698

IEEE TRANSACTIONS ON POWER ELECTRONICS, VOL. 27, NO. 2, FEBRUARY 2012

Modular Multipulse Rectier Transformers in Symmetrical Cascaded H-Bridge Medium Voltage Drives
Mehdi Abolhassani, Senior Member, IEEE
AbstractA new approach to improve the power quality of highpower medium voltage multilevel drives is presented. A modular transformers strategy in conjunction with modular power electronics cubes is developed. By applying this technology, the input current harmonics decreases to well below the requirement of IEEE 519-1992 while the amount of capacitance installed in the drive is signicantly reduced. In addition, by employing modular transformers technology and efcient cooling, power density of the drive is increased by 15%. The input power factor of drive is also improved. This paper details the new approach, analyses, and test results. Index TermsCascaded symmetrical drive, medium voltage drive, multilevel drive, power quality.

I. INTRODUCTION

ULTILEVEL power conversion for use in high-power applications has been receiving increasing attention over the past few years. Numerous topologies and modulation strategies have been introduced and studied extensively for utility and drive applications in the recent literature [1][27]. The concept of multilevel power conversion has been gaining popularity mainly due to improved power quality, lower switching losses, better electromagnetic compatibility, and higher voltage capability. These converters are suitable in high-voltage and highpower applications due to their ability to synthesize waveforms with better harmonic spectrum and attain higher voltages with a limited maximum device rating. These improvements in power conversion are achieved by using multiple voltage steps strategy that is essential for a medium voltage operation for lowering dv/dt and reducing stress on motor winding insulations. One of the most appealing multilevel inverter topologies is a series cascaded H-bridge inverter. This topology is attractive because of its modularity and the simplicity of the control. The H-bridge power cubes are connected in series on their ac side to achieve medium voltage and low-harmonics distortion. In practice, the number of power cubes in the cascaded inverter

is mainly determined by its operating voltage and manufacturing cost. Since this topology consists of series power conversion cubes, the voltage and power level may be easily scaled. However, this topology requires a large number of isolated dc voltage sources to supply each power cube which is achieved by isolation transformers and diode rectiers. The major concerns associated with a diode rectier is that it generates nonsinusoidal currents, referred to as harmonics currents, into the utility. Harmonics currents cause harmonics voltage distortion, additional heating, losses, and electromagnetic interference. Such H-bridge multilevel inverters have also been implemented successfully in the industrial applications for highpower drives [6], [7]. The cascaded H-bridge multilevel inverter is composed of multiple units of single-phase H-bridge power cubes. Voltage and current harmonics in power transmission and distribution have become a serious problem. In response to the power quality of typical power distribution systems in terms of harmonic current distortion and power factor, IEEE 519 [28] and IEC EN 61000-3 [29] standards specify regulation governing harmonic compliance. To cancel some of the most troublesome harmonics components of the input current of the drive, the phase-shifted multiwindings isolation transformers are used to supply power to the cubes [1], [2], [5], [6], [8]. However, to meet the requirements of IEEE 519 standard, the impedance of transformer should be high and a large amount of capacitance must be accommodated in the dc bus of power cubes to make it stiff. This requirement makes both transformers and power cube bulky and expensive. In this paper, a new modular transformers strategy is introduced. In this technology, both primary and secondary windings of modular transformer are phase shifted to assure maximum harmonics cancellation and power quality improvement of the input power. In addition, as it will be shown that the power density and cooling are also improved. II. SUMMARY OF THE PROPOSED TOPOLOGY Fig. 1 shows a multipower cube voltage-source inverter [7], [8]. This inverter topology has shown reduced harmonics in the output voltage and in the input current, competitive cost, and high efciency comparable with alternative converters. In this converter, each power cube includes a single-phase inverter at the output and a three-phase uncontrolled six-pulse rectier at the input side. The presence of a diode rectier with a capacitive lter generates important current harmonics at the input of each power cube. These harmonics are reduced by introducing several phase-shifted secondary in the input transformer, resulting

