Recent developments of high power converters for industry andtraction applications

The introduction of new high power devices like integrated gate commutated thyristors (IGCTs) and high voltage insulated gate bipolar transistors (IGBTs) accelerates the broad use of pulse width modulation (PWM) voltage source converters in industrial and traction applications. This paper summarizes the state-of-the-art of power semiconductors. The characteristics of IGCTs and high voltage IGBTs are described in detail. Both the design and loss simulations of a two level 1.14 MVA voltage source inverter and a 6 MVA three-level neutral point clamped voltage source converter with active front end enable a detailed comparison of both power semiconductors for high power PWM converters. The design and the characteristics of a commercially available IGCT neutral point clamped PWM voltage source converter for medium voltage drives are discussed. Recent developments and trends of traction converters at DC mains and AC mains are summarized     

Design of a Soft-Switched 6-kW Battery Charger for Traction Applications

Auxiliary power converters for traction rolling stock applications have to operate under difficult conditions, including high-input voltages which are subject to wide fluctuations, high temperatures, and harsh environmental constraints. Additionally there is often a need for silent operation, which implies switching frequencies above 20 kHz. Increasingly, high-frequency DC-DC converters are being used for these applications, with their advantages of reduced size and weight. However, the requirement to accommodate high-input voltages and switch at high frequencies is challenging for a conventional hard-switched converter based on IGBTs, which makes soft-switching topologies an attractive alternative. This paper presents the design strategy for a zero-voltage switched (ZVS) 6-kW battery charger switching at 20 kHz using IGBTs. This paper illustrates how the design is a tradeoff between managing the hard-switch turn-on losses at light load, minimizing the duty cycle loss caused by soft-switching delays, and minimizing the effects of tail current-switching losses. These tradeoffs affect the selection of the ZVS capacitors, the determination of the series inductance value, the transformer turns ratio, and the selection of the IGBTs to be used. Design details, theoretical predictions, and experimental results are presented in this paper for the conversion system that was developed.     

Voltage Balancing Control for a Three-Level Diode-Clamped Converter in a Medium-Voltage Transformerless Hybrid Active Filter

This paper discusses a transformerless hybrid active filter integrated into the 6.6-kV, 1-MW adjustable-speed motor drive having a three-phase diode rectifier at the front end. The hybrid filter consists of an active filter using a three-level diode-clamped pulsewidth modulator converter rated at 60 kVA, and a 250-kVA passive filter tuned to the seventh harmonic frequency. They are directly connected in series without a transformer. This circuit configuration enables one to use 1.2-kV insulated gate bipolar transistors because the dc voltage of the three-level converter is 1.32 kV (20% of 6.6 kV). Voltage balancing control characterized by superimposing a sixth harmonic zero-sequence voltage on the active filter voltage reference in each phase is introduced to the three-level converter with triangle carrier modulation. Experimental waveforms obtained from a 400-V, 15-kW downscaled system verify the viability and effectiveness of the proposed hybrid filter, keeping the two dc capacitor voltages well-balanced.     

Zero-Voltage and Zero-Current Switching Full-Bridge DC–DC Converter With Auxiliary Transformer

A novel zero-voltage and zero-current switching (ZVZCS) full-bridge phase-shifted pulsewidth modulation (PWM) converter using insulated gate bipolar transistors (IGBTs) with auxiliary transformer is proposed to improve the properties of the previously presented converters. ZVZCS for all power switches is achieved for full load range from no-load to short circuit by adding active energy recovery snubber and auxiliary circuits. The principle of operation is explained and analyzed and experimental results are presented. The features and design considerations of the converter are verified on a 3-kW, 50-kHz IGBT based experimental circuit.     

A Bidirectional Isolated DC–DC Converter as a Core Circuit of the Next-Generation Medium-Voltage Power Conversion System

This paper describes a bidirectional isolated dc-dc converter considered as a core circuit of 3.3-kV/6.6-kV high-power-density power conversion systems in the next generation. The dc-dc converter is intended to use power switching devices based on silicon carbide (SiC) and/or gallium nitride, which will be available on the market in the near future. A 350-V, 10-kW and 20 kHz dc-dc converter is designed, constructed and tested. It consists of two single-phase full-bridge converters with the latest trench-gate insulated gate bipolar transistors and a 20-kHz transformer with a nano-crystalline soft-magnetic material core and litz wires. The transformer plays an essential role in achieving galvanic isolation between the two full-bridge converters. The overall efficiency from the dc-input to dc-output terminals is accurately measured to be as high as 97%, excluding gate drive and control circuit losses from the whole loss. Moreover, loss analysis is carried out to estimate effectiveness in using SiC-based power switching devices. Loss analysis clarifies that the use of SiC-based power devices may bring a significant reduction in conducting and switching losses to the dc-dc converter. As a result, the overall efficiency may reach 99% or higher     

