Motor Airgap Torque Harmonics Due to Cascaded H-Bridge Inverter Operating with Failed Cells

This paper proposes the expressions for the motor airgap torque harmonics induced by a cascaded H-bridge inverter operating with failed cells. These variable frequency drive systems (VFDs), are widely used in oil and gas applications, where a torsional vibration evaluation is a critical challenge for field engineers. This paper proposes mathematical expressions that are crucial for an accurate torsional analysis during the design stage of VFDs, as required by international standards such as API 617, API 672, etc. By accurately reconstructing the electromagnetic torque from the stator voltages and currents in the (αβ0) reference frame, the obtained expressions enable the precise prediction of the exact locations of torque harmonics induced by the inverter under various real-world operating conditions, without the need for installed torque sensors. The neutral-shifted and peak-reduction fault-tolerant control techniques are commonly adopted under faulty operation of these VFDs. However, their effects on the pulsating torques harmonics in machine air-gap remain uncovered. This paper fulfils this gap by conducting a detailed evaluation of spectral characteristics of these fault-tolerant methods. The theoretical analyses are supported by MATLAB/Simulink 2024 based offline simulation and Typhoon based virtual real-time simulation results performed on a (4.16 kV and 7 MW) vector-controlled induction motor fed by a 7-level cascaded H-bridge inverter. According to the theoretical analyses- and simulation results, the Neutral-shifted and Peak-reduction approaches rebalance the motor input line-to-line voltages in the event of an inverter’s failed cells but, in contrast to the normal mode the carrier, all the triplen harmonics are no longer suppressed in the differential voltage and current spectra due to inequal magnitudes in the phase voltages. These additional current harmonics induce extra airgap torque components that can excite the lowly damped eigenmodes of the mechanical shaft found in the oil and gas applications and shut down the power conversion system due torsional vibrations.