Motor drives represent electric equipment used for speed control of electric motors. Varieties of industrial applications, such as assembly, pumps, fans etc., require motors and they consume huge amount of electric energy. Compared with traditional motor drives, which can only send energy from grid to motor, a regenerative motor drive can achieve bi-directional power flow control between motors and utility grid. Regenerative motor drives are excellent candidates for reducing power loss in motor-related applications. One of the most essential parts of a regenerative motor drive power cell is dc-link capacitors. They create suitable dc-link voltages and smooth the voltage waveforms. Reliability, or lifetime of dc-link capacitors highly affect power cell lifetime, and power loss in dc-link capacitor is also another issue that worth noticing. This thesis focuses on the lifetime modeling and lifetime improvement of dc-link capacitors in a regenerative cascaded H-bridge medium-voltage motor drive. The lifetime modeling bases itself on the mechanisms of dominant lifetime stresses in practical operations. A proposed method is used to reduce a dominant current harmonic component in dc-link capacitors. With the proposed lifetime model and harmonic-reduction method, dc-link capacitor lifetime improvement can be anticipated in this motor drive model. Less power losses in those dc-link capacitor banks can also be achieved. / Thesis / Master of Applied Science (MASc)

The past few decades have seen a rapid sales increase and technological development of electric vehicles (EVs). As the key part of the electrical powertrain systems, the traction machine drive systems in modern EVs are composed of voltage source inverters (VSI) and electric machines. In this thesis, multiphase VSIs are studied and designed to achieve volume reductions when compared with existing 3-phase benchmark VSIs. Different existing switching strategies for arbitrary phase number multiphase VSIs are investigated resulting in an understanding of best practice and a newly proposed switching strategy. Thus, the first contribution of this thesis is switching strategies that support subsequent investigations and experimental validation. DC-link capacitor and heat sink are two bulkiest components in VSIs and hence it is more efficient to decrease their volumes to achieve the compactness improvement. The investigation methodology and procedure for arbitrary phase number VSI DC-link capacitor requirements, i.e. capacitance and RMS current ratings, are firstly developed. Increased phase number decreases the DC-link capacitor requirements and hence the VSI volume significantly. Throughout this analysis, the connected multiphase machine is considered appropriately, though no electric machine design is described in the thesis. While other authors have studied DC-link current ripple, this thesis qualifies and quantifies the system benefits. This is the second contribution. Multiphase VSIs thermal models are built and their respective thermal performances studied and evaluated against a reference 3-phase benchmark VSI. The power loss deviation among different semiconductor dies is lower or even eliminated in the multiphase VSIs. Furthermore, the multiphase integrated design VSIs have a significant heat sink volume reduction when compared to the 3-phase benchmark VSI. This study and concluding benefits are the third contribution. Finally, comparative test validations are made on an experimental set-up designed to illustrate the benefits of a 9-phase against a reference 3-phase system. Here, the test hardware and implementation are carefully designed to representatively illustrate performance benefits. / Thesis / Doctor of Philosophy (PhD)

AC/DC adapters mostly employ two-stage topology: Power Factor Correction (PFC) pre-regulation stage followed by an isolated DC/DC converter stage. Low power AC/DC adapters require a small size to be competitive. Among their components, the bulk DC-link capacitor is one of the largest because it should keep the output voltage with low ripple. Also, the size of this capacitor is penalized due to the universal line voltage application. Synchronization through employing leading edge modulation for the first PFC stage and trailing edge modulation for the second DC/DC converter stage can significantly reduce the ripple current and ripple voltage of the DC-link capacitor. Thus, a smaller DC-link capacitance can be used, lowering the cost and size of the AC/DC adapter. Benefits of the synchronous switching scheme were already demonstrated experimentally. However, no mathematical analysis was presented. In this thesis, detailed mathematical analyses in per-unit quantity are given to facilitate the calculation of the DC-link capacitor ripple current reduction with Leading/Trailing Edge Modulation strategies. One of the limitations of leading/trailing edge modulation is that the switching frequencies of the two stages need to be equal to achieve the best reduction of the DC-link capacitor ripple current. The DC-link capacitor ripple current will become larger if the switching frequency of the DC/DC converter is larger than that of the PFC pre-regulator, which blocks us to employ higher frequency for isolated DC/DC converter to reduce its transformer size. This thesis proposed a new Leading/Trailing Edge Modulation strategy to further reduce the DC-link bulk capacitor ripple current when switching frequency of DC/DC converter stage is twice the switching frequency of PFC stage. This proposed pulse width modulation scheme was verified by simulation. Experimental results obtained through digital control based on FPGA are also presented in this thesis.

