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1600 IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS, VOL. 52, NO.

6, DECEMBER 2005

An Efficient Multilevel-Synthesis Approach


and Its Application to a 27-Level Inverter
Feel-Soon Kang, Member, IEEE, Sung-Jun Park, Member, IEEE, Man Hyung Lee, Senior Member, IEEE,
and Cheul-U Kim, Member, IEEE

Abstract—This paper presents an efficient multilevel-synthesis complexity and introduces voltage-imbalance problems. Con-
scheme and its application to a 27-level inverter. In the proposed sequently, these multilevel-inverter schemes are not suitable
multilevel scheme, this can be realized by an array of switching for increasing the output-voltage levels because of their large
devices composing full-bridge inverter modules and proper mixing
of each transformer terminal voltage. The most different aspect, number of switching devices. To increase the number of the
compared to the conventional approach, in the synthesis of the output-voltage levels in order to obtain high-quality output-
multilevel output waveform is the utilization of a combination of voltage waveforms by means of multilevel-inverter schemes,
transformers rather than the accumulation of capacitor voltage the above problems should be solved in advance.
sources. A 27-level inverter consists of three full-bridge modules In this research paper, an efficient multilevel-waveform-
and their corresponding transformers. Quasi-sinusoidal voltage
waves can be generated from a suitable selection of the turns ratio synthesis technique is suggested. The basic principle is that the
of the transformer. The validity of the proposed system is verified continuous-output-voltage levels can be synthesized by addi-
by computer-aided simulation and experimental results using a tion or subtraction of the instantaneous voltages generated from
500-W prototype, which can generate a 110-V ac output voltage different voltage levels. In the proposed multilevel scheme,
from a 12-V dc input. this can be realized by an array of switching devices com-
Index Terms—Cascaded transformer, multilevel inverter, total posing full-bridge inverter modules and proper mixing of each
harmonic distortion (THD). transformer terminal voltage. The commutation of the switches
permits the addition or the subtraction of the terminal voltages
I. I NTRODUCTION of each transformer. The most different aspect, compared to
the conventional multilevel approaches, in the synthesis of the
R ECENTLY, multilevel inverters have emerged as a new
kind of power-conversion systems. General multilevel
inverters have an arrangement of power switching devices and
multilevel output levels is the utilization of a voltage combina-
tion of transformers rather than the accumulation of capacitor
capacitor voltage sources. By the control of the switching voltage sources. The validity of the proposed multilevel-
devices, they can synthesize stepped output voltages with low synthesis scheme is verified through simulation results. Then,
harmonic distortions. The principal motivation for multilevel a new multilevel-inverter topology and its control scheme are
topologies is the increase of power, the reduction of voltage presented. It consists of three full-bridge inverter modules and
stress on the power switching devices, and the generation of their corresponding three transformers, which have a series-
high-quality output voltages and sinusoidal currents [1]–[6]. In connected secondary winding. Consequently, the multilevel
the viewpoint of the latter, three presentable topologies can be inverter synthesizes a 27-level output voltage with considerably
considered for multilevel inverters: diode clamped (or neutral reduced harmonic components. It shows a low total harmonic
clamped) [7], flying capacitors (or capacitor clamped) [8], and distortion (THD) of approximately 1.248%. Compared to the
cascaded H-bridge cells with separate dc sources [9]. Theoret- conventional approaches, considering the same output-voltage
ically, they can synthesize an infinite output-voltage level. By level of a 27-level inverter, it can save on the number of the
increasing the number of levels in the inverter, the output volt- main switches and diodes up to 77% without considering the
ages have more steps generating a staircase waveform, which power rating of the devices. In addition, the gate amps and their
has a reduced harmonic distortion. However, a large number independent voltage sources are proportionally reduced to the
of levels increase the number of switching devices, gate amp, number of the used switches.
diodes, and other passive elements. Moreover, it causes control
II. P ROPOSED M ULTILEVEL I NVERTER
Manuscript received July 29, 2003; revised December 22, 2004. Abstract
published on the Internet September 26, 2005. An earlier version of this paper
A. Basic Principle of the Proposed Multilevel Synthesis
was presented at IEEE IECON’03, Roanoke, VA, November 2–6, 2003.
F.-S. Kang is with the Department of Control and Instrumentation Engineer-
Generally, conventional multilevel inverters include an array
ing, Hanbat National University, Daejeon 305-719, Korea (e-mail: feelsoon@ of switching devices and capacitor voltage sources, the output
ieee.org; feelsoon@hanbat.ac.kr). of which generate voltages with stepped waveforms. The com-
S.-J. Park is with the Department of Electrical and Electronics, Chonnam Na-
tional University, Gwangju 500-757, Korea (e-mail: sjpark1@chonnam.ac.kr). mutation of the switches permits the addition of the capacitor
M. H. Lee is with the School of Mechanical Engineering, Pusan National voltages, which reach high voltage at the output, while the
University, Pusan 609-735, Korea (e-mail: manhlee@pusan.ac.kr). switching devices withstand only reduced voltages. Fig. 1(a)
C.-U. Kim is with the Department of Electrical Engineering, Pusan National
University, Pusan 609-735, Korea (e-mail: kimcu@pusan.ac.kr). shows a basic concept of the general multilevel-waveform-
Digital Object Identifier 10.1109/TIE.2005.858715 synthesis method with different numbers of levels, for which

