Multilevel Converters For Large Electric Drives
Multilevel Converters For Large Electric Drives
Multilevel Converters For Large Electric Drives
1, JANUARY/FEBRUARY 1999
Abstract—This paper presents transformerless multilevel con- the dc voltage to variable frequency and variable voltage for
verters as an application for high-power and/or high-voltage motor speed control.
electric motor drives. Multilevel converters: 1) can generate near- Motor damage and failure have been reported by industry
sinusoidal voltages with only fundamental frequency switching;
2) have almost no electromagnetic interference or common-mode as a result of some ASD inverters’ high-voltage change rates
voltage; and 3) are suitable for large voltampere-rated motor , which produced a common-mode voltage across the
drives and high voltages. The cascade inverter is a natural fit for motor windings. High-frequency switching can exacerbate the
large automotive all-electric drives because it uses several levels problem because of the numerous times this common mode
of dc voltage sources, which would be available from batteries voltage is impressed upon the motor each cycle. The main
or fuel cells. The back-to-back diode-clamped converter is ideal
where a source of ac voltage is available, such as in a hybrid problems reported have been “motor bearing failure” and
electric vehicle. Simulation and experimental results show the “motor winding insulation breakdown” because of circulat-
superiority of these two converters over two-level pulsewidth- ing currents, dielectric stresses, voltage surge, and corona
modulation-based drives. discharge [2]–[4].
Index Terms—Cascade inverter, common-mode voltage, diode- Only recently have motor insulation failures become a
clamped inverter, electric vehicle, motor drive, multilevel con- problem with some ASD’s because the increased switching
verter, multilevel inverter. speed of contemporary power semiconductor devices causes
steep voltage wavefronts to appear at the motor terminals. The
I. INTRODUCTION voltage change rate sometimes can be high enough
to induce corona discharge between the winding layers.
Present power semiconductors can be turned on and off
A. Background within 1 s for 600 V and higher voltages which can generate
broadband electromagnetic interference (EMI). These high-
D ESIGNS FOR heavy-duty electric and hybrid-electric
vehicles (EV’s) that have large electric drives will require
advanced power electronic inverters to meet the high power
speed semiconductor switches allow faster PWM carrier fre-
quencies. Although the high-frequency switching can increase
demands ( 250 kW) required of them. Development of large the motor running efficiency and is well above the acoustic
electric drive trains for these vehicles will result in increased noise level, the associated dielectric stresses between
fuel efficiency, lower emissions, and likely better vehicle insulated winding turns are also greatly increased.
performance (acceleration and braking). Some PWM-controlled inverters can also cause large in-
Transformerless multilevel inverters are uniquely suited stantaneous common-mode voltages to appear at the motor
for this application because of the high voltampere ratings terminals. These common-mode voltages appear across the
possible with these inverters [1]. For EV’s, a cascaded H- motor shaft to ground and induce bearing currents, which lead
bridges inverter can be used to drive the traction motor from to erosion of the bearing material and early mechanical failure.
a set of batteries or fuel cells. Where generated ac voltage Multilevel inverters overcome these problems because their
is available, such as from an alternator or generator, a back- individual devices have a much lower per switching,
to-back diode-clamped converter can convert this source to and they operate at high efficiencies because they can switch
variable-frequency ac voltage for the driven motor. at a much lower frequency than PWM-controlled inverters.
Multilevel inverters also solve problems with some present
two-level pulsewidth modulation (PWM) adjustable-speed B. Multilevel Inverters
drives (ASD’s). ASD’s usually employ a front-end diode The multilevel voltage source inverters’ unique structure
rectifier to convert utility ac voltage to dc voltage and an allows them to reach high voltages with low harmonics without
inverter with PWM-controlled switching devices to convert the use of transformers or series-connected synchronized-
switching devices. The general function of the multilevel
Paper IPCSD 98–68, presented at the 1998 IEEE Applied Power Electronics inverter is to synthesize a desired voltage from several levels
Conference and Exposition, Anaheim, CA, February 15–19, and approved of dc voltages. For this reason, multilevel inverters can easily
for publication in the IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS by provide the high power required of a large electric drive.
the Industrial Drives Committee of the IEEE Industry Applications Society.