Manuscript received August 17, 2010; revised January 10, 2011; accepted April 21, 2011. Date of current version January 9, 2012. This work was supported by the TECO-Westinghouse Motor Company. Recommended for publication by Associate Editor S.-K. Sul. The author is with the TECO-Westinghouse Motor Company, Research and Development Department,Round Rock, TX 78681 USA (e-mail: abolhasm@tecowestinghouse.com). Color versions of one or more of the gures in this paper are available online at http://ieeexplore.ieee.org. Digital Object Identier 10.1109/TPEL.2011.2161593

0885-8993/$26.00 2011 IEEE

ABOLHASSANI: MODULAR MULTIPULSE RECTIFIER TRANSFORMERS IN SYMMETRICAL CASCADED H-BRIDGE

699

Fig. 1.

Multicube voltage inverter.

in a more complicated construction and higher cost. In Fig. 1, each phase of the inverter is congured with three power cubes in series. Hence, nine isolated dc bus are required. The input power quality has been improved by having multiple of 20 phase shift in transformer secondary windings. By applying the phase shift, the transformer is congured to obtain 18-pulse current waveform in utility side. However, in this technology, the phase shifting of secondary windings cannot effectively cancel the harmonics. The main obstacle to obtain the highest possible harmonics cancellation is the manufacturing process and less degree of freedom in secondary windings which is very difcult to implement in the small phase shift required for efcient harmonics cancellation. The objective of the new approach is to provide modular transformers conguration to supply power cubes in multilevel inverters with improved power quality while providing scalability and modularity. The modular transformers technology with appropriate phase shifting in secondary windings and primary windings can eliminate the most troublesome harmonics in utility side of the multilevel inverter. Another objective of the new approach is to provide modular transformers congurations to eliminate the need for a single large transformer that is difcult to manufacture, install, and package. In the new approach,

modular transformers technology is used. Each transformer has at least one secondary winding and both primary and secondary windings are phase shifted for optimum harmonics cancellation. The amount of phase shift of secondary and primary windings can be formulated as following: Ns = Ndc NT (1)

sec =

(360/Npulse ) Ns sec NT

(2)

prim =

(3)

where NT is the number of transformer modules, Ndc is the number of the required isolated dc source, NS is the number of secondary windings in each module, Npulse is the number of rectier pulses, sec is the secondary windings phase-shift in each module, and prim is the primary winding phase shift in each module. As an example, if three power cubes are connected in series to make one phase of the inverter, nine isolated power sources are required for the three-phase inverter (Ndc = 9).

700

IEEE TRANSACTIONS ON POWER ELECTRONICS, VOL. 27, NO. 2, FEBRUARY 2012

Fig. 2.

Proposed modular inverter.

If three transformer modules are desired (NT = 3), the phase shift between secondary windings of each transformer for sixpulse rectier can be calculated as: Ns = 9/3 = 3; sec = (360/6)/3 = 20 . The primary windings phase shift can be calculated: prim = 20/3 = 6.7 . In this example, each transformer module is equal to an 18pulse transformer. However, with applying the phase shift in primary of the modular transformer congurations, each set of secondary windings of modular transformers has a multiple of 6.67 phase shift as referred to the input voltage. Hence, the modular transformers in this conguration act as a 54-pulse transformer. This conguration is explained in Fig. 2. In Fig. 2 the secondary windings of each transformer module have been congured as polygon connections and primary windings are congured as extended delta connections. However, the secondary and primary windings can be connected in extended star, zigzag, extended delta, and polygon congurations as well. In general, this conguration is applied to 4160-V drives. Power cubes consist of 1700-V insulated gate bipolar transistor (IGBT) that are fed by three-phase 765 V ac secondaries of transformer modules. The rectiers charge the capacitors to 1050-V dc. To limit inrush current to the power cubes, short circuit voltage impedance of transformers need to be in the range of 7%8% per unit. Since the drives are normally fed by medium voltage 2300 13800 V, the number of turns in primary of transformer modules is much higher. Hence, applying small phase shift in primaries is feasible and easy. As shown a simple six-pulse rectier is used to feed each power cube. Therefore, the input current to each cube contains enormous harmonics. By applying