0278-0046/$20.00 © 2005 IEEE


KANG et al.: MULTILEVEL-SYNTHESIS APPROACH AND ITS APPLICATION TO A 27-LEVEL INVERTER 1601

Fig. 1. Basic concept of the general and the proposed multilevel-waveform


synthesis. (a) General approach. (b) Proposed method.
Fig. 2. Single-phase full-bridge inverter and cascaded connection of the sec-
an ideal switch with several positions represents the action ondary winding of transformers. (a) Single-phase full-bridge inverter module.
(b) Cascaded connection of the secondary winding of the transformer.
of the switching devices. A two-level inverter generates an
output voltage with two values with respect to the negative
terminal of the capacitor, while the three-level inverter gen- Therefore, the output voltage can be determined by the dc input
erates three voltages, and so on [1], [2], [4]–[6]. Fig. 1(b) voltage and the turns ratio of the transformer. Because a general
shows a basic principle of the proposed multilevel-waveform- inverter system has a constant dc input source, it is desirable
synthesis method. Considering the array of individual voltage that the turns ratio of the transformer determines the amplitude
sources having different values, the continuous-output-voltage of output voltage. Fig. 2(b) shows a cascaded connection of the
levels can be synthesized by the selection of suitable switching secondary turns ratio of the transformers to obtain a large num-
combinations. In the proposed multilevel scheme, this can be ber of output-voltage levels. In the level selection of the output
realized by an array of switching devices composing full- voltage, it should be noted that the focuses are both the result
bridge inverter modules and proper mixing of each transformer of the output-voltage combination of the inverter and the de-
terminal voltage. The most different aspect, compared to the termination of the turns ratio of the transformer, which can
conventional approach, in the synthesis of the multilevel output synthesize a continuous-output-voltage level with an integral
waveform is the utilization of a combination of transformers ratio. Because each full-bridge inverter module can generate
rather than the accumulation of capacitor voltage sources. three levels, the required turns ratio of the secondary winding,
which can generate a continuous-output-voltage level with an
integral ratio, can be selected as
B. Proposed Multilevel Inverter
Fig. 2(a) shows a single-phase full-bridge inverter connected ak = a · 3k−1 , k = 1, 2, 3, . . . . (1)
with a transformer. The output voltage Vo appears as +aVdc ,
0, and −aVdc according to the ON–OFF conditions of switching Here, k means the rank of the stacked transformers in series,
devices, where a is the secondary turns ratio of the transformer. and a is determined by the turns ratio of the transformer
1602 IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS, VOL. 52, NO. 6, DECEMBER 2005

TABLE I
EACH TURNS RATIO OF THE SECONDARY WINDING OF THE
TRANSFORMER IN SERIES CONNECTION

Fig. 4. Expected output-voltage levels and each terminal voltage of the


transformer.

