SYSTEM AND METHOD FOR POWER CONVERSION

BACKGROUND

Embodiments of the disclosure relate generally to systems and methods for power conversion.

At least some known converters have been used as power conversion device for converting power from one form to another. In particular, multi-level converters are increasingly used for performing power conversion in a wide range of applications due to the advantages of high power quality waveform and high voltage capability. For example, multi-level converters or multi-level inverters are being used in industrial areas, including but not limited to, petro-chemistry, papermaking industry, mine, power plant, and water treatment plant, to provide electric power (e.g., AC electric power) for driving one or more loads such as AC electric motor.

In general, the converters are constructed to have a particular topology, such as three-level NPC topology, two phase H-bridge cascaded topology, and so on. However, these topologies used in the converters still cannot provide ideal input/output waveforms. Therefore, it is desirable to provide systems and methods with new or improved topology to address one or more of the above-mentioned limitations of current systems and methods.

BRIEF DESCRIPTION

In accordance with one aspect of the present disclosure, a converter is provided. The converter includes a first converter module and a second converter module coupled to the first converter in a nested manner. Each of the first converter module and the second converter module includes a plurality of switch units. When the converter is operated to perform power conversion, at least two of the plurality of switch units is configured to be switched both in a complementary pattern and a non-complementary pattern.

In accordance with another aspect of the present disclosure, a converter is provided. The converter includes a first converter module and a second converter module coupled to the first converter in a nested manner. Each of the first converter module and the second converter module includes a plurality of switch units. At least one of the switch units comprises at least two switch devices connected in series.

In accordance with another aspect of the present disclosure, a method for driving a converter is provided. The converter includes at least a first converter module and a second converter module coupled together to form a nested neutral point piloted topology. The first or second converter module includes at least a first switch unit and a second switch unit. The method includes providing a first main driving signal for driving the first switch unit; and providing a second main driving signal for driving the second switch unit to allow the first and second switch units to be switched both in a complementary pattern and a non-complementary pattern.

In accordance with another aspect of the present disclosure, a method for driving a converter is provided. The converter includes at least a first converter module and a second converter module coupled together to form a nested neutral point piloted topology. Each of the first and second converter modules includes a plurality of switch units, and at least one of the plurality of switch units includes at least a first switch device and a second switch device coupled in series. The method includes: disassembling a main driving signal into a first optical driving signal and a second optical driving signal; converting the first optical driving signal into a first electrical driving signal; converting the second optical driving signal into a second electrical driving signal; supplying the first electrical driving signal to the first switch device; and supplying the second electrical driving signal to the second switch device.

In accordance with another aspect of the present disclosure, a method of using a power conversion device to perform power conversion between a grid and a three-phase electric motor is provided. The power conversion device includes an AC-DC converter and a DC-AC converter. At least one of the AC-DC converter and the DC-AC converter includes a first converter module and a second converter module coupled together to form a nested neutral point piloted topology. The first or second converter module includes at least a first switch unit and a second switch unit that are arranged to be switched both in a complementary pattern and a non-complementary pattern. The method includes converting first three-phase AC voltage received from the grid into DC voltage using the AC-DC converter; converting the DC voltage into a second three-phase AC voltage using the DC-AC converter; and supplying the second three-phase AC voltage to the three-phase electric motor.

In accordance with another aspect of the present disclosure, a driving unit for driving a converter is provided. The converter includes at least a first converter module and a second converter module coupled together to form a nested neutral point piloted topology. Each of the first and second converter modules includes a plurality of switch units, and at least one of the plurality of switch units includes at least a first switch device and a second switch device coupled in series. The driving unit includes a main disassembling circuit configured to disassemble a main driving signal into at least a first optical driving signal and a second optical driving signal; a first driving circuit coupled to the main disassembling circuit, the first driving circuit configured to convert the first optical driving signal to a first electrical driving signal, and supply the first electrical driving signal to the first switch device to allow the first switch device to be switched on or off accordingly; and a second driving circuit coupled to the main disassembling circuit, the second driving circuit configured to convert the second optical driving signal to a second electrical driving signal, and supply the second electrical driving signal to the second switch device to allow the second switch device to be switched on or off synchronously with respect to the first switch device accordingly.

In accordance with another aspect of the present disclosure, a power conversion device is provided. The power conversion device is coupled between a power grid and a three-phase electric motor. The power conversion device includes an AC-DC converter configured to receive first AC voltage provided from the power grid and convert the first AC voltage to DC voltage; and a DC-AC converter coupled to the AC-DC converter, the DC-AC converter configured to receive the DC voltage, convert the DC voltage into a second AC voltage, and supply the second AC voltage to the three-phase electric motor. At least one of the AC-DC converter and the DC-AC converter comprises at least a first converter module and a second converter module coupled together forming a nested neutral point piloted topology, each of the first and second converter modules comprises a plurality of switch units. When the power conversion device is configured to perform power conversion, at least two of the switch units are operated to have opposite switching state and same switching state in one switching control cycle.

In accordance with another aspect of the present disclosure, a wind power generation system is provided. The wind power generation system includes a first converter configured to convert a first AC electric power to DC electric power; and a second converter coupled to the first converter, the second converter configured to convert the DC electric power to a second AC electric power. At least one of the first and second converters includes at least a first converter module and a second converter module coupled together to from a nested neutral point piloted topology, and each of the first and second converter modules comprise a plurality of switching units.

In accordance with another aspect of the present disclosure, a solar power generation system is provided. The solar power generation system includes a first converter configured to convert a first DC electric power to second DC electric power; and a second converter coupled to the first converter, the second converter configured to convert the second DC electric power to an AC electric power. At least one of the first and second converters comprises at least a first converter module and a second converter module coupled together to from a nested neutral point piloted topology, and each of the first and second converter modules comprise a plurality of switching units.

