Ultracapacitor Based Ride Through System for Control Power Supplies in High Power Converters

High power converters are used in variable speed induction motor drive applications. Riding through a short term power supply glitch is becoming an important requirement in these power converters. The power converter uses a large number of control circuit boards for its operation. The control power supply need to ensure that any glitch in the grid side does not affect any of these control circuit boards. A power supply failure of these control cards results in shut down of the entire system. The paper discusses the ride through system developed to overcome voltage sags and short duration outages at the power supply terminals of the control cards in these converters. A 240VA non-isolated, bi-directional buck-boost converter has been designed to be used along with a stack of ultracapacitors to achieve the same. A micro-controller based digital control platform made use of to achieve the control objective. The design of the ultracapacitor stack and the bidirectional converter is described the performance of the experimental set-up is evaluated.

Apparatus and method for heat-run test on high-power PWM converters with low energy expenditure

Before installation, a voltage source converter is usually subjected to heat-run test to verify its thermal design and performance under load. For heat-run test, the converter needs to be operated at rated voltage and rated current for a substantial length of time. Hence, such tests consume huge amount of energy in case of high-power converters. Also, the capacities of the source and loads available in the research and development (R&D) centre or the production facility could be inadequate to conduct such tests. This paper proposes a method to conduct heat-run tests on high-power, pulse width modulated (PWM) converters with low energy consumption. The experimental set-up consists of the converter under test and another converter (of similar or higher rating), both connected in parallel on the ac side and open on the dc side. Vector-control or synchronous reference frame control is employed to control the converters such that one draws certain amount of reactive power and the other supplies the same; only the system losses are drawn from the mains. The performance of the controller is validated through simulation and experiments. Experimental results, pertaining to heat-run tests on a high-power PWM converter, are presented at power levels of 25 kVA to 150 kVA.

A New Family of Soft Transition Converters: Design Example and Dynamic Model

The soft switching converters evolved through the resonant load, resonant switch, resonant transition and active clamp converters to eliminate switching losses in power converters. This paper briefly presents the operating principle of the new family of soft transition converters; the methodology of design of these converters is presented through an example. In the proposed family of converters, the switching transitions of both the main switch and auxiliary switch are lossless.When these converters are analysed in terms of the pole current and throw voltage, the defining equations of all converters belonging to this family become identical.Such a description allows one to define simple circuit oriented model for these converters. These circuit models help in evaluating the steady state and dynamic model of these converters. The standard dynamic performance functions of the converters are readily obtainable from this model. This paper presents these dynamic models and verifies the same through measurements on a prototype converter.

A new family of soft transition converters: Design and dynamic model

The soft switching converters evolved through the resonant load, resonant switch, resonant transition and active clamp converters to eliminate switching losses in power converters. This paper briefly presents the operating principle of the new family of soft transition converters; the methodology of design of these converters is presented through an example. In the proposed family of converters, the switching transitions of both the main switch and auxiliary switch are lossless. When these converters are analysed in terms of the pole current and throw voltage, the defining equations of all converters belonging to this family become identical.Such a description allows one to define simple circuit oriented model for these converters. These circuit models help in evaluating the steady state and dynamic model of these converters. The standard dynamic performance functions of the converters are readily obtainable from this model. This paper presents these dynamic models and verifies the same through measurements on a prototype converter.

Digital Dead Time Logic and Protection Circuitry for PWM Voltage Source Converters

Power semiconductor devices have finite turn on and turn off delays that may not be perfectly matched. In a leg of a voltage source converter, the simultaneous turn on of one device and the turn off of the complementary device will cause a DC bus shoot through, if the turn off delay is larger than the turn on delay time. To avoid this situation it is common practice to blank the two complementary devices in a leg for a small duration of time while switching, which is called dead time. This paper proposes a logic circuit for digital implementation required to control the complementary devices of a leg independently and at the same time preventing cross conduction of devices in a leg, and while providing accurate and stable dead time. This implementation is based on the concept of finite state machines. This circuit can also block improper PWM pulses to semiconductor switches and filters small pulses notches below a threshold time width as the narrow pulses do not provide any significant contribution to average pole voltage, but leads to increased switching loss. This proposed dead time logic has been implemented in a CPLD and is implemented in a protection and delay card for 3- power converters.