TABLE II
SWITCHING FUNCTIONS ACCORDING TO OUTPUT-VOLTAGE LEVEL

Fig. 3. Equivalent circuit of the proposed multilevel inverter employing


cascaded three transformers with a series-connected secondary winding.

when the input voltage is νab ; therefore, its value determines


the difference between output levels. Table I illustrates the
secondary turns ratio of the transformer following (1). The With the switching functions as defined in (3), the overall
possible number of output-voltage levels when it employs n output voltage (Vo ) of the proposed inverter is expressed as
number of transformers is written as ∞

Vo = SFBn · an · Vdc . (4)
Vn = 3n , n = 1, 2, 3, . . . (2) n=1

where n is the number of cascaded transformers. The switching From the result of (4), it can be found that three transformers
functions of single-phase full-bridge inverter shown in Fig. 2(a) having a series-connected secondary winding can synthesize a
are summarized as 27-level output voltage, and an 81-level output voltage with
four transformers. If the number of transformer is boundless,
SFB = 1 : Q2 , Q3 = ON the output-voltage levels are infinite, which is similar to the
SFB = 0 : Q1 , Q3 (or Q2 , Q4 ) = ON analog one. However, a large number of transformers can be a
SFB = −1 : Q1 , Q4 = ON. (3) cause of cost increase and manufacturing problems. Therefore,
KANG et al.: MULTILEVEL-SYNTHESIS APPROACH AND ITS APPLICATION TO A 27-LEVEL INVERTER 1603

Fig. 7. Simulated waveforms of the proposed multilevel inverter with three


Fig. 5. Reference and output voltages of the proposed multilevel inverter. series-connected transformers: a 27-level inverter.
(a) Reference and output voltages for 1/4 cycle. (b) Determination of corre-
sponding duration. TABLE III
PROTOTYPE SPECIFICATIONS OF THE PROPOSED MULTILEVEL INVERTER

Fig. 4 shows the expected output-voltage levels and each


terminal voltage of the transformer. It is very useful to under-
stand the multilevel synthesizing procedure. Table II lists the
Fig. 6. Control block diagram of the proposed multilevel inverter. switching functions according to each output-voltage level in
the case of positive output voltage. For a negative case, they
it should be selected considering the amplitude of input voltage, can be easily obtained by multiplying -1 to Table II. In the
the THD of output voltage, and the system price. case of SFB3 , which is the switching function of the lowest
The equivalent circuit of the proposed multilevel inverter em- inverter module, it takes a naught when a desired output level is
ploying three transformers with a series-connected secondary equivalent or lower than a fourth level in Table II. In contrast, it
winding is shown in Fig. 3. In this figure, the output voltage by takes a unity when a wanted output-voltage level is higher than
the switching function can be rewritten as the fourth level. The switching function SFB3 can be expressed
by using C language as (6). For the sake of convenience, we

3
just deal with the positive portion given in Table II. Here, all
Vo = SFBn · an · Vdc = (9SFB3 + 3SFB2 + SFB1 ) · a · Vdc
variables are considered as an integer (int).
n=1
(5)
if (m ≤ 4) then SFB3 = 0
where a1 = a, a2 = 3a, a3 = 9a, and SFBn {1, 0, −1}. if (m > 4) then SFB3 = 1. (6)
1604 IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS, VOL. 52, NO. 6, DECEMBER 2005

Fig. 8. Experimental waveforms of the output voltage and terminal voltage


of each transformer in a no-load condition. (a) Output-voltage waveform.
(b) Terminal voltage of each transformer. Fig. 9. FFT results of the output voltage according to load conditions.
(a) No-load condition. (b) With a resistive load of 20 Ω.
Here, m means the number of output-voltage levels. The
switching function SFB2 of the middle inverter is deter-
mined as maximum number of output levels for the positive portion is 13,
  except for zero, the amplitude of the quarter sine wave is
(m + 1) divided into 13, with the same height. Then, t1 –t13 are deter-
if =0 then SFB2 = 0
3%3 mined. Fig. 5(b) shows the method to determine the duration of
  a corresponding output-voltage level. The output-voltage level
(m + 1)
if =1 then SFB2 = 1 is determined by an average value between points A and B,
3%3
  which are selected by comparison with the reference voltage.
(m + 1) The output-voltage level is selected between one level lower
if =2 then SFB2 = −1 (7)
3%3 and the upper one compared to a desired output level. The
maintaining time (Tm ) of the output voltage +mVdc is given by
where % is a modulus operator. The switching function SFB1 this figure as Tp+1 − Tp . In order to determine those durations,
of the upper inverter is determined by the output voltage is normalized by 13aVdc ; then, each level’s
duration is given as
if (m%3) = 0 then SFB1 = 0
  
if (m%3) = 1 then SFB1 = 1 m−1
+ 1
13aVdc
−1 13 26
Tm = sin , m = 1, 2, 3, . . . (9)
if (m%3) = 2 then SFB1 = −1. (8) Vp

