Controller implementation using analog reconfigurable hardware (FPAA)

This Thesis has the main target to make a research about FPAA/dpASPs devices and technologies applied to control systems. These devices provide easy way to emulate analog circuits that can be reconfigurable by programming tools from manufactures and in case of dpASPs are able to be dynamically reconfigurable on the fly. It is described different kinds of technologies commercially available and also academic projects from researcher groups. These technologies are very recent and are in ramp up development to achieve a level of flexibility and integration to penetrate more easily the market. As occurs with CPLD/FPGAs, the FPAA/dpASPs technologies have the target to increase the productivity, reducing the development time and make easier future hardware reconfigurations reducing the costs. FPAA/dpAsps still have some limitations comparing with the classic analog circuits due to lower working frequencies and emulation of complex circuits that require more components inside the integrated circuit. However, they have great advantages in sensor signal condition, filter circuits and control systems. This thesis focuses practical implementations of these technologies to control system PID controllers. The result of the experiments confirms the efficacy of FPAA/dpASPs on signal condition and control systems.

A nearly constant switching frequency current hysteresis controller with generalized parabolic boundaries using 12-sided polygonal voltage space vectors for IM drives

In this paper, a current hysteresis controller with parabolic boundaries for a 12-sided polygonal voltage space vector inverter fed induction motor (IM) drive is proposed. Parabolic boundaries with generalized vector selection logic, valid for all sectors and rotational direction, is used in the proposed controller. The current error space phasor boundary is obtained by first studying the drive scheme with space vector based PWM (SVPWM) controller. Four parabolas are used to approximate this current error space phasor boundary. The system is then run with space phasor based hysteresis PWM controller by limiting the current error space vector (CESV) within the parabolic boundary. The proposed controller has simple controller implementation, nearly constant switching frequency, extended modulation range and fast dynamic response with smooth transition to the over modulation region.

A Medium-Voltage Inverter-Fed IM Drive Using Multilevel 12-Sided Polygonal Vectors, With Nearly Constant Switching Frequency Current Hysteresis Controller

In this paper, a current error space vector (CESV)-based hysteresis current controller for a multilevel 12-sided voltage space vector-based inverter-fed induction motor (IM) drive is proposed. The proposed controller gives a nearly constant switching frequency operation throughout different speeds in the linear modulation region. It achieves the elimination of 6n +/- 1, n = odd harmonics from the phase voltages and currents in the entire modulation range, with an increase in the linear modulation range. It also exhibits fast dynamic behavior under different transient conditions and has a simple controller implementation. Nearly constant switching frequency is obtained by matching the steady-state CESV boundaries of the proposed controller with that of a constant switching frequency SVPWM-based drive. In the proposed controller, the CESV reference boundaries are computed online, using the switching dwell time and voltage error vector of each applied vector. These quantities are calculated from estimated sampled reference phase voltages. Vector change is decided by projecting the actual current error along the computed hysteresis space vector boundary of the presently applied vector. The estimated reference phase voltages are found from the stator current error ripple and the parameters of the IM.

A Nearly Constant Switching Frequency Current Error Space Vector Based Hysteresis Controller for an IM Drive with 12-sided Polygonal Voltage Space Vectors

In this paper, a current error space vector (CESV) based hysteresis controller for a 12-sided polygonal voltage space vector inverter fed induction motor (IM) drive is proposed, for the first time. An open-end winding configuration is used for the induction motor. The proposed controller uses parabolic boundary with generalized vector selection logic for all sectors. The drive scheme is first studied with a space vector based PWM (SVPWM) control and from this the current error space phasor boundary is obtained. This current error space phasor boundary is approximated with four parabolas and then the system is run with space phasor based hysteresis PWM controller by limiting the CESV within the parabolic boundary. The proposed controller has increased modulation range, absence of 5th and 7th order harmonics for the entire modulation range, nearly constant switching frequency, fast dynamic response with smooth transition to the over modulation region and a simple controller implementation.

Implementation of intelligent data acquisition system for ITER fast controllers using RIO devices.

