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Abstract—The number of voltage levels available in pulsewidth output ac filters (large ac filter inductors are expensive, increase
modulation (PWM) voltage source inverters can be increased by losses, and have a large fundamental voltage drop).
using a split-wound coupled inductor within each inverter leg and Parallel-connected inverter modules, which either use cur-
interleaved PWM switching of the upper and lower switches. The
magnetizing inductance of the symmetrical split-wound inductor rent ripple cancellation or alternatively multilevel PWM output
filters the high-frequency PWM voltage differences between the voltages [1]–[9] [e.g., Fig. 1(c), (e), and (f)], are widely used
upper and lower switches. The same inductor presents a three-level techniques for increasing the effective PWM and current ripple
PWM voltage at the inverter output terminals, with the winding frequency above the device switching frequency. This often re-
leakage inductance being located in series with the low-frequency sults in lower device losses, smaller inductors, a lowering of the
output current. Deadtime PWM signal delays can be reduced as
dc-rail short circuits are not possible: as a result, the quality and current ripple magnitude, and a faster inverter transient response.
voltage range of the PWM output is improved. Since the inductor Parallel-connected modules often use interleaved PWM and ac
windings are technically exposed to high-frequency PWM ac volt- filter inductors connected between the modules to achieve high-
ages with no dc components, device voltage drops help to reduce frequency current ripple cancellation and a lower output current
the buildup of winding dc currents. Theoretical analysis and a sam- ripple. There are many current balancing issues [4]–[8] and since
ple design case are presented to illustrate how to design suitable
inductors for the various topologies. Simulation and experimental the various inductors cannot be guaranteed to have the same
results are used to illustrate the operation of the proposed inverter characteristics, harmonic current cancellation may not be opti-
structures. mal. Inverters with increased PWM levels have been proposed
Index Terms—Coupled inductors, interleaved pulsewidth mod- in motor drives [9] and interleaved PWM is used in parallel-
ulation (PWM), multilevel inverters, PWM rectifiers, single-phase connected inverters [10], [11], boost converters [12], [13], buck
rectifiers. converters [14], [15], and an asymmetrical bridge [16]. Cou-
pled inductors [17] and interleaved PWM techniques [18],
three-level half-bridge [20], and four-level half-bridge [21] are
I. INTRODUCTION also used in many situations. PWM signal deadtimes are used
to avoid shorting the dc supply, and many papers have been
HE STANDARD two-switch and four-switch inverters
T [Fig. 1(a) and (b)] are the preferred topologies in many
low-power single-phase systems such as fractional horsepower
written to provide compensation for their undesirable features
[21]–[24].
The proposed inverter topology differs from many of these
ac drives, lighting equipment, alternative energy systems, etc. As
schemes because, rather than adding more switch modules and
the performance factors, power level and fundamental operating
ac inductors, coupled inductors are included inside the standard
frequencies are increased, the ac filter inductor size and device
modules using interleaved PWM of the upper and lower switches
switching frequencies become restrictive design factors: high
in an inverter leg [see Fig. 2(a) and (b)]. Multilevel PWM output
energy storage requirements increase the inductor size, and max-
voltages are obtained with a PWM frequency higher than the
imum switching frequencies are limited by power losses, gate
switching frequency. The resultant topologies use smaller ac
drive restrictions, pulsewidth modulation (PWM) deadtimes,
filter inductors, faster transient response, fewer switches, do not
etc. As a result, the high-frequency current ripple at the inverter
experience critical dc supply shorts, improve the quality of the
output may not be as low as required and can cause problems
PWM waveforms by eliminating the need for switch deadtimes,
such as excessive heating in motor drives, electromagnetic in-
and are immune to circulating currents.
terference (EMI)/RF interference (RFI), and larger-than-desired
Fig. 1. Single-phase multilevel inverters. (a) Standard two-switch inverter leg. (b) Standard four-switch H-bridge. (c) Stacked dual inverter. (d) Eight-switch
H-bridge. (e) Interleaved dual inverter: current ripple cancellation. (f) Interleaved dual inverter with multilevel PWM voltage output.