In accordance with another aspect of the present disclosure, an uninterruptible power system is provided. The uninterruptible power system includes a first converter configured to convert a first AC electric power to DC electric power; an energy storage device coupled to the first converter, the energy storage converter configured to store the DC electric power provided from the first converter; and a second converter coupled to the first converter and the energy storage device, the second converter configured to convert DC electric power provided from the energy storage device or from the first converter to a second AC electric power. At least one of the first and second converters comprises at least a first converter module and a second converter module coupled together to from a nested neutral point piloted topology, and each of the first and second converter modules comprise a plurality of switching units.

DRAWINGS

These and other features, aspects, and advantages of the present disclosure will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:

FIG. 1 illustrates a block diagram of a system in accordance with an exemplary embodiment of the present disclosure;

FIG. 2 illustrates a detailed diagram of a converter of the system shown in FIG. 1 in accordance with an exemplary embodiment of the present disclosure;

FIG. 3 illustrates a schematic diagram of a single phase leg of the converter shown in FIG. 2 in accordance with an exemplary embodiment of the present disclosure;

FIG. 4 illustrates waveforms of switching signals supplied to the eight switch units in the first phase leg shown in FIG. 3 and corresponding voltage and current waveforms in accordance with an exemplary embodiment of the present disclosure;

FIG. 5 illustrates an output voltage waveform of the converter shown in FIG. 2 in accordance with an exemplary embodiment of the present disclosure;

FIG. 6 illustrates a schematic diagram of a first type switch unit used in the converter shown in FIG. 2 in accordance with an exemplary embodiment of the present disclosure;

FIG. 7 illustrates a schematic diagram of a first type switch unit used in the converter shown in FIG. 2 in accordance with another exemplary embodiment of the present disclosure;

FIG. 8 illustrates a schematic diagram of a second type switch unit used in the converter shown in FIG. 2 in accordance with an exemplary embodiment of the present disclosure;

FIG. 9 illustrates a schematic diagram of a second type switch unit used in the converter shown in FIG. 2 in accordance with another exemplary embodiment of the present disclosure;

FIG. 10 illustrates a schematic diagram of one phase leg of a converter in accordance with an exemplary embodiment of the present disclosure;

FIG. 11 illustrates at least part of a drive unit in accordance with an exemplary embodiment of the present disclosure;

FIG. 12 illustrates a block diagram of at least part of a drive unit in accordance with another exemplary embodiment of the present disclosure;

FIG. 13 is a flowchart which outlines an implementation of a method for driving a converter in accordance with an exemplary embodiment of the present disclosure;

FIG. 14 illustrates a flowchart of a method for driving a converter in accordance with an exemplary embodiment of the present disclosure; and

FIG. 15 illustrates a power conversion method in accordance with an exemplary embodiment of the present disclosure.

DETAILED DESCRIPTION

In an effort to provide a concise description of these embodiments, not all features of an actual implementation are described in the one or more specific embodiments. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.

Unless defined otherwise, technical and scientific terms used herein have the same meaning as is commonly understood by one of ordinary skill in the art to which this disclosure belongs. The terms “first,” “second,” and the like, as used herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. Also, the terms “a” and “an” do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items. The term “or” is meant to be inclusive and mean either any, several, or all of the listed items. The use of “including,” “comprising,” or “having” and variations thereof herein are meant to encompass the items listed thereafter and equivalents thereof as well as additional items. The terms “connected” and “coupled” are not restricted to physical or mechanical connections or couplings, and can include electrical connections or couplings, whether direct or indirect. The terms “circuit,” “circuitry,” and “controller” may include either a single component or a plurality of components, which are either active and/or passive components and may be optionally connected or otherwise coupled together to provide the described function.

Embodiments disclosed herein generally relate to converters which may be configured to perform power conversion for converting one form of electric power (e.g., DC or AC electric power) to another form of electric power (DC or AC electric power) in a unidirectional or bidirectional manner. In particular, in some embodiments, the inventors of the present disclosure have worked together to propose a new converter topology or an improved nested neutral point piloted (NPP) topology for use in converters. The technical advantages or benefits of utilizing such a new or improved nested NPP topology is that the converter can be operated to provide better output waveforms, thereby output voltage ripples can be significantly suppressed, the volume or weight of the filter can be reduced, as well as the power capability of the converter can be improved. As used herein, “nested NPP” refers to an arrangement that at least two converter modules having the same or different structures can be coupled or cascaded together in an inside-to-outside or outside-to-inside manner (also can be viewed as left-to-right or right-to-left) in connection with the use of flying capacitors, to achieve higher output levels. In one example, a five-level converter can be constructed by nesting one three-level converter module with another three-level converter module. In another example, a seven-level converter can be constructed by nesting a three-level converter module with a five-level converter module. Also, the seven-level converter can be constructed by nesting three three-level converter modules one by one. It is apparent that converters capable of providing higher output levels can be constructed by nesting more converter modules together.

In some embodiments, on basis of the proposed new or improved nested NPP topology, the converter module used for nesting can be arranged to have a plurality of switch units. For example, a three-level converter module can be constructed to have at least one switch unit in a first longitudinal arm, at least one switch unit in a second longitudinal arm, and at least two switch units in a transverse arm. In some embodiments, at least two of the plurality of switch units can be switched on and/or off both in a complementary pattern and a non-complementary pattern. As used herein, “complementary pattern” refers one switch unit is on and another switch unit is off and vice versa. As used herein, “non-complementary pattern” refers to two switch units are operated to have the same switching states, such as both on and both off.

In some embodiments, on basis of the proposed new or improved nested NPP topology, in one or more switching control cycles, redundant switching states of the switching signals supplied to the plurality of switch units can be selectively used to balance the voltages of flying capacitors arranged in the converter.

In some embodiments, on basis of the proposed new or improved nested NPP topology, during at least a part of one switching control cycle, at least one switching signal supplied to the plurality of switch units can be blocked or masked to reduce switching numbers of the switch units, so as to reduce power loss.

In some embodiments, on basis of the proposed new or improved nested NPP topology, at least some of the switch units arranged in the converter module can be configured to have a structure formed by multiple series-connected switch devices. In some embodiments, the multiple series-connected switch devices can utilize low voltage rating switch devices, and the specific number of the switch devices can be determined based at least in part on associated operating parameters of the converter, such as DC-link voltages and nominal voltages of the switch devices.