Manuscript released for publication September 8, 1998. As the number of levels increases, the synthesized output
L. M. Tolbert and F. Z. Peng are with Oak Ridge National Laboratory, Oak waveform has more steps, which produces a staircase wave
Ridge, TN 37831-8038 USA. that approaches a desired waveform. Also, as more steps are
T. G. Habetler is with the School of Electrical and Computer Engineering,
Georgia Institute of Technology, Atlanta, GA 30332-0250 USA. added to the waveform, the harmonic distortion of the output
Publisher Item Identifier S 0093-9994(99)00454-5. wave decreases, approaching zero as the number of levels in-
0093–9994/99$10.00 1999 IEEE
Authorized licensed use limited to: UNIVERSIDAD POLITECNICA SALESIANA. Downloaded on March 02,2022 at 18:17:03 UTC from IEEE Xplore. Restrictions apply.
TOLBERT et al.: MULTILEVEL CONVERTERS FOR LARGE ELECTRIC DRIVES 37
Authorized licensed use limited to: UNIVERSIDAD POLITECNICA SALESIANA. Downloaded on March 02,2022 at 18:17:03 UTC from IEEE Xplore. Restrictions apply.
38 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 35, NO. 1, JANUARY/FEBRUARY 1999
Authorized licensed use limited to: UNIVERSIDAD POLITECNICA SALESIANA. Downloaded on March 02,2022 at 18:17:03 UTC from IEEE Xplore. Restrictions apply.
TOLBERT et al.: MULTILEVEL CONVERTERS FOR LARGE ELECTRIC DRIVES 39
Fig. 3. Switching pattern swapping of the 11-level cascade inverter for balancing battery charge.
the controller as 1024 states per cycle. A constant volt- III. BACK-TO-BACK DIODE-CLAMPED CONVERTER DRIVE
age/frequency control technique was applied to the motor drive
system. As a user interface, a potentiometer was adjusted While cascade inverters are ideal where separate dc sources
to apply an external 0–3-V signal to the controller. The are available, in most instances, an ac voltage source is the
0–3-V signal mapped directly to a 0–60-Hz fundamental only convenient power supply. For these cases, a multilevel
frequency for the gate signals sent to the inverter. Also, back-to-back diode-clamped converter can best interface with
the switching patterns corresponding to the various modula- the source of ac power and yet still meet the high-power and/or
tion indexes were mapped from the 0–3-V external control high-voltage requirements of the driven motor.
signal. Two six-level diode-clamped inverters connected back-to-
Fig. 6 shows experimental waveforms of the 11-level back are shown in Fig. 7. The dc bus for these two in-
battery-fed cascade inverter prototype driving a 208-V three- verters consists of a series of electric energy storage de-
phase induction motor at 50% and 80% rated speed using the vices—batteries or capacitors. The voltage across each storage
aforementioned fundamental frequency switching scheme. As device is . The voltage stress across each switching device
can be seen from the waveforms, both the line–line voltage is limited to through the clamping diodes.
and current are almost sinusoidal. EMI and common-mode
voltage are also much less than what would result from a A. General Structure and Operation
two-level PWM inverter because of the inherently low Table I lists the voltage output levels possible for one phase
(21 times less than a two-level drive) and sinusoidal voltage of the diode-clamped inverter using the negative dc rail as
output. a reference voltage. State condition 1 means the corresponding
Authorized licensed use limited to: UNIVERSIDAD POLITECNICA SALESIANA. Downloaded on March 02,2022 at 18:17:03 UTC from IEEE Xplore. Restrictions apply.
