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STEPPED WAVE

SYNTHESIS

FROM PRE-PROGRAMMED

PWM INVERTERS WITH COMMON DC-DC CONVERTER SUPPLY


SUJlT K. BEWAS*, Sr. Member and B. BASAK** ., Member
Dept. of ElectricalEngg., Jadavpur University, Calcutta 700 032, INDIA, **Dept. of Electrical Engg., Bengal Engg. College (Deemed Univ.), Howrah 711 103, INDIA,

Abstract :Steppedwaveform inverters have the advantages of low harmonic distyqion of voltage compared to the ideal sinusoidal waveform This paper presents a new concept in the realisation of stepped output waveforms by combining directly, the outputs of several PWM inverters, each fed from isolated windings of a high frequency dc-dc converter The output waveform is optimisedto achieve a minimumTHD with a given number of switches, operating in any suitable combination of full or half bridge inverters Details regarding the study of such combinations, including experimental ver~ication,is described in the paper INTRODUCTION
Inverters with a fixed frequency output and near-sinusoidal waveform finds wide application as an ac power source Several types of schemes have been used for the inverter system so as to produce a controlled magnitude sinusoidal waveform at the output with as low distortion as possible. Inthis regard, inverters whose output waveform is constructed to form a stepped approximation to a sinewave have the advantage of achieving a maximumtotal harmonic distortion (THD) limit without the use of any low-pass filter circuit. Stepped voltage waveform inverters in the past have been built by combining the outputs of several power frequency square wave inverters with suitable transformer connections, where the outputs of individual inverters are phase shifted from one another [I] shown in Fig. 1. The resulting output waveas form, is in the form of a stepped approximation to a sinewave, where the harmonics are significantly reduced. The reduction or elimination of harmonics depend upon the number of individual inverters used and the transformer ratios used for the combination. This scheme has the disadvantage of using often complex transtormer connections, which is bulky due to the lowfrequency rating of the output transformers along with a large number of individual inverters and thus have slowly lost popularity. This paper presentsa new concept inthe synthesis of stepped waveforms by directly combining the output of several preprogrammed PWM invertersin series, without the use of any lowfrequency output transformer The individual inverters are fed from a common dc to dc converter supply, with multiple, isolated outputs, from a single high frequency transformer This ensures relatively smaller size of the system while maintainingfixed step heights such that the output voltage THD is restricted Further, the final output voltage control is achieved by controlling the pulsewidthof the dc to dcconverter alone, without disturbing the individual inverters A special feature of this new topology is that the output supply frequency can be easily varied, if required, since no transformers are present in the output path

Various combinations of PWM patterns are analysed as generated by various combinations of inverters, including both half-bridge and full-bridge types In each case, the waveforms are optimised with regard to achieving a minimum value of THD for a given number of inverters and minimum number of total switches The results of these studies are presented in the foregoing section along with experimental waveforms

V2

f----l

0 -

l-----l

0-

L--l

Fig 1 : ConventsonalStepped- Waveform Generation


NEW STEPPED WAVEFORM TECHNIQUE
In the new technique presented here, low frequency (power frequency) output transformers are not used The outputs of several PWM inverters each operating from its isolated dc supply, are connected inseries to generate a steppedwaveform As an example using two full bridge inverters in series [2],the operation is explainedwith reference to Fig 2a In this example only two full bridge inverters are used, with different (but fixed) dc voltage inputs and the outputs of these inverters are connected in series without any transformer Inverter no 1 has an input dc voltage of magnitudeV I and generates a specific PWM output whose positive half-cycle is shown in Fig 2a Inverter No 2 has an input dc voltage of magnitude V2 and generates a rectangular waveshape as shown in the same figure The two inverters are phase locked so that two patterns maintain fixed relationship with respect to their half-cycle crossings Thus, the resulting waveform obtained by series connection of the two outputs become multistepped in nature without the use of any transformer connection at the output The duration of the steps, I e , the angles 0 to 64 IS 1 controlled by the P W M patterns of the

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individual inverters. A similar waveform is generated for the negative half-cycle, so that a symmetrical alternatingwaveform is created The requirement for two different dc supplies with a fixed relationshipbetween them, is easily solved by generatingthese from two individualoutputs of a dc to dc converter, operating at highfrequencyfrom the low voltage battery. Thus, automatically, isolation and voltage step-up IS provided along with a drastic reduction in size of the power transformer. In case two half bridge inverters are used, the resulting waveform generation is depicted in Fig 2b. Note that the output of each half bridge inverter has only two levels : positive or negative and has no zero level. Thus, by using combinations of full and half bridge inverters with different voltage levels and PWM patterns, it is possible to generate a wide range of waveforms with different number of total switches.