Fig. 3. Magnetic core and winding arrangements for the coupled inductors. Fig. 5. Equivalent circuits of the proposed inverter leg. (a) Transformer equiv-
(a) Windings located on the center limb. (b) Layered winding. alent model. (b) Output terminal model. (c) Circuit model between the switches.
Fig. 4. Switching states of the proposed inverter leg. (a) Basic switching cell.
(b) S a U , S b L ON: v a = v d c /2. (c) S a U , S a L OFF: v a = v d c /2. (d) S a U OFF,
S a L ON: v a = 0. (e) S a U ON, S a L OFF: v a = v d c .
Fig. 7. Experimental waveforms for the split-wound coupled inductor and inverter leg. (a) 60 Hz fundamental cycle. (b) Expanded waveforms.
show that high-quality three-level sinusoidally modulated PWM A. AC Supply Filter Inductor Ls
voltages are obtained at the output terminals (see ia and va ). The The maximum high-frequency pk-pk current ripple for the ac
nature of the voltage waveform va illustrates that the leakage
filter inductor Ls is ∆Im ax and can be sized relative to the 60 Hz
inductance between the windings is low. The inductor voltage pk-pk value of the ac output current Ipp using Ris , Rf , and Rv
vaUL [Fig. 7(b)] illustrates that the PWM cycle inductor volt-
age is symmetrical with no dc component. This feature exists Ipp fc Vdc
Ris = Rf = Rv = √ . (2)
over the complete output voltage range; hence, no winding dc ∆Im ax fs 2Vs
current drifts or core saturation is produced by the interleaved
PWM control scheme. Hence, for the test condition, Ris = 20, Rv = 1.06, and Rf =
There is always a concern that dc and circulating currents are 166.7.
produced in parallel-connected inverters. Ideally, the parallel For the standard two-switch inverter leg, ∆Im ax occurs when
circuit paths have identical voltage drops and the natural vari- the inverter output terminal has a 50% duty ratio with the volt-
ations in the device operating conditions can cause unbalanced age switching between +Vdc and −Vdc [Fig. 1(a)]. The supply
currents. The device voltage drops in the proposed topology inductor Ls sees a PWM voltage that is a symmetrical square
produce a net negative voltage drop across the inductor (equal wave at the carrier frequency fc and magnitude Vdc
to one switch and one diode voltage drop on average) that acts Vdc 2Ipp fc Ls
against dc current drifts or circulating currents. Experimental ∆Im ax = Ris = . (3)
2fc Ls Vdc
testing illustrated that the switch turn-OFF times can produce a
positive inductor voltage drop, and hence, a dc current. How- Equations (1)–(3) can be used to link Lsp.u. with ∆Im ax . Similar
ever, practically, this can be overcome easily by introducing a analysis can be conducted for each of the topologies shown in
small difference between the switching of the upper and lower Figs. 1(a) and (b), and 2(a) and (b), with the results given in
switches to provide a small net negative inductor winding volt- Table I.
age drop, and hence, guarantee that no dc current builds up. Hence, suitable inductors to meet the test conditions are as
It should be noted, however, that the inductor windings have a follows.
natural dc current component determined by the magnitude of 1) Two-switch inverter leg (Lsp.u. = (1.57)[(20 × 1.06)/
the ac output current (see iaU , iaL in Fig. 7). 166.7] = 0.2 p.u.): With Lbase = 45 mH and Ls = 9 mH,
this inductor will have a 20% fundamental voltage drop at
IV. RIPPLE CURRENT AND INDUCTOR SIZE the rated current.
2) Four-switch standard H-bridge (Lsp.u. = 0.392[(20 ×
The analysis presented in this section uses a per unit system to
1.06)/166.7] = 0.05 p.u.): With Lbase = 45 mH, Ls =
allow inductor sizes to be chosen based upon the current ripple
2.25 mH, this inductor will have a 5% fundamental volt-
Vs2 age drop at the rated current.