Still in some embodiments, to ensure synchronous switching of the multiple series-connected switch devices, multiple driving circuits are provided to supply switching signals for the multiple switch devices. Further, in some embodiments, each switch device is arranged with a snubber circuit to ensure that the multiple switch devices can share substantially the same voltage during the process that the switch devices are switched on and/or off.

It is apparent to those skilled in the art that the new or improved nested NPP topology as proposed herein can be specifically implemented as an AC-DC converter (also can be referred to as rectifier) for converting single-phase, three-phase, or multiple-phase alternating-current voltage into DC voltage. Furthermore, the new or improved nested NPP topology as proposed herein can be specifically implemented as a DC-AC converter (also can be referred to as inverter) for converting DC voltage into single-phase, three-phase, or multiple-phase alternating-current voltage, such that one or more particular load such as three-phase AC electric motor can be driven to work.

FIG. 1 illustrates a block diagram of a system 100 in accordance with an exemplary embodiment of the present disclosure. The system 100 may be any appropriate converter-based system that is capable of being configured to implement the new or improved nested NPP topology as disclosed herein. In some embodiments, the system 100 may be a multi-level converter-based system suitable for high power and high voltage applications. For example, the system 100 can be utilized in the following areas, including but not limited to, petro-chemistry, papermaking industry, mine, power plant, and water treatment plant, for driving one or more particular loads, such as pump, fan, and conveying device.

As illustrated in FIG. 1, the system 100 generally includes a power conversion device 120 and a control device 140 coupled in communication with the power conversion device 120. In one embodiment, the control device 140 is arranged to be in electrical communication with the power conversion device 120 and may transmit control signals 106 to the power conversion device 120 via one or more electrical links or wires for example. In another embodiment, the control device 140 may be in optical communication with the power conversion device 120 and can transmit the control signals 106 to the power conversion device 120 via an optical communication link, such as one or more optical fibers for example. The control device 140 may include any suitable programmable circuits or devices such as a digital signal processor (DSP), a field programmable gate array (FPGA), a programmable logic controller (PLC), and an application specific integrated circuit (ASIC). The power conversion device 120 can be operated to perform unidirectional or bidirectional power conversion between a first power device 110 and a second power device 130 in response to the control signals 106 transmitted from the control device 140.

In one embodiment, as shown in FIG. 1, the power conversion device 120 may include a first converter 122, a DC link 124, and a second converter 126. In one embodiment, the first converter 122 may be an AC-DC converter which is configured to convert first electric power 102 (e.g., first AC electric power) provided from the first power device 110 (e.g., power grid) into DC electric power 123 (e.g., DC voltage). In some specific embodiments, the first converter 122 may be constructed to have a rectifier bridge structure formed by multiple diodes for converting AC electric power to DC electric power. Alternatively, the first converter 122 may employ the nested NPP topology which will be described in detail below with reference to FIG. 2. In one embodiment, the DC-link 124 may include multiple capacitors configured to filter first DC voltage 123 provided from the first converter 122, and supply second DC voltage 125 to the second converter 126. In one embodiment, the second converter 126 may be a DC-AC converter which is configured to convert the second DC voltage 125 into a second AC voltage 104, and supply the second AC voltage 104 to the second power device 130 (e.g., AC electric motor). In one embodiment, the second converter 126 may be constructed with controlled switch devices arranged to have the nested NPP topology which will be described in detail below with reference to FIG. 2. Although not illustrated in FIG. 1, in some embodiments, the system 100 may include one or more other devices and components. For example, one or more filters and/or circuit breakers can be placed between the first power device 110 and the power conversion device 120. Also, one or more filters and/or circuit breakers can be placed between the power conversion device 120 and the second power device 130.

In other embodiments, the system 100 constructed with the new or improved nested NPP topology disclosed herein can also be used in power generation systems, including but not limited to, wind power generation systems, solar/photovoltaic power generation systems, hydropower generation systems, and combinations thereof. In one embodiment, the first power device 110 may include one or more wind turbines which are configured to provide variable-frequency electric power. The first converter 122 may be an AC-DC converter and the second converter 126 may be a DC-AC converter, such that the variable-frequency electric power 102 can be converted into a fixed-frequency electrical power 104, for example, 50 Hertz or 60 Hertz AC power. The fixed-frequency electrical power 104 may be supplied to the second power device 130 such as a power grid for transmission and/or distribution. In some embodiments, the second power device 130 may include a load such as an electric motor used in a vehicle, a fan, or a pump, which can be driven by the second electric power 104. In some embodiments, when the system 100 is implemented as a solar power generation system, the first converter 122 may be a DC-DC converter for performing DC electric power conversion. In some occasions, the first converter 122 can be omitted, such that the second converter or DC-AC converter 126 is responsible for converting DC electric power provided from the first power device 110 (e.g., one or more solar panels) into AC electric power.

In some other embodiments, the system 100 may also be used in areas that are desirable to use uninterruptible/uninterrupted power system (UPS) for maintaining continuous power supply. In such applications, the power conversion device 120 of the system 100 may also be configured to have the new or improved nested NPP topology. In one embodiment, the first converter 122 may be an AC-DC converter which is configured to convert first AC electric power provided from the first power device 110 (e.g., power grid) into DC electric power. The system 100 may also include an energy storage device 127 which is configured to receive and store the DC electric power provided from the first converter 122. In one embodiment, the second converter 126 may be a DC-AC converter which is configured to convert the DC electric power provided from the first converter 122 or DC electric power obtained from the energy storage device 127 into second AC electric power, and supply the second electric power to the second power device 130 (e.g., a load).

