A Low-Loss PWM Method to Improve the Efficiency and Dynamic Performance of Electric Vehicle Traction Inverters and Grid Connected Photovoltaic Converters

Voltage Source Inverter (VSI) is an integral component that converts DC voltage to AC voltage suitable for driving the electric motor in Electric Vehicles/Hybrid Electric Vehicles (EVs/HEVs) and integration with electric grid in grid-connected photovoltaic (PV) converter. Performance of VSI is significantly impacted by the type of Pulse Width Modulation (PWM) method used.In this work, a new PWM method called 240° Clamped Space Vector PWM (240CPWM) is studied extensively. 240CPWM method has the major advantages of clamping a phase to the positive or negative rail for 240° in a fundamental period, clamping of two phases simultaneously at any given instant, and use of only active states, completely eliminating the zero states. These characteristics lead to a significant reduction in switching losses of the inverter and lower DC link capacitor current stress as compared to Conventional Space Vector PWM. A unique six pulse dynamically varying DC link voltage is required for 240CPWM instead of constant DC link voltage to maintain sinusoidal output voltage. Voltage mode control of DC-DC stage with Smith predictor is developed for shaping the dynamic DC link voltage that meets the requirements for fast control. Experimental results from a 10 kW hardware prototype with 10 kHz switching frequency validate the superior performance of 240CPWM in EV/HEV traction inverters focusing on loss reduction and DC link capacitor currents. Full load efficiency with the proposed 240CPWM for the DC-AC stage even with conventional Silicon devices exceeds 99%. Performance of 240CPWM is evaluated in three phase grid-connected PV converter. It is verified experimentally that 240CPWM performs well under adverse grid conditions like sag/swell and unbalance in grid voltages, and under a wide range of power factor. Undesired low frequency harmonics in inverter currents are minimized using the Harmonic Compensator that results in Total Harmonic Distortion (THD) of 3.5% with 240CPWM in compliance with grid interconnection standards. A new, combined performance index is proposed to compare the performance of different PWM schemes in terms of switching loss, THD, DC link current stress, Common Mode Voltage and leakage current. 240CPWM achieves the best value for this index among the PWM methods studied.