MMC Submodule Group Control for Scalable HVDC Voltage Conversion

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Solution Overview

Problem

Modular multilevel converters (MMCs) face challenges in control complexity and scalability for high-power medium-voltage (MV) and high-voltage (HV) direct current (HVDC) applications due to the large number of submodules (SMs), leading to increased THD, circulating currents, and reduced reliability.

Innovation Solution

A scale-up control methodology for MMCs that allows for easy adjustment of the number of SMs without significant control modifications, using a distributed control structure with local controllers for capacitor voltage balancing and eliminating the need for a central controller, enabling flexible expansion and fault tolerance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If the number of submodules (SMs) is increased to achieve high DC voltage levels for HVDC applications, then the voltage level and power capability are improved, but the control complexity and computational burden increase significantly

Engineering Contradiction:
ImproveDC voltage levelVSAvoidcontrol complexity
Core Design Contradiction:
PowerVSDevice complexity

Solution Approach 1:

The patent divides the MMC system into multiple sets, where each set contains a specific number of submodules. This segmentation allows the control system to manage subsets of SMs independently, reducing the computational burden on the central controller. Each set can be controlled with a fixed number of SMs, making the control algorithm scalable and manageable even as the total number of SMs increases to achieve high voltage levels.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent introduces a new control dimension by organizing SMs into sets with hierarchical control structure. Instead of controlling all SMs uniformly, the system uses set-based organization where each set operates semi-independently. This dimensional organization transforms the control problem from managing N individual SMs to managing M sets with N/M SMs each, significantly reducing control complexity while maintaining the ability to achieve high DC voltage levels.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

2Manufacturing precision

If the number of submodules (SMs) is increased to reduce total harmonic distortion (THD), then the voltage quality is improved, but the circulating currents and control complexity increase

Engineering Contradiction:
Improvevoltage qualityVSAvoidcontrol complexity
Core Design Contradiction:
Manufacturing precisionVSDevice complexity

Solution Approach 1:

By segmenting SMs into sets, the patent enables independent control of each set's capacitor voltages. This segmentation allows the system to achieve low THD through coordinated control of multiple sets while managing circulating currents at the set level rather than system-wide, reducing overall control complexity.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent employs capacitor voltage balancing control that dynamically adjusts the voltage parameters of individual SMs within each set. By changing the voltage parameters of SMs in a coordinated manner across multiple sets, the system achieves low THD output while managing circulating currents through parameter optimization rather than increasing overall control complexity.

Inventive Principle:
Principle #35Parameter changes

3Ease of operation

If a central controller is used to manage all submodules, then centralized control is achieved, but the communication burden and system reliability are reduced

Engineering Contradiction:
Improvecentralized controlVSAvoidsystem reliability
Core Design Contradiction:
Ease of operationVSReliability

Solution Approach 1:

The patent segments the control function into central and local components. The central controller manages high-level coordination between sets, while local controllers handle day-to-day control of individual sets. This segmentation reduces the communication burden on the central controller and improves reliability through distributed control, as failures in one local controller do not compromise the entire system.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent introduces local controllers as intermediary devices between the central controller and the submodules. These local controllers act as mediators that handle communication and control tasks locally, reducing the direct communication burden on the central controller and improving system reliability through distributed intelligence. The local controllers can operate semi-independently, maintaining system functionality even when central communication is compromised.

Inventive Principle:
Principle #24Intermediary (Mediator)

4Ease of manufacture

If the control system is designed for a fixed number of submodules, then initial control is simplified, but scalability and adaptability are reduced

Engineering Contradiction:
Improvecontrol design simplicityVSAvoidscalability
Core Design Contradiction:
Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The patent designs the control system with universal set-based modules that can handle any number of submodules. Each set is designed with the same control structure and capabilities, making the system universally applicable regardless of the total number of SMs. This multi-functionality allows the same control algorithm to scale from small to large systems without requiring fundamental redesign, maintaining both simplicity and adaptability.

Inventive Principle:
Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent implements a dynamic control architecture where the number of sets and SMs per set can be adjusted based on system requirements. The control system dynamically adapts to different configurations by reorganizing SMs into appropriate sets, enabling scalability while maintaining control simplicity. This dynamic reconfigurability allows the system to evolve from initial deployment to expanded configurations without sacrificing control design simplicity.

Inventive Principle:
Principle #15Dynamics

Data Source

PatentUS11824461B2MMC submodules scale-up methodology for MV and HV power conversion system applications
Publication Date: 2023.11.21 NORTH CAROLINA STATE UNIV
  • US11824461B2 patent drawing
  • US11824461B2 patent drawing
  • US11824461B2 patent drawing

AI summary

Various examples are provided related to modular multilevel converter (MMC) scale-up control methodologies which can be applied for MV and HV DC applications. In one example, an MMC includes first and second legs each with submodule (SM) groups connected in series, where each SM group includes a plurality of SMs; local group controllers that can control a corresponding SM group; and a central controller that can control output voltage of the MMC via the local group controllers. The local group controllers can provide capacitor voltage balancing (CVB) control of corresponding SM groups.