuration between the DC link circuit and the output, and wherein the controller is operative to provide the switching control signals to the four switching devices of the switching circuit to provide the output voltage having an amplitude of one of at least two discrete levels at the output.

11. The power conversion system of claim 1, wherein the switching circuit includes four switching devices connected in an H-bridge configuration between the DC link circuit and the output, and wherein the controller is operative to provide the switching control signals to the four switching devices of the switching circuit to provide the output voltage having an amplitude of one of at least two discrete levels at the output.

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

an AC input;

a rectifier coupled with the AC input;

a DC circuit coupled with the rectifier and including at least one capacitance;

a switching circuit including a plurality of switching devices coupled between the DC circuit and an output, the switching circuit operative according to a plurality of switching control signals to provide an output voltage having an amplitude of one of at least two discrete levels at the output;

a first output control switch coupled between a first node of the switching circuit and a first output terminal, the first output control switch operative according to at least one output switching control signal in a first state to allow current to flow between the first node of the switching circuit and the first output terminal, and in a second state to prevent current from flowing between the first node of the switching circuit and the first output terminal;

a second output control switch coupled between a second node of the switching circuit and a second output terminal, the second output control switch operative according to at least one output switching control signal in a first state to allow current to flow between the second node of the switching circuit and the second output terminal, and in a second state to prevent current from flowing between the second node of the switching circuit and the second output terminal; and

a bypass switch coupled across the output of the switching circuit, the bypass switch operative according to a bypass switching control signal in a nonconductive state and in a conductive state to bypass the output of the switching circuit.

13. The power cell of claim 12, further comprising an input switch coupled between the AC input and the switching circuit, the input switch being operative according to an input switching control signal in a first state to allow current to flow between the AC input and the switching circuit and a second state to prevent current from flowing between the AC input and the switching circuit.

14. The power cell of claim 13, wherein the switching circuit includes four switching devices connected in an H-bridge configuration between the DC circuit and the output.

15. The power cell of claim 12, wherein the switching circuit includes four switching devices connected in an H-bridge configuration between the DC circuit and the output.

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

electrically disconnecting all switching devices of a switching circuit of the power stage from an output of the power stage, wherein electrically disconnecting the switching circuit from the outpost comprises opening a pair of output control switches; and

electrically connecting two output terminals of the power stage to one another to bypass the power stage, wherein electrically connecting the two output terminals to one another comprises closing a bypass switch.

17. The method of claim 16, comprising opening the pair of output control switches before closing the bypass switch.

18. The method of claim 16, comprising electrically disconnecting the switching circuit from an input of the power stage.

19. The method of claim 16, wherein the pair of output control switches includes a first output control switch coupled between a first node of the switching circuit and a first output terminal, and a second output control switch coupled between a second node of the switching circuit and a second output terminal;

and wherein electrically disconnecting all the switching devices of the switching circuit of the power stage from the output of the power stage comprises;

opening the first output control switch; and

opening the second output control switch.

20. The method of claim 16, wherein the output control switches are semiconductor-based switches, contractors or relays.