40 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 35, NO. 1, JANUARY/FEBRUARY 1999
such that each blocking diode has the same voltage rating
as the active switches, will require diodes in series;
consequently, the number of diodes required for each phase
is . Thus, the number of blocking diodes
are quadratically related to the number of levels in a diode-
clamped converter [13]–[15].
B. Experimental Results
A six-level back-to-back 10-kW diode-clamped converter
prototype that was designed to operate at a three-phase line
voltage of 208 V has been built and experimentally tested as an
ASD for an induction motor load. The controllable switching
devices used for the converter were 100-V 100-A MOSFET’s.
Each internal dc level of the converter had a capacitance of
6.72 mF.
Fig. 9 shows the source voltage , the source current
(a)
, drawn by the converter, the inverter output load voltage
, and the load current , drawn by a 5-hp induction
motor operating at 75% rated speed. This prototype diode-
clamped rectifier drew a source current that had a THD of 3%
and could be controlled such that the input power factor was
1.0. The output voltage at the motor terminals had a THD that
varied between 4.5%–5.3%, and the converter output current
had a THD of 3%.
Additionally, the experiment shows that the output line
voltage is reduced by 11 times with the six-level
converter as compared to a traditional two-level PWM drive.
The dramatic reduction in by one order in magnitude
and two orders in repetition (switching frequency) can prevent
motor windings and bearings from failure. This 11-step stair-
case output voltage waveform approaches a sinewave, thus
having no common-mode voltage and no voltage surge to the
motor windings.
(b)
Fig. 6. Experimental waveforms of a battery-fed cascade inverter prototype C. Efficiency
driving an induction motor at (a) 50% rated speed and (b) 80% rated speed.
To compare the efficiencies of a multilevel inverter oper-
ating with fundamental frequency switching and a two-level
switch is on, and 0 means the switch is off. Note that each inverter using PWM, the losses in the two inverters have to
active device is only switched once per cycle. Each phase be characterized.
has five complementary switch pairs such that turning on one The losses in an inverter can be described by
of the switches of the pair requires that the other switch be
turned off. The complementary switch pairs for phase leg (4)
are , and where is the conducting loss and is the switching loss.
. In the fundamental frequency-controlled multilevel inverter,
Fig. 8 shows the voltage waveform for one phase of a six- the switching power losses can be approximated by
level inverter. The line voltage consists of a phase-leg
voltage and a phase-leg voltage. The resulting line voltage - (5)
is an 11-level staircase waveform. This means that an -level
diode-clamped inverter has an -level output phase voltage where is the frequency of the modulation, or reference,
and a -level output line voltage [15]. waveform. The switching power losses in a two-level PWM
Although each active switching device is only required to inverter can be approximated by
block a voltage level of , the clamping diodes require (6)
-
different voltage ratings for reverse voltage blocking. Using
phase of Fig. 7 as an example, when all the lower switches where is the frequency of the PWM carrier waveform [21].
– are turned on, must block four voltage levels, If and are assumed to be the same for the active devices
or . Similarly, must block , must block in the multilevel inverter and two-level PWM inverter, the
, and must block . If the inverter is designed difference in (5) and (6) is the factor , which is known as
Authorized licensed use limited to: UNIVERSIDAD POLITECNICA SALESIANA. Downloaded on March 02,2022 at 18:17:03 UTC from IEEE Xplore. Restrictions apply.
TOLBERT et al.: MULTILEVEL CONVERTERS FOR LARGE ELECTRIC DRIVES 41
Fig. 7. Six-level diode-clamped back-to-back converter structure for adjustable-speed motor drive system.
TABLE I
DIODE-CLAMPED SIX-LEVEL CONVERTER VOLTAGE
LEVELS AND CORRESPONDING SWITCH STATES
Fig. 9. Experimental voltage and current waveforms at the input and output
of the back-to-back diode-clamped converter prototype.
