10kw three-phase sic pfc rectifier...10kw three-phase sic pfc rectifier semicon® europa, nov 13-18,...
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10kW Three-phase SiC PFC Rectifier
SEMICON® EUROPA, Nov 13-18, 2018, Munich, Germany
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Contents
• General PFC Concept
• 3 Phase System and PFC Control
• Simulation
• Understanding the losses
• 3 Phase PFC Implementation
• Results
2/2/20182
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General PFC Concept
2/2/20183
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DIODE BRIDGE
• DISTORTION FACTOR = 0.61• DISPLAC. FACTOR = 0.96• PF = 0.59
Definition of Power Factor
1,1 cos
(VA) PowerApparent
(W) Power Real
RMS
RMS
RMSRMS
avg
I
I
IV
PPF
DISPLACEMENT
FACTOR
DISTORTION
FACTOR
Real Power (W)
Reactive
Power
(VAR)φ1
VI
cos(1)
VI
• DISTORTION FACTOR = 1• DISPLACEMENT FACTOR < 1• PF < 1
• DISTORTION FACTOR < 1• DISPLACEMENT FACTOR = 1• PF < 1
POWER
FACTOR
V
I
• DISTORTION FACTOR = 1• DISPLACEMENT FACTOR = 1• PF = 1
PFC TARGET
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3 Phase System and PFC Control
2/2/20185
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3-phase PFC: Selected Topology
The 3-phase PFC control concept works as an inverter for motor application. Only the control strategy changes. This
configuration would allow to control the reactive power because of “Q” axis availability.
• 3 Half Bridges.
• Each half bridge connected to a input
phase voltage.
• Input voltages form a unique system.
Power Flow
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Goal of the PFC is to control the voltage across the inductors.
3 Phase PFC: Voltage Relationship, ABC Model
σ𝑖=𝐴,𝐵,𝐶 𝐸𝑖𝑀=0
𝐸𝐴𝑀 = ത𝐸 ∙ cos(𝜔𝑡)
𝐸𝐵𝑀 = ത𝐸 ∙ cos(𝜔𝑡 − 23𝜋)
𝐸𝐶𝑀 = ത𝐸 ∙ cos(𝜔𝑡 − 43𝜋)
-400
-300
-200
-100
0
100
200
300
400
0 0.005 0.01 0.015 0.02 A
B
C
EA,(t1)
EC,(t1)
EB,(t1)
ES
EB(t1)
EC(t1)
EA(t1)
SUPPLY VOLTAGE TIME
VECTOR SPACE
CS
C
SCNCNCL
BS
B
SBNBNBL
AS
A
SANANAL
iRdt
diLVuev
iRdt
diLVuev
iRdt
diLVuev
00,
00,
00,
VDC
A
B
C
N
0VN0
EAN
VA0
d1 d2 d3
VLA
SYSTEM VOLTAGE EQUATIONS IN „ABC“ DOMAIN
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Bus Voltage Limitation and Driving Capability
VOLTAGE SOURCE INVERTER
VDC
SAH
SAL
SBH
SBL
SCH
SCL
• When FETs are left “OPEN”, the HW is operating
as a diode bridge because of the FWD.
• The target DC BUS voltage has to be higher
than the line to line voltage amplitude:
𝑽𝑫𝑪 = 𝟔𝑬𝑹𝑴𝑺,𝑷𝑯𝑨𝑺𝑬
When the switches are modulating, the following vectors
can be provided in the vector space domain.
ES,MAX = 0.57 VDC
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System Reference: From 3φ Stationary To 2φ Rotating
A
B
C
EA,(t1)
EC,(t1)
EB,(t1)
ES
(αβ) = [T0]·(ABC)
A
B
C
α
β
φ
ES
CLARKE
α
β
𝜗
D
Q
ES
GE
OM
ETR
ICTIM
E
(DQ) = [T 𝜗𝑆 ]·(αβ)
PARK
Φ = 0
ϑ [rad]
EAM
EBM
ECM
-400
-300
-200
-100
0
100
200
300
400
ϑ [rad]
Eα
Eβ
ϑ [rad]
ED
EQ
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3 Phase PFC: (DQ) Model
2/2/201810
• Input quantities are transformed by means of
Clarke/Park matrix.
• ED EQ are the supply voltages expressed in the DQ
domain.
• iD, iQ are the phase currents in the DQ domain.