phase shift in primary and secondaries of transformer modules, a 54-pulse current waveform in utility side is obtained. Therefore, the most of current harmonics are canceled and the amount of remaining harmonics will be well below the requirements of IEEE-519 standard. Fig. 3 depicts the system conguration for four power cubes in series per phase and four modular transformers. So, Ns = 12/4 = 3, and sec = 60/3 = 20 , and prim = 20/4 = 5 . Fig. 4 depicts the system conguration for four power cubes per phase and three modular transformers. So, Ns = 12/3 = 4, and sec = 60/4 = 15 , and prim = 15/3 = 5 . As is clear, the modular transformers explained in Figs. 3 and 4 demonstrate a 72 pulse current waveform in utility side.

III. ANALYSES AND EXPERIMENTAL RESULTS Fig. 5 shows a prototype 1500 hp, 4160-V drive. The system schematic has been shown in Fig. 2. Three 500-kVA transformer modules have been congured to obtain 54-pulse current waveform in utility side. To increase power density in cabinet and effective cooling, the transformers are mounted horizontally and side by side. Fig. 6 shows the modular transformer cabinet. The schematic of power cubes have been shown in Fig. 2. A three-phase diode rectier fed by one of the 765-V ac secondary windings of modular transformers, charges dc bus to 1050-V dc. The dc bus feeds a single-phase H-bridge inverter consisting of four 1700-V IGBTs that generate the PWM output voltage.

ABOLHASSANI: MODULAR MULTIPULSE RECTIFIER TRANSFORMERS IN SYMMETRICAL CASCADED H-BRIDGE

701

Fig. 3. System conguration for four modular transformers and four power cubes in series.

Fig. 4. System conguration for three modular transformers and four power cubes in series.

Phase-shifted multicarrier modulation strategy is used to generate multilevel inverter output voltage [30]. The drive has been tested on 1000-hp dynamometer facility equipped with 4160-V, 1000-HP, 4 pole induction motor. The dynamometer test beds include back to back motor generator sets. The utility supplies only the losses to the loop. The prototype controls the speed of the motor as the generator act as load and apply braking torque. A Yokogawa WT 1600 power analyzer has been used to analyze the input and output power quality of the prototype. Fig. 7 depicts the input current and voltage into the drive at 1000-hp load and 60 Hz. The input voltage has 3% total harmonic distortion (THD) while the THD of input current is 3.7%. Fig. 8 depicts the frequency spectrum analyses of the

input current to the drive at 1000 hp and 60 Hz. The amplitude of fundamental is shown as 112.54. The largest harmonics currents th th are I5 = 1.855 A, and I7 = 2.25 A. Fig. 9 shows the output current and voltage of the drive at 1000 hp and 60-Hz load. Motor current has a THD of 1.2% and output voltage contain 2.1% THD. Based on IEEE 519, all the THD measurements have been done for the rst 41st harmonics. However, the input current to the drive with taking advantage of 54-pulse transformer modules conguration has very little harmonics. It should be noted that the power source to drive in this experiment was weak and contained harmonics too.

702

IEEE TRANSACTIONS ON POWER ELECTRONICS, VOL. 27, NO. 2, FEBRUARY 2012

Fig. 7. Input voltage and current into the drive at 1000 hp and 60 Hz; (a) and (b) Input phase current, (b) and (c) input line to line voltage.

Fig. 5.

1500 hp, 4160-V prototype.

Fig. 8.

Frequency spectrum of input current at 1000 hp and 60 Hz.

TABLE I SUMMARY OF INPUT AND OUTPUT POWER QUALITY OF THE NEW APPROACH AT DIFFERENT LOAD POINTS

Fig. 6.

Modular transformers prototype.