AC/DC adapters mostly employ two-stage topology: Power Factor Correction (PFC) pre-regulation stage followed by an isolated DC/DC converter stage. Low power AC/DC adapters require a small size to be competitive. Among their components, the bulk DC-link capacitor is one of the largest because it should keep the output voltage with low ripple. Also, the size of this capacitor is penalized due to the universal line voltage application. Synchronization through employing leading edge modulation for the first PFC stage and trailing edge modulation for the second DC/DC converter stage can significantly reduce the ripple current and ripple voltage of the DC-link capacitor. Thus, a smaller DC-link capacitance can be used, lowering the cost and size of the AC/DC adapter. Benefits of the synchronous switching scheme were already demonstrated experimentally. However, no mathematical analysis was presented. In this thesis, detailed mathematical analyses in per-unit quantity are given to facilitate the calculation of the DC-link capacitor ripple current reduction with Leading/Trailing Edge Modulation strategies. One of the limitations of leading/trailing edge modulation is that the switching frequencies of the two stages need to be equal to achieve the best reduction of the DC-link capacitor ripple current. The DC-link capacitor ripple current will become larger if the switching frequency of the DC/DC converter is larger than that of the PFC pre-regulator, which blocks us to employ higher frequency for isolated DC/DC converter to reduce its transformer size. This thesis proposed a new Leading/Trailing Edge Modulation strategy to further reduce the DC-link bulk capacitor ripple current when switching frequency of DC/DC converter stage is twice the switching frequency of PFC stage. This proposed pulse width modulation scheme was verified by simulation. Experimental results obtained through digital control based on FPGA are also presented in this thesis.

No description available.

Multilevel inverter technology has emerged recently as a very important alternative in the area of high-power medium-voltage energy control. Voltage operation above semiconductor device limits, lower common mode voltages, near sinusoidal outputs together with small dv/dt’s, are some of the characteristics that have made this power converters popular for industry and modern research. However, the existing solutions suffer from some inherent drawbacks like common mode voltage problem, DC-link capacitor voltage fluctuation etc. Cascaded multi-level inverter with open-end winding induction motor structure promises significant improvements for high power medium-voltage applications. This dissertation investigates such cascaded multi-level inverters for open-end winding induction motor drive with reduced switch count. Similar to the conventional two-level inverters, other multi-level inverters with PWM control generate alternating common mode voltage (CMV). The alternating common mode voltage coupled through the parasitic capacitors in the machine and results in excessive bearing current and shaft voltage. The unwanted shaft voltage may cross the limit of insulation breakdown voltage and cause motor failure. This alternating common mode voltage adds to the total leakage current through ground conductor and acts as a source of conducted EMI which can interfere with other electronic equipments around. As the number of level increase in the inverter, different voltage levels are made available by using DC-link capacitor banks, instead of using different isolated power supplies. The intermediate-circuit capacitor voltages which are not directly supplied by the power sources are inherently unstable and require a suitable control method for converter operation, preferably without influence on the load power factor. Apart from normal operation, the sudden fault conditions may occur in the system and it is necessary to implement the control strategy considering this condition also. A five-level inverter topology with cascaded power circuit structure is proposed in this dissertation with the strategy to eliminate the common mode voltage and also to maintain the balance in the DC-link capacitor voltages. The proposed scheme is based on a dual five-level inverter for open-end winding induction motor. The principle achievement of this work is the reduction of power circuit complexity in the five-level inverter compared to a previously proposed five-level inverter structure for open-end winding IM drive with common mode voltage elimination. The reduction in the number of power switching devices is achieved by sharing the two two-level inverters for both the inverter structures. The resultant inverter structure can produce a nine-level voltage vector structure with the presence of alternating common mode voltage. The inverter structure is formed by cascading conventional two-level inverters together with NPC three-level inverters. Thus it offers modular and simpler power bus structure. As the power circuit is realised by cascading conventional two-level and NPC three-level inverters the number of power diodes requirements also reduced compared to the conventional NPC five-level inverters. The present proposed structure is implemented for the open-end winding induction motor and the power circuit offers more number of switching state redundancies compared to any conventional five-level inverter. The inverter structure required half the DC-link voltage compared to the DC-link voltage required for the conventional five-level inverter structure for induction motor drive and this reduces the voltage stress on the individual power devices. The common mode voltage is eliminated by selecting only the switching states which do not generate any common mode voltage in pole voltages hence there will be no common mode voltage at the motor phase also. The technique of using the switching state selection for the common mode voltage elimination, cancels out the requirement of the filter for the same purpose. As the inverter output is achieved without the presence of common mode voltage, the dual inverter can be fed from the common DC-link sources, without generating any zero sequence current. Hence the proposed dual five-level inverter structure requires only four isolated DC supplies. The multi-level inverters supplied by single power supply, have inherent unbalance in the DC-link capacitor voltages. This unbalance in the DC-link capacitor voltages causes lower order harmonics at the inverter output, resulting in torque pulsation and increased voltage stress on the power switching devices. A five-level inverter with reduced power circuit complexity is proposed to achieve the dual task of eliminating common mode voltage and DC-link capacitor voltage balancing. The method includes the analysis of current through the DC-link capacitors, depending on the switching state selections. The conditions to maintain all the four DC-link capacitor voltages are analysed. In an ideal condition when there is no fault in the power circuit the balance in the capacitor voltages can be maintained by selecting switching states in consecutive intervals, which have opposite effect on the capacitor voltages. This is called the open loop control of DC-link capacitor voltage balancing, since the capacitor voltages are not sensed during the selection of the switching states. The switching states with zero common mode voltages are selected for the purpose of keeping the capacitor voltages in balanced condition during no fault condition. The use of any extra hardware is avoided. The proposed open loop control of DC-link capacitor voltage balancing is capable of keeping the DC-link capacitor voltages equal in the entire modulation region irrespective of the load powerfactor. The problem with the proposed open loop control strategy is that, it can not take any corrective action if there is any initial unbalance in the capacitor voltages or if any unbalance occurs in the capacitor voltages during operation of the circuit,. To get the corrective action in the capacitor voltages due occurrence of any fault in the circuit, the strategy is further improved and a closed loop control strategy for the DC-link capacitor voltages is established. All the possible fault conditions in the four capacitors are identified and the available switching states are effectively used for the corrective action in each fault condition. The strategy is implemented such a way that the voltage balancing can be achieved without affecting the output fundamental voltage. The proposed five-level inverter structure presented in this thesis is based on a previous work, where a five-level inverter structure is proposed for the open-end winding induction motor. In that previous work 48 switches are used for the realization of the power circuit. It is observed that all the available switching states in this previous work are not used for any of the performance requirement of CMV elimination or DC-link voltage balancing. So, in this proposed work, the power circuit is optimized by reducing some of the switches, keeping the performance of the inverter same as the power circuit proposed in the previous work. The five-level inverter proposed in this thesis used 36 switches and the number of switching states is also reduced. But, the available switching states are sufficient for the CMV elimination and DC-link capacitor voltage balancing. The advantage of the modular circuit structure of this proposed five-level inverter is further investigated and the inverter structure is modified to a seven-level inverter structure for the open end winding induction motor. The proposed power circuit of the seven-level inverter uses only 48 switches, which is less compared to any seven-level inverter structure for the open end winding induction motor with common mode voltage elimination. The power circuit is reduced by sharing four two-level inverters to both the individual seven-level inverters in both the sides of the of the open end winding induction motor. The cascaded structure eliminates the necessity of the power diodes as required by the conventional NPC multilevel inverters. The proposed seven-level inverter is capable of producing a thirteen-level voltage vector hexagonal structure with the presence of common mode voltage. The common mode voltage elimination is achieved by selecting only the switching states with zero common mode voltage from both the inverters and the combined inverter structure produce a seven-level voltage vector structure with zero common mode voltage. The switching frequency is also reduced for the seven-level inverter compared to the proposed five-level inverter. The advantage of this kind of power circuit structure is that the number of power diode requirement is same in both five-level and seven-level inverters. Since there is no common mode voltage in the output voltages, the dual seven-level inverter structure can be implemented with the common DC-link voltage sources for both the sides. Six isolated power supplies are sufficient for both the seven-level inverters. The available switching states in this proposed seven-level inverter are further analysed to implement the open loop and closed loop capacitor voltage balancing and this allow the power circuit to run with only three isolated DC supplies. All the proposed work presented in this thesis are initially simulated in SIMULINK toolbox and then implemented in a form of laboratory prototype. A 2.5KW open end winding induction motor is used for the implementation of these proposed works. But all these work general in nature and can be implemented for high power drive applications with proper device ratings.