The complete inv example using two stages ' (i) a step-up dc to dc converter with isolation,producing the isolated voltages V I and V2,and (ii) a PWM inverter stage consisting of two full bridge inverters, generating the stepped final output waveform. The dc to dc converter, switching at a frequency more than 20 kHz, generates an alternating flux in a high frequency transformer. The converter is configured as a push-pullcircuit due to lower cost in low input voltage applications, but other topologies like half- or full-bridgi can also be adopted. Also, the ripple frequency of the output dc in the case of push-pull or bridge will be twice the switching frequency of transistors or output diodes, facilitating a smaller size of filter choke and capacitor with reduced switching loss. Further, the two isolated dc outputs can be coupled through a single filter choke to maintain reasonabl good regulation of the output voltages while the chokes serve to smoothen the voltage ripples [3] The forward of flyback type of converte f but it does not offer full utilisationo the tra flux does not reverse, resulting in larger si same output power. Also, the dc output ripple frequency in this case is same as that of the semiconductor switch, with higher peak currents in the switch (as powerflow is during only less than half the switching time period), even though the benefit of the coupled output inductor is availa us, in such cases, the size of transformer and erlergy s transformerfor flyback converter) is high switching loss. The high frequency output from the two secondary windin of the ferrite transformer, are rectified by individual bridge rectifiers using ultra-fast recovery diodes. This configuration facilities operation at the higR frequency, high voltage output stages, while the two dc

(a) Example of two full bridges in series

between their dc output voltages. The common core for the two ric chokes helps in cross regulation between the two outputs due to load variations As such, since the two inverter outputs are connectedin series, the load sharing between them is fixed By the ratio of their rms voltages. Thus, any change in the load connected to final output will cause a balanced change in dc cqrr inverters, maintaining the ratio between system presented, the output waveform maintains a very good consistency of step heights to are controlled in the inverter In the example depicted inverters is bridge circuit built or Bipolar Transihtors The CO drive pulses to each of the sw
(b) Example of two half bridges in series Fig 2 : Principle of PWM to Stepped-wave Generation
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Inv 2

erates the isolated per tyidge so as to


I

produce the desired output wavefo tern are stored in an EPROM, which triggeredby aclock pulse from an oscill

AC
OUTPUT

Fig 3

: Complete Schematic of New Stepped-wave Inverter (1-phase Example)

from the EPROM directly reproduce the programmed drive patterns for the total eight transistors, so that they produce the desired waveshape in each bridge with phase lock between the bridges. Changing the clock frequency will change the output fundamental frequency. In this scheme, the output rms voltage is directly dependant on the fixed waveshape and the dcvoltage input to the inverters (which must be in a fixed ratio).. Thus, the only way to change the output voltage is to change the magnitude of the dc to dc converteroutputs through pulse width control of the semiconductorswitches driving the push-pull transformer. In this way, the ratio V I :V2 between the dc voltage inputs to the two inverters is maintained, ensuring no change in the output THD. The control of the dc to dc converter is achieved through standard SMPS control IC. Eventhough the preceeding example used only two numbers of inverters, each full bridge type, in the general case there may be any number of inverters (two or more) in series. Further, they may be in any combination of full bridge or half bridge types. However, it must be noted that for the same output voltage and power, a half bridge inverter must use twice the input dc voltage required by a full bridge circuit. Thus, the h.f. transfomer output ratios must be modified accordingly depending on the specific inverter configuration. Further, a half bridge inverter uses only half the total semiconductor switches compared to a full bridge type, but cost is not half since each switch used is of higher voltage, while two capacitors with large ripple current capacity are also required to split the dc bus and the h.f. rectifier diodes are of higher voltage also. Systems can be designed to generate 3-phase outputs also. This may be achieved by three individual sets of inverters, one for each phase, or by suitably designing the PWM pattern of inverters such that a few may be used common to all phases, thereby reducing the total number of switches used. As an exampleof the latter type, a single 3-phase invertermay be used, with three separate 1-phase PWM inverters, each connected in
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series per phase to the main 3-phase inverter, as shown in Fig 4. OPTlMlSATlON The process of optimisation with reference to the system under discussion is related to minimisation of the number of individual inverters,minimisationof the total number of switches, without exceedinga specifiedTHD value, say the usual 5% limit, without the necessityof any output filters. However,if small filters are permitted at the output, then lesser number of switches can be used in conjunctionwith the filters to restrain THD below 5%.

In the example illustrated earlier, only two numbers of inverters were used, both full bridge type with four switches each. In

1-f'I-I I N V E RTER

R
c

1- PH
INVERTER

B
0

: Block Schematic of 3-phase Inverter System

the general case, any number of inverters (two or higher) can be used to increasethe numberof steps and thus reduceTHD. Also, the inverter can be all full-bridge, all half-bridge or combinations of both types so as to save on the total number of switches used. Thus, there exists a wide combination of inverter types and number of invertersfrom which the desired configuration can be selected to meet specific demands.
It must be rememberedthat the positive half cycle of the final output shall not have any negative area and vice versa for negative half cycle, so that THD is maintained minimum. Also, if a full bridge inverter is used, its output can have three levels in PWM mode : positive, negative or zero. However, if a half bridge inverter is used, its output can have only two levels : positive or negative. The resulting step levels are decided by the relative magnitude and polarity of voltage during the specific step interval. The first step may start from zero or any positive angle as suitable for optimisation.