Fig. 10 depicts the variation of input voltage THD of the drive at different load points. Fig. 11 shows the variation of the input current THD of the drive at different load points. As is clear, the THD of the current will drop to less than 5% at 50% of the load (750 hp) and higher. Fig. 12 depicts the variation of output voltage THD of the drive at different load points. Fig. 13 shows the variation of the motor current THD of the drive at different load points. Table I tabulates the summary of power quality of the drive at different loads. As is shown, the power factor of the drive is always higher that 0.96.

To show the effectiveness of the new approach, the new drive has been compared to the commercially available, 1000 hp, 4160-V Robicon Perfect Harmony drive. The Robicon drive schematic is shown in Fig. 1. The Robicon drive has also been tested using the same 1000 hp dynamometer. Fig. 14 depicts some of the experimental results at 60 Hz and 1000 hp load for

ABOLHASSANI: MODULAR MULTIPULSE RECTIFIER TRANSFORMERS IN SYMMETRICAL CASCADED H-BRIDGE

703

Fig. 13. Fig. 9. Output voltage and current of the drive at 1000 hp and 60 Hz; (a) and (b) Output motor phase current, (c) and (d) Output line to line voltage.

Variation of motor current THD of the prototype versus load.

Fig. 10.

Variation of input voltage THD of the prototype versus load power.

Fig. 14. Experimental results for 1000 hp, 4160-V Robicon Perfect Harmony drive at 60 Hz and 1000-hp load; (a) Output voltage. (b) Output Current. (c) Cube input voltage. (d) Cube input current.

Fig. 11.

Variation of input current THD of the prototype versus load.

Fig. 12.

Variation of output voltage THD of the prototype versus load.

Robicon Perfect Harmony drive. Fig 14(a) shows the line to line output voltage. Fig. 13(b) depicts the output current. Fig. 14(c) shows the line to line input voltage to a power cube. As the secondary current of transformer contains harmonics, the ac voltage is also distorted. The input voltage has also a at top which happens during the conduction period of a diode. Fig 14 (d) shows the input current to a cube. As is clear, because of the six-step diode rectier, the cube input current is rich in harmonics. Both drives have been tested at 60-Hz output frequency and 1000 hp load at 1000hp dynamometer. Table II depicts the input- and output-power quality comparison. The THDs have been measured for the rst 41st harmonics. As is clear from Table II, although the amount of installed capacitance in each cube has decreased by 24%, the input current harmonics have been improved signicantly. Besides, by using the modular transformers conguration and effective cooling method, the power density has been improved by 15%. The main reason for this increase is that the cabinet space is utilized more efciently in modular transformers conguration. As in single transformer conguration, there is not that much exibility in mounting the transformer. As the space is utilized much more efciently, and because of unique conguration of transformer windings horizontally, the heat associated with windings losses of transformers can be dissipated more effectively. One of the advantages of mounting the modular transformers

