A Seven-Level Converter Using a Combination of Staircase and PWM Switching Methods Hossein Sepahvand, Mehdi Ferdowsi, and Keith A. Corzine Missouri University of Science and Technology Rolla, MO 65409 USA Abstract- In this paper, a new method is proposed for switching a multilevel converter. In this converter two HBridge cells are connected in series with each phase of a three-phase diode-clamped converter. Operation of main converter and one of H-Bridge cells is based on the staircase switching method. Switching angles of the three phase converter and one of the H-Bridges are selected in a way to generate the fundamental harmonic of the phase and eliminate the fifth and seventh harmonics. However, the switching pattern of the second H-Bridge cell is based on PWM method. This cell generates the remaining parts of the desired sinusoidal waveform. Combination of these converters and their switching methods results in an output waveform with low harmonics. Simulation and experimental results agree with each other and show the proper operation of the proposed method. I INTRODUCTION Multilevel converters are formed by combining two or more separate voltage sources to synthesize single or threephase (commonly sinusoidal) voltage waveforms [1]. In general, by increasing the number of levels, the synthesized voltage waveform becomes closer to its sinusoidal reference. This leads to reduced harmonic distortions when compared with conventional converters. In addition, multilevel converters benefit from other advantage such as low electromagnetic emissions, high efficiency, lower voltage stress on switches, and modularity [1-6]. Furthermore, due to high VA (volt-amp) ratings of multilevel converters, they are one of the best choices for electric motor drives in hybrid power-trains [2, 3, 7, 8]. The cascaded H-Bridge multilevel converter consists of two or more H-Bridge cells connected in series. This type of converter has been applied to high-power and high-quality applications including static VAR generation (SVG) [9, 10], active filters, reactive power compensators [11], photovoltaic power conversion [10, 12], and uninterruptable power supplies (UPS). In this paper, a seven-level converter is investigated. First, a three-phase diode-clamped converter is used as main converter. Then, each phase of the main converter is cascaded with two H-Bridge cells. The main converter and the first HBridge generate a staircase waveform. Their switching angles are selected in a way to eliminate the fifth and seventh harmonics of the output voltage. In addition these two converters generate the fundamental harmonic of each phase. The second H-Bridge which operates based on a PWM 978-1-4244-5226-2/10/$26.00 ©2010 IEEE method generates the subtraction of the reference signal (sinusoidal waveform) and the waveform that the main and first H-Bridge converters generate. The task of this converter is to eliminate the remaining low frequency harmonics generated in the first two converters and it does not contribute in generating the fundamental harmonic of the output. Therefore the voltage source of this converter can be replaced with a capacitor voltage source. Furthermore, in this topology if the second H-bridge cell of a phase is out of the circuit there will not be any change in the fundamental harmonic of that phase. Therefore if any fault happens in the second H-bridge cell it can be removed from the active circuit with the bypass circuit. In this paper the proposed method is described and switching angles are chosen in a way to eliminate the fifth and seventh harmonics of the output voltage waveform. Then simulation results using MATLAB/Simulink are provided. Finally, the experimental results of the proposed method are presented. II TOPOLOGY AND SIMULATION OF THE SEVEN LEVEL CONVERTER Inverter topology which is used in this paper consists of two cascaded H-bridge cells per phase and one three-phase staircase inverter. The topology of the seven-level inverter is shown in Fig. 1. In this topology, the main converter is a three phase inverter fed with a dc voltage of 4 . Each phase 2301 V V3a Vdc V2a Vdc 4Vdc a Vb V c Vdc V3b V dc V3c Vdc V2b V2c Vdc V1a Fig. 1. Topology of the converter 90 80 3 70 1, 2, and 3 60 50 2 40 30 1 20 10 1.147 0 1 1.852 1.488 1.2 1.4 1.6 2.523 1.8 2 2.2 2.4 2.6 Modulation Index (m) Fig. 3. Solutions for the switching angles when the elimination of the fifth and seventh harmonics is intended Fig. 2. Staircase output voltage waveform made by combination of main converter and H-bridge1 of the main converter is connected in series with two Hbridges to form the final voltage of each phase of the multilevel converter. The voltage sources feeding the two Hwhich is one fourth of the bridges are chosen to be voltage source of the main converter. The output of the second H-bridge cell in each phase is connected in parallel with a bypass circuit. This bypass circuit removes the second H-bridge cell when any fault happens on this H-bridge cell. The main converter and the first H-bridge (H-bridge1) in each phase operate in the staircase waveform generation