A basic requirement of the data acquisition systems used in long pulse fusion experiments is the real time physical events detection in signals. Developing such applications is usually a complex task, so it is necessary to develop a set of hardware and software tools that simplify their implementation. This type of applications can be implemented in ITER using fast controllers. ITER is standardizing the architectures to be used for fast controller implementation. Until now the standards chosen are PXIe architectures (based on PCIe) for the hardware and EPICS middleware for the software. This work presents the methodology for implementing data acquisition and pre-processing using FPGA-based DAQ cards and how to integrate these in fast controllers using EPICS.

Active Vibration Suppression of One-dimensional Nonlinear Structures Using Optimal Dynamic Inversion

A flexible robot arm can be modeled as an Euler-Bernoulli beam which are infinite degrees of freedom (DOF) system. Proper control is needed to track the desired motion of a robotic arm. The infinite number of DOF of beams are reduced to finite number for controller implementation, which brings in error (due to their distributed nature). Therefore, to represent reality better distributed parameter systems (DPS) should be controlled using the systems partial differential equation (PDE) directly. In this paper, we propose to use a recently developed optimal dynamic inversion technique to design a controller to suppress nonlinear vibration of a beam. The method used in this paper determines control forces directly from the PDE model of the system. The formulation has better practical significance, because it leads to a closed form solution of the controller (hence avoids computational issues).

The changing face and role of CACSD

Computer Aided Control Engineering involves three parallel streams: Simulation and modelling, Control system design (off-line), and Controller implementation. In industry the bottleneck problem has always been modelling, and this remains the case - that is where control (and other) engineers put most of their technical effort. Although great advances in software tools have been made, the cost of modelling remains very high - too high for some sectors. Object-oriented modelling, enabling truly re-usable models, seems to be the key enabling technology here. Software tools to support control systems design have two aspects to them: aiding and managing the work-flow in particular projects (whether of a single engineer or of a team), and provision of numerical algorithms to support control-theoretic and systems-theoretic analysis and design. The numerical problems associated with linear systems have been largely overcome, so that most problems can be tackled routinely without difficulty - though problems remain with (some) systems of extremely large dimensions. Recent emphasis on control of hybrid and/or constrained systems is leading to the emerging importance of geometric algorithms (ellipsoidal approximation, polytope projection, etc). Constantly increasing computational power is leading to renewed interest in design by optimisation, an example of which is MPC. The explosion of embedded control systems has highlighted the importance of autocode generation, directly from modelling/simulation products to target processors. This is the 'new kid on the block', and again much of the focus of commercial tools is on this part of the control engineer's job. Here the control engineer can no longer ignore computer science (at least, for the time being). © 2006 IEEE.

The changing face and role of CACSD

Computer Aided Control Engineering involves three parallel streams: Simulation and modelling, Control system design (off-line), and Controller implementation. In industry the bottleneck problem has always been modelling, and this remains the case - that is where control (and other) engineers put most of their technical effort. Although great advances in software tools have been made, the cost of modelling remains very high - too high for some sectors. Object-oriented modelling, enabling truly re-usable models, seems to be the key enabling technology here. Software tools to support control systems design have two aspects to them: aiding and managing the work-flow in particular projects (whether of a single engineer or of a team), and provision of numerical algorithms to support control-theoretic and systems-theoretic analysis and design. The numerical problems associated with linear systems have been largely overcome, so that most problems can be tackled routinely without difficulty - though problems remain with (some) systems of extremely large dimensions. Recent emphasis on control of hybrid and/or constrained systems is leading to the emerging importance of geometric algorithms (ellipsoidal approximation, polytope projection, etc). Constantly increasing computational power is leading to renewed interest in design by optimisation, an example of which is MPC. The explosion of embedded control systems has highlighted the importance of autocode generation, directly from modelling/simulation products to target processors. This is the 'new kid on the block', and again much of the focus of commercial tools is on this part of the control engineer's job. Here the control engineer can no longer ignore computer science (at least, for the time being). ©2006 IEEE.

