CONTROL OF A MODULAR MULTILEVEL DC/DC CONVERTER FOR REGENERATIVE APPLICATIONS

CHAPTER-3

MODULAR MULTILEVEL DC/DC CONVERTER

3.1 INTRODUCTION:
In the previous section, discussed about the supercapacitor along with
bidirectional converters as an energy storage device for regenerative applications. So,
here discussion is on the MMC (Modular Multilevel dc/dc Converter) for regenerative
applications with the reduction of energy storage in the storage elements i.e. in fossil
fuels, supercapacitors (SC) depending on the applications.
The energy stored in the storage element is high in above converters. So, the size
of the converter increases which is not suitable for regenerative applications. This
problem can be overcome by using new converter named as MMC (modular multilevel
converter).
MMC name itself says that it has a variety structure in multilevel structure for
dc/dc applications and it is mostly used for the applications to achieve the high voltage
from the low voltage storage elements. Multilevel converters are extensively used in the
power renovation in high power applications. These multilevel converters reduce EMI
problems, voltage stress on the devices. So, many literatures discussed about the
conversion of ac-dc, dc-ac, and dc-dc.
In dc/dc applications, multilevel structure reduces or even eliminates the magnetic
components size and leads to the reduction of size & cost in electric vehicle (EV)
applications. These dc/dc converters meet more charge balance compare to other power
conversion converters. These converters can achieve about 98% efficiency and easy to
integrate in traction purposes. In case of dc/ac conversion have three types of multilevel
converters. Similarly for multilevel dc/dc conversion three types of converters are used
named as
a. Modular multilevel capacitor clamped dc/dc converter
b. Modular multilevel flying capacitor dc/dc converter
c. Modular multilevel cascaded dc/dc converter

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 CONTROL OF A MODULAR MULTILEVEL DC/DC CONVERTER FOR REGENERATIVE APPLICATIONS

Before proceeding to multilevel concept, basically converters sub modules have two
types. They are
a. Half bridge converter
b. Full bridge converter
a. Half bridge converter:
Normally half bridge bidirectional converters have two switches in series with
antiparallel diodes. One side has source and other side load as shown in Fig. 3.1.

Fig. 3.1. Half bridge

b. Full bridge converter:
Full bridge bidirectional converter has four switches two are in series in one leg
and other two are in another leg and these two legs are in parallel. One side has source
and other side has load as shown in Fig. 3.2.

Fig. 3.2. Full Bridge

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 CONTROL OF A MODULAR MULTILEVEL DC/DC CONVERTER FOR REGENERATIVE APPLICATIONS

3.2 MODULAR CAPACITOR CLAMPED DC/DC CONVERTER:

Normal capacitor clamped converter used in inverter applications. But due to
modular structure it is used in dc/dc applications. The modular structure of capacitor
clamped converter and its switching states are shown in Fig. 3.3.

Fig. 3.3. Modular structure of capacitor clamped dc/dc converter

Table 3.1 Charging and discharging of capacitors

From the above table 3.1 it is concluded that the converter can charge and
discharge the capacitors present in the circuit diagram very quickly within two sub
intervals of time. This shows the utilization of components

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 CONTROL OF A MODULAR MULTILEVEL DC/DC CONVERTER FOR REGENERATIVE APPLICATIONS

3.3 MODULAR FLYING CAPACITOR DC/DC CONVERTER:

The modular structure of the multilevel flying capacitor dc/dc converter and their
switching states are shown in Fig. 3.4.

k
m

m
sa1 sb1

g
a

a
vdc''

k
m
k
m
sb2
sa2

a
g

a
vdc2 vdc2'

k
m

k
m
sa3
sb3
l
g

a
vdc2''

vdc vdc1 vdc1'

k

k
m

m
sa1' sb1'
g

g
a

a
vdc3 vdc3' vdc3''
k

k
m

m
sa2' sb2'
g

g
a

a
k

k
m

sa3' sb3'
g

g
a

Fig. 3.4. Four level flying capacitor dc/dc converter

Table 3.2 switching states of flying capacitor dc/dc converter

Vao Switching states (a) Vbo Switching states (b)
Sa1 Sa2 Sa3 Sb1 Sb2 Sb3
3Vdc 1 1 1 3Vdc 1 1 1
2Vdc 1 1 0 2Vdc 1 1 0
1 0 1 1 0 1
0 1 1 0 1 1
1Vdc 1 0 0 1Vdc 1 0 0
0 1 0 0 1 0
0 0 1 0 0 1
0 0 0 0 0 0 0 0

From the Table 3.2, it is concludes that the output changes depending upon the switching
states of the converter.

