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Hybrid Pulse Width Modulation For Improving Reliability of DC-Link Capacitors of NPC Inverter in Photovoltaic Systems
Hybrid Pulse Width Modulation For Improving Reliability of DC-Link Capacitors of NPC Inverter in Photovoltaic Systems
Received 20 November 2023, accepted 24 January 2024, date of publication 29 January 2024, date of current version 8 February 2024.
Digital Object Identifier 10.1109/ACCESS.2024.3359231
ABSTRACT Reliability improvement of the Photovoltaic (PV) inverter has a high potential for reducing
the cost of PV energy. The DC-link capacitor is one of the main components influencing the reliability of
PV inverter systems. Various pulse-width modulation (PWM) methods have been proposed to increase the
lifetime of the DC-link capacitor by reducing its ripple current. However, state-of-the-art PWM methods for
reducing capacitor ripple current increase the output current THD. Nevertheless, its optimal application to
achieve the target lifetime without unnecessary deterioration in output current THD has not been discussed.
This paper proposes a PWM method for improving the lifetime of the DC-link capacitor of the NPC inverter.
In addition, a mission-profile-based optimal application of the proposed PWM method with conventional
Space Vector Modulation (SVM) called a hybrid MLZSVM method is presented for achieving the target
lifetime of the DC-link capacitor with minimized negative effect on the output THD of the NPC inverter.
The proposed hybrid PWM concept is verified by the case study based on an annual mission profile of the PV
system. Finally, the feasibility and effectiveness of the proposed method are verified through experiments.
where ICL and ICU are lower and upper capacitor cur-
rents, respectively. Therefore, through the reduction of IN , into the DC-link capacitors when the small voltage vectors
a decrease in the current of DC-link capacitors is able to be are selected during SVM. It results in a lifetime reduction of
achieved. DC-link capacitors.
The voltage vectors have different effects on IN since it
is determined by currents of the specific phases connected III. PROPOSED SPACE VECTOR MODULATION FOR
to the neutral point as shown in Fig. 3. As shown in Fig. 3 REDUCTION OF DC-LINK CURRENTS
(a) when the switching state is [ONN], which is one of the A. VOLTAGE VECTORS BASED SPACE VECTOR
small voltage vectors, the phase-A is connected to the neutral MODULATION METHOD (MLZSVM)
point, and phase-B and phase-C are connected to the negative According to the analysis carried out in Section II, the small
DC-link. Therefore, IN is equal to the current of phase-A voltage vectors make IN become the maximum phase current
(Ia ). In the case of the switching state [PON] of the medium in the conventional SVM. Therefore, a modified switching
voltage vector, as illustrated in Fig. 3 (b), the current of phase- sequence for reducing the DC-link ripple current is required
B (Ib ) becomes IN . However, as shown in Fig. 3 (c), even for the reliability improvement of the NPC inverter through
though the three phases are connected to the neutral point the lifetime increase of the DC-link capacitor. The main idea
when the switching state is [OOO], IN is zero because the of the proposed method is to replace the small voltage vector
summation of the three-phase currents is zero. Finally, the with the adjacent large and zero voltage vectors so that Vref is
large voltage vectors such as [PNN] make IN zero because generated by using medium, large, and zero voltage vectors.
any phases are not connected to the neutral point as shown It is named Medium-Large-Zero SVM (MLZSVM) in this
in Fig. 3 (d). It can be seen from the above analysis that the paper.
small voltage vectors have the most significant effect on the The proposed MLZSVM can be applied by dividing each
DC-link current. sector of the space vector diagram into two sub-regions (a)
In conventional SVM, the reference voltage vector Vref and (b). If Vref is located in Sector 1-(b) as shown in Fig. 5,
is generated by the closest voltage vectors to Vref . If Vref in conventional SVM, the switching sequence is [ONN]-
is located in Sector I-(b) as shown in Fig. 2, SVM selects [PNN]-[PON]-[POO]-[PON]-[PNN]-[ONN] as shown in
the closest voltage vectors V1 , V7 , and V13 to generate Vref . Fig 6 (a). However, in the proposed MLZSVM, the zero
In Sector 1, |Ia | is the largest current among three-phase voltage vector V0 and large voltage vector V13 are used
currents as shown in Fig. 4. It becomes IN when V1 is selected instead of the small voltage vector V1 . It is possible since
during SVM. In Sector 2, the largest current |Ic | flows into the the composition of V0 and V13 is equal to V1 . Therefore,
neutral point due to V2 . Consequently, a large current flows the switching sequence is established as [OOO]-[PON]-
FIGURE 7. The voltage vectors for generating the reference voltage under
(a) Method-I (b) Method-II.
