article · IEEE Access
A new clamped diode multilevel DC/DC buck power converter topology has been developed to improve DC motor drive systems. The circuit integrates four cascaded MOSFET power switches, three clamping diodes, and four series-connected voltage cells. Designed to overcome the current and torque ripples caused by hard switching in traditional chopper circuits, the configuration enhances reference voltage tracking while maintaining low voltage ripples and reduced electromagnetic interference noise. Operating a DC motor with this system scales down armature current ripples and torque ripples by a factor matching the number of voltage cells. Validated through both simulations and experimental testing on a physical DC motor prototype, the setup also lowers mechanical vibration and acoustic noise by approximately 13 decibels when subjected to continuous variable input voltage patterns.
Electric motors often suffer from mechanical vibration, acoustic noise, and electromagnetic interference due to abrupt electrical switching in standard power circuits. Mitigating these ripples through multilevel power conversion protects mechanical components, creates quieter machinery, and enhances power quality. By smoothing the supplied voltage and current, motor drive systems can run more reliably with reduced physical wear and lower electrical interference.
This technology is relevant to manufacturers of DC motor drives and industrial power electronics aiming to suppress acoustic noise, mechanical stress, and electromagnetic interference. The system appears to be applied and tested, as it has been validated via both simulations and an experimental DC motor prototype. Moving towards commercial implementation would require further operational development to adapt the multi-cell design for target industrial equipment.
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This paper presents a new topology of clamped diode multilevel DC/DC buck power converter for a DC motor system. The proposed converter circuit consists of four cascaded MOSFET power switches with three clamping diodes and four voltage sources (voltage cells) connected in series. The main objective of the new topology is to reduce current ripples and torque ripples that are associated with hard switching of the traditional chopper circuit. When the voltage profile of this converter is applied on a DC motor, it positively affects the performance of the DC motor armature current and the generated dynamic torque. The output voltage of the proposed topology shows an adequate performance for tracking of reference voltage with small ripples that are normally reflected into smaller EMI noise. Moreover, it has been shown that the operation of the DC motor with the newly proposed chopper topology greatly decreases the motor armature current ripples and torque ripples by a factor equal to the number of the connected voltage cells. Both simulation and experimental results on a prototype of a DC motor are provided to validate the proposed chopper topology. The results prove that the mechanical vibration and acoustic noises have also been reduced roughly by 13 dBs with a continuous variable input voltage pattern.
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DOI: 10.1109/access.2019.2912315
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