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Published in IET Power Electronics
Received on 29th April 2010
Revised on 27th August 2010
doi: 10.1049/iet-pel.2010.0139
ISSN 1755-4535
Abstract: A recently introduced method of improving converter input current waveforms as well as power factor are re-evaluated
under non-ideal operating conditions, that is, variable DC bus and unbalanced supply. The proposed method makes use of a novel
controlled front-end diode rectifier of a rectifier – inverter structure. The technique involves the use of bi-directional bi-pass
switches across the front-end rectifier, with a dSPACE-based intelligent control algorithm. The operation of the converter is
fully analysed as possible DC/AC drives and a complete design example is provided. The main feature of the topology is low
cost, small size, high power factor and simplicity. It is found to be a universal retrofit for DC drives, and in the front-end
rectifier of existing three-phase AC drives, UPS etc. for power factor correction without any passive or active filtering.
Fig. 1 Front-end rectifier with three bi-directional switches and the switch layout
a conventional three-phase diode rectifier, resulting in With the above method, the input current THD can be as
periodical intervals where such current is null. The effect is low as 6.6% and input PF as high as 0.996. However, this
a low input PF and high harmonic distortion of the input simple diode rectifier was proposed to operate with a fixed
current. Each of the bidirectional switches Sa , Sb and Sc is load and fixed ‘optimal’ input inductance [2]. Since the
turned on during a specific interval, providing an alternative bidirectional switches are operated independent of load on
path for the input current. Thus the input current waveform the rectifier bridge, this method cannot provide optimum
is well shaped to nearly sinusoidal and a gate pulse with a input PF as well as input current THD under varying load
fixed duration of 1/12 of line voltage period (308) results in conditions. For example, the rectifier input PF can drop
a remarkable improvement of the input PF and input current below 0.9 and input current THD increased to 20% due to
total harmonic distortion (THD). the input current discontinuity at low-power conditions.
The rated output voltage of the converter can be calculated Fig. 2 depicts the rectifier performance at fixed bi-directional
by assuming the phase current to be zero when vt ¼ 1808 [2]. switch conduction under various load conditions. When
delivering a higher power than rated value, the rectifier
√ operates in a non-efficient mode as the PF suddenly drops
36 2Vi
VO = √ = 1.366Vi (1) (Fig. 2b). The phase shift between input current and voltage
7p 3 of the rectifier is found to exceed 308, resulting in a lower
input PF. At the same time, the voltage drop across the input
where VO is the rated output voltage and Vi is the input line to inductance is large due to the high input current [10–13].
line voltage.
Assuming that the input current supplies the load during 2 Proposed method at variable DC
the 908– 1208 interval, the critical input inductance can be bus power
determined by using (2) [2].
In this work, a unity PF front-end rectifier is proposed which
36 √ V2 V2 can operate either as a dc (Fig. 1) or an ac drive with a rear-
L = (2 2 − 3) · 3i = 3.8489 × 10−2 · i (2) end inverter as shown in Fig. 3. The rectifier– inverter
7 2p fPO fPO
structure can function at varying load conditions and supply
where f is the ac system frequency, Po and is the rectifier rated voltage and overcomes all the drawbacks mentioned above.
output power. It is achieved through the intelligent controller that varies
900 IET Power Electron., 2011, Vol. 4, Iss. 8, pp. 899 –907
& The Institution of Engineering and Technology 2011 doi: 10.1049/iet-pel.2010.0139
www.ietdl.org
the conduction period of bidirectional switches. These and 8. In stages 3, 6 and 9, only two phases are conducting
switches operate at only two times the line frequency and and the third phase current is discontinuous. For stage 1 in
its gating circuit is relatively simple. Owing to the low- 0 2 a interval, the following equations can be obtained
frequency nature of the switching patterns, power losses are with reference to Fig. 4a
reduced and low-cost devices can be used. This results in a
significant reduction in cost. ⎧
⎪ di
⎪
⎪ va = L a + vMN
⎪
⎪ dt
2.1 Converter operation below its rated power ⎨
di 1
vb = −L b − Vdc + vMN (3)
⎪
⎪ dt 2
When the output power is lower than the rated output power, ⎪
⎪
bidirectional switch conduction angle a is adjusted to make ⎪
⎩ v = L dic + 1 V + v
c
the output voltage constant and at the rated value. Due to dt 2 dc MN
Fig. 4 Topological stages for ‘08 –1808’ interval of the input voltage Va
a Stage 1: 0 2 a interval
b Stage 2: a 2 ( p/3 2 b) interval
c Stage 3: ( p/3 2 b) 2 p/3 interval
d Stage 4: p/3 2 ( p/3 + a) interval
For a 2 ( p/3 2 b) interval, (8) can be obtained according to For a small value of b, one can obtain the approximate
Fig. 4b equation as
⎧ p
di b≃ −a (13)
⎪
⎪ va = L a + vMN 6
⎪
⎪
⎪
⎪ dt
⎪
⎨ di 1 In order to find the relationship between the conduction angle
vb = −L b − Vdc + vMN a and normalised dc link current, numerous attempts have
dt 2 (8)
⎪
⎪
⎪
⎪ dic 1 been made utilising Table 1. The following relationship was
⎪
⎪ v =L + V + vMN
⎪ c
⎩ dt 2 dc found to best match its behavioural pattern
ia − ib + ic = 0
a = 14.9 + 15.1k (14)
The voltage vMN and the phase current ia can be calculated as
(9) and (10), respectively. a is in degree and k denotes the normalised dc link current
with respect to the rated dc link current.