mode. However the second H-bridge (H-bridge2) of each phase operates in PWM. Switching angles of the main and the first H-bridge are selected in a way to eliminate the fifth and seventh harmonics of the synthesized voltage. The sum of the output waveforms of the main inverter and H-bridge1 ) for phase a is shown in Fig. 2. ( Since in a three-phase system, the third harmonics is naturally canceled; therefore, switching angles can be chosen to eliminate the fifth and seventh harmonics. In the other words, the solution of the following system of equations yields the desired modulation index and eliminates the fifth and seventh harmonics in the output voltage waveform of the first two converters (i.e. main and H-bridge cells). Nonlinear system of equations for elimination of the fifth and seventh harmonics is as follow: 5 7 5 7 5 7 , , 4 ∞ 1 cos , , ,.. sin nωt cos (1) where , , and are switching angles of the output voltage waveform. Equation (1) consists of three variables , and ) which can be chosen to satisfy three ( , conditions. Since it is required to generate an output voltage waveform which has variable amplitude in its fundamental harmonic, one of the variables is already committed. Therefore, it is possible to satisfy two other conditions with the remaining variables. (2) here m denotes the modulation index and is defined as 4 A. Elimination of the Fifth and Seventh Harmonics The Fourier series expansion of the staircase output voltage waveform which is shown in Fig. 2 is [6, 13, 14]: 0 0 (3) where is the peak voltage of the desired fundamental frequency of the converter. In order to solve the system of equations in (2), several approaches, including resultant theory, have been proposed [13, 15, 16]. In addition to the discussed methods, one can use MATLAB nonlinear solvers to solve these nonlinear systems of equations. This method can be used without dealing with the complexity of the previously proposed methods [13, 15, 16]. The results are depicted in Fig. 3 [6]. As it is shown, when m is between 1.488 and 1.852, two sets of solutions exist. B. Switching Fundamentals of H-bridge2 The reference for PWM switching of H-Bridge2 is generated by subtracting the sum of output waveforms of the main inverter and H-Bridge1 from the desired sinusoidal waveform (reference). The amplitude of sinusoidal waveform 2302 (a) V 1 a (V) 100 0 -100 0.01 V 2 a (V) V 1 a +V 2 a (V) 0.01 0.02 0.03 0.02 0.03 0.02 0.03 0.02 0.03 0.02 0.03 (c) 100 0 -100 PWM Ref (V) V 3 a (V) 0.03 0 -40 0.01 (d) 40 0 -40 0.01 (e) 40 0 -40 0.01 (f) 100 V a (V) 0.02 (b) 40 0 -100 0.01 time (s) Fig. 4. Simulation results (a) Main converter output, (b) H-bridge1 output, (c) desired sinusoidal waveform and sum of the main and H-bridge1 converters, (d) PWM reference waveform of H-bridge2, (e) H-bridge3 output, (f) total converter output waveform ( ) is equal to the amplitude of the fundamental harmonic of the sum of the voltages generated by the main inverter and H). In the other word, the main and the first bridge1 ( H-Bridge make a staircase waveform and the second HBridge makes the rest of a sinusoidal waveform. By choosing this reference for H-Bridge2, this H-bridge will have no contribution in generation of the fundamental harmonic of the output of the corresponding phase. Note that if the H-bridge2 is bypassed at least 5th and 7th harmonics are still eliminated in the output of the corresponding phase. The converter is simulated in MATLAB/Simulink to verify the operation of the proposed method. Fig. 4 shows the output waveforms of all inverters. In Fig. 4(a) and (b) the output waveform of the main and H-bridge1 converters are shown, respectively. The desired sinusoidal waveform and sum of the voltages generated by the main and H-bridge1 converters ) are shown in Fig. 4(c). Note that based on the ( desired amplitude of the output waveform, modulation index can be found and by using (2) and Fig. 3 the switching angles for the main and H-bridge1 converters can be obtained. The difference between the desired output waveform and ( ) is shown in Fig. 4(d). In Fig. 4(e) and (f), the output of H-Bridge2 and the total output of the converter are shown, respectively. III EXPERIMENTAL RESULTS In order to verify the simulation results, a hardware prototype of the system is developed. The voltage source of the main converter is 120 V and 30 V voltage sources are used for H-bridge1 and H-bridge2 cells. The control scheme is implemented in a TMS320F2812 digital signal processor (DSP) which is connected to the IGBTs using fiber optic cables. The switching frequency for H-bridge2 is 6 kHz. Experimental result for the converter when m is equal to 2.137 is shown in Fig. 5. In this figure, the top waveform is the output of phase a of the converter ( ). The middle waveform is the summation of the voltage generated by the ). The waveform in main and H-bridge2 converters ( the bottom of the Fig. shows the output waveform of Hbridge2 ( ). IV CONCLUSION In this paper, a new method to implement and control a multilevel converter is proposed. 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