Model based control for closed loop testing of 1-D engine simulation models

1-D engine simulation models are widely used for the analysis and verification of air-path design concepts and prediction of the resulting engine transient response. The latter often requires closed loop control over the model to ensure operation within physical limits and tracking of reference signals. For this purpose, a particular implementation of Model Predictive Control (MPC) based on a corresponding Mean Value Engine Model (MVEM) is reported here. The MVEM is linearised on-line at each operating point to allow for the formulation of quadratic programming (QP) problems, which are solved as the part of the proposed MPC algorithm. The MPC output is used to control a 1-D engine model. The closed loop performance of such a system is benchmarked against the solution of a related optimal control problem (OCP). As an example this study is focused on the transient response of a light-duty car Diesel engine. For the cases examined the proposed controller implementation gives a more systematic procedure than other ad-hoc approaches that require considerable tuning effort. © 2012 IFAC.

Transputer control of a Puma 560 robot via the virtual bus

The robot control problem is discussed with regard to controller implementation on a multitransputer array. Some high-performance aspects required of such controllers are described, with particular reference to robot force control. The implications for the architecture required for controllers based on computed torque are discussed and an example is described. The idea of treating a transputer array as a virtual bus is put forward for the implementation of fast real-time controllers. An example is given of controlling a Puma 560 industrial robot. Some of the practical considerations for using transputers for such control are described.

Joint servoing for robust manipulator force control

An experimental and theoretical comparison is made of force control performance with different types of innerloop joint servoing techniques. The problem of disturbance rejection and sensitivity to plant dynamics variations (robustness) is addressed. Position, velocity, strain gauge derived joint torque, and current servos are designed and implemented on a specially instrumented industrial robot, and the end-effector force feedback performances achieved are compared. Joint strain derived torque servoing is found to provide the best overall robust force control performance. Experimental results of the robust hard-on-hard contact achieved with the novel force controller implementation based on joint torque sensing are provided. Conclusions are drawn on the force control performance achievable on a geared robot given the joint servoing technique.

Virtual simulator for mobile robots navigation systems

This paper presents the virtual environment implementation for project simulation and conception of supervision and control systems for mobile robots, that are capable to operate and adapting in different environments and conditions. This virtual system has as purpose to facilitate the development of embedded architecture systems, emphasizing the implementation of tools that allow the simulation of the kinematic conditions, dynamic and control, with real time monitoring of all important system points. For this, an open control architecture is proposal, integrating the two main techniques of robotic control implementation in the hardware level: systems microprocessors and reconfigurable hardware devices. The implemented simulator system is composed of a trajectory generating module, a kinematic and dynamic simulator module and of a analysis module of results and errors. All the kinematic and dynamic results shown during the simulation can be evaluated and visualized in graphs and tables formats, in the results analysis module, allowing an improvement in the system, minimizing the errors with the necessary adjustments optimization. For controller implementation in the embedded system, it uses the rapid prototyping, that is the technology that allows, in set with the virtual simulation environment, the development of a controller project for mobile robots. The validation and tests had been accomplish with nonholonomics mobile robots models with diferencial transmission. © 2008 IEEE.

Controladores robustos do tipo LQG/LTR de ordem reduzida para sistemas MIMO com saídas independentes de seus modos não dominantes

O objetivo principal desta dissertação é apresentar uma solução eficiente, prática e de simples implementação para um problema recorrente em projetos de controladores robustos multivariáveis do tipo LQG/LTR: a elevada ordem que estes controladores podem obter dependendo das complicações apresentadas pelo sistema dificultando para que este possa ser controlado de maneira satisfatória. Para que esta meta seja alcançada, é apresentada uma técnica de redução do modelo de sistemas com metodologia bastante descomplicada, dispensando qualquer necessidade de complexas programações para a sua utilização. Esta metodologia porém, é somente aplicável a uma classe bastante específica de sistema. Em suma, o sistema deve possuir variáveis de estado desacopladas do restante do sistema, ou seja, variáveis que não sofram influências de outras e que também não provoquem grande efeito nas saídas do sistema. Foi escolhido um sistema multivariável de sexta ordem, com duas entradas e duas saídas para que a técnica de redução de ordem de modelo seja testada. Este sistema possui as características especiais mencionadas anteriormente bem como exige o projeto de compensador dinâmico e a adição de integradores às suas saídas para que seja controlado adequadamente. Este trabalho pretende apresentar o procedimento de todo o projeto mencionado, desde a obtenção de um modelo de ordem reduzida até a implementação do controlador LQG/LTR. Em seguida, o controlador obtido é testado através de diversas simulações e os resultados encontrados são discutidos para a avaliação da eficácia e da praticidade do método proposto para obtenção de controladores de ordem reduzida.