• ω is the fundamental frequency of the input
voltage.
• VD and VQ are the voltage generated by the control
in the DQ domain that will be used for the PWM
generation.ELECTRICAL QUANTITIES ON DQ
DOMAIN ARE CONSTANT VALUES
L
DC
QQDD
DC
QDSQS
Q
SQ
DQSDS
D
SD
R
usisi
dt
duC
ViLiRdt
diLe
ViLiRdt
diLe
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3 Phase PFC Control Scheme on DQ Domain
SPECIFICATION
Input voltage:
230V RMS 3-Phase voltage, 50Hz.
Output Voltage:
700V
Switching Frequency:
70kHz
Control Frequency:
20kHz
Source Inductance:
300uH
Output capacitance:
470uF
Ref. Fig 11.23 “Control in power electronics” Author. M.P. Kazmierkowski et al. 2002
DQ SYSTEM
MAKES PI
REGULATION
POSSIBLE!
CONTROL ALGORITHM
FIXED DURING TEST
CONDITIONS
3 MODULATION
STRATEGIES TESTED
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3 Phase PFC: Applied Modulation Strategies
2/2/201812
• A modification into the zero sequence voltage doesn’t affect the voltage applied to the inverter phases, however it
will affect noise between DC output and PE.
• An impact on the input filter should be expected, even if in this presentation EMI FILTER was not considered.
PWM Adaptive
Modulator
Public Information2/2/201813
Simulations
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3 Phase PFC Simulink Model, Behavioral
ADC & PWM
Peripherals
Control Strategy
(C-code)ANALOG INPUTS
PWM
OUTPUT
PARAMETERS
• FCLK = 84 Mhz
• FPWM = 70 Khz
• FCNTR = 20 Khz
• DEAD TIME = 1.1%
HARDWARE
• LS = 300 uH
• RS = 0,04 Ohm
• RHL = 72 Ohm
• RFL = 36 Ohm
70kh pwm freq
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3 Phase PFC SPICE Model, Quantitative
INPUTSSENSINGCONTROL STRATEGY POWER
STAGE
THE PARAMETERS SELECTED FOR RUNNING SPICE SIMULATION WERE ALIGNED WITH THE SIMULINK ONES.
Public Information2/2/201816
Understanding the Losses
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Choke Inductor Losses (simplified)
𝑃𝐿,𝐶𝑂𝑅𝐸 = 𝑘 ∙ 𝑓𝑎 ∙ 𝐵𝑃𝐾𝑐
• k, a and c are core material dependent.
• f is the high switching frequency
• BPK is half the flux density ripple calculated considering
the current ripple introduced by the inductance selected
𝐵𝑃𝐾 = 𝜇0𝜇𝑅𝑁∆𝐼
2.
𝑃𝐿,𝐽𝑂𝑈𝐿𝐸 = 𝑅𝑊·I 2RMS
• Where RW is the winding resistance.
• IRMS is the circulating current for a certain power level
with a known input voltage.
700V
EXN(t)
IX
XLX
VX0
VLX
0
N
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FETs Losses in Space Vector Modulation (1/2)
iA
iB
iC
dA
d'A
dB
d'B
dC
d'C
M1
M2
M3
M4
M5
M6
A
B
C
Notes
• During tDT both switches on each leg are fully OFF.
• FETs are bidirectional when turned ON and current flows according source and drain voltage potential.
• vA is depending on phase voltage and star voltage when low side FET OFF and current into the node.
tDT
dA
dB
dC
TPWM
M2 D1
D4
M1 M2D1
M3 D4
D6 M5 D6
iA
iB
iC
HARD
ON – OFF
HARD
OFF – ON
SOFT
ON - OFF
SOFT
OFF – ON
LEG A M2 - [1] M2 - [4] M1 - [3] M1 - [2]
LEG B M3 – [3] M3 – [2] M4 – [1] M4 – [4]
LEG C (as B) M5 – [3] M4 – [2] M6 – [1] M4 – [4]
1 2 3 4
1 2 3 4
1 2 3 4
SWITCHING LOSSESPL,SW → fPWM
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FETs Losses in Space Vector Modulation (2/2)
•Since all the FETs are equal we simplify the calculation with the following formula
𝑃𝐽 = 3 ∙ 𝑅𝐷𝑆,𝑂𝑁 𝑇 ∙ 𝐼𝑅𝑀𝑆2
𝑃𝑆𝑊 = 3 ∙ 𝐸𝑂𝐹𝐹 + 𝐸𝑂𝑁 ∙ 𝑓𝑃𝑊𝑀
NoteBy designing a different modulation strategy, the number of transitions could be decreased by 33% and together with an appropriate timing based on current amplitude, a switching loss minimization can be achieved
Public Information2/2/201820
3 Phase PFC Implementation
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3 Phase PFC – Power Board Concept (1/2)
Digital
Analog INP
Note
Note:
VBUS,MIN = 265·√6 = 650V
CURR SEN.