Characterization and Comparison of High Blocking Voltage IGBTs and IEGTs Under Hard- and Soft-Switching Conditions

The market of converters connected to transmission lines continues to require insulated gate bipolar transistors (IGBTs) with higher blocking voltages to reduce the number of IGBTs connected in series in high-voltage converters. To cope with these demands, semiconductor manufactures have developed several technologies. Nowadays, IGBTs up to 6.5-kV blocking voltage and IEGTs up to 4.5-kV blocking voltage are on the market. However, these IGBTs and injection-enhanced gate transistors (IEGTs) still have very high switching losses compared to low-voltage devices, leading to a realistic switching frequency of up to 1 kHz. To reduce switching losses in high-power applications, the auxiliary resonant commutated pole inverter (ARCPI) is a possible alternative. In this paper, switching losses and on-state voltages of NPT-IGBT (3.3 kV-1200 A), FS-IGBT (6.5 kV-600 A), SPT-IGBT (2.5 kV-1200 A, 3.3 kV-1200 A and 6.5 kV-600 A) and IEGT (3.3 kV-1200 A) are measured under hard-switching and zero-voltage switching (ZVS) conditions. The aim of this selection is to evaluate the impact of ZVS on various devices of the same voltage ranges. In addition, the difference in ZVS effects among the devices with various blocking voltage levels is evaluated.     

A 6.6-kV Transformerless Motor Drive Using a Five-Level Diode-Clamped PWM Inverter for Energy Savings of Pumps and Blowers

This paper describes a 6.6-kV adjustable-speed motor drive for pumps and blowers without transformer. The power conversion system consists of a front-end diode rectifier, a five-level diode-clamped pulsewidth modulation (PWM) inverter with a voltage balancing circuit, and a hybrid active filter for harmonic-current mitigation of the diode rectifier. The control of the inverter is characterized by superimposing a third-harmonic zero-sequence voltage on each of the three-phase reference voltages to achieve the so-called overmodulation and reduce the switching stress of insulated gate bipolar transistors (IGBTs). A 200-V 5.5-kW downscale model is designed, constructed, and tested with focus on the five-level PWM inverter and the voltage balancing circuit. Experimental results obtained from the 200-V downscale model verify the viability and effectiveness of the 6.6-kV adjustable-speed motor drive, showing that the four split dc capacitor voltages are well balanced in all the operating conditions and that the switching stress of the IGBTs is reduced at low modulation indexes.     

采用辅助变压器的零电压零电流开关全桥直-直变换器

本文给出了一种新型的零电压零电流开关全桥移相脉宽调制变换器,该变换器采用IGBT为功率开关管,在传统变换器的基础上通过增加辅助变压器的方式提高了变换器的性能,通过增加正激能量恢复缓冲器和辅助电路,使变换器在各种负载以及短路工作状态下都能够保证所有开关管实现零电压零电流开关工作模式。介绍了变换器的工作原理并通过试验得到了较好的结果。     

Novel zero-current-switching PWM converters

This paper presents a new family of pulsewidth-modulated (PWM) converters, featuring soft commutation of the semiconductors at zero current (ZC) in the transistors and zero voltage (ZV) in the rectifiers. Besides operating at constant frequency and with reduced commutation losses, these new converters have output characteristics similar to the hard-switching-PWM counterpart, which means that there is no circulating reactive energy that would cause large conduction losses. The new family of zero-current-switching (ZCS)-PWM converters is suitable for high-power applications using insulated gate bipolar transistors (IGBTs). The advantages of the new ZCS-PWM boost converter employing IGBTs, rated at 1.6 kW and operating at 20 kHz, are presented. This new ZCS operation can reduce the average total power dissipation in the semiconductors practically by half, when compared with the hard-switching method. This new ZCS-PWM boost converter is suitable for high-power applications using IGBTs in power-factor correction. The principle of operation, theoretical analysis, and experimental results of the new ZCS-PWM boost converter are provided in this paper to verify the performance of this new family of converters     

