Flying-Capacitor Converter Modulation for Soft Switching

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Solution Overview

Problem

Conventional multilevel converters with flying capacitors experience high switching losses due to hard switching, which is not optimal in terms of energy efficiency.

Innovation Solution

A modulator for a flying-capacitor type multilevel converter that determines a critical intermediate output level closest to the reference signal and outputs only target levels different from this critical level, thereby avoiding hard switching and achieving soft-switching conditions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If hard switching is used in conventional multilevel converters, then the switching operation is simple and straightforward, but switching losses are high and energy efficiency deteriorates

Engineering Contradiction:
Improveswitching lossesVSAvoidmodulator complexity
Core Design Contradiction:
Loss of energyVSDevice complexity

Solution Approach 1:

The modulator determines the critical level in advance by comparing the reference signal with all available output levels before generating switching signals. This preliminary identification of the critical level enables the system to proactively select target levels that avoid hard switching, thereby reducing switching losses while maintaining controlled complexity through structured preprocessing

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The modulator dynamically adjusts the selection of target levels based on the real-time critical level determination. By adaptively choosing from multiple redundant switching states and target levels depending on the reference signal characteristics and identified critical level, the system optimizes energy efficiency while managing complexity through flexible, condition-based decision making

Inventive Principle:
Principle #15Dynamics

2Productivity

If the switching frequency is increased to improve output signal quality, then the approximation of the reference signal improves, but switching losses increase due to hard switching

Engineering Contradiction:
Improveswitching frequencyVSAvoidswitching losses
Core Design Contradiction:
ProductivityVSLoss of energy

Solution Approach 1:

The invention converts the potentially harmful effect of frequent switching (which would increase losses in hard switching mode) into a beneficial outcome by implementing soft switching. Through critical level determination and intelligent target level selection, the system enables high switching frequency operation necessary for good output signal quality while simultaneously reducing switching losses by ensuring soft switching conditions are met at each transition

Inventive Principle:
Principle #22Blessing in disguise (Convert harm into benefit)

3Reliability

If all target levels including the critical level are output, then the control is comprehensive, but hard switching occurs leading to high switching losses

Engineering Contradiction:
Improvecontrol accuracyVSAvoidswitching losses
Core Design Contradiction:
ReliabilityVSLoss of energy

Solution Approach 1:

The modulator extracts and identifies the critical level from the set of all available output levels by comparing the reference signal with each level. This extraction process enables the selective exclusion of the critical level from target level output, thereby preventing hard switching and reducing energy losses while maintaining comprehensive control through the intelligent selection of alternative target levels from the remaining set

Inventive Principle:
Principle #2Taking out (Extraction)

Data Source

PatentUS12081142B2Modulator for flying-capacitor type multilevel converter, multilevel converter, and method for operating multilevel converter
Publication Date: 2024.09.03 ABB E-MOBILITY BV
  • US12081142B2 patent drawing
  • US12081142B2 patent drawing
  • US12081142B2 patent drawing

AI summary

A modulator for a flying-capacitor type multilevel converter receives, at an input, a time-variant reference signal and provides, at an output, a sequence of target levels, to provide switching signals for switching between discrete output levels of the multilevel converter according to the shape of the reference signal. The modulator determines a critical level as an intermediate output level of the multilevel converter which is closest to the level of the reference signal; and outputs only target levels corresponding to output levels different from the critical level.