Multiphase Design and Control Techniques Applied to a Forward Micro-Inverter

En la última década la potencia instalada de energía solar fotovoltaica ha crecido una media de un 49% anual y se espera que alcance el 16%del consumo energético mundial en el año 2050. La mayor parte de estas instalaciones se corresponden con sistemas conectados a la red eléctrica y un amplio porcentaje de ellas son instalaciones domésticas o en edificios. En el mercado ya existen diferentes arquitecturas para este tipo de instalaciones, entre las que se encuentras los módulos AC. Un módulo AC consiste en un inversor, también conocido como micro-inversor, que se monta en la parte trasera de un panel o módulo fotovoltaico. Esta tecnología ofrece modularidad, redundancia y la extracción de la máxima potencia de cada panel solar de la instalación. Además, la expansión de esta tecnología posibilitará una reducción de costes asociados a las economías de escala y a la posibilidad de que el propio usuario pueda componer su propio sistema. Sin embargo, el micro-inversor debe ser capaz de proporcionar una ganancia de tensión adecuada para conectar el panel solar directamente a la red, mientras mantiene un rendimiento aceptable en un amplio rango de potencias. Asimismo, los estándares de conexión a red deber ser satisfechos y el tamaño y el tiempo de vida del micro-inversor son factores que han de tenerse siempre en cuenta. En esta tesis se propone un micro-inversor derivado de la topología “forward” controlado en el límite entre los modos de conducción continuo y discontinuo (BCM por sus siglas en inglés). El transformador de la topología propuesta mantiene la misma estructura que en el convertidor “forward” clásico y la utilización de interruptores bidireccionales en el secundario permite la conexión directa del inversor a la red. Asimismo el método de control elegido permite obtener factor de potencia cercano a la unidad con una implementación sencilla. En la tesis se presenta el principio de funcionamiento y los principales aspectos del diseño del micro-inversor propuesto. Con la idea de mantener una solución sencilla y de bajo coste, se ha seleccionado un controlador analógico que está originalmente pensado para controlar un corrector del factor de potencia en el mismo modo de conducción que el micro-inversor “forward”. La tesis presenta las principales modificaciones necesarias, con especial atención a la detección del cruce por cero de la corriente (ZCD por sus siglas en inglés) y la compatibilidad del controlador con la inclusión de un algoritmo de búsqueda del punto de máxima potencia (MPPT por sus siglas en inglés). Los resultados experimentales muestran las limitaciones de la implementación elegida e identifican al transformador como el principal contribuyente a las pérdidas del micro-inversor. El principal objetivo de esta tesis es contribuir a la aplicación de técnicas de control y diseño de sistemas multifase en micro-inversores fotovoltaicos. En esta tesis se van a considerar dos configuraciones multifase diferentes aplicadas al micro-inversor “forward” propuesto. La primera consiste en una variación con conexión paralelo-serie que permite la utilización de transformadores con una relación de vueltas baja, y por tanto bien acoplados, para conseguir una ganancia de tensión adecuada con un mejor rendimiento. Esta configuración emplea el mismo control BCM cuando la potencia extraída del panel solar es máxima. Este método de control implica que la frecuencia de conmutación se incrementa considerablemente cuando la potencia decrece, lo que compromete el rendimiento. Por lo tanto y con la intención de mantener unos bueno niveles de rendimiento ponderado, el micro-inversor funciona en modo de conducción discontinuo (DCM, por sus siglas en inglés) cuando la potencia extraía del panel solar es menor que la máxima. La segunda configuración multifase considerada en esta tesis es la aplicación de la técnica de paralelo con entrelazado. Además se han considerado dos técnicas diferentes para decidir el número de fases activas: dependiendo de la potencia continua extraída del panel solar y dependiendo de la potencia instantánea demandada por el micro-inversor. La aplicación de estas técnicas es interesante en los sistemas fotovoltaicos conectados a la red eléctrica por la posibilidad que brindan de obtener un rendimiento prácticamente plano en un amplio rango de potencia. Las configuraciones con entrelazado se controlan en DCM para evitar la necesidad de un control de corriente, lo que es importante cuando el número de fases es alto. Los núcleos adecuados para todas las configuraciones multifase consideradas se seleccionan usando el producto de áreas. Una vez seleccionados los núcleos se ha realizado un diseño detallado de cada uno de los transformadores. Con la información obtenida de los diseños y los resultados de simulación, se puede analizar el impacto que el número de transformadores utilizados tiene en el tamaño y el rendimiento de las distintas configuraciones. Los resultados de este