FIGURE 13. The transient waveforms of outputs when the output power
and power factor change under MLZSVM.
FIGURE 14. Space vector diagram for the proposed hybrid PWM method. It is seen that there is a trade-off between the RMS value
of the DC-link capacitor current and the output current
THD. Therefore, θh is needed to be properly selected so
that the required reliability performance of the capacitor is
achieved with a minimum negative impact on the output
current THD. By this strategy, the proposed MLZSVM is
applied only when necessary for the target lifetime. Thus,
the unnecessary distortion of the output current can be
minimized.
The effect of the proposed method on the neutral point
voltage is analyzed. Under the proposed MLZSVM, only the
medium voltage vectors affect the neutral point voltage. For
example, when the reference voltage vector is in Sector 1
as shown in Fig. 14, the switching state [PNO] or [PON]
charges the lower capacitor because phase-C or phase-B is
connected to the neutral point, and their currents have nega-
tive values. Conversely, the switching states [NPO] or [NOP],
which are symmetrical to [PNO] and [PON], respectively,
are selected when the reference voltage vector is in Sector 4.
These switching states discharge the lower capacitor because
phase-C and phase-B currents have positive values. Since the
amounts of charge and discharge in Sector 1 and Sector 4
FIGURE 15. Simulation results of line-to-line voltages, output currents are the same, and this principle applies to other sectors as
and DC-link capacitor current under different θ h in the hybrid MLZSVM well, the MLZSVM maintains the neutral point voltage at the
method (a) SVM θh = 0 ◦ (b) θh = 20 ◦ (c) θh = 40 ◦ (d) θh = 60 ◦ .
same value. In the hybrid MLZSVM, since the MLZSVM is
applied for the hybrid modulation angle (θh ) symmetrically
based on the large voltage vector and the conventional SVM
put current THD increases from 1.37 % to 2.9 %, 3.68 is applied to the rest of the area, the two capacitor voltages
%, and 4.1 % when θh are 20 ◦ , 40 ◦ , and 60 ◦ , respec- are balanced to the same value. As shown in Fig. 16, two
tively. On the other hand, the RMS value of the DC-link capacitor voltages are maintained at the same value when the
capacitor current decreases as θh increases from 15.1 A to hybrid MLZSVM with different hybrid modulation angles is
11.7 A, 8.1 A, and 2.9 A when θh is 20 ◦ , 40 ◦ , and 60 ◦ , applied. It obviously shows that the proposed MLZSVM does
respectively. not affect the neutral point voltage.
The power loss analysis is carried out based on the power
loss of the power devices and DC-link capacitors under the
different modulation schemes as summarized in TABLE 2. IV. MISSOPM PROFILE BASED OPTIMAL APPLICATION
The power loss of the NPC inverter is reduced when the OF HYBRID PWM
proposed MLZSVM is applied under the considered power In this section, an optimal application strategy of Hybrid
ranges, and it has lower power loss as θh increases. Further- PWM based on the lifetime of the DC-link capacitor con-
more, compared with Method-I and Method-II, the proposed sidering a mission profile is presented. An annual mission
method also has a lower power loss. However, its difference is profile of the PV system shown in Fig. 17, recorded in Ari-
not significant. Therefore, it can conclude that the proposed zona, USA, is considered for the case study. Thermal stress
MLZSVM does not negatively affect the power loss of the is one of the main causes of wear-out failure of aluminum
inverter. However, the proposed MLZSVM increases the out- electrolytic capacitors. Therefore, this case study is carried
put current THD, and it may lead to a higher power loss of out by focusing on the lifetime of the capacitor due to thermal
the filter inductor. stress.