In all the above equations, the value of 'n' exists only for odd numbers due to waveform symmetry.

Since there is no simple way to computethe variables, only an iterative procedure can be used for the optimisation. The criterion adopted is the minimum value of the THD, considering harmonics upto the 99th. Out of several combinations possible of full and half bridge inverters in series , only six cases were selected in I-phase application for the optimisation procedure These are . Case 1 Two full bridge inverters

Case 2 . Three full bridge inverters Case 3 : Two full bridge and one half bridge inverters Case ,4 ' One full bridge and two half bridge inverters Case 5
'

In general, the peak magnitude of the 'n'th harmonic of final output is given by [4] :
an=

Three half bridge inverters

& [E, cosn e, + E, cosn e, + .........+ E, cosn e,] ..__.. (I


,

Case 6 : Four half bridge inverters The final results confirmed thai the above cases were adequate for the study since the THD spread obtained was around 5% as desired, with a reasonable number o semiconductor f switches. The results of optimisationare presented in Table Ifor all the above SIX cases, white the corresponding harmonic spectra are showil in Fig 5

where E, is the step height at position 0, The percentage THD is given by Percentage THD
n=7

(an)2

x 100 ,..........,....

Lble

164

..

2 8 5

CASE I V

15 21

27

33 39 45
5

9
CASE V

15 21

27 33 39 45

(1
3
3

15

21

27

33 39

45

15

21

27

33 39

45

CASE VI

1 5 ;
Fig 5

27

33 39 45

15

21

27

33 39

45

: Harmonic Spectra for Selected Cases of 1-phase Inverter Systems

(% Harmonic Content Versus Order of Harmonics)


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EXPERIMENTAL RESULTS
One prototype inverter system was built and tested in the laboratory, as per case 1, using two full bridge inverters in spries. It was rated for operation from a 48 volt dc input with output load capacity of 250 VA at 230 volts, 50 Hz.the push-pull converter was designed to operate at 50 kHz using parallel-connected MOSFETs. The transformer was designed using ferrite cores and insulated multiple-conductorswere used for the windings to reduce skin-effect losses. The transformer output windings were in the ratio of 1.3, each rectified by a bridge rectifier using ultrafast-recovery diodes The dc outputs were filtered through a common choke wound on ferrite core.-The series connected outputs of the inverters was loaded directly.Fig 6 shows the oscillograms of individual inverter outputs and the final stepped waveform.

CONCLUSION
This paper has presented a new approach to the generation of stepped voltage waveform without using power frequency transformer connections. It is based on the concept of combining the outputs of several synchronised PWM inverter3 in series, whose inputs are fed from separate isolated dc supplies, with fixed ratios between their voltages. The ratio controls the step height while step angles are programmed into the PWM inverter control circuit. The individual inverters may be either full or half bridge types. The isolated dcsources are generated from a given dc supply through a high frequency transformer, whereby the size of the inverter is drastically reduced The inverters may be built in three-phase versions also. Study has been made on the waveform optimisation through the selection of different number and combinations of full and half bridge inverters in series, such that the output THD is minimum. Results indicate that for ?-phase configuration, it is possible to achieve less than 5% T H 6 using only eight semiconductor switches (Case6). Hhowever, it should also be noted that compared to full bridge circuits half bridge circuits, use only half the number of semiconductor switches, but its cost is much more than half as explained earlier Thus, selection of the specific combination should not be done solely on the basis of minimum switches

REFERENCES
B D. Bedford and R G. Hoft, Principles of inverter Circuits, J. Wiley, N. York, 1974

(a) Individual Inverter Outputs

S K. Biswas, B. Basak and T.K. Basu, A low distortion inverter without low-frequency magnetics for UPS application, Proceedings of IEEE PEDS95 conference 1995, pp 347-352.

H Matsuo and F Kurokawa, Precise regulation of multiple output voltages in a dc to dc converter, conference Record 1980,Pwr. Electr. Sp. Conference, pp 275-283
T. Lissack and J Appelbaum, Stepped voltage DC/AC inverter-Part I : Analysis, IEEE Trans on Ind Electr & Con. Inst. Vol IECI-24, No 2, pp 192-199, May 1977

Final

Output
100 Vkdiv

-, Stepped voltage DC/AC inverter -Part II : Optimal conStruction of waveforms by means of discrete levels, I E E Trans. on Ind. Electr. & Con. Inst., Vol IECI-24, No 3, pp 273-276, Aug 1977.

APPENDIX

(b) Combined Stepped Waveform


Fig 6 : Experimental Oscillograms(Time scale=2ms/div)
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For each of the six cases presented under case study, the waveforms for each of the constituent inverters is shown in Fig 7 for a quarter of a cycle. The final waveshape can be obtained by adding the constituent inverter waveforms graphically. The angles shown have values as given in Table 1

Fig

: Waveform Construction for Inverter System in each Case Under Study


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