Fig. 5(a) shows the command voltage of the inverter and its
output-voltage waveform. Because it has a symmetric configu- where Vp is the peak value of the normalized command sine
ration, the selection of the output level and its corresponding voltage, and m means the number of the output-voltage level.
duration, which define the switching functions, can be per- In (9), m is calculated up to the number that arcsine is not
formed by a quarter portion of one period. As the possible exceeding unity. It is proportional to the amplitude of the output
KANG et al.: MULTILEVEL-SYNTHESIS APPROACH AND ITS APPLICATION TO A 27-LEVEL INVERTER 1605

TABLE IV
COMPONENTS COMPARISON BETWEEN CONVENTIONAL MULTILEVEL INVERTERS AND THE PROPOSED 27-LEVEL INVERTER

command voltage, and it has a maximum value of 13. A control to the filtering effect of the reactance of cascaded transformers.
block diagram of the proposed multilevel inverter is shown From these facts, it is clear that the proposed multilevel inverter
in Fig. 6. It basically depends on the traditional proportional in higher load conditions can generate a more sinusoidal output
and integrational (PI) control. The reference voltage Vref is voltage than those cases of a lower or a no-load condition.
generated by the feedback of the output voltage via the PI The THD to the output voltage is measured 1.248% at a
controller. It is used to determine and calculate the output- 500-W load.
voltage level and its corresponding duration. Component comparison between conventional multilevel in-
verters and the proposed multilevel inverter with 27 output
levels is given in Table IV. It is compared with the conventional
III. S IMULATION AND E XPERIMENTAL R ESULTS
multilevel inverters, i.e., diode clamped, flying capacitor, and
At first, we performed the simulation to prove the availabil- cascaded H-bridge multilevel inverters. In the case of the diode-
ity of the proposed multilevel approach. The simulation was clamped type, a large number of clamping diodes is a severe
implemented by using C language, and it was considered to drawback, and a lot of balancing capacitors is a disadvantage
the resistive load. Fig. 7 shows the simulation result of the of the flying-capacitor method. Among them, the cascaded type
proposed multilevel inverter. Here, Vcom is the staircase wave looks good for the multilevel inverter. However, each cell of
to determine the output voltage, as given in Fig. 5(a). In this the cascaded type requires its own isolated power supply. The
case, a 27-level output-voltage waveform can be synthesized provision of these isolated supplies is the main limitation in
because it employs three transformers having the turns ratio of the power electronic circuit design. From the comparison, it
1 : a, 1 : 3a, and 1 : 9a, respectively. Each terminal voltage of is clear that the most outstanding advantage of the proposed
the transformer is also shown in Fig. 7 as V1 , V2 , and V3 . multilevel-inverter schemes is the reduced main switching de-
Based on the simulation results, the proposed multilevel vices and diodes. Forty switching devices can be saved without
inverter was tested by a prototype. As a controller, the digital considering the current rating of the used switching devices.
signal processor (DSP) TMS320F241 was used. Specifications In addition, the gate amp is proportional to the number of the
of the prototype are listed in Table III. In the no-load condi- switching devices.
tion, the result output-voltage waveform is shown in Fig. 8(a). We note that the proposed multilevel approach is suitable for
The implemented multilevel inverter has a 27-level output- constant voltage and constant frequency (CVCF) applications
voltage waveform by the combination of the series-connected such as uninterruptible power supply (UPS) and photovoltaic
transformers 1 : a, 1 : 3a, and 1 : 9a in sequence. As shown inverter systems because of the property of the transformer
in this result, it is clear that the output-voltage waveform is used. However, this method is not desirable for the motor drives
very similar to a sinusoidal one, owing to a large number of employing variable-frequency (VF) control method because of
output-voltage levels. In addition, the output voltage will turn the transformer saturation.
into a more sinusoidal wave if the output load current increases,
since the inductance components of cascaded transformers are
IV. C ONCLUSION
operated as a high-performance filter; it will be proved from
Fig. 9. As a result, the proposed multilevel inverter needs no The basic principle of the suggested multilevel-inverter
additional output filters. Fig. 8(b) shows the terminal output scheme is that the continuous-output-voltage levels can be
voltages of each transformer. We can notice that the sum of synthesized by the addition or subtraction of the instantaneous
V1 , V2 , and V3 synthesizes the output voltage V o . Fig. 9(a) voltages generated from different voltage levels. In the pro-
and (b) shows the fast Fourier transform (FFT) results of the posed multilevel inverter, this can be realized by an array
output voltage with a no-load condition and a resistive load of of switching devices composing full-bridge inverter modules
20 Ω, respectively. Although Fig. 9(a) has some low harmonic and proper mixing of each transformer terminal voltage. The
components such as 3, 5, 7, 11, and other harmonics, they are most different aspect, compared to the conventional multilevel
however sufficiently eliminated, as shown in Fig. 9(b), owing approaches, in the synthesizing of the multilevel output levels
1606 IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS, VOL. 52, NO. 6, DECEMBER 2005