18758 VOLUME 12, 2024
J.-H. Choi et al.: Hybrid PWM for Improving Reliability of DC-Link Capacitors of NPC Inverter
FIGURE 16. Two DC-link capacitor voltages under SVM and MLZSVM with
different hybrid modulation angles (θh ).
FIGURE 24. Experimental results of the output current in time and frequency domains, line-to-line
voltage, and capacitor current in time and frequency domains under the proposed hybrid MLZSVM
with different θh (a) θh = 0◦ (SVM), (b) θh = 20◦ , (c) θh = 40◦ , (d) θh = 60◦ .
time by which failure in 10 % of a population occurs. Namely, D. OPTIMAL APPLICATION STRATEGY OF HYBRID
the reliability is 0.9 at that time. MLZSVM
Fig. 21 shows the unreliability function of the DC-link The B10 lifetime of 38 years is achieved when the pro-
capacitor under the given mission profile with different PWM posed MLZSVM is applied to all regions. It means that
methods when they are applied in all regions. As expected the applied region can be reduced through the proposed
from the analysis results of the DC-link capacitor (See Fig. 9), hybrid MLZSVM strategy to satisfy the target B10 lifetime
the proposed MLZSVM has the longest lifetime due to the of 30 years, which results in a decrease in the output current
best ability to reduce the DC-link capacitor current. Under the THD.
assumption that the target B10 lifetime of the DC-link capaci- Fig. 22 shows the unreliability functions of the DC-link
tor is 30 years, the proposed MLZSVM and Method-II satisfy capacitor under different θh in the hybrid MLZSVM method.
the target lifetime as 38 years and 34.4 years, respectively, θh of 0 ◦ means that the conventional SVM is applied to all
whereas the conventional SVM and Method-I cannot meet regions. A target B10 lifetime of 30 years can be satisfied
the requirement as 14.3 years and 22.8 years, respectively. when θh is 40 ◦ , where the output current THD is 3.68 % as
analyzed in section C of III. Therefore, the improved output increases as θh increases. It means the increase in output
THD can be achieved compared with when the MLZSVM is current THD as θh increases in the hybrid MLZSVM method.
applied in all regions (i.e. θh = 60 ◦ ), where the output current The RMS value of the upper capacitor current (ICU ) is 5.9 A
THD is 4.1 %. In the case when the hybrid PWM concept is under the conventional SVM, and it decreases when the
applied with Method-II, the required θh is 50 ◦ to meet the B10 regions where MLZSVM is applied (θh ) increase as 4.5 A,
lifetime of 30 years, and the output current THD is 3.92%. 3.2 A, and 1.3 A when θh is 20 ◦ , 40 ◦ , and 60 ◦ , respectively.
Method-1 is not considered since it cannot satisfy the target The decrease in ICU can also be seen from its FFT analysis.
lifetime of 30 years. It is seen from the above result that the Especially, the capacitor current at 10 kHz notably decreases
proposed hybrid MLZSVM method is the most effective for as θh increases. The different effects on the reduction of the
satisfying the target lifetime when the output current THD is DC-link capacitor current depending on θh are also clearly
considered at the same time. Furthermore, the unnecessary seen from the experimental results. The reduction of the
deterioration in output current THD can be curbed through DC-link capacitor current results in lower power loss and
the hybrid PWM strategy. thus lower Th . Consequently, the lifetime of the capacitor
In this paper, the hybrid modulation angle (θh ) has been increases. The trade-off between the capacitor current and
chosen by mainly focusing on the lifetime of the PV inverter output current THD is also confirmed.
so that a B10 lifetime of 30 years is achieved under the given The experimental results clearly show the feasibility
mission profile of the PV system. and effectiveness of the proposed method and its optimal
The required θh could be different depending on the target application for lifetime improvement without unnecessary
lifetime of PV inverters, the mission profile of PV systems, deterioration in output current THD.