Minimization of grid current distortion in parallel-connected converters through carrier interleaving

Identical parallel-connected converters with unequal load sharing have unequal terminal voltages. The difference in terminal voltages is more pronounced in case of back-to-back connected converters, operated in power-circulation mode for the purpose of endurance tests. In this paper, a synchronous reference frame based analysis is presented to estimate the grid current distortion in interleaved, grid-connected converters with unequal terminal voltages. Influence of carrier interleaving angle on rms grid current ripple is studied theoretically as well as experimentally. Optimum interleaving angle to minimize the rms grid current ripple is investigated for different applications of parallel converters. The applications include unity power factor rectifiers, inverters for renewable energy sources, reactive power compensators, and circulating-power test set-up used for thermal testing of high-power converters. Optimum interleaving angle is shown to be a strong function of the average of the modulation indices of the two converters, irrespective of the application. The findings are verified experimentally on two parallel-connected converters, circulating reactive power of up to 150 kVA between them.

Circulating power test setup for a PWM rectifier motor drive

Power converters burn-in test consumes large amount of energy, which increases the cost of testing, and certification, in medium and high power application. A simple test configuration to test a PWM rectifier induction motor drive, using a Doubly Fed Induction Machine (DFIM) to circulate power back to the grid for burn-in test is presented. The test configuration makes use of only one power electronic converter, which is the converter to be tested. The test method ensures soft synchronization of DFIM and Squirrel Cage Induction Machine (SCIM). A simple volt per hertz control of the drive is sufficient for conducting the test. To synchronize the DFIM with SCIM, the rotor terminal voltage of DFIM is measured and used as an indication of speed mismatch between DFIM and SCIM. The synchronization is done when the DFIM rotor voltage is at its minimum. Analysis of the DFIM characteristics confirms that such a test can be effectively performed with smooth start up and loading of the test setup. After synchronization is obtained, the speed command to SCIM is changed in order to load the setup in motoring or regenerative mode of operation. The experimental results are presented that validates the proposed test method.

Design Of Start-up Power Circuit For Control Power Supplies With Wide Input Voltage Variation

This paper presents the design of a start up power circuit for a control power supply (CPS) which feeds power to the sub-systems of High Power Converters (HPC). The sub-systems such as gate drive card, annunciation card, protection and delay card etc; needs to be provided power for the operation of a HPC. The control power supply (CPS) is designed to operate over a wide range of input voltage from 90Vac to 270Vac. The CPS output supplies power at a desired voltage of Vout =24V to the auxiliary sub-systems of the HPC. During the starting, the power supply to the control circuitry of CPS in turn, is obtained using a separate start-up power supply. This paper discusses the various design issues of the start-up power circuit to ensure that start-up and shut down of the CPS occurs reliably. The CPS also maintains the power factor close to unity and low total harmonic distortion in input current. The paper also provides design details of gate drive circuits employed for the CPS as well as the design of on-board power supply for the CPS. Index terms: control power supply, start-up power supply, DSFC, pre-regulator

Thermal test method for high power three-phase grid-connected inverters

Semiconductor device junction temperatures are maintained within datasheet specified limits to avoid failure in power converters. Burn-in tests are used to ensure this. In inverters, thermal time constants can be large and burn-in tests are required to be performed over long durations of time. At higher power levels, besides increased production cost, the testing requires sources and loads that can handle high power. In this study, a novel method to test a high power three-phase grid-connected inverter is proposed. The method eliminates the need for high power sources and loads. Only energy corresponding to the losses is consumed. The test is done by circulating rated current within the three legs of the inverter. All the phase legs being loaded, the method can be used to test the inverter in both cases of a common or independent cooling arrangement for the inverter phase legs. Further, the method can be used with different inverter configurations - three- or four-wire and for different pulse width modulation (PWM) techniques. The method has been experimentally validated on a 24 kVA inverter for a four-wire configuration that uses sine-triangle PWM and a three-wire configuration that uses conventional space vector PWM.

