Designing and Analysing Power Electronics Systems Using Simscape and SimPowerSystems Gernot Schraberger Industry Manager, Europe Industrial Automation & Machinery, Energy Production MathWorks 2012 The MathWorks, Inc. 1
Agenda Overview of Power Electronic Converters Principle Task & Applications of Power Electronic Converters Functional Principles Physical Structure Trends Challenges Model-Based Design of Power Electronic Converters 2
Principle Tasks of Power Electronic Converters Conversion of Electric Energy with respect to - Voltage in/out - Current in/out - Variable load - Frequencies in /out - Different load types (R,L,C) - Compensation of reactive power - Feedback of energy DC V in i in PEC i out V out DC R L - 3-phase - 3
Applications with Power Electronic Converters Motor Drives Inverters with variable frequency, current control Power Supplies Often with variable input voltage amplitude and frequency Inverters for Regenerative Energy Production Wind turbines, solar farms Voltage Support & Power Transmission Equipment FACTS (flexible AC transmission systems) reactive power compensators HVDC (high voltage DC transmission) Coupling of grids Automotive & Trains (Hybrid) electric vehicles, trains 4
ABB Accelerates Application Control Software Development for Power Electronic Controller Challenge Adopt a more efficient development process using tools that accelerate the design of new application software for a high-powered electronic controller for power converters Solution Use MathWorks tools to design and validate their control algorithms while streamlining the application software development process for the controller Results Development times and costs reduced Development process improved Highly accurate code generated AC 800PEC controller. Our system engineers can program, simulate, and verify the AC 800PEC controller s regulation software very rapidly in MATLAB and Simulink. Fritz Wittwer ABB Link to user story 5
Functional principles Periodic energizating & deenergizating an energy store (inductors or capacitors) Power electronic switches like IGBTs, MOSFETS used for periodic switching Switches driven by PWM or similar more advanced algorithms i v in v out i L R t t 6
Physical structure Control Unit Power Unit DC Power FOC Control (d,q) (a,b,c) PWM Generator Driver Electronics Power Switches M (a,b,c) (d,q) Supervisory Logic Sensors Power Unit Power electronic switches Driver electronics Filters Control Unit Current/ voltage control algorithms (Field oriented control) Controller output drive PWM Supervisory logic (Overheating, prevent Shortcircuit switching) Current /voltage sensors Reading sensors via ADCs Filtering sensor signals ADCs 7
Trends System integration Multidomain systems (electronical, thermal, controls, mechanical) Energy Efficiency Decreasing Switching Power Losses by short switching times Local Energy Stores for energy feedback Increasing power & power density in switching device Series connection of IGBTs multilevel converters Cooling concepts Rapid & flexible control concepts Highly dynamic control Robustness for varying operating conditions (load, voltages ) 8
Challenges Predicting system behavior in early development state Underestimating system complexity Duration of iteration cycles in development Time consuming testing Expert know-how hidden in undocumented code 9
Relative cost to fix an error What is the Most Expensive Project Stage to Find Errors In? Errors introduced early but found late in the process are expensive to fix! Errors introduced in: coding phase design phase requirements phase Requirements phase Design phase Coding phase Testing phase Project phase where error is fixed Source: Return on Investment for Independent Verification & Validation, NASA, 2004. 10
Start Testing on Day One RESEARCH REQUIREMENTS DESIGN Environment Models Mechanical Thermal Electrical Supervisory Logic Control Algorithms IMPLEMENTATION TEST & VERIFICATION C, C++ VHDL, Verilog Structured Text MCU DSP FPGA ASIC PLC TEST SYSTEM INTEGRATION 11
Early Verification of Concept Predict dynamic system behavior by simulating - Less physical prototypes DESIGN Environmental Models Mechanical Thermal Electrical Control Algorithms Use of simulation results for system design - What / if studies - Short iteration cycles Idea Supervisory Logic Simple model Detailed model 12
Appropriate Methods of Modeling DESIGN Environmental Models Mechanical Thermal Electrical Control Algorithms Supervisory Logic Data Modeli ng Algorit hm Devel opme nt Control & filter algorithms (Simulink) Control & Supervisory Logics (Stateflow) Electronical, thermal, mechanical systems (Physical Modeling) Embedded Digital Software Electronics VHDL, C, C++ Verilog MCU DSP FPG ASIC Integr Reuse of legacy code ation & engineering data from Implement - Cosimulation V&V - Exiting algorithms in C, MATLAB 13
Integrated Control Design DESIGN Environmental Models Mechanical Thermal Electrical Control Algorithms Reuse of the model for extracting plant description directly from model Algorit Automated hm creation of a linearized small signal equivalent Devel model at selected operating points opme Interactive and automatic control design according Linear Control Theory Data Modeli ng Supervisory Logic Embedded Digital Software Electronics VHDL, C, C++ Verilog MCU DSP FPG ASIC Robust control design Integr by considering converter ation behavior at several operating points in parallel Implement V&V 14
Test and validate in real-time RESEARCH REQUIREMENTS DESIGN Environmental Models Mechanical Electrical Control Algorithms Supervisory Logic Rapid Prototyping of Control Algorithms Fast implementation of algorithms in C & HDL for functional testing in RT IMPLEMENTATION C, C++ VHDL, Verilog Structured Text MCU DSP FPGA ASIC PLC Hardware-In-The-Loop Testing of Plant Capability of testing critical scenarios without risk of damaging HW 15
Automatic Production Code Generation RESEARCH DESIGN REQUIREMENTS General Code generation in C/C++, HDL, IEC61131- Structured Text Control Algorithms Supervisory Logic IMPLEMENTATION Fast implementation by automatic code generation from models Support of fixed point data format in simulation and code generation Prevention of implementation errors Algorithm development independent of implementation HW C, C++ VHDL, Verilog MCU DSP FPGA ASIC Structured Text PLC C-Code Integration of Legacy C/C++-Code Automated integration with variety of Embedded IDEs and µp/dsp 16
Traceability from Requirements to Code RESEARCH REQUIREMENTS DESIGN Environmental Models Linking Requirements with Model Blocks and generated Code Find corresponding locations easily in model and code Mechanical Electrical Control Algorithms Supervisory Logic IMPLEMENTATION 17
Benefits of Model-Based Design RESEARCH DESIGN REQUIREMENTS Predict system behavior in early development state Mechanical C, C++ Environment Models Thermal Supervisory Logic Control Algorithms IMPLEMENTATION VHDL, Verilog Electrical Structured Text MCU DSP FPGA ASIC PLC TEST & VERIFICATION Handle system complexity Short iteration cycles Less physical prototypes Fast implementation by automatic code generation INTEGRATION Reuse of test cases 18