Multilevel Power Converter Phase Control Harmonic Reduction

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Solution Overview

Problem

Multilevel power conversion systems face challenges in efficiently managing harmonics and reducing the size and complexity of power stage filters, particularly in regenerative applications, where existing solutions often require large and heavy LCL filters to meet harmonic standards.

Innovation Solution

The implementation of a multiphase multilevel regenerative power converter with a controller that provides non-zero phase relationships between switching rectifier and inverter control signals, allowing for selective harmonic reduction and potentially eliminating the need for large power stage filters by using carrier signal phase shifting and trap filters.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-generated harmful factors

If large LCL filters are used to meet harmonic standards, then harmonic filtering performance is improved, but the size and weight of the power converter system increases

Engineering Contradiction:
Improveharmonic contentVSAvoidfilter size and weight
Core Design Contradiction:
Object-generated harmful factorsVSWeight of stationary object

Solution Approach 1:

The patent applies carrier signal phase shifting by changing the phase angle parameter of the control signals. By adjusting the phase relationship between carrier signals of different power stages, the patent achieves harmonic cancellation without requiring large physical filters, thus resolving the contradiction between harmonic filtering performance and system size/weight

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The patent replaces the mechanical/physical LCL filter system with an electronic control system that uses phase-shifted carrier signals. This substitution eliminates the need for large inductors and capacitors while maintaining harmonic filtering effectiveness through controlled phase relationships in the switching signals

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

2Object-generated harmful factors

If complex filter designs are implemented to reduce harmonics, then harmonic distortion is reduced, but device complexity increases

Engineering Contradiction:
Improveharmonic distortionVSAvoidfilter design complexity
Core Design Contradiction:
Object-generated harmful factorsVSDevice complexity

Solution Approach 1:

Instead of complex filter circuitry, the patent changes the control parameter (carrier signal phase angle) to achieve harmonic reduction. This parameter-based approach simplifies the device design while maintaining effective harmonic distortion reduction through phase-controlled switching

Inventive Principle:
Principle #35Parameter changes

3Power

If traditional rectifier control is used, then power conversion is achieved, but harmonic injection into the grid occurs

Engineering Contradiction:
Improvepower conversion capabilityVSAvoidgrid harmonic injection
Core Design Contradiction:
PowerVSObject-generated harmful factors

Solution Approach 1:

The patent employs periodic switching action with phase-shifted carrier signals for the rectifier stages. This periodic control strategy, where switching occurs at specific phase angles, enables power conversion while the phase shifting creates destructive interference of harmonic components, preventing their injection into the grid

Inventive Principle:
Principle #19Periodic action

Solution Approach 2:

The patent converts the potentially harmful harmonic effects into a beneficial control mechanism. By intentionally introducing phase shifts in the carrier signals, the harmonics that would normally be harmful are transformed into a useful tool for active harmonic cancellation and grid current purification

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

Data Source

PatentEP3783792A1Multilevel power converter with AFE power cell phase control
Publication Date: 2021.02.24 ROCKWELL AUTOMATION TECH INC
  • EP3783792A1 patent drawingFigure 1
  • EP3783792A1 patent drawingFigure 2
  • EP3783792A1 patent drawingFigure 3

AI summary

Power conversion systems and methods to control a multiphase multilevel regenerative power converter with multilevel phase circuits that individually include multiple regenerative power stages with respective power stage outputs connected in series, the individual power stages comprising a DC link circuit a switching rectifier coupled between a respective transformer secondary circuit and the DC link circuit, and a switching inverter coupled between the DC link circuit and the respective power stage output, including a controller that provides inverter switching control signals to control the respective switching inverters, provides rectifier switching control signals to control the respective switching rectifiers, and controls a non-zero phase relationship between the rectifier switching control signals of the respective switching rectifiers.