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This work deals with the sizing of submodule capacitors for modular multilevel converters (MMCs) used for variable speed drives for medium voltage and high voltage electric machines. Variable speed drives are required to run over a wide frequency range from zero to a few hundred Hz or even over 1 kHz. Under low frequency operation (

This article presents the design and development of a 7-kV dc bus, 1-MVA, 0–1000 Hz modular multilevel converter (MMC) prototype for high speed medium-voltage variable frequency drives. The system is designed based on 1.7-kV silicon carbide (SiC) mosfet s. First, the full in-depth design of the prototype is provided, including the submodules, arm inductors, and system integration. Then, the unique control scheme and the control hardware design are presented to achieve the full-frequency range operation. The power loss based on Si and SiC devices is analyzed. Finally, experimental results are presented to demonstrate the performance of both the SiC-based submodule and the full-scale MMC system. Compared with the traditional Si-based solution, the established SiC MMC can reduce the drive system volume by 75% and achieve 325% power density, and the peak energy efficiency reaches around 99.35%.

Errors in the injected high-frequency circulating currents are originally investigated for modular multilevel converters (MMCs) in low-speed drive operation. The mathematical analysis reveals that the magnitude and phase errors in the injected circulating currents cause serious energy imbalance in the MMC arms, resulting in large voltage fluctuations in the submodules. Furthermore, these fluctuations get larger when the circulating currents are injected at higher frequencies, which reduces the drive system stability and damages the submodule capacitors. A remedy approach is proposed to minimise the error effects by adjusting the circulating current command. A full-scale system comprising a 1 MVA MMC and a 1 MW induction machine is simulated to verify the theoretical analysis. The experimental investigation of a down-scale MMC feeding an inductor is also conducted to validate the theoretical results.

Low frequency operation in the modular multilevel converters (MMCs) is enabled by applying a reference common mode voltage and circulating currents at a frequency much higher than the desired output frequency. The frequency of injected common-mode signals is limited for maintaining a good performance in the circulating current control. Firstly, this paper theoretically analyzes the effect of increasing the frequency of injected common-mode signals by evaluating the error between reference and actual circulating currents. Secondly, we introduce an additional parameter in the reference circulating current to enhance the suppression of MMC's capacitor voltage fluctuations. Intensive computer simulations are developed for a seven-level MMC driving a medium-voltage induction motor drive system to verify the circulating current error analysis and assess the capacitor voltage fluctuations. Finally, the proposed technique for suppressing the capacitor voltage fluctuations is experimentally validated on a 600-V three-level MMC feeding an inductive load. The voltage fluctuations are reduced by more than 50% (63.6%) when the proposed technique is applied with a high common-mode frequency.

Modular Multilevel Converters have been proposed to be a viable topology for medium voltage and high power motor drives due to the stackable structure of the topology. This allows for a transformer-less drive, better output current THD and reduces input and output filter sizes compared to traditional topologies. Replacing the traditional Si IGBT based submodules with SiC MOSFETs has been shown to improve the overall efficiency of the MMC. However, the lower switching losses of SiC MOSFETs have not been fully utilized to realize further system level improvements in the MMC. In this paper, the impact of the SiC MOSFETs on the efficiency, power density and output current THD of the drive is compared against Si IGBTs using analytical and simulation. A 7 kV dc bus, 4.16 kV ac, 1 MVA, 0-1,000 Hz medium voltage variable speed drive based on 1.7 kV devices based is used for the comparison.

A novel discharging control strategy is proposed and implemented for submodules in modular multilevel converters (MMCs). By sequentially controlling the arm currents of a MMC to the arm resistors, all submodule capacitors are discharged safely and rapidly without adding additional devices and circuits, resulting in improved performance and reduced cost. Both open- and closed-loop control methods are evaluated for effectiveness of the new control strategy. Simulation and experimental results are provided to validate the new control strategy.

The errors between the reference and actual injected circulating currents are investigated for modular multilevel converters (MMCs) in low frequency operation. These errors cause low frequency oscillatory power components in the MMC arms and large voltage fluctuations in the submodule capacitors. By adjusting the circulating current reference with a single parameter, it is possible to compensate the errors and suppress the undesired voltage fluctuations. Computer simulations and experimental results are provided to verify the theoretical derivations.

This paper studies the phenomenon of resonant oscillation in Modular Multilevel Converters (MMCs) for variable frequency operation. Without proper control, it may easily induce huge MMC inner circulating currents and damage major power devices. A Laplace model is established to clarify the mechanism of resonant oscillation in MMCs, and Bode diagrams are used to study the frequency response over a wide frequency range. Meanwhile, a straightforward resonant suppression method based on circulating current control is used to damp out the resonant condition, and a cross comparison is conducted in terms of system losses, capacitor voltage ripples, and load voltage harmonics with and without the resonant oscillation. Both simulation and experimental results are provided to validate the MMC resonant oscillation theory and its suppression control method.

Modular multilevel converters (MMCs), with the filter-less and transformer-less features, are considered as a promising topology for high-efficiency medium voltage (MV) high voltage (HV) drive systems. However, at low frequencies (< 30 Hz), a large current ripple flowing through the capacitors of each submodule will cause significant capacitor voltage fluctuation. This paper proposes an optimal submodule capacitor selection based on the common mode voltage injection. The proposed sizing model includes two functions: a) accurately estimating the capacitor voltage ripple based on the drive system parameters; and b) identifying the minimum capacitance of the submodule capacitors based on the allowed maximum capacitor voltage fluctuations. Simulation and hardware-in-the-loop (HIL) test results show that the error between the actual and estimated values of the voltage fluctuation is within 3% using the proposed model.