Authorized licensed use limited to: UNIVERSIDAD POLITECNICA SALESIANA. Downloaded on March 02,2022 at 18:17:03 UTC from IEEE Xplore. Restrictions apply.
42 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 35, NO. 1, JANUARY/FEBRUARY 1999
Authorized licensed use limited to: UNIVERSIDAD POLITECNICA SALESIANA. Downloaded on March 02,2022 at 18:17:03 UTC from IEEE Xplore. Restrictions apply.
TOLBERT et al.: MULTILEVEL CONVERTERS FOR LARGE ELECTRIC DRIVES 43
REFERENCES
[1] L. M. Tolbert and F. Z. Peng, “Multilevel inverters for large automotive
drives,” in Conf. Rec. All Electric Combat Vehicle 2nd Int. Conf.,
Dearborn, MI, June 8–12, 1997, vol. 2, pp. 209–214.
[2] S. Bell and J. Sung, “Will your motor insulation survive a new adjustable
frequency drive?,” IEEE Trans. Ind. Applicat., vol. 33, pp. 1307–1311,
Sept./Oct. 1997.
[3] J. Erdman, R. Kerkman, D. Schlegel, and G. Skibinski, “Effect of PWM
inverters on AC motor bearing currents and shaft voltages,” IEEE Trans.
Fig. 12. Internal dc-bus voltage levels as diode-clamped converter output Ind. Applicat., vol. 32, pp. 250–259, Mar./Apr. 1996.
frequency is varied between 30–60 Hz. [4] A. H. Bonnett, “A comparison between insulation systems available for
PWM-Inverter-Fed Motors,” IEEE Trans. Ind. Applicat., vol. 33, pp.
1331–1341, Sept./Oct. 1997.
converter operating without active dc-bus voltage control. The [5] D. Divan, “Low-stress switching for efficiency,” IEEE Spectrum, vol.
33, pp. 33–39, Dec. 1996.
waveforms show that the overall bus voltage remains fairly [6] F. Z. Peng, J. S. Lai, J. W. McKeever, and J. VanCoevering, “A
constant over a cycle, and the internal bus voltages vary only multilevel voltage-source inverter with separate dc sources for static
slightly. The figure shows that, if the prototype multilevel var generation,” IEEE Trans. Ind. Applicat., vol. 32, pp. 1130–1138,
Sept./Oct. 1996.
converter is applied to loads with speed that does not change [7] F. Z. Peng and J. S. Lai, “Dynamic performance and control of a
often or rapidly, the 6.72 mF of capacitance is sufficient for static var generator using cascade multilevel inverters,” IEEE Trans.
Ind. Applicat., vol. 33, pp. 748–755, May/June 1997.
good dc-bus voltage regulation. [8] F. Z. Peng, J. W. McKeever, and D. J. Adams, “A power line conditioner
The inverter was controlled to deliver a continuously vary- using cascade multilevel inverters for distribution systems,” in Conf.
ing frequency between 30–60 Hz; it took approximately 35 s Rec. IEEE-IAS Annu. Meeting, Oct. 1997, pp. 1316–1321.
[9] N. S. Choi, G. C. Cho, and G. H. Cho, “Modeling and analysis of a static
to change between these frequency limits. Fig. 12 shows var compensator using multilevel voltage source inverter,” in Conf. Rec.
the same waveforms as Fig. 11 but for a period of 100 s. IEEE-IAS Annu. Meeting, Oct. 1993, pp. 901–908.
Without active dc-bus voltage control, the overall bus voltage [10] C. Hochgraf, R. Lasseter, D. Divan, and T. A. Lipo, “Comparison of
multilevel inverters for static var compensation,” in Conf. Rec. IEEE-IAS
varied from 258 to 304 Vdc. The internal dc voltage levels Annu. Meeting, Oct. 1994, pp. 921–928.
varied by as much as 16 Vdc. Deceleration of the motor by [11] F. Z. Peng and J. S. Lai “A static var generator using a staircase wave-
regenerative braking caused the voltage to increase from its form multilevel voltage-source converter,” in Conf. Rec. PCIM/Power
Quality Conf., Dallas, TX, Sept. 1994, pp. 58–66.
nominal value, and acceleration caused the voltage to decrease [12] R. W. Menzies and Y. Zhuang, “Advanced static compensation using
from its nominal value. The experimental results have shown a multilevel GTO thyristor inverter,” IEEE Trans. Power Delivery, vol.