is the utilization of a voltage combination of transformers Sung-Jun Park (M’01) received the B.S., M.S.,
rather than the accumulation of capacitor voltage sources. The and Ph.D. degrees in electrical engineering from
Pusan National University, Busan, Korea, in 1991,
validity of the proposed multilevel-synthesis scheme is verified 1993, and 1996, respectively. He also received the
through simulation and experimental results. Consequently, the Ph.D. degree in mechanical engineering from Pusan
multilevel inverter synthesizes a 27-level output voltage with National University in 2002.
From 1996 to 2000, he was an Assistant Professor
considerably reduced harmonic components of approximately in the Department of Electrical Engineering, Koje
1.248%. Compared with the conventional approaches, consid- College, Koje, Korea. From 2000 to 2003, he was an
ering the same output-voltage level of a 27-level inverter, it can Assistant Professor in the Department of Electrical
Engineering, Tong-Myong College, Busan, Korea.
save on the number of the main switches and diodes up to 77% Since 2003, he has been with the Department of Electrical Engineering,
without considering of the power rating of the switching de- Chonnam National University, Gwangju, Korea, as an Assistant Professor.
vices. In addition, the gate amps and their independent voltage His research interests are in power electronics, motor control, mechatronics,
micromachine automation, and robotics.
sources are proportionally reduced to the number of the used Dr. Park is a member of the Korea Institute of Electrical Engineering (KIEE)
switches. and the Korea Institute of Power Electronics (KIPE).