Three-level diode-clamped inverter is being widely used these days. Extensive research has been carried out on pulse width modulation (PWM) strategies for a three-level inverter. The most widely used PWM strategies are sine-triangle pulse width modulation (SPWM) and centered space vector pulse width modulation (CSVPWM). The influence of these PWM strategies on the DC-link capacitor current and voltage ripple is studied in this thesis. The sizing of the DC capacitor depends on value of the maximum RMS current flowing through it. In this work, an analytical expression for capacitor RMS current is derived as a function of operating conditions like modulation index, power factor angle of the load and peak load current. The worst case current stress on the capacitor is evaluated using the analytical expression. The capacitor RMS current is found to be the same in SPWM and CSVPWM schemes. The analytical expression is validated through simulations and experiments on a 3kVA MOSFET based three-level inverter. Harmonic analysis of the capacitor current is helpful in better evaluation of capacitor power loss. Therefore, harmonic analysis of the capacitor current is carried out, using the techniques of geometric wall model and double Fourier integral for SPWM and CSVPWM schemes. The theoretical predictions are validated through experiments. The capacitor RMS current is divided into low-frequency RMS current (where low frequency component is defined as a component whose frequency is less than half the switching frequency) and high-frequency RMS current. The capacitor voltage ripple is estimated analytically for SPWM and CSVPWM schemes, using the low-frequency and high-frequency capacitor RMS current. The voltage ripples due to SPWM and CSVPWM schemes are compared. It is found that the voltage ripple with SPWM is higher than that with CSVPWM. A simplified method to estimate the capacitor power loss, without the requirement of FFT analysis of capacitor current, is proposed. The results from this simplified method agree reasonably well with the results from the detailed method. A space vector based modulation scheme is proposed, which reduces the capacitor RMS current at high power factor angles. However, the proposed method leads to higher total harmonic distortion (THD) than CSVPWM. Simulation and experimental results, comparing CSVPWM and the proposed PWM, are presented.