Switching-Cell Arrays—An Alternative Design Approach in Power Conversion

The conventional design of voltage-source power converters is based on a two-level half-bridge configuration and the selection of power devices designed to meet the full application specifications (voltage, current, etc.). This leads to the need to design and optimize a large number of different devices and their ancillary circuitry and prevents taking advantage from scale economies. This paper proposes a paradigm shift in the design of power converters through the use of a novel configurable device consisting on a matrix arrangement of highly optimized switching cells at a single voltage class. Each switching cell consists of a controlled switch with antiparallel diode together with a self-powered gate driver. By properly interconnecting the switching cells, the switching-cell array (SCA) can be configured as a multilevel active-clamped leg with a different number of levels. Thus, the SCA presents adjustable voltage and current ratings, according to the selected configuration. For maximum compactness, the SCA can be conceived to be only configurable by the device manufacturer upon the customer needs. For minimum cost, it can also be conceived to be configurable by the customer, leading to field-configurable SCAs. Experimental results of a 6 × 3 field-configurable SCA are provided to illustrate and validate this design approach.