Method and apparatus for bypassing cascaded h-bridge (CHB) power cells and power sub cell for multilevel inverter

• US 9,912,221 B2
• Filed: 08/03/2016
• Issued: 03/06/2018
• 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
• Application Number:
  US15/227,407
• Publication Number:
  US 20160344278A1
• Time in Patent Office: 580 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 circuit including at least one capacitance coupled between first and second DC link nodes,

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

a switching circuit including a plurality of switching devices coupled between the DC link circuit and the 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, and

a single relay or contactor, comprising;

a coil,

a first normally closed output control contact coupled between a first internal node of the switching circuit and a first output terminal of the output, the first output control contact operative in a first state to allow current to flow between the first internal node and the first output terminal when the coil is deenergized, and operative in a second state to prevent current from flowing between the first internal node and the first output terminal when the coil is energized,

a second normally closed output control contact coupled between a second internal node of the switching circuit and a second output terminal of the output, the second output control contact operative in a first state to allow current to flow between the second internal node and the second output terminal when the coil is deenergized, and operative in a second state to prevent current from flowing between the second internal node and the second output terminal when the coil is energized, and

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

a controller operative to selectively energize the coil of at least one of the plurality of power stages to bypass the at least one power stage;

wherein the single relay or contactor further comprises a third normally closed contact coupled between the first DC link node and a first DC node of a rectifier, the third contact operative in a first state to allow current to flow between the first DC link node and the first DC node when the coil is deenergized, and operative in a second state to prevent current from flowing between the first DC link node and the first DC node.

2. The power conversion system of claim 1, wherein the controller is a local controller providing switching control signals to operate the plurality of switching devices of the switching circuit of the at least one power stage;

and wherein the controller is operative to selectively energize the coil of the at least one power stage to bypass the at least one power stage.

3. The power conversion system of claim 1, comprising:

at least one local controller providing the switching control signals to operate the plurality of switching devices of the switching circuit of the at least one power stage; and

a second controller operative 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 3, wherein the single relay or contactor further comprises:

a fourth normally closed contact coupled between a second DC node of the rectifier and the second DC link node, the fourth contact operative in a first state to allow current to flow between the second DC node and the second DC link node when the coil is deenergized, and operative in a second state to prevent current from flowing between the second DC node and the second DC link node when the coil is energized.

5. The power conversion system of claim 1, wherein the single relay or contactor further comprises:

a fourth normally closed contact coupled between a second DC node of the rectifier and the second DC link node, the fourth contact operative in a first state to allow current to flow between the second DC node and the second DC link node when the coil is deenergized, and operative in a second state to prevent current from flowing between the second DC node and the second DC link node when the coil is energized.

6. The power conversion system of claim 1, wherein the single relay or contactor is an N-pole, single-throw device, where N is an integer having a value of 3 or more.

7. The power conversion system of claim 6, wherein the controller is a local controller providing switching control signals to operate the plurality of switching devices of the switching circuit of the at least one power stage;

and wherein the controller is operative to selectively energize the coil of the at least one power stage to bypass the at least one power stage.

8. The power conversion system of claim 6, comprising:

at least one local controller providing the switching control signals to operate the plurality of switching devices of the switching circuit of the at least one power stage; and

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

9. The power conversion system of claim 8, wherein the single relay or contactor further comprises:

a fourth normally closed contact coupled between a second DC node of the rectifier and the second DC link node, the fourth contact operative in a first state to allow current to flow between the second DC node and the second DC link node when the coil is deenergized, and operative in a second state to prevent current from flowing between the second DC node and the second DC link node when the coil is energized.

10. The power conversion system of claim 6, wherein the single relay or contactor further comprises:

a fourth normally closed contact coupled between a second DC node of the rectifier and the second DC link node, the fourth contact operative in a first state to allow current to flow between the second DC node and the second DC link node when the coil is deenergized, and operative in a second state to prevent current from flowing between the second DC node and the second DC link node when the coil is energized.

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

a DC link circuit including at least one capacitance coupled between first and second DC link nodes;

an output;

a switching circuit including a plurality of switching devices coupled between the DC link circuit and the 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; and

a single relay or contactor, comprising;

a coil,

a first normally closed output control contact coupled between a first internal node of the switching circuit and a first output terminal of the output, the first output control contact operative in a first state to allow current to flow between the first internal node and the first output terminal when the coil is deenergized, and operative in a second state to prevent current from flowing between the first internal node and the first output terminal when the coil is energized,

a second normally closed output control contact coupled between a second internal node of the switching circuit and a second output terminal of the output, the second output control contact operative in a first state to allow current to flow between the second internal node and the second output terminal when the coil is deenergized, and operative in a second state to prevent current from flowing between the second internal node and the second output terminal when the coil is energized,

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

a third normally closed contact coupled between the first DC link node and a first DC node of a rectifier, the third contact operative in a first state to allow current to flow between the first DC link node and the first DC node when the coil is deenergized, and operative in a second state to prevent current from flowing between the first DC link node and the first DC node.

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

energizing a coil of a single relay or contactor to open first and second normally closed output control contacts and to close a normally open bypass control contact to bypass an output of the power stage;

wherein energizing the coil opens a third normally closed contact coupled between a first DC link node and a first DC node of a rectifier to prevent current from flowing between the first DC link node and the first DC node.