CURR. SEN.
CURR. SEN.
700V
vA
vB
vC
iA
iB
iC
24V
vBUS
24V
Inrush OFF
ISO-GATE DRIVER
15V
PWM
EN
FAULT
3V3
ISO-GATE DRIVER
15V
PWM
EN
FAULT
3V3
ISO-GATE DRIVER
15V
PWM
EN
FAULT
3V3
ISO-GATE DRIVER
15V
PWM
EN
FAULT
3V3
ISO-GATE DRIVER
15V
PWM
EN
FAULT
3V3
ISO-GATE DRIVER
15V
PWM
EN
FAULT
3V3
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3 Phase PFC – Power Board Concept (2/2)
Digital
Analog INP
Note
SIGNAL
CONDITIONING
FOR 3V3 uC
DCDC CONVERTER[390-850]/24V
390 V 24VDIGITAL
ISOLATORGATE
DRIVER
5V
REF.
IN+IN-XEN
ISODCDC
20V
ISO-GATE DRIVER
3V3
RSRC
RSINK
DESAT
15V
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3 Phase PFC Power Board
TOP VIEW BOTTOM VIEW
SIZE
375 x 240mm
Public Information2/2/201824
Results
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SiC Switching Behavior
INPUT VOLT: 230 Vrms
OUTPUT POWER: 10kW
EFFICIENCY: 97.6%
FPWM: 80kHz
DC OUT: 719.44V
DC RIPPLE: 29.4V
RG,ON: 22 Ohm
RG,OFF: 4.7 Ohm
L(Is = 0, F = 1kHz): 600 uH
TURN OFF ≈ 65 Vns-1 TURN ON ≈ 38 Vns-1
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Overview of the Experiment
INDUCTOR [μH]FA
CT
OR
S SWITCH. FREQUENCY [kHz]
MODULATION [type]
450
70
DIS1 FBM SVM
120
DIS1 FBM SVM
OUTPUT POWER [kW] [3..10] [3..10] [3..10] [3..10] [3..10] [3..10]
70
DIS1 FBM SVM
120
DIS1 FBM SVM
[3..10] [3..10] [3..10] [3..10] [3..10] [3..10]
EFFICIENCY [η]
Ideally 100%
TOTAL HARMONIC DISTORTION [THD]
IEEE STD 519
7.0 3.5 2.5 1.0 0.5 8
POWER FACTOR [PF]
Ideally „1"
PHASE DELAY [φ]
Ideally „0°"
330M
ETR
ICS
Testing conditions
Input voltage:
230VRMS @ 50Hz
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Current Shape @ 10 kW 7
0 k
Hz
12
0 k
Hz
DISCONTINOUOS 1 FLAT BOTTOM SPACE VECTOR
THD1: 4.7%THD2: 5.8%THD3: 4.4%
THD1: 5.1%THD2: 6.5%THD3: 6.2%
THD1: 4.9%THD2: 5.6%THD3: 5.0%
THD1: 8.1%THD2: 8.3%THD3: 8.0%
THD1: 3.7%THD2: 4.2%THD3: 3.7%
THD1: 3.6%THD2: 3.5%THD3: 3.0%
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Efficiency Result
Note
Thermal steady state reached @ 10kW.
Power Supply: Chroma 61511, DC Load: ELR-91500-30, Power Analyzer:
Zimmer LMG500 Oscilloscope: Yokogawa DLM6054
.
• Factor with the highest impact is the output power at
which the board is working.
• Efficiency is affected by the modulation strategy
selected, a variation in average of 0.5% can be
considered which, in turn, affects switching losses.
• Modulation frequency and inductor selection have a
smaller influence on efficiency result. Most likely
they are compensating each other.
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Power Factor & THD
Public Information2/2/201830
Thank you
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