Post-Fault Energy Usage Optimization for Multilevel Inverter with Integrated Battery

This paper presents a novel sorting algorithm for modular multilevel inverters (MMCs) with integrated batteries, designed to ensure the uninterrupted operation of electric vehicles (EVs) under post-fault conditions. The proposed system structure consists of an MMC with four full-bridge modules per phase, where one module acts as a spinning reserve during normal operation. The algorithm addresses a single switch fault per phase by operating the faulted module in half-bridge mode, ensuring all batteries remain operational and maintaining full power output and battery capacity without any noticeable changes for the vehicle operator. Unlike conventional fault-tolerant strategies that often reduce power output or disable affected modules, the proposed algorithm isolates the faulty switch while preserving system output. This approach avoids derating and eliminates the need for immediate maintenance, enabling the EV to continue operating under fault conditions. Simulation and experimental results validate the effectiveness of the algorithm under a single switch fault scenario, demonstrating its ability to maintain autonomy and consistent power delivery. This work demonstrates a fault-tolerant MMC principle, offering a robust and scalable solution for enhancing reliability and user satisfaction in EV power systems.