análisis, presentado en esta tesis, se utilizan posteriormente para comparar las distintas configuraciones. Muchas otras topologías se han presentado en la literatura para abordar los diferentes aspectos a considerar en los micro-inversores, que han sido presentados anteriormente. La mayoría de estas topologías utilizan un transformador de alta frecuencia para solventar el salto de tensión y evitar problemas de seguridad y de puesta a tierra. En cualquier caso, es interesante evaluar si topologías sin aislamiento galvánico son aptas para su utilización como micro-inversores. En esta tesis se presenta una revisión de inversores con capacidad de elevar tensión, que se comparan bajo las mismas especificaciones. El objetivo es proporcionar la información necesaria para valorar si estas topologías son aplicables en los módulos AC. Las principales contribuciones de esta tesis son: • La aplicación del control BCM a un convertidor “forward” para obtener un micro-inversor de una etapa sencillo y de bajo coste. • La modificación de dicho micro-inversor con conexión paralelo-series de transformadores que permite reducir la corriente de los semiconductores y una ganancia de tensión adecuada con transformadores altamente acoplados. • La aplicación de técnicas de entrelazado y decisión de apagado de fases en la puesta en paralelo del micro-inversor “forward”. • El análisis y la comparación del efecto en el tamaño y el rendimiento del incremento del número de transformadores en las diferentes configuraciones multifase. • La eliminación de las medidas y los lazos de control de corriente en las topologías multifase con la utilización del modo de conducción discontinuo y un algoritmo MPPT sin necesidad de medida de corriente. • La recopilación y comparación bajo las mismas especificaciones de topologías inversoras con capacidad de elevar tensión, que pueden ser adecuadas para la utilización como micro-inversores. Esta tesis está estructurada en seis capítulos. El capítulo 1 presenta el marco en que se desarrolla la tesis así como el alcance de la misma. En el capítulo 2 se recopilan las topologías existentes de micro-invesores con aislamiento y aquellas sin aislamiento cuya implementación en un módulo AC es factible. Asimismo se presenta la comparación entre estas topologías bajo las mismas especificaciones. El capítulo 3 se centra en el micro-inversor “forward” que se propone originalmente en esta tesis. La aplicación de las técnicas multifase se aborda en los capítulos 4 y 5, en los que se presentan los análisis en función del número de transformadores. El capítulo está orientado a la propuesta paralelo-serie mientras que la configuración con entrelazado se analiza en el capítulo 5. Por último, en el capítulo 6 se presentan las contribuciones de esta tesis y los trabajos futuros. ABSTRACT In the last decade the photovoltaic (PV) installed power increased with an average growth of 49% per year and it is expected to cover the 16% of the global electricity consumption by 2050. Most of the installed PV power corresponds to grid-connected systems, with a significant percentage of residential installations. In these PV systems, the inverter is essential since it is the responsible of transferring into the grid the extracted power from the PV modules. Several architectures have been proposed for grid-connected residential PV systems, including the AC-module technology. An AC-module consists of an inverter, also known as micro-inverter, which is attached to a PV module. The AC-module technology offers modularity, redundancy and individual MPPT of each module. In addition, the expansion of this technology will enable the possibility of economies of scale of mass market and “plug and play” for the user, thus reducing the overall cost of the installation. However, the micro-inverter must be able to provide the required voltage boost to interface a low voltage PV module to the grid while keeping an acceptable efficiency in a wide power range. Furthermore, the quality standards must be satisfied and size and lifetime of the solutions must be always considered. In this thesis a single-stage forward micro-inverter with boundary mode operation is proposed to address the micro-inverter requirements. The transformer in the proposed topology remains as in the classic forward converter and bidirectional switches in the secondary side allows direct connection to the grid. In addition the selected control strategy allows high power factor current with a simple implementation. The operation of the topology is presented and the main design issues are introduced. With the intention to propose a simple and low-cost solution, an analog controller for a PFC operated in boundary mode is utilized. The main necessary modifications are discussed, with the focus on the zero current detection (ZCD) and the compatibility of the controller with a MPPT algorithm. The experimental results show the limitations of the selected analog controller implementation and the transformer is identified as a main losses contributor. The