704

IEEE TRANSACTIONS ON POWER ELECTRONICS, VOL. 27, NO. 2, FEBRUARY 2012

TABLE II COMPARISON OF INPUT AND OUTPUT POWER QUALITY FOR ROBICON PERFECT HARMONY AND NEW APPROACH AT 1000 hp AND 60 HZ

IV. CONCLUSION A new approach to enhance the power quality of medium voltage high horse power multi-level drives has been presented. A modular transformers technology has been introduced. By having phase-shift in primaries and secondaries of transformer modules, the highest degree of power quality is achieved. A prototype has been fabricated and tested and compared with commercially available product. The experimental results show the input power quality improved signicantly. In addition, by having modular transformers congurations, the power density has been increased by 15%. ACKNOWLEDGMENT The author would like to thank Mr. T. Keister, Mr. R. Edwards, Mr. A. Skorcz, Mr. E. Ledezma, Mr. S. Satumahanti, Mr. R. Pipho, and Mr. H. Manzoor. REFERENCES
[1] M. Abolhassani, R. Edwards, T. Keister, A. Skorcz, E. Ledezma, and C. H. Liao, Modular multi-pulse transformer rectier for use in symmetric multi-level power converter, U.S. Patent pending, Pub. No. US 20100073970 A1, Mar. 25, 2010. [2] M. Abolhassani, R. Edwards, T. Keister, A. Skorcz, E. Ledezma, C. H. Liao, Modular multi-pulse transformer rectier for use in asymmetric multi-level power converter, U.S. Patent 7 830 681, Nov. 9, 2010. [3] J. S. Lai and F. Z. Peng, Multilevel convertersA new breed of power converters, in Proc. Conf. Rec. IEEE-IAS Annu. Meeting, 1995, pp. 2348 2356. [4] B. S. Suh, G. Sinha, M. D. Manjrekar, and T. A. Lipo, Multilevel power conversionAn overview of topologies and modulation strategies, in Proc. OPTIM, 1998, AD-11AD-24. [5] M. Marchesoni, M. Mazzucchelli, and S. Tenconi, A non-conventional power converter for plasma stabilization, in Proc. IEEE Power Electron. Spec. Conf., 1988, pp. 122129. [6] P. W. Hammond, Medium voltage PWM drive and method, U. S. Patent 5 625 545, 1997. [7] P. W. Hammond, A new approach to enhance power quality for medium voltage AC drives, IEEE Trans. Ind. Appl., vol. 33, no. 1, pp. 202208, Jan./Feb. 1997. [8] M. D. Manjrekar, P. K. Steimer, and T. A. Lipo, Hybrid multilevel power conversion system: A competitive solution for high-power applications, IEEE Trans. Ind. Appl., vol. 36, no. 3, pp. 834841, May/Jun. 2000. [9] K. Ichikawa, Multiple inverter system, U.S. Patent 6 229 722 B1, May 8, 2001. [10] F. Blaabjerg, Editorial for the IEEE Transactions on Power Electronics, January 2009, IEEE Trans. Power Electron., vol. 24, no. 1, pp. 35, Jan. 2009. [11] P. Xiao, G. K. Venayagamoorthy, and K. A. Corzine, Seven-level shunt active power lter for high-power drive systems, IEEE Trans. Power Electron., vol. 24, no. 1, pp. 613, Jan. 2009. [12] F. H. Khan and L. M. Tolbert, Multiple-loadsource integration in a multilevel modular capacitor-clamped DCDC converter featuring fault tolerant capability, IEEE Trans. Power Electron., vol. 24, no. 1, pp. 14 24, Jan. 2009. [13] Z. Du, L. M. Tolbert, B. Ozpineci, and J. N. Chiasson, Fundamental frequency switching strategies of a seven-level hybrid cascaded H-bridge multilevel inverter, IEEE Trans. Power Electron., vol. 24, no. 1, pp. 25 33, Jan. 2009. [14] J. Biela, U. Drofenik, F. Krenn, J. Miniboeck, and J. W. Kolar, Threephase Y-rectier cyclic 2 out of 3 DC output voltage balancing control method, IEEE Trans. Power Electron., vol. 24, no. 1, pp. 3444, Jan. 2009. [15] Q. Song and W. Liu, Control of a cascade STATCOM with star conguration under unbalanced conditions, IEEE Trans. Power Electron., vol. 24, no. 1, pp. 4558, Jan. 2009. [16] Y.-C. Chang and C.-M. Liaw, Design and control for a charge-regulated yback switch-mode rectier, IEEE Trans. Power Electron., vol. 24, no. 1, pp. 5974, Jan. 2009.

Fig. 15.

Scheme of the cooling system.

horizontally is that the presence of the hot spots in windings of transformers are eliminated, and the temperature of the coils is more evenly distributed along the surface and length of each coil. Fig. 15 demonstrates the cooling path in the drive. As is clear in Fig. 6, the transformer windings are separated by air channels. The cool air is forced to go through the air channels. Therefore, the winding losses are dissipated directly from the heat source. Since the cooling capability has been improved in modular transformers design, the power density is increased accordingly.

