Six-Switch Three-Level DCM Boost Rectifier Modulation

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Solution Overview

Problem

Existing DCM boost rectifiers face challenges in achieving low total harmonic distortion (THD) across a wide load range while maintaining high efficiency and minimizing stress on IGBTs, often requiring alternative topologies or additional passive filters that introduce resonance issues.

Innovation Solution

A six-switch three-level DCM boost rectifier topology with a quasi-optimal modulation strategy that individually boosts each rectified phase, using a cost function analysis to control the ON time of switchable boost rectifiers, thereby improving THD and reducing IGBT stress.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-generated harmful factors

If alternative topologies or additional passive filters are used to reduce THD, then input THD is improved, but device complexity and potential resonance issues worsen

Engineering Contradiction:
Improveinput THDVSAvoiddevice complexity
Core Design Contradiction:
Object-generated harmful factorsVSDevice complexity

Solution Approach 1:

The patent changes the operating parameters of the DCM boost rectifier by implementing a quasi-optimal modulation strategy that dynamically adjusts the switching duty cycle. This allows the rectifier to achieve low input THD (less than 7.5%) across the entire load range by optimizing the conduction mode, without requiring additional passive filters or alternative topologies.

Inventive Principle:
Principle #35Parameter changes

2Object-generated harmful factors

If additional passive filters are added to improve THD, then input THD is improved, but resonance issues and device complexity worsen

Engineering Contradiction:
Improveinput THDVSAvoidresonance stability
Core Design Contradiction:
Object-generated harmful factorsVSReliability

Solution Approach 1:

The patent extracts and eliminates the need for additional passive filters by implementing a six-switch three-level DCM boost rectifier topology with quasi-optimal modulation. This approach achieves low THD through controlled switching operations alone, removing the source of potential resonance issues that would arise from adding LC filters to the system.

Inventive Principle:
Principle #2Taking out (Extraction)

3Device complexity

If conventional modulation strategies are used, then device simplicity is maintained, but input THD and IGBT stress worsen

Engineering Contradiction:
Improvemodulation strategy complexityVSAvoidinput THD
Core Design Contradiction:
Device complexityVSObject-generated harmful factors

Solution Approach 1:

The patent implements a dynamic modulation strategy that adapts the switching duty cycle based on real-time operating conditions. The quasi-optimal modulation continuously adjusts the ON time of the IGBTs to maintain discontinuous conduction mode across varying load conditions, achieving low THD and reduced IGBT stress without requiring complex additional hardware.

Inventive Principle:
Principle #15Dynamics

4Adaptability or versatility

If the rectifier operates across the entire load range, then adaptability is improved, but maintaining low THD and high efficiency becomes more difficult

Engineering Contradiction:
Improveload range adaptabilityVSAvoidinput THD
Core Design Contradiction:
Adaptability or versatilityVSObject-generated harmful factors

Solution Approach 1:

The patent employs a feedback-based quasi-optimal modulation strategy that monitors the operating conditions and adjusts the switching duty cycle accordingly. This feedback mechanism ensures the rectifier maintains low input THD and high efficiency across the entire load range by dynamically optimizing the conduction mode and switching parameters based on real-time performance data.

Inventive Principle:
Principle #23Feedback

Data Source

PatentUS7474081B2AC/DC converter and method of modulation thereof
Publication Date: 2009.01.06 ABB (SCHWEIZ) AG
  • US7474081B2 patent drawing
  • US7474081B2 patent drawing
  • US7474081B2 patent drawing

AI summary

An apparatus having a rectifier topology for use on a three-phase electrical system is disclosed. The apparatus includes an input filter at each phase, a rectifier set at each phase in power communication with and downstream of each respective input filter, and a separate and independent booster section at each phase in power communication with and downstream of each respective rectifier set. Each booster section comprises two switches, thereby providing a six-switch three-level discontinuous conduction mode (DCM) boost rectifier.