Turning now to FIG. 2, which illustrates a detailed topology diagram of a converter 200 in accordance with an exemplary embodiment of the present disclosure. In one embodiment, the converter 200 can be used as the second converter 126, or more particularly, a DC-AC converter. In one embodiment, the converter 200 includes a first port 202 and a second port 204, both of which are configured to receive DC voltage such as the DC voltage 123 (see FIG. 1) provided from the first converter 122. The first port 202 is electrically coupled to a first DC line 206, and the second port 204 is electrically coupled to a second DC line 208. A DC-link 210 is also electrically coupled between the first port 202 and the second port 204 for performing filtering operations with respect to the received DC voltage and maintaining substantially constant voltage for subsequent switch devices coupled thereto. In one embodiment, the DC-link 210 includes a first capacitor 212 and a second capacitor 214 coupled in series between the first DC line 206 and the second DC line 208. A DC middle point 216 is defined between the first capacitor 212 and the second capacitor 214. In other embodiments, the DC-link 210 may include more than two capacitors, and at least part of the capacitors can be coupled in series or in parallel.

With continuing reference to FIG. 2, the converter 200 comprises a first phase leg 220, a second phase leg 250, and a third phase leg 280. Each of the three phase legs 220, 250, 280 is electrically coupled between the first DC line 206 and the second DC line 208 for receiving DC voltage provided from the DC link 210 and providing output voltage at its corresponding output port. More specifically, in one embodiment, the first phase leg 220 provides a first phase AC voltage through first output port 235, the second phase leg 250 provides a second phase AC voltage through second output port 265, and the third phase leg 280 provides a third phase AC voltage through third output port 295. The first phase AC voltage, the second phase AC voltage, and the third phase AC voltage are offset from one another by 120 degrees. It should be understood that, when the converter 200 is implemented as an AC-DC converter, the three output ports 235, 265, 295 can be configured to receive input AC voltages. Thus, the three output ports 235, 265, 295 can be generally referred to as AC ports. Similarly, the first port 202 and the second port 204 can also be configured to output DC voltage, in which case the two ports 202, 204 can be generally referred to as DC ports.

Please referring to FIG. 2 and FIG. 3 together, in one embodiment, the first phase leg 220 includes at least two converter modules that are constructed to have the same structure. The two converter modules are coupled together in a nested manner to achieve a higher level phase leg. More specifically, the first phase leg 220 includes a first converter module 222 and a second converter module 224 coupled together in a nested manner. In one embodiment, the first converter module 222 can be configured to provide an output voltage having 2n₁+1 levels, and the second converter module 224 can be configured to provide an output voltage having 2n₂+1 levels, where n₁and n₂are both equal to or larger than one, and n₁is equal to n₂. In another embodiment, n₁can be arranged to be different than n₂. In the illustrated embodiment, the first converter module 222 and the second converter module 224 are arranged to provide five-level output voltages. In particular, each of the first and second converter modules 222, 224 is configured to have six connecting terminals for the purpose of connecting with corresponding connecting terminals of other converter modules.

More specifically, in one embodiment, the first converter module 222 includes a first longitudinal arm 201, a second longitudinal arm 203, and a transverse arm 205. It should be noted that “longitudinal” and “transverse” used herein are used for reference only, and not intended to limit the scope of the invention to specific orientations. The first longitudinal arm 201 includes a first switch unit 228 which has one end formed as first-longitudinal-arm first connecting terminal 237 and another end formed as first-longitudinal-arm second connecting terminal 218. The second longitudinal arm 203 includes a second switch unit 232 arranged in the same direction as the first switch unit 228. The second switch unit 232 has one end formed as second-longitudinal-arm first connecting terminal 241 and another end formed as second-longitudinal-arm second connecting terminal 229. The transverse arm 205 includes a third switch unit 234 and a fourth switch unit 236 that are reversely coupled in series. The third switch unit 234 has one end formed as transverse-arm first connecting terminal 226, and the fourth switch unit 236 has one end formed as transverse-arm second connecting terminal 239. In one embodiment, the transverse-arm second connecting terminal 239 is electrically connected to a flying-capacitor middle point 223 defined between a first flying capacitor 225 and a second flying capacitor 227. In addition, two ends of the first flying capacitor 225 are electrically connected to the two connecting terminals 237, 239 respectively, and two ends of the second flying capacitor 227 are electrically connected to the two connecting terminals 241, 239 respectively.

Similarly, the second converter module 224 includes a first longitudinal arm 207, a second longitudinal arm 209, and a transverse arm 271. The first longitudinal arm 207 includes a fifth switch unit 238 which has one end formed as first-longitudinal-arm first connecting terminal 217 and another end formed as first-longitudinal-arm second connecting terminal 211. The second longitudinal arm 209 includes a sixth switch unit 242 arranged in the same direction as the fifth switch unit 238. The sixth switch unit 242 has one end formed as second-longitudinal-arm first connecting terminal 221 and another end formed as second-longitudinal-arm second connecting terminal 215. The transverse arm 271 includes a seventh switch unit 244 and an eighth switch unit 246 that are reversely coupled in series. The seventh switch unit 244 has one end formed as transverse-arm first connecting terminal 219, and the eighth switch unit 246 has one end formed as transverse-arm second connecting terminal 213. In one embodiment, the transverse-arm second connecting terminal 216 is electrically connected to a DC-link middle point 236 defined between the first capacitor 212 and the second capacitor 214 of the DC-link 210. In addition, two ends of the first capacitor 212 are electrically connected to the two connecting terminals 211, 213 respectively, and two ends of the second capacitor 214 are electrically connected to the two connecting terminals 213, 215 respectively.

In the illustrated embodiment, it can be seen that a nested NPP structure is formed by electrically connecting the two connecting terminals 217, 237, electrically connecting the two connecting terminals 219, 239, and electrically connecting the two connecting terminals 241, 221. It can be understood that, in other embodiments, similar connection can be made to form higher level converter by connecting three or more than three six-terminal converter modules. In the illustrated embodiment, since the first converter 222 is arranged as an inner-most block, the three connecting terminals 218, 226, 229 of the first converter 222 are commonly connected with the AC port 235 for receiving or providing AC voltage. In addition, since the second converter 224 is arranged as an outer-most block, the first-longitudinal-arm second connecting terminal 211 is electrically connected to the first DC port 202 through the first DC line 206, and the second-longitudinal-arm second connecting terminal 215 is electrically connected to the second DC port 204 through the second DC line 208, so as to receive or provide DC voltage.