10, pp. 732–738, Apr. 1995.
that active control of the dc-bus voltage by the converter or a [13] J. S. Lai and F. Z. Peng, “Power converter options for power system
larger capacitance is required for the dc voltage levels if the compatible mass transit systems,” in Conf. Rec. PCIM/Power Quality
motor speed is going to change fairly rapidly and less variation and Mass Transit System Compatibility Conf., Dallas, TX, Sept. 1994,
pp. 285–294.
in the overall dc-bus voltage is desired. [14] F. Z. Peng, J. S. Lai, J. McKeever, and J. VanCoevering, “A multilevel
voltage-source converter system with balanced dc voltages,” in Proc.
1995 IEEE Power Electronics Specialists Conf., pp. 1144–1150.
[15] J. S. Lai and F. Z. Peng, “Multilevel converters—A new breed of power
IV. CONCLUSION converters,” IEEE Trans. Ind. Applicat., vol. 32, pp. 509–517, May/June
1996.
A multilevel cascade inverter with separate dc sources and [16] J. K. Steinke, “Control strategy for a three phase ac traction drive with
a multilevel diode-clamped back-to-back converter have been three level GTO PWM inverter,” in Proc. IEEE PESC’88, 1988, pp.
431–438.
proposed for use in large electric drives. Simulation and [17] M. Klabunde, Y. Zhao, and T. A. Lipo, “Current control of a 3 level
experimental results have shown that, with a control strategy rectifier/inverter drive system,” in Conf. Rec. IEEE-IAS Annu. Meeting,
Oct. 1994, pp. 2348–2356.
that operates the switches at fundamental frequency, these [18] J. Zhang, “High performance control of a three level IGBT inverter fed
converters have low output voltage THD and high efficiency ac drive,” in Conf. Rec. IEEE-IAS Annu. Meeting, 1995, pp. 22–28.
and power factor. [19] G. Sinha and T. A. Lipo, “A four level rectifier-inverter system for
drive applications,” in Conf. Rec. IEEE-IAS Annu. Meeting, Oct. 1996,
In summary, the main advantages of using multilevel con- pp. 980–987.
verters for large electric drives include the following. [20] R. W. Menzies, P. Steimer, and J. K. Steinke, “Five-level GTO inverters
for large induction motor drives,” IEEE Trans. Ind. Applicat., vol. 30,
1) They are suitable for large voltampere-rated and/or high- pp. 938–944, July/Aug. 1994.
voltage motor drives. [21] Y. Ikeda, J. Itsumi, and H. Funato, “The power loss of the PWM
2) These multilevel converter systems have higher effi- voltage-fed inverter,” in Conf. Rec. IEEE PESC’88, 1988, pp. 277–283.
[22] J. S. Lai, R. W. Young, and J. W. McKeever, “Efficiency consideration
ciency because the devices can be switched at minimum of DC link soft-switching inverters for motor drive applications,” in
frequency. Conf. Rec. IEEE PESC’94, 1994, pp. 1003–1010.
Authorized licensed use limited to: UNIVERSIDAD POLITECNICA SALESIANA. Downloaded on March 02,2022 at 18:17:03 UTC from IEEE Xplore. Restrictions apply.
44 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 35, NO. 1, JANUARY/FEBRUARY 1999
Authorized licensed use limited to: UNIVERSIDAD POLITECNICA SALESIANA. Downloaded on March 02,2022 at 18:17:03 UTC from IEEE Xplore. Restrictions apply.