R EFERENCES
[1] J. Rodriguez, J. S. Lai, and F. Z. Peng, “Multilevel inverters: A survey of
topologies, controls, and applications,” IEEE Trans. Ind. Electron., vol. 49,
no. 4, pp. 724–738, Aug. 2002.
[2] J. S. Lai and F. Z. Peng, “Multilevel converters—A new breed of power Man Hyung Lee (S’79–M’83–SM’01) was born
converters,” IEEE Trans. Ind. Appl., vol. 32, no. 3, pp. 509–517, May/Jun. in Korea in 1946. He received the B.S. and M.S.
1996. degrees in electrical engineering from Pusan Na-
[3] C. Hochgraf, R. Lasseter, D. Divan, and T. A. Lipo, “Comparison of tional University, Busan, Korea, in 1969 and 1971,
multilevel inverters for static var compensation,” in Proc. IEEE Industry respectively, and the Ph.D. degree in electrical and
Applications Society (IAS) Conf., Denver, CO, 1994, pp. 921–928. computer engineering from Oregon State University,
[4] M. Manjreker and G. Venkataramanan, “Advanced topologies and modu- Corvallis, in 1983.
lation strategies for multilevel inverters,” in Proc. IEEE Power Electronics From 1971 to 1974, he was an Instructor in the
Specialists Conf. (PESC), Baveno, Italy, 1996, pp. 1013–1018. Department of Electronics Engineering, Korea Mil-
[5] C. Newton and M. Sumner, “Multilevel converters a real solution to itary Academy. He was an Assistant Professor in
medium/high-voltage drives?,” Power Eng. J., vol. 12, no. 1, pp. 21–26, the Department of Mechanical Engineering, Pusan
Feb. 1998. National University, from 1974 to 1978. From 1978 to 1983, he held positions
[6] B. S. Shu, G. Sinha, M. D. Manjrekar, and T. A. Lipo, “Multilevel as a Teaching Assistant, Research Assistant, and Postdoctoral Fellow at Oregon
power conversion—An overview of topologies and modulation strate- State University. Since 1983, he has been a Professor in the College of
gies,” in Proc. Optimisation Electrical and Electronic Equipments, Brasov, Engineering, Pusan National University, where he is also currently a POSCO
Romania, 1998, pp. 1–14. Chair Professor in the School of Mechanical Engineering. His research interests
[7] A. Nabae, I. Takahashi, and H. Akagi, “A neutral-point clamped PWM are in estimation, identification, stochastic processes, bilinear systems, mecha-
inverter,” IEEE Trans. Ind. Appl., vol. IA–17, no. 5, pp. 518–523, tronics, micromachine automation, and robotics. He is the author of more than
Sep./Oct. 1981. 550 technical papers.
[8] T. A. Meynard and H. Foch, “Multilevel conversion: High voltage coppers Dr. Lee was the Program Chair of the 1998 4th ICASE Annual Conference,
and voltage-source inverters,” in Proc. IEEE Power Electronics Specialists General Cochairmen of the 2001 IEEE International Symposium on Industrial
Conf. (PESC), Toledo, Spain, 1992, pp. 397–403. Electronics (ISIE), and is General Cochairmen of the 2004 IEEE IECON. He is
[9] M. Marchesoni, M. Mazzucchelli, and S. Tenconi, “A non conventional a member of the American Society of Mechanical Engineers, Society for Indus-
power converter for plasma stabilization,” in Proc. IEEE Power Electronics trial and Applied Mathematics, and Society of Photo-Optical Instrumentation
Specialists Conf. (PESC), Kyoto, Japan, 1988, pp. 122–129. Engineers.

Feel-Soon Kang (S’99–M’03) received the M.S.


and Ph.D. degrees from Pusan National University,
Busan, Korea, in 2000 and 2003, respectively.
From 2003 to 2004, he was with the Department
of Electrical Engineering, Osaka University, Osaka, Cheul-U Kim (S’85–M’87) received the B.S. degree
Japan, as a Post-Doctoral Fellow. Since 2004, he in electrical engineering from Pusan National Uni-
has been with the Department of Control and Instru- versity, Busan, Korea, in 1969, the M.S. degree from
mentation Engineering, Hanbat National University, the University of Electro-Communications, Japan,
Daejon, Korea, as a full-time Lecturer. His research in 1974, and the Ph.D. degree from Chung-Ang
activities are in the area of power electronics, includ- University, Korea, in 1986.
ing design and control of power converters, multi- Since 1975, he has been a Professor at Pusan
level inverters for photovoltaic systems, and sustain drivers for ac plasma National University. His research activities are in the
displays. area of power electronics and motor control, includ-
Dr. Kang received a Student Award from the IEEE Industrial Electronics ing cyclo-converter design, drive systems, and high-
Society, and the Best Presentation Prize at the IEEE IECON’01 held in Denver, efficiency switch-mode power supplies. His current
CO, in 2001. He was also honored with an Academic Award from the Graduate research interests include the design of highly efficient sustain drivers for ac
School of Pusan National University in 2003. He is an Associate Editor for the plasma display panel driving.
IEEE TRANSACTIONS ON INDUSTRIAL ELECTRONICS. He is a member of Dr. Kim is a member of the Korea Institute of Electrical Engineering, Korea
the Korea Institute of Electrical Engineering (KIEE) and the Korea Institute of Institute of Power Electronics, Korea Institute of Illuminating and Electrical
Power Electronics (KIPE). Installation Engineers, Japan Institute of Electrical Engineers, and the IEEE.

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