With continuing reference to FIG. 2, the second phase leg 250 is configured with similar structure as the first phase leg 220. For example, the second phase leg 250 also includes a first converter module 252 and a second converter module 254 that are coupled together in a nested manner. Each of the first and second converter modules 252, 254 has six connection terminals for connecting to corresponding terminals of other converter module. The first converter module 252 includes four switch units 258, 262, 264, 266, and the second converter module 254 includes four switch units 268, 272, 274, 276. The four switch units 258, 262, 264, 266 are connected in series to form a longitudinal arm, and another four switch units 268, 272, 274, 276 are connected in series to form a transverse arm. Two ends of the longitudinal arm are electrically connected to the first DC line 206 and the second DC line 208 respectively. One end of the transverse arm is electrically connected to the DC middle point 216, and the other end of the transverse arm is electrically connected to a joint connection 263 defined between the two switch units 258, 262. In addition, the second phase leg 250 includes two flying capacitors 255, 257 connected in series to form a flying capacitor arm. The two flying capacitors 255, 257 define a flying-capacitor middle point 253 which is electrically connected to a joint connection defined between the two switch units 266, 274. Another end of the first flying capacitor 255 is connected to a joint connection defined between the two switch units 268, 258, and another end of the second flying capacitor 257 is electrically connected to a joint connection defined between the two switch units 262, 272.

With continuing reference to FIG. 2, the third phase leg 280 is configured with similar structure as the first phase leg 220. For example, the third phase leg 280 also includes a first converter module 282 and a second converter module 284 that are coupled together in a nested manner. Each of the first and second converter modules 282, 284 has six connection terminals for connecting to corresponding terminals of other converter module. The first converter module 282 includes four switch units 288, 292, 294, 296, and the second converter module 284 includes four switch units 298, 302, 304, 306. The four switch units 288, 298, 292, 302 are connected in series to form a longitudinal arm, and another four switch units 294, 296, 304, 306 are connected in series to form a transverse arm. Two ends of the longitudinal arm are electrically connected to the first DC line 206 and the second DC line 208 respectively. One end of the transverse arm is electrically connected to the DC middle point 216, and the other end of the transverse arm is electrically connected to a joint connection 293 defined between the two switch units 288, 292. In addition, the third phase leg 280 includes two flying capacitors 285, 287 connected in series to form a flying capacitor arm. The two flying capacitors 285, 287 define a flying-capacitor middle point 283 which is electrically connected to a joint connection defined between the two switch units 296, 304. Another end of the first flying capacitor 285 is connected to a joint connection defined between the two switch units 298, 288, and another end of the second flying capacitor 287 is electrically connected to a joint connection defined between the two switch units 292, 302.

In one embodiment, each of the first phase leg 220, the second phase leg 250, and the third phase leg 280 is configured to provide output voltage of five levels. In particular, the switching states of the switch units in the first leg 220 are shown below in table 1.

TABLE 1

Switching states of the first phase leg

Switching states

First
Second
Third
Fourth

Sixth
Seventh
Eighth

Output
switch
switch
switch
switch
Fifth switch
switch
switch
switch

voltage
unit
unit
unit
unit
unit
unit
unit
unit

level
228
232
234
236
238
242
244
246

2
1
0
0
1
1
0
0
1

1
1
0
0
1
0
0
1
1

0
0
1
1
1
0
0
1

0
0
0
1
1
0
0
1
1

1
0
0
1
0
1
1
0

0
1
1
0
1
0
0
1

−1
0
0
1
1
0
1
1
0

0
1
1
0
0
0
1
1

−2
0
1
1
0
0
1
1
0

It can be seen from table-1, the first phase leg 220 can be controlled to provide output voltage having five different levels of “2,” “1,” “0,” “−1,” “1” by selectively controlling the switching states of the eight switch units in the first phase leg 220. It also can be seen when the output voltage level is “2” or “−2,” there exists a sole combination switching states for the eight switch units. In contrast, when the output voltage level is “1” and “−1,” there exist two combination switching states for the eight switch units. When the output voltage level is “0,” there exist three combination switching states for the eight switch units. In some embodiments, the voltage of the first and second flying capacitors 285, 287 can be balanced by selectively using the switching states of the switch units. Furthermore, as shown in table-1, the switch units of the first phase leg 220 are switched on and/or off in a complementary pattern. For example, the switching states of first switch unit 228 and the second switch unit 234 are switched in opposite states. Likewise, each of the switch unit pairs 232, 234; 238, 244; and 242, 246 are switched in opposite states.

FIG. 4 illustrates waveforms of switching signals supplied to the eight switch units in the first phase leg 220 and corresponding voltage and current waveforms in accordance with an exemplary embodiment of the present disclosure. As shown in FIG. 4, the switch units of the first phase leg 220 can be further configured to be switched on and/or off in a non-complementary pattern. For example, when the output voltage level is transitioning from “1” to “2,” the switching signal for the seventh switch unit 244 (T2) becomes logic “0,” while the switching signal for the fifth switch unit 238 (T1) becomes logic “1” after a short time delay t_d(also known as dead-zone time). It is known that it usually takes longer time to turn off a switch device than turn on a switch device. Thus, the purpose of introducing such a short time delay is to avoid a short-circuit condition of the two flying capacitors when both switch units are in the ON state. In other words, during such a time delay t_d, both the seventh switch unit 244 (T2) and the fifth switch unit 238 (T1) are turned off, that is, the two switch units 244, 238 are controlled to operate in a non-complementary pattern. After the time delay t_d, the seventh switch unit 244 (T2) remains off and the fifth switch unit 238 (T1) is turned on, in this case, the two switch units 244, 238 are controlled to operate in a complementary pattern.