Design of transformerless quasi-broad-band matching networks forlumped complex loads using nonuniform transmission lines

A simple design method for transformerless and lossless quasi-broadband matching of a lumped RC load is presented by use of a parabolic nonuniform transmission line. The key idea in removing an ideal transformer from the matching network is based on impedance transformation of the nonuniform transmission line, whose mixed lumped and distributed equivalent circuit contains an ideal transformer. Illustrative examples and some design curves are presented     

PWM-PD multiple output DC/DC converters: operation and control-loop modeling

In this paper, PWM-PD multiple output dc/dc converters are presented. Operation analysis and power block design are shown. Furthermore, a small-signal model is developed for the PWM-PD multiple output dc/dc converters working in continuous conduction mode. The control-block is presented and the closed-loop circuit performances, such as the line, load and cross regulation, are obtained analytically. Finally, experimental results for a PWM-PD converter, with three fully regulated outputs and with transformer, are shown.     

A multiple-switch high-voltage DC-DC converter

Series connection of power devices has evolved into a mature technique and is widely applied in HV DC power systems. Static and dynamic voltage balance is ensured by shunting individual devices with dissipative snubbers. The snubber losses become pronounced for increased operating frequencies and adversely affect power density. Capacitive snubbers do not exhibit these disadvantages, but they require a zero-voltage switching mode. Super-resonant power converters facilitate the principle of zero-voltage switching. A high-voltage DC-DC power converter with multiple series-connected devices is proposed. It allows the application of nondissipating snubbers to assist the voltage sharing between the multiple series-connected devices and lowers turnoff losses. Simulation results obtained with a circuit simulator are validated in an experimental power converter operating with two series-connected devices. The behavior of the series connection is examined for MOSFETs and IGBTs by both experimental work with a 2 kW prototype and computer simulation. Applications can be found in traction and heavy industry, where the soft-switching power converter is directly powered from a high-voltage source     

An overview of the reliability prediction related aspects of high power IGBTs in wind power applications

Reliability is becoming more and more important as the size and number of installed Wind Turbines (WTs) increases. Very high reliability is especially important for offshore WTs because the maintenance and repair of such WTs in case of failures can be very expensive. WT manufacturers need to consider the reliability aspect when they design new power converters. By designing the power converter considering the reliability aspect the manufacturer can guarantee that the end product will ensure high availability. This paper represents an overview of the various aspects of reliability prediction of high power Insulated Gate Bipolar Transistors (IGBTs) in the context of wind power applications. At first the latest developments and future predictions about wind energy are briefly discussed. Next the dominant failure mechanisms of high power IGBTs are described and the most commonly used lifetime prediction models are reviewed. Also the concept of Accelerated Life Testing (ALT) is briefly reviewed.     

A contactless power transfer system using a series–series–parallel resonant converter

In this article, a contactless power transfer system using a series–series–parallel resonant converter (SSPRC) is proposed. The proposed converter can improve on or eliminate the disadvantages of the contactless system based on conventional resonant converters, since it independently compensates for a primary side leakage inductance, a secondary side leakage inductance and a magnetising inductance. The proposed converter also reduces the circulating currents and the reactive power by controlling the phase angle difference between the inverter output voltage and the current. In addition, the system design can be simplified, since the voltage gain is determined only by the transformer turns ratio for the overall load range without being affected by the other transformer parameters. The proposed converter is analysed with respect to the gain and current margin. The system design procedure is then described for the proposed circuit based on the circuit analysis. Finally, the experimental results are presented in order to verify the proposed contactless power supply.     

An improved ZCS-PWM commutation cell for IGBT's application

An improved zero-current-switching pulsewidth-modulation (ZCS-PWM) commutation cell is proposed, which is suitable for high-power applications using insulated gate bipolar transistors (IGBTs) as the power switches. It provides ZCS operation for active switches with low-current stress without voltage stress and PWM operating at constant frequency. The main advantage of this cell is a substantial reduction of the resonant current peak through the main switch during the commutation process. Therefore, the RMS current through it is very close to that observed in the hard-switching PWM converters. Also, small ratings auxiliary components can be used. To demonstrate the feasibility of the proposed ZCS-PWM commutation cell, it was applied to a boost converter. Operating principles, theoretical analysis, design guidelines and a design example are described and verified by experimental results obtained from a prototype operating at 40 kHz, with an input voltage rated at 155 V and 1 kW output power. The measured efficiency of the improved ZCS-PWM boost converter is presented and compared with that of hard-switching boost converter and with some ZCS-PWM boost converters presented in the literature. Finally, this paper presents the application of the proposed soft-switching technique in DC-DC nonisolated power converters     