Vdc
vMN = − (9) 2.2 Converter operation above its rated power
6
When the output power demand is higher than the rated
di V output power, the conduction angle is adjusted to maintain
va = L a + dc (10)
dt 3 the output voltage constant around the value VO . In this
case, as expected, the conduction angle a will be larger
Employing the value of ia at vt ¼ a as the initial value of than 308. The phase current is continuous and b equals to
Stage Equation
√
1. 0 2 a 2V
ia (t) = √i (1 − cos vt)
vL 3
p √
2V V tV a
2. a − −b ia (t) = √i (1 − cos vt) − dc dc
3 vL 3 3L 3vL
p p √ √
2Vi p
2V p
V t V a p
3. −b − ia (t) = sin b − cos vt + + √i 1 − cos − b − dc dc − b + 2a
3 3 2 vL 6 vL 3 3 2L 6vL 3
√ √
p p 2Vi 2V 3 p V t V p
4. − +a ia (t) = sin b + √i − cos vt − cos − b − dc dc − b + 2a
3 3 2 vL vL 3 2 3 2L 6vL 3
p
2p √ √ p
2Vi 2V 3 2V t V 2p
5. +a − −b ia (t) = sin b + √i − cos vt − cos − b − dc dc − b + 3a
3 3 2 vL vL 3 2 3 3L 6vL 3
√ √
2p 2p 2Vi p
2V 3 √ V tV a
6. −b − ia (t) = 2 sin b − cos vt − + √i − 3 sin b − dc dc
3 3 2 vL 3 vL 3 2 2L 2vL
√ √
2p 2p 2Vi 2V √ V tV a
7. − +a ia (t) = sin b + √i (1 − cos vt − 3 sin b) − dc dc
3 3 vL vL 3 2L 2vL
√ √
2p 2Vi 2V √ V t V a Vdc a
8. + a − (p − b) ia (t) = sin b + √i (1 − cos vt − 3 sin b) − dc dc
3 2 vL vL 3 3L 9vL 3vL
9. (p 2 b 2 p) ia(t) ¼ 0
902 IET Power Electron., 2011, Vol. 4, Iss. 8, pp. 899 –907
& The Institution of Engineering and Technology 2011 doi: 10.1049/iet-pel.2010.0139
www.ietdl.org
Table 2 Input current expressions at individual stage for conduction angle a (thus pulse width). The proposed
Pout . PO(rated) control circuit block diagram is shown as Fig. 5. The dc
link voltage is also detected and compared with reference
Stage Equation
voltage to provide the required compensation for a. Due to
√ the uncontrolled characteristic of diode rectifier, a tiny
1. 0 2 a 2V 2pVdc Vdc a
ia (t) = − √i cos vt + − compensation can lead to optimum performance.
vL 3 9 vL 6 vL
√
p 2V Vdc t Vdc a 2pVdc
2. a − ia (t) = − √i cos vt + − +
3 vL 3 3L 6 vL 9 vL 3 Design example and implementation
p √
p 2V Vdc t Vdc a 5pVdc A sinusoidal PWM (SPWM) voltage source inverter, a
3. − +a ia (t) = − √i cos vt + − +
3 3 vL 3 2L 6 vL 18vL popular topology in industry for ease of implementation,
p 2p √ is used as the rear-end converter for the intended
2V 2Vdc t Vdc a pVdc
4. +a − ia (t) = − √i cos vt + − + rectifier – inverter ac motor drive topology as depicted in
3 3 vL 3 3L 3vL 3vL
√
Fig. 3.