With continuing reference to FIG. 4, in case the output voltage 563 has a level of “1,” the switching signal supplied to the fifth switch unit 238 (T1) is low level signal. Conventionally, to ensure complementary switching, the switching signal supplied to the seventh switch unit 244 (T2) should be a high level signal. In the illustrated embodiment, because electrical current can be flowing through the anti-parallel diode in association with the seventh switch unit 244 (T2), thus, the switching signal supplied to the seventh switch unit 244 (T2) can be temporarily blocked or masked to reduce switching numbers as well as reduce power loss due to the unnecessary switching actions. In this case, the fifth switch unit 238 and the seventh switch unit 244 are also operated in a non-complementary pattern. Similarly, as shown in FIG. 4, the fourth switch unit 234 (S3) and the second switch unit 232 (S4) can also be operated in complementary pattern and non-complementary pattern due to the introduction of delay time t_d. Furthermore, as shown in FIG. 4, in one embodiment, during the single switching control cycle starting from t₀to t₈, the switching signals supplied to the switch units T2, T3, S2, S3 in the transverse arm are blocked in predetermined time period, so as to reduce switching numbers as well as power loss. In other embodiment, switching signals supplied to switch units T1, T4, S1, S4 in the longitudinal arm can be blocked to reduce switching numbers as well as power loss.

FIG. 5 illustrates an output voltage waveform 560 of the converter shown in FIG. 2 in accordance with an exemplary embodiment of the present disclosure. As shown in FIG. 5, with the use of converter having a nested NPP topology, one phase leg of the converter can provide output voltage having five levels with good waveforms.

FIG. 6 illustrates a schematic diagram of a first type switch unit 310 contained in the converter as shown in FIG. 2 in accordance with an exemplary embodiment of the present disclosure. In one embodiment, the first type switch unit 310 can be any one of the switch units in the longitudinal arm of the three phase legs. In a particular embodiment, the first four switch units 238, 228, 232, 242 in the longitudinal arm of the first phase leg 220 can be configured to be exactly the same as the switch unit 310. More specifically, in one embodiment, the switch unit 310 includes a first switch device 316, a second switch device 318, and an n^thswitch device 322, where n is equal to or larger than two. In addition, in one embodiment, the first switch device 316 is connected in parallel with a first anti-parallel diode 324, the second switch device 318 is connected in parallel with a second anti-parallel diode 326, and the n^thswitch device 322 is connected in parallel with an n^thanti-parallel diode 328. In some conditions, each switch device can be integrated with the anti-parallel diode to form a single device. Because the first switch device 316, the second switch device 318, and the n^thswitch device 322 are connected in series between the DC lines 206, 208, each of the switch devices is applied with a portion of the DC voltage. Thus, low nominal voltage switch device can be used to replace a single switch device 312 (as shown in FIG. 6, the single switch device 312 is also integrated with an anti-parallel diode 314) which has a high nominal voltage. Non-limiting examples of the switch device that may be used in the converter may include metal oxide semiconductor field effect transistor (MOSFET), insulated gate bipolar transistor (IGBT), and integrated gate commutated thyristor (IGCT).

FIG. 7 illustrates a schematic diagram of a first type switch unit 320 in accordance with another exemplary embodiment of the present disclosure. The first type switch unit 320 shown in FIG. 7 is substantially similar to the first type switch unit 310 shown in FIG. 6. For example, the first type switch unit 320 also includes a first switch device 316, a second switch device 318, and an n^thswitch device 322, where n is equal to or larger than two. The first type switch unit 320 also includes a first anti-parallel diode 324, a second anti-parallel diode 326, and an n^thanti-parallel diode 328, each of which is coupled in parallel with a corresponding switch device. In addition, the first type switch unit 320 further includes a first snubber circuit 323 arranged in association with the first switch device 316, a second snubber circuit 325 arranged in association with the second switch device 318, and a third snubber circuit 327 arranged in association with the third switch device 322. In a particular embodiment, the first, second, and third snubber circuits 323, 325, 327 can be formed by one or more passive electronic devices such as capacitors, resistors, and so on. The purpose of providing these snubber circuits 323, 325, 327 is to ensure voltage to be shared equally among the switch devices 316, 318, 322 during the dynamic switching processes.

FIG. 8 illustrates a schematic diagram of a second type switch unit 330 used in the converter shown in FIG. 2 in accordance with an exemplary embodiment of the present disclosure. In one embodiment, the second type switch unit 330 can be any one of the switch unit in the transverse arm of the three phase legs. In a particular embodiment, the first four switch units 234, 236, 244, 246 in the transverse arm of the first phase leg 220 can be configured to be exactly the same as the switch unit 320. More specifically, in one embodiment, the switch unit 320 includes a first switch device 336, a second switch device 338, and an m^thswitch device 342, where m is equal to or larger than two. In addition, in one embodiment, the first switch device 336 is connected in parallel with a first anti-parallel diode 344, the second switch device 338 is connected in parallel with a second anti-parallel diode 346, and the m^thswitch device 342 is connected in parallel with an m^thanti-parallel diode 348. In some conditions, each switch device can be integrated with the anti-parallel diode to form a single device. Because the first switch device 316, the second switch device 318, and the m^thswitch device 342 are connected in series between the DC lines 206, 208, each of the switch devices is applied with a portion of the DC voltage. Thus, low nominal voltage switch device can be used to replace a single switch device 332 (as shown in FIG. 8, the single switch device 332 is also integrated with an anti-parallel diode 334) which has a high nominal voltage. Non-limiting examples of the switch device that may be used in the converter may include metal oxide semiconductor field effect transistor (MOSFET), insulated gate bipolar transistor (IGBT), and integrated gate commutated thyristor (IGCT).

In some embodiments, the switch devices 336, 338, 342 in the second type switch unit 330 can be arranged to be the same as the switch devices 316, 318, 322. In other embodiments, different switch devices having different voltage ratings can be used. In addition, in some embodiments, the number of the switch devices arranged in the first type switch unit 310 can be the same as or different from the number of switch devices arranged in the second type switch unit 330. In some embodiments, the exact number of the switch devices used in the first or second switch units 310, 330 can be determined based on associated operating parameters of the converter, such as DC-link voltages and nominal voltages of the switch devices.

