Reliability Improvement of Regenerative Cascaded H-bridge (CHB) Medium-Voltage Drive

Abstract

High power converters are widely used in many industries. At power levels in the range of Mega Watt (MW), power conversion at medium voltage (MV) is preferred due to better efficiency and lower cost. For medium voltages applications, multilevel converters are widely adopted due to the features they offer with respect to two-level converters. Cascaded H-bridge topology is a widely adopted multilevel topology because of its modularity, scalability, and reliability. The conventional cascaded H-bridge topology allows two-quadrant operation. In order to allow fourquadrant operation, an active front end version of the cascaded H-bridge topology has been proposed in literature and recently commercialized. In the field, power converters operates under harsh loading and environmental conditions. The resulting stresses imposed on converter components cause their gradual degradation. In cascaded H-bridge converters, typically power cell components such as power modules, DC-bus capacitors, and control PCBs are v highly stressed. Under these stresses power cell components degrade and require replacement in the field, otherwise unexpected failures may occur. The thesis aim is to address power cell components reliability through proposing novel regenerative cascaded H-bridge converter control schemes to reduce components stresses and failure probability without increasing size, cost, or complexity. First, a novel PWM active front end control scheme has been proposed to reduce the inherent ripple current stresses on the DC-bus capacitors. Second, the thesis proposes a novel grid or near grid switching frequency front end control scheme to reduce stresses on power modules and the power cell cooling requirements. Third, novel cascaded H-bridge front end control schemes are proposed to reduce the sensor count, thereby decreasing failure rate and cutting down cost. The proposed work has been thoroughly validated through detailed 9- cell regenerative cascaded H-bridge system simulation and experimentation.