A novel active power quality compensator topology for electrified railway

To improve the power quality of traction power system, a novel active power quality compensator (APQC) and a new compensating currents detection method are proposed. The APQC consists of a three-phase voltage source converter and a Scott transformer. The Scott transformer, taken as an isolation transformer, not only connects the three-phase converter to the traction power system, but also converts the traction power system to a nearly balanced three-phase power system. Therefore, a general three-phase converter could be used in APQC. Regarding the traction substation as a compensating object, the power quality of a traction substation can be improved integrally. Simulation and prototype experimental results show that the proposed APQC is able to compensate reactive power, harmonic, and negative-sequence currents in two feeders of a traction substation.     

A New Family of Zero-Current-Switching (ZCS) PWM Converters

A new family of zero-current-switching (ZCS) pulsewidth-modulated (PWM) converters which uses a new ZCS-PWM switch cell is presented in this paper. The main switch and auxiliary switch operate at ZCS turn-on and turn-off, and all the passive semiconductor devices in the ZCS-PWM converter operate at zero-voltage-switching (ZVS) turn-on and turn-off. Besides operating at constant frequency and with reduced commutation losses, these new converters have no additional current stress in comparison to the hard-switching converter counterpart. The new family of ZCS-PWM converters is suitable for high-power applications using insulated gate bipolar transistors (IGBTs). The PWM switch model and state-space averaging approach is used to estimate and examine the steady-state and dynamic character of the system. The principle of operation, theoretical analysis, and experimental results of the new ZCS-PWM boost converter, rated 1 kW and operating at 30 kHz, are provided in this paper to verify the performance of this new family of converters.     

Novel Three-Phase AC–AC Sparse Matrix Converters

A novel three-phase ac-ac sparse matrix converter having no energy storage elements and employing only 15 IGBTs, as opposed to 18 IGBTs of a functionally equivalent conventional ac-ac matrix converter, is proposed. It is shown that the realization effort could be further reduced to only nine IGBTs in an ultra sparse matrix converter (USMC) in the case where only unidirectional power flow is required and the fundamental phase displacement at the input and at the output is limited to plusmnpi/6. The dependency of the voltage and current transfer ratios of the sparse matrix converters on the operating parameters is analyzed and a space vector modulation scheme is described in combination with a zero current commutation method. Finally, the sparse matrix concept is verified by simulation and experimentally using a 6.8-kW/400-V very sparse matrix converter, which is implemented with 12 IGBT switches, and USMC prototypes.     

New family of zero-current-switching PWM converters using a new zero-current-switching PWM auxiliary circuit

A new family of zero-current-switching (ZCS) pulsewidth-modulation (PWM) converters using a new ZCS-PWM auxiliary circuit is presented in this paper. The main switch and auxiliary switch operate at ZCS turn-on and turn-off, and the all-passive semiconductor devices in the ZCS-PWM converters operate at zero-voltage-switching (ZVS) turn-on and turn-off. Besides operating at constant frequency and reducing commutation losses, these new converters have no additional current stress and conduction loss in the main switch in comparison to the hard-switching converter counterpart. The PWM switch model and state-space averaging approach is used to estimate and examine the steady-state and dynamic character of the system. The new family of ZCS-PWM converters is suitable for high-power applications using insulated gate bipolar transistors (IGBTs). The principle of operation, theoretical analysis, and experimental results of the new ZCS-PWM boost converter, rated 1.6 kW and operating at 30 kHz, are provided in this paper to verify the performance of this new family of converters.     

Novel zero-current-transition PWM converters

A new family of zero-current-transition (ZCT) pulsewidth-modulated (PWM) converters is proposed. The new family of converters implements zero-current turn-off for power transistor(s) without increasing voltage/current stresses and operates at a fixed frequency. The proposed converters are deemed most suitable for high-power applications where the minority-carrier semiconductor devices (such as IGBTs, BJTs, and MCTs) are predominantly used as the power switches. Theoretical analysis is verified on a 100 kHz, 1 kW ZCT-PWM boost converter using an IGBT