and also how the DC-link is designed. Therefore, they should
be considered for determining θh as performed in this paper. VI. CONCLUSION
In the case that the specific mission profile of the PV inverter This paper proposes the MLZSVM method for increasing the
is not available, the worst-case mission profile could be con- lifetime of the DC-link capacitor of the NPC inverter. The
sidered to guarantee the lifetime of the DC-link capacitors. proposed method has a better ability to reduce the DC-link
Furthermore, since the θh affects not only the reliability of capacitor current compared with the state-of-the-art PWM
the DC-link capacitor but also the power quality, there is methods considered in this paper developed for the same
a trade-off between them. It means that the power qual- purpose. Therefore, the DC-link capacitor has the longest
ity or filter size can be a limiting factor for selecting the lifetime under the proposed MLZSVM. In the case study,
hybrid modulation angle. Therefore, it should be determined when the proposed method is applied in all regions, the B10
properly by considering the requirements of the target appli- lifetime is 38 years which is about 2.7 times longer than that
cations for reliability and power quality. This principle can be under the conventional SVM, which is 14.3 years. Further-
extended to other applications. more, a mission-profile-based optimal application strategy of
the proposed MLZSVM called the hybrid MLZSVM strategy
V. EXPERIMENTAL RESULTS is presented. Through the proposed hybrid MLZSVM, the
Experiments are carried out to verify the feasibility and MLZSVM is applied to the specific regions only as necessary
effectiveness of the proposed hybrid MLZSVM under the to achieve the target lifetime of the DC-link capacitor, which
following conditions: DC-link voltage (VDC ): 400 V, switch- prevents unnecessary deterioration in output current THD.
ing frequency (fsw ): 10 kHz, output frequency (fout ): 60 Hz, In the case study, the required hybrid modulation angle (θh )
DC-link capacitors (CDC ): 3300 µF, Load (R-L): 20 , and is 40 ◦ to satisfy a target B10 lifetime of 30 years which
1.5 mH. is smaller than that when the hybrid PWM method with
Fig. 23 shows the collector-emitter voltage (i.e. voltage Method-II is applied, where the required θh is 50 ◦ . Through
stress) of each power device of phase-A under the SVM and the proposed hybrid MLZSVM, less distortion in the output
the MLZSVM. Regardless of the modulation schemes, the current can be achieved, which is 3.68 % compared with the
collector-emitter voltage of the power devices is 200 V which hybrid PWM modulation with Method-II and the case where
is half of the DC-link voltage. There is no difference in the the proposed hybrid PWM strategy is not applied, which are
applied voltage stress on the power devices between SVM 3.92 % and 4.1 %, respectively. Finally, the feasibility and
and MLZSVM. effectiveness of the proposed hybrid MLZSVM method can
Fig. 24 shows experimental results of the output current in be verified through the experiments. The proposed method
time and frequency domains, line-to-line voltage, and upper also be applied to different cases for different target lifetimes
capacitor current in time and frequency domains under the under different mission profiles of PV systems.
proposed hybrid MLZSVM with different θh of 0 ◦ , 20 ◦ , 40 ◦ ,
and 60 ◦ , respectively. It is seen that the output current is pro-
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modulation index range,’’ IEEE Trans. Power Electron., vol. 36, no. 5, Aalborg University, in 1995.
pp. 5250–5261, May 2021. He was with ABB-Scandia, Randers, Denmark,
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Expo. (APEC), Mar. 2022, pp. 1804–1811. such as the Series (four volumes) Control of Power Electronic Converters and
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Datasheet, Dec. 2019. power electronics and its applications, such as in wind turbines, PV systems,
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and optimization of hybrid DC-link capacitor banks,’’ IEEE Trans. Power Dr. Blaabjerg has received the 38 IEEE Prize Paper Awards, the IEEE
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under grid voltage unbalances,’’ IEEE Trans. Power Electron., vol. 34, in-Chief of IEEE TRANSACTIONS ON POWER ELECTRONICS, from 2006 to 2012.
no. 5, pp. 4064–4078, May 2019. He was a Distinguished Lecturer of the IEEE Power Electronics Society,
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with improved efficiency and reliability in photovoltaic systems,’’ IEEE 2011 and from 2017 to 2018. From 2019 to 2020, he served as the President
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