FIG. 9 illustrates a schematic diagram of a second type switch unit 340 in accordance with another exemplary embodiment of the present disclosure. The second type switch unit 340 shown in FIG. 9 is substantially similar to the second type switch unit 330 shown in FIG. 8. For example, the second type switch unit 340 also includes a first switch device 336, a second switch device 338, and an m^thswitch device 342, where m is equal to or larger than two. The second type switch unit 340 also includes a first anti-parallel diode 344, a second anti-parallel diode 346, and an m^thanti-parallel diode 348, each of which is coupled in parallel with a corresponding switch device. In addition, the second type switch unit 340 further includes a first snubber circuit 343 arranged in association with the first switch device 336, a second snubber circuit 345 arranged in association with the second switch device 338, and a third snubber circuit 347 arranged in association with the third switch device 342. In a particular embodiment, the first, second, and third snubber circuits 343, 345, 347 can be formed by one or more passive electronic devices such as capacitors, resistors, and so on. The purpose of providing these snubber circuits 343, 345, 347 is to ensure voltage to be shared equally among the switch devices 336, 338, 342 during the dynamic switching process.

FIG. 10 illustrates a schematic diagram of one phase leg of a converter in accordance with another exemplary embodiment of the present disclosure. In particular, the single phase leg 400 shown in FIG. 10 can be used to replace one or more of the three phase legs 220, 250, 280 shown in FIG. 2. In the illustrated embodiment, the single phase leg 400 is configured to provide an output voltage having seven levels. As shown in FIG. 10, the single phase leg 400 includes a first port 402 and a second port 404 for receiving or providing DC voltages. The single phase leg 400 also includes a DC-link 460 for filtering the DC voltages and providing substantially constant voltage to the switch unit or switch devices connected to the DC-link 460. The single phase leg 400 also includes a third port 405 for providing or receiving AC voltages. In one embodiment, the DC-link 460 is electrically coupled between a first DC line 406 and a second DC line 408, and the first DC-link 406 includes a first capacitor 462 and a second capacitor 464 connected in series.

Referring to FIG. 10, the single phase leg 400 also includes a first converter module 410, a second converter module 420, and a third converter module 430 connected in a nested manner substantially similar to the single phase leg 220 shown in FIG. 3. In the illustrated embodiment, each of the three converter modules 410, 420, 430 is configured to provide three-level output voltage, such that the single phase leg 400 can provide seven-level output voltage. In other embodiments, the single phase leg can also be constructed by nesting a five-level converter module with a three-level converter module. Similar to the single phase leg 220 shown in FIG. 3, each of the three converter modules 410, 420, 430 is arranged to have six connecting terminals for connecting to corresponding connecting terminals of other converter modules. As shown in FIG. 10, the first converter module 410 includes four switch units 412, 414, 416, 418, the second converter module 420 includes four switch units 422, 424, 426, 428, and the third converter module 430 includes four switch units 432, 434, 436, 438. Of these switch units, six switch units 432, 422, 412, 414, 424, 434 are connected in series to form a longitudinal arm, another six switch units 438, 436, 428, 426, 418, 416 are connected in series to form a transverse arm. One end of the transverse arm is electrically connected to DC middle point 412 of the DC link 460, and the other end of the transverse arm is electrically connected to a joint connection defined between the two switch units 412, 414. The single phase leg 400 also includes a first flying capacitor 442 and a second flying capacitor 444 connected in series to form a first flying capacitor arm 440. The single phase leg 400 also includes a third flying capacitor 452 and a fourth flying capacitor 454 connected in series to form a second flying capacitor arm 450. One end of the first flying capacitor 442 and one end of the second flying capacitor 444 are commonly connected to joint connection 443 defined between the two switch units 418, 426. The other end of the first flying capacitor 442 is connected to joint connection defined between the two switch units 422, 412, and the other end of the second flying capacitor 444 is connected to a joint connection defined between the two switch units 414, 424. One end of the third flying capacitor 452 and one end of the fourth flying capacitor 454 are commonly connected to joint connection 453 defined between the two switch units 436, 428. The other end of the third flying capacitor 452 is connected to joint connection defined between the two switch units 432, 422, and the other end of the fourth flying capacitor 454 is connected to a joint connection defined between the two switch units 424, 434.

FIG. 11 illustrates at least a part of a drive unit 500 in accordance with an exemplary embodiment of the present disclosure. The drive unit 500 can be used to drive any one of the switch units shown in FIG. 2 and FIG. 10. As shown in FIG. 10, the drive unit 500 includes a main disassembling circuit 512, a first drive circuit 412, a second drive circuit 516, and a p^thdrive circuit 518, where p is equal to or larger than two. In one embodiment, the number of the drive circuits is the same as the number of the switch devices that are series connected in the switch unit. In one embodiment, the main disassembling circuit 512 is arranged to be in optical communication (e.g., through one or more optical fibers) with the first drive circuit 514, the second drive circuit 516, and the n^thdrive circuit 518. The main disassembling circuit 512 is configured to receive a main driving signal 542 and disassemble the main drive signal 542 into a first optical driving signal 544, a second optical driving signal 546, and a p^thoptical driving signal 548, where p is equal to or larger than two. The main driving signal 542 may be generated from the control device 140 shown in FIG. 1 through the implementation of one or more modulation algorithms, including but not limited to, pulse width modulation algorithm, space vector pulse width modulation algorithm, as so on. The first drive circuit 514 is configured to convert the first optical driving signal 544 into a first electric driving signal 552, and supply the first electric driving signal 552 to the first switch device 522. The second drive circuit 516 is configured to convert the second optical driving signal 546 into a second electric driving signal 554, and supply the second electric driving signal 554 to the second switch device 524. The p^thdrive circuit 518 is configured to convert the p^thoptical driving signal 548 into p^thelectric driving signal 550, and supply the p^thelectric driving signal 550 to the p^thswitch device 526. The first switch device 522 is connected in parallel with a first anti-parallel diode 528, the second switch device 524 is connected in parallel with a second anti-parallel diode 532, and the p^thswitch device 526 is connected in parallel with a p^thanti-parallel diode 534. In some embodiments, the first electric driving signal 552, the second electric driving signal 554, and the p^thelectric driving signal 550 are supplied in a manner to allow the first switch device 522, the second switch device 524, and the p^thswitch device 526 can be turned on and/or off simultaneously.