Ls = Lsp.u. Lb Pbase = Vs Ibase Lbase = . (1) 3) Two-switch coupled inductor (Lsp.u. = 0.392[(20 ×
2πfs Pbase
1.06)/166.7] = 0.05 p.u.): Ls is the same as for the four-
A test condition is used to compare the inductor size and the switch H-bridge, 2.25 mH, with a 5% fundamental voltage
high-frequency current ripple for the various inverter topologies: drop across the inductor at rated current.
Vs = 120 V, fs = 60 Hz, Is,pk = 10 A, ∆Im ax = 5% peak-to- 4) Four-switch coupled inductor (Lsp.u. = 0.1[(20 ×
peak (pk-pk), Vdc = 1.5 Vs , switching frequency fc = 10 kHz 1.06)/166.7] = 0.0127 p.u.): With Lbase = 45 mH
(note: Vs is the ac load voltage). and Ls = 0.57 mH, this inductor will have a 1.3%
SALMON et al.: SINGLE-PHASE MULTILEVEL PWM INVERTER TOPOLOGIES USING COUPLED INDUCTORS 1263
TABLE I TABLE II
DESIGN PARAMETERS FOR THE AC FILTER INDUCTOR L s DESIGN PARAMETERS FOR THE COUPLED INDUCTOR L t
Fig. 9. Experimental comparison between the standard H-bridge and the proposed H-bridge. (a) Standard. (b) Using coupled inductors.
V. INDUCTOR DESIGN STUDY inductors used is less than the weight of the ac filter inductor
required for the standard H-bridge.
Inductor design parameters are compared here for a single-
phase four-switch H-bridge inverter using the following design 1) Standard H-bridge: WtTotal = 2222 g.
criteria: Vs = 120 V, fs = 60 Hz, Is = 7 A, with fc = 20 kHz 2) Proposed H-bridge (∆It,m ax = 6 A): WtTotal = 650 +
2 × 265 = 1170 g.
and Vdc = 200 V. Designs are considered for several max-
imum current ripple magnitudes: ∆It,m ax = 1.5, 4, and 6 A 3) Proposed H-bridge (∆It,m ax = 4 A): WtTotal = 650 +
(see Table III). 2 × 402 = 1604 g.
4) Proposed H-bridge (∆It,m ax = 1.5 A): WtTotal = 650 +
Inductors used in Table III are:
1) Ls1 : standard H-bridge ac inductor; 2 × 1002 = 2652 g.
If the winding ripple current is made too small, e.g.,
2) Ls2 : ac inductor for the proposed H-bridge;
∆It,m ax = 1.5 A, the total inductor weight required can be
3) Ls3 : experimental ac inductor used for the proposed
H-bridge; increased above that required for the standard inverters: if too
large, ∆It,m ax = 6 A, excessive core losses can be experienced.
4) Lta,b : H-bridge coupled inductors (1: ∆It,m ax = 1.5 A,
These results illustrate that the proposed topology can halve the
2: ∆It,m ax = 4 A, 3: ∆It,m ax = 6 A).
The coupled inductor required for each winding current ripple number of switches and can also be used to lower the com-
bined inductor weight. This weight reduction is limited by the
can be compared with each other and the ac filter inductor Ls .
Several design guidelines were used. winding dc magnetizing current component and the inductor
1) Low-permeability cores with a distributed airgap were core losses. Magnetic cores with lower core loses should be
considered rather than those used here. The main benefit of the
considered for all the ac inductors due to their slow sat-
uration characteristics. The maximum permissible core proposed approach is to allow multilevel PWM switching using
saturation was set at 50%. half the power electronics and suitable for applications using an
inductive load such as a motor.
2) High-permeability ferrite cores with an airgap were not
considered, as all inductors can be exposed to surge cur-
rents and have significant “dc flux” and energy storage.