An Integrated Design Procedure for High Frequency AC Inductors for Inverters

Inductors are important energy storage elements that are used as filters in switching power converters. The operating efficiency of power inductors depend on the initial design choices and they remain as one of the most inefficient elements in a power converter. The focus of this paper is to explore the inductor design procedure from the point of efficiency and operating temperature. A modified form of the area product approach is used as starting point for the inductor design. The equations which estimate the power loss in core and copper winding are described. The surface temperature of the inductor is modelled using heat transfer equations for radiation and natural convection. All design assumptions are verified by actual experimental data and results show a good match with the analysis.

Measurement of IGBT switching characteristics and loss using coaxial current transformer

Device switching times and switching energy losses are required over a wide range of practical working conditions for successful design of insulated gate bipolar transistor (IGBT) based power converters. This paper presents a cost-effective experimental setup using a co-axial current transformer for measurement of IGBT switching characteristics and switching energy loss. Measurements are carried out on a 50A, 1200V IGBT (SKM50GB123D) for different values of gate resistance, device current and junction temperature. These measurements augment the technical data available in the device datasheet.Short circuit transients are also investigated experimentally under hard switched fault as well as fault under load conditions.

Filter Configuration and PWM Method For Single Phase Inverters with Reduced Conducted EMI Noise

Electromagnetic Interference (EMI) noise is one of the major issues during the design of the grid-tied power converters. Presence of high dv/dt in Common Mode (CM) voltage, excites the parasitic capacitances and causes injection of narrow peaky current to ground. This results in high EMI noise level. A topology consisting of a single phase PWM-rectifier with LCL filter, utilising bipolar PWM method is proposed which reduces the EMI noise level by more than 30dB. This filter topology is shown to be insensitive to the switching delays between the legs of the inverter. The proposed topology eliminates high dv/dt from the dc-bus CM voltage by making it sinusoidal. Hence, the high frequency CM current injection to ground is minimized.

Filter Configuration and PWM Method For Single-Phase Inverters With Reduced Conducted EMI Noise

Electromagnetic interference (EMI) noise is one of the major issues during design of grid-tied power converters. A novel LCL filter topology for a single-phase pulsewidth modulation (PWM) rectifier that makes use of bipolar PWM method is proposed for a single-phase to three-phase motor drive power converter. The proposed topology eliminates high dv/dt from the dc-bus common-mode (CM) voltage by making it sinusoidal. Hence, the high-frequency CM current injection to the ground and the motor-side CM current are minimized. The proposed filter configuration makes the system insensitive to circuit non-idealities such as mismatch in inductors values, unequal turn-on and turn-off delays, and dead-time mismatch between the inverter legs. Different variants of the filter topology are compared to establish the effectiveness of the proposed circuit. Experimental results based on the EMI measurement on the grid side and the CM current measurement on the motor side are presented for a 5-kW motor drive. It is shown that the proposed filter topology reduces the EMI noise level by about 35 dB.

Gate Drive Card for High Power Three Phase PWM Converters

Gate driver is an integral part of every power converter, drives the power semiconductor devices and also provides protection for the switches against short-circuit events and over-voltages during shut down. Gate drive card for IGBTs and MOSFETs with basic features can be designed easily by making use of discrete electronic components. Gate driver ICs provides attractive features in a single package, which improves reliability and reduces effort of design engineers. Either case needs one or more isolated power supplies to drive each power semiconductor devices and provide isolation to the control circuitry from the power circuit. The primary emphasis is then to provide simplified and compact isolated power supplies to the gate drive card with the requisite isolation strength and which consumes less space, and for providing thermal protection to the power semiconductor modules for 3-� 3 wire or 4 wire inverters.

A unified model for auxiliary switch commutated DC-DC converters

A novel ZVS auxiliary switch commutated variation for all DGDC converter topologies has been proposed in 2006. With proper designation of the circuit variables (throw current I and the pole voltage V), all these converters are seen to be governed by an identical set of equations. With idealized switches, the steady-state performance is obtainable in an analytical form. The conversion ratio of the converter topologies is obtained. A generalized equivalent circuit emerges for all these converters from the steady-state conversion ratio. It also provides a dynamic model as well. With these generalized steady-state equivalent circuits, small signal analysis of these converters may be carried out readily. It enables one to use the familiar state space averaged results of the standard PWM DGDC converters for the resonant counterparts. Th dc and ac models reveals that dc and low frequency behaviour of the proposed family of converters is similiar to that of its PWM parent