FIG. 12 illustrates a block diagram of at least part of a drive unit 500 in accordance with another exemplary embodiment of the present disclosure. The drive unit 500 shown in FIG. 12 is substantially similar to what has been shown and described with reference to FIG. 11. For example, the drive unit 500 shown in FIG. 12 also includes a main disassembling circuit 512, a first drive circuit 514, a second drive circuit 516, and a p^thdrive circuit 518. In particular, in the illustrated embodiment, the first switch device 522 is arranged with a first snubber circuit 529, the second switch device 524 is arranged with a second snubber circuit 531, and the p^thswitch device 526 is arranged with a p^thsnubber circuit 533. In one embodiment, each of the three snubber circuits 529, 531, 533 are coupled in parallel with the three switch devices 522, 524, 526 respectively. In other embodiments, these snubber circuits 529, 531, 533 can be coupled in series or both in series and in parallel with the switch devices 522, 524, 526 respectively. The use of these snubber circuits 529, 531, 533 can ensure substantially synchronous switching actions of the switch devices 522, 524, 526, such that voltage applied to these switch devices 522, 524, 526 can be shared equally during the dynamic switching processes.

FIG. 13 is a flowchart which outlines an implementation of a method 560 for driving a converter, or more particularly, a converter configured to have a nested NPP topology as shown in FIG. 2. At least some of the blocks/actions illustrated in method 560 may be programmed with software instructions stored in a computer-readable storage medium. The computer-readable storage medium may include volatile and nonvolatile, removable and non-removable media implemented in any method or technology. The computer-readable storage medium includes, but is not limited to, RAM, ROM, EEPROM, flash memory or other memory technology, CD-ROM, digital versatile disks (DVD) or other optical storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other non-transitory medium which can be used to store the desired information and which can be accessed by one or more processors.

In one embodiment, the method 560 may start to implement from block 562. At block 562, an action is performed to provide first main driving signal to a first switch unit, for example, the fifth switch unit 238 of the second converter module 224 of the first phase leg 220. As shown in FIG. 4, when the output voltage level is “2,” the main driving signal supplied to the fifth switch unit 238 both include logic “0” and logic “1” signals due to the introduction of a time delay t_d.

In one embodiment, the method 560 may further include a block 564. At block 564, an action is performed to provide second main driving signal to a second switch unit, for example, the seventh switch unit 244 of the second converter module 244 of the first phase leg 220. As shown in FIG. 4, when the output voltage level is “2,” the second main driving signal supplied to the seventh switch unit 244 is always a logic “0” signal. Thus, the fifth switch unit 238 and the seventh switch unit 244 can be controlled to operate both in a complementary pattern and a non-complementary pattern.

FIG. 14 illustrates a flowchart of a method 600 for driving a converter such as the converter shown in FIG. 2.

In one embodiment, the method 600 may start to implement from block 602. At block 602, a main driving signal is disassembled into at least a first optical driving signal and a second optical driving signal. The action performed at block 602 may be accomplished by the main disassembling circuit 512 shown in FIG. 11 or FIG. 12.

In one embodiment, the method 600 may further include a block 604. At block 604, the first optical driving signal is converted into a first electric driving signal, which is responsible by the first drive circuit 514 shown in FIG. 11 or FIG. 12.

In one embodiment, the method 600 may further include a block 606. At block 606, the second optical driving signal is converted into a second electric driving signal, which is responsible by the second drive circuit 516 shown in FIG. 11 or FIG. 12.

In one embodiment, the method 600 may further include a block 608. At block 608, the first electric driving signal is supplied to a first switch device in the switch unit.

In one embodiment, the method 600 may further include a block 610. At block 610, the second electric driving signal is supplied to a second switch device in the switch unit. In some embodiments, the first electric driving signal and the second electric driving signal are supplied in a manner to allow the first and second switch devices are turned on and/or off substantially synchronously. Still in some embodiments, snubber circuits may be arranged in association with the switch devices to ensure voltage can be shared equally among the switch devices.

FIG. 15 illustrates a power conversion method 700 in accordance with an exemplary embodiment of the present disclosure. In some specific embodiments, the power conversion method 700 may be implemented with the use of a converter constructed with a new or improved nested NPP topology as shown in FIG. 2.

In one embodiment, the method 700 may start to implement from block 702. At block 702, a first converter (e.g., an AC-DC converter) is used to convert a first AC voltage provided from a power source such as a power grid into a DC voltage. In particular, the first converter is arranged to have the nested NPP topology to perform AC-DC power conversion. In some other embodiments, it is possible to use passive devices such as a rectifier formed to have diode bridge structure to convert the first AC voltage into DC voltage.

In one embodiment, the method 700 may further include a block 704. At block 704, a second converter (e.g., DC-AC converter or inverter) is used to convert the DC voltage into a second AC voltage. In some embodiments, the second converter is also designed to have the nested NPP topology for performing DC-AC power conversion.

In one embodiment, the method 700 may further include a block 706. At block 706, the second AC voltage is supplied to a load such as an AC motor. When the second AC voltage is a three-phase AC voltage, the AC motor can be a three-phase AC motor.

While the invention has been described with reference to exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. Furthermore, the skilled artisan will recognize the interchangeability of various features from different embodiments. Similarly, the various method steps and features described, as well as other known equivalents for each such methods and feature, can be mixed and matched by one of ordinary skill in this art to construct additional assemblies and techniques in accordance with principles of this disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.

SYSTEM AND METHOD FOR POWER CONVERSION

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CPC

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