2p 2p 2V Vdc t Vdc a 2pVdc
5. − +a ia (t) = − √i cos vt − + +
3 3 vL 3 2L 3 vL 9 vL
√
3.1 Bi-directional switch ratings
2p 2V V t V a pVdc
6. +a −p ia (t) = − √i cos vt − dc + dc + Taking phase ‘a ’ as reference, the peak current through the
3 vL 3 3L 6 vL 9 vL
bidirectional switch can be calculated by substituting
vt ¼ 408 (the upper limiter of a) into the equation of stage
1 in Table 2. Hence, (16) can be used to calculate the
zero. Therefore there are six well-known conduction stages
bidirectional switch peak current.
and two-phase conduction stages 3, 6 and 9 of low-power
operation do not exist here. The phase current in each
stage is investigated and expressions are developed and PO
Isw(peak) = 0.6291 (16)
presented in Table 2. Similarly utilising the equations in Vi
Table 2, the relationship between a and k can be
expressed as follows Since the switch is off during the 408 – 1808 and 2208 – 3608
intervals the rms value of the switch’s current is given by
a = 30k (15) (17) and the average current is calculated using (18).
PO
2.3 Design of front-end rectifier controller under Isw(rms) = 0.1225 (17)
unbalanced supply Vi
2202
Lcritical = 3.8489 × 10−2 = 24.84 mH
50 × 1500
For the rated output power of 1.5 kW, the dc link voltage
of the front-end rectifier is calculated with (1) and results in
Fig. 6 Input phase current and its spectral composition at various load conditions
a 40% rated load
b 120% rated load
4 Operation under variable DC bus and Table 4 Performance parameters with controller under varying
input line inductances input inductances
b
The rated dc link voltage is 294.05 V Fig. 7 Top view of the hardware prototype without the motor load
904 IET Power Electron., 2011, Vol. 4, Iss. 8, pp. 899 –907
& The Institution of Engineering and Technology 2011 doi: 10.1049/iet-pel.2010.0139
www.ietdl.org
Fig. 8 Input current and voltage and current FFT of the proposed prototype at rated load
Fig. 9 Bi-directional switch conduction angles (a) at different DC Van + a2 Vbn + aVcn
Vn = (21)
bus load conditions 3
YASKAWA VS-6006V7 1.5 kW commercial three-phase where a ¼ 1/1208 and a 2 ¼ 1/2408. The unbalance factor
Inverter. The proposed scheme is able to improve the input u can be defined as [14]
current THD to 5.0% and the input PF to 0.99. This is a
remarkable improvement in PF and THD. The experimental |Vn |
results agree with the MATLAB predicted waveforms and u= (22)
Vp
also as presented in Table 3.
The controller maintains the dc link voltage variation
within 3% of its rated value throughout its operation. And
the conduction angle a at different load conditions is shown The specification of 10% unbalance supply is chosen as
in Fig. 9. follows:
Fig. 10 Input current waveform and their FFTs under 10% unbalanced supply
Fig. 11 Phase ‘a’ current and current FFT under 10% unbalanced supply
mostly the third harmonics in all the three phases to shoot up. encountered and the bidirectional switch controller with
Such non-characteristic harmonics are always absent in a its built-in capability can handle common unbalance well.
balanced three-phase system. The principal cause of PF The PF remains high as confirmed by the results of Fig. 11.
degradation under unbalance supply is due to the generation
of third and other triplen (3∗ N, N ¼ 1, 3, 5. . .) harmonics in 5.2 Hardware experimental results
the input current [14]. These can be attributed to the
unequal conduction of the power diodes of the front-end The current waveforms for phase ‘a ’, both in the time and
bridge rectifier. It was previously shown [14] that the phase frequency domain, are shown in Fig. 11.
with the highest input voltage has the highest conduction The supply voltage unbalance causes deterioration in the input
period and the lowest supply causes shortest period, PF and input current THD of the rectifier–inverter structure.
exceeding or falling short respectively of their typical 1208 However, with the proposed controller, the input current THD
conduction period. This causes the three-phase currents to for all three phases is below 10% approx., and the input PF is
be different from one another resulting in non-cancellation above 0.95. Under such severe 10% unbalance, phase ‘b’ (not
of the zero sequence (triplen) components. shown) suffers the maximum degradation resulting in
It was also found that unbalance in supply voltage phase somewhat lower PF. However, with the intelligent controller
angles will cause similar effect, and for the same reason. that automatically varies the switch conduction angles to
Unbalance in both the magnitude and phase of supply minimise the effect of unbalance, this deterioration is under
voltages will also affect the converter performance in a commonly accepted (as well as IEE) standard of 10%. Under a
similar fashion, only to add to the triplen harmonics. typical 5–7% supply unbalance the controller is most
However, such severe cases (10% or above) are rarely effective, and the converter input PF is above 0.98.
906 IET Power Electron., 2011, Vol. 4, Iss. 8, pp. 899 –907
& The Institution of Engineering and Technology 2011 doi: 10.1049/iet-pel.2010.0139
www.ietdl.org
6 Conclusions 3 Maswood, A.I., Fangrui, L.: ‘A novel variable hysteresis band current
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