main objective of this thesis is to contribute in the application of control and design multiphase techniques to the PV micro-inverters. Two different multiphase configurations have been applied to the forward micro-inverter proposed in this thesis. The first one consists of a parallel-series connected variation which enables the use of low turns ratio, i.e. well coupled, transformers to achieve a proper voltage boost with an improved performance. This multiphase configuration implements BCM control at maximum load however. With this control method the switching frequency increases significantly for light load operation, thus jeopardizing the efficiency. Therefore, in order to keep acceptable weighted efficiency levels, DCM operation is selected for low power conditions. The second multiphase variation considered in this thesis is the interleaved configuration with two different phase shedding techniques: depending on the DC power extracted from the PV panel, and depending on the demanded instantaneous power. The application of interleaving techniques is interesting in PV grid-connected inverters for the possibility of flat efficiency behavior in a wide power range. The interleaved variations of the proposed forward micro-inverter are operated in DCM to avoid the current loop, which is important when the number of phases is large. The adequate transformer cores for all the multiphase configurations are selected according to the area product parameter and a detailed design of each required transformer is developed. With this information and simulation results, the impact in size and efficiency of the number of transformer used can be assessed. The considered multiphase topologies are compared in this thesis according to the results of the introduced analysis. Several other topological solutions have been proposed to solve the mentioned concerns in AC-module application. The most of these solutions use a high frequency transformer to boost the voltage and avoid grounding and safety issues. However, it is of interest to assess if the non-isolated topologies are suitable for AC-module application. In this thesis a review of transformerless step-up inverters is presented. The compiled topologies are compared using a set benchmark to provide the necessary information to assess whether non-isolated topologies are suitable for AC-module application. The main contributions of this thesis are: • The application of the boundary mode control with constant off-time to a forward converter, to obtain a simple and low-cost single-stage forward micro-inverter. • A modification of the forward micro-inverter with primary-parallel secondary-series connected transformers to reduce the current stress and improve the voltage gain with highly coupled transformers. •The application of the interleaved configuration with different phase shedding strategies to the proposed forward micro-inverter. • An analysis and comparison of the influence in size and efficiency of increasing the number of transformers in the parallel-series and interleaved multiphase configurations. • Elimination of the current loop and current measurements in the multiphase topologies by adopting DCM operation and a current sensorless MPPT. • A compilation and comparison with the same specifications of suitable non-isolated step-up inverters. This thesis is organized in six chapters. In Chapter 1 the background of single-phase PV-connected systems is discussed and the scope of the thesis is defined. Chapter 2 compiles the existing solutions for isolated micro-inverters and transformerless step-up inverters suitable for AC-module application. In addition, the most convenient non-isolated inverters are compared using a defined benchmark. Chapter 3 focuses on the originally proposed single-stage forward micro-inverter. The application of multiphase techniques is addressed in Chapter 4 and Chapter 5, and the impact in different parameters of increasing the number of phases is analyzed. In Chapter 4 an original primary-parallel secondary-series variation of the forward micro-inverter is presented, while Chapter 5 focuses on the application of the interleaved configuration. Finally, Chapter 6 discusses the contributions of the thesis and the future work.

Motor controller simulation and embedded implementation for a blood pump

This study was a step forward in modeling, simulation and microcontroller implementation of a high performance control algorithm for the motor of a blood pump. The rotor angle is sensed using three Hall effect sensors and an algorithm is developed to obtain better angular resolution from the three signals for better discrete-time updates of the controller. The performance of the system was evaluated in terms of actual and reference speeds, stator currents and power consumption over a range of reference speeds up to 4000 revolutions per minute. The use of fewer low cost Hall effect sensors compared to expensive high resolution sensors could reduce the cost of blood pumps for total artificial hearts.