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 CONTROL OF A MODULAR MULTILEVEL DC/DC CONVERTER FOR REGENERATIVE APPLICATIONS

3.4 MODULAR MULTILEVEL CASCADED DC/DC CONVERTER:

The modular structure of the cascaded dc/dc converter in both half bridge and the
full bridge modes are shown below

E
m

m
IGBT/Diode6 IGBT/Diode7

C
g

g
UDC 1

E
m

m
IGBT/Diode8 IGBT/Diode9

C
g

g
E

E
m

m
IGBT/Diode10 IGBT/Diode11
C

C
g

g
UDC 2
E

E
m

m
IGBT/Diode12 IGBT/Diode13
C

C
g

Fig. 3.5. Circuit diagram of modular multilevel cascaded

full bridge dc/dc converter
E
m

IGBT/Diode
USC 1
C
g

ESR1
E
m

L
IGBT/Diode1
C
g

E
m

USC 2 IGBT/Diode2
C
g

ESR2
E
m

UDC
IGBT/Diode3
C
g

E
m

IGBT/Diode4
C
g

USC 3
E
m

IGBT/Diode5
ESR3
C
g

Fig. 3.6. Simulation diagram of modular multilevel cascaded

full bridge dc/dc converter

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 CONTROL OF A MODULAR MULTILEVEL DC/DC CONVERTER FOR REGENERATIVE APPLICATIONS

Here for dc/dc conversion the cascaded half bridge bidirectional converters are used over
the other converters due to following advantages:
i. Self powered capability
ii. Low voltage stress on the devices
iii. Modular structure
iv. Easy to eliminate the faulty cell
v. Capable for high power applications
vi. Simple in construction

3.5 BASIC MODULAR MODEL:

E
m

IGBT/Diode
USC 3
C
g

L3
E
m

ESR3
IGBT/Diode1
UDC 3
C
g

Fig. 3.7. Basic modular model

3.5.1 Circuit operation:

First the supercapacitors are fully charged. When the upper switch is ON then the
current flows from USC3 through IGBT1 and L1 to UDC3, here L1 is fully charged. When
IGBT1 is closed power freewheels through diode D2 to UDC3.When vehicle applies a
break then the energy flow back to supercapacitor through diode D1.Here again L1 is
charged in reverse polarity and freewheels through IGBT2 to UDC3 when the switch is
ON, the ON/OFF periods of IGBT’S are controlled through PWM techniques as shown in
Fig. 3.6.

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 CONTROL OF A MODULAR MULTILEVEL DC/DC CONVERTER FOR REGENERATIVE APPLICATIONS

Fig. 3.8. Simulation diagram of basic modular model

Fig. 3.9. Simulation results of input current

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 CONTROL OF A MODULAR MULTILEVEL DC/DC CONVERTER FOR REGENERATIVE APPLICATIONS

Fig. 3.10. Simulation results of diode current

Fig. 3.11. Simulation results of inductor current

Fig. 3.8 shows the simulation diagram of the two-level MMC which is an basic
modular model and it is an HB converter works in two quadrants having bidirectional in
current unidirectional in voltage. Fig. 3.9 and Fig. 3.10 show the input current & diode
current of the converter represents that the current outputs having lot of ripples. The
converter with ripples on output side will not show better impact in regenerative
applications. So, the above problems can overcome by different level cascaded and
MMCs.

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 CONTROL OF A MODULAR MULTILEVEL DC/DC CONVERTER FOR REGENERATIVE APPLICATIONS

3.6 FOUR-LEVEL MMC:

Fig. 3.12. Simulation diagram of four-level MMC

Fig. 3.13. Simulation results of inductor current

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 CONTROL OF A MODULAR MULTILEVEL DC/DC CONVERTER FOR REGENERATIVE APPLICATIONS

Fig. 3.14. Simulation results of supercapacitor current

As shown in Fig. 3.13 and Fig. 3.14, four level MMC settled down very quickly,
less rise time & requires less inductance compare to the buck and boost converter.

3.7 Summary:

In section 3.1 explained about the MMC (Modular Multilevel dc/dc Converter)
and classification of MMC. Section 3.2 about the half bridge and the full bridge modules.
Section 3.3 for multilevel diode clamped dc/dc converter, section 3.4 for flying capacitor
dc/dc converter, section 3.5 for cascaded multilevel both half bridge and full bridge
structure and their respective advantages over other converters, section 3.6 about basic
modular model results and section 3.7 about the 4-level MMC. In following sections,
about the seven level MMC used in HVDC applications due to high voltages.

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