3) The wire size was chosen to have the minimum cross VI. EXPERIMENTAL WAVEFORMS
section suitable for the rms current with no attempt to The experimental waveforms presented in this section used
minimize the Cu losses. a general-purpose laboratory test inverter with the following
4) The maximum ripple in the ac flux (Bac ) and manufacturer inductors (see Fig. 8) and load parameters.
data was used to estimate the core losses. This produces a 1) Vs = 120 V; Is = 7 A, fs = 60 Hz, Vdc = 200 V, fc =
large overestimate in the predicted core losses but is useful 20 kHz.
for comparison purposes. 2) Standard H-bridge: ac filter inductor = Ls1 .
Note that the designs for the ac filter inductors (Ls1 and Ls2 3) Proposed H-bridge: ac filter inductor = Ls3 .
in Table III) were chosen to give the same current ripple in 4) Coupled inductor = Lt1a,b , Lt2a,b .
both the bridge types, e.g., the standard H-bridge and the pro- The same standard laminated iron ac filter inductor was used
posed H-bridge (see ∆Im ax in Table III). For the experimental in all cases (Ls3 = 1 mH, Fig. 8) to allow comparison of the
waveforms, a 1-mH inductor was used for both cases (Ls3 in ac load current ripple magnitude. The interleaved PWM signals
Fig. 8) to compare the effect on the ac current ripple of using the were generated using a TI TMS320F2812 DSP.
proposed H-bridge rather than the standard H-bridge. A typical Since the proposed four-switch H-bridge produces five-level
design table for the various inductors is given in Table III and all PWM voltage waveforms across its two output terminals com-
the inductors used in experimental testing are shown in Fig. 8. pared with the three-level in the standard H-bridge, the out-
For the coupled inductor Lt (see Table III), the winding ripple put current ripple is reduced by 25% relative to the standard
current cases of 4 and 1.5 A, the total weight, WtTotal , of the H-bridge (Fig. 9).
SALMON et al.: SINGLE-PHASE MULTILEVEL PWM INVERTER TOPOLOGIES USING COUPLED INDUCTORS 1265
Fig. 10. Experimental comparisons of the coupled inductor winding currents as a result of using different inductor sizes (see Table III for the inductor parameters).
(a) L ta , b = L t2 a , b . (b) L ta , b = L t1 a , b .
VII. CONCLUSION
The use of a coupled split-wound inductor has been described
to allow interleaved PWM switching of the upper and lower
switches in an inverter leg. This increases the number of PWM
voltage levels at the inverter output terminals and doubles the
PWM frequency. The main benefits of this topology are the
Fig. 11. Experimental waveforms for the proposed inverter leg illustrating the following.
three-level PWM output voltage and a “raised cosine” winding current wave
shape: L ta , b = L t1 a , b (see Table III for the inductor parameters).
1) Multilevel PWM uses half the power electronics of alter-
native schemes; e.g., when compared with the standard
topologies, two-level is increased to three-level and three-
level is increased to five-level.
2) The load high-frequency current ripple in the ac output
current is lowered, which can lower the losses in the ac fil-
ter inductor or an ac motor: the latter has potential benefits
in terms of increasing the motor power ratings and effi-
ciency of the machine. These features have great potential
in high-speed machine drives. The multilevel output volt-
age waveforms also places less stress on the motor wind-
ings and help to alleviate motor winding dv/dt stresses.
3) The ac filter inductor can be reduced in size and its fun-
damental voltage drop reduced: this results in more fun-
damental voltage reaching the load.
Fig. 12. Experimental coupled inductor winding dc magnetizing current ic m
4) The switch control deadtimes can be eliminated, helping
compared with the ac load current ia : L ta , b = L t1 a , b (see Table III for the to improve the quality of the PWM voltage generation
inductor parameters). and increasing the maximum potential output voltage and
switching frequency.
5) The coupled inductor provides excellent protection against
The magnitude of the coupled inductor winding current rip- dc-rail shoot-through conditions.
ple does not affect the load current ripple or the quality of the
PWM output voltage waveforms (Figs. 9 and 10). The coupled
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