ABOLHASSANI: MODULAR MULTIPULSE RECTIFIER TRANSFORMERS IN SYMMETRICAL CASCADED H-BRIDGE

705

[17] A. Luo, Z. Shuai, Z. J. Shen, W. Zhu, and X. Xu, Design considerations for maintaining DC-side voltage of hybrid active power lter with injection circuit, IEEE Trans. Power Electron., vol. 24, no. 1, pp. 7584, Jan. 2012. [18] Y. Jang and M. M. Jovanovic, A bridgeless PFC boost rectier with optimized magnetic utilization, IEEE Trans. Power Electron., vol. 24, no. 1, pp. 8593, Jan. 2009. [19] F. D. Freijedo, J. Doval-Gandoy, O. Lopez, and E. Acha, A generic openloop algorithm for three-phase grid voltage/current synchronization with particular reference to phase, frequency, and amplitude estimation, IEEE Trans. Power Electron., vol. 24, no. 1, pp. 94107, Jan. 2009. [20] J.-M. Kwon and B.-H. Kwon, High step-up active-clamp converter with input-current doubler and output-voltage doubler for fuel cell power systems, IEEE Trans. Power Electron., vol. 24, no. 1, pp. 108115, Jan. 2009. [21] Y.-C. Liu and Y.-M. Chen, A systematic approach to synthesizing multiinput DCDC converters, IEEE Trans. Power Electron., vol. 24, no. 1, pp. 116127, Jan. 2009. [22] K. I. Hwu and Y. T. Yau, KY converter and its derivatives, IEEE Trans. Power Electron., vol. 24, no. 1, pp. 128137, Jan. 2009. [23] A. Schild, J. Lunze, J. Krupar, and W. Schwarz, Design of generalized hysteresis controllers for DC DC switching power converters, IEEE Trans. Power Electron., vol. 24, no. 1, pp. 138146, Jan. 2009. [24] J. Zhang, H. S.-H. Chung, A. W.-L. Lo, and T. Huang, Extended ant colony optimization algorithm for power electronic circuit design, IEEE Trans. Power Electron., vol. 24, no. 1, pp. 147162, Jan. 2009. [25] H.-C. Chen, Single-loop current sensorless control for single-phase boost-type SMR, IEEE Trans. Power Electron., vol. 24, no. 1, pp. 163 171, Jan. 2009. [26] J. Hobraiche, J.-P. Vilain, P. Macret, and N. Patin, A new PWM strategy to reduce the inverter input current ripples, IEEE Trans. Power Electron., vol. 24, no. 1, pp. 172180, Jan. 2009. [27] G. Feng, E. Meyer, and Y.-F. Liu, A digital two-switching-cycle compensation algorithm for input-voltage transients in DCDC converters, IEEE Trans. Power Electron., vol. 24, no. 1, pp. 181191, Jan. 2009.

[28] IEEE Recommended Practices and Requirements for Harmonic Control in Electrical Power Systems, IEEE Standard 519-1992, Jun. 1992. [29] Limits for Harmonic Currents Emissions, IEC Standard 61000-3-2, 1995. [30] B. Wu, High-Power Converters and AC Drives.. Hoboken, NJ: Wiley, 2006.

Mehdi T. Abolhassani (SM07) received the Ph.D. degree in electrical engineering from Texas A&M University, College Station. He is currently a Principal R&D Engineer with TECO-Westinghouse Motor Company, Round Rock, TX. He has years of experience in teaching graduate and undergraduate courses. He is a well-experienced Electrical Engineer with 15 years of experience in designing, manufacturing, and testing of permanent magnet motor drives and power electronic converters from fractional horsepower to 2 MW in applications in automotive, traction, industrial, home appliances, and wind energy. He has years of leadership experience in various product development from concept to production. He contributed some chapters DSP-Based Electromechanical Motion Control, and of Handbook of Power Electronics, 2nd Edition: Devices, Circuits and Applications. He holds 18 issued or pending U.S. and international patents. He is also the author of 20 journal and conference papers. His main research interests include medium voltage drives, electrical machine design and control, variable speed drives for traction and propulsion applications, power electronics for automotive, and wind energy conversion systems.