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Advanced Measurement Technology for Power Electronics Systems SOUTH AMERICA
Gabriel Ortiz and Johann W. KolarPower Electronic Systems Laboratory
ETH Zurich, Switzerland Keynote
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Agenda
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IntroductionPower electronics’ designer goalTypical and future power electronics measurement situations
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► Power Electronics Engineer Goal- Design a power electronic system which complies with a certain set performance indices
- Performance Indices
• Power density [kW/dm3]• Power per unit weight [kW/kg]• Relative costs [kW/$]• Relative losses [%]• Failure rate [h-1]
Source: Ch. GammeterConverter for airborn wind turbine
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► Assessing System’s Performance- Translation of system requirements into components’ requirements- Example: boost-type PFC rectifier with resonant-type isolation DC-DC converter stage
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► Assessing System’s Performance- Translation of system requirements into components’ requirements- Example: boost-type PFC rectifier with resonant-type isolation DC-DC converter stage
• Boost-type rectifier
Boost Inductor:• DC-biased core losses• High-frequency copper losses
Boost Switch/Diode:• Hard-switching losses• Conduction losses
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► Assessing System’s Performance- Translation of system requirements into components’ requirements- Example: boost-type PFC rectifier with resonant-type isolation DC-DC converter stage
• Boost-type rectifier• Isolated DC-DC converter
Boost Inductor:• DC-biased core losses• High-frequency copper losses
Boost Switch/Diode:• Hard-switching losses• Conduction losses
Isolation Transformer:• Non-sinusoidal core excitation• Litz wire high-frequency losses
DC-DC converter switches:• Soft-switching losses (ZVS/ZCS)• Conduction losses
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► Assessing System’s Performance- Translation of system requirements into components’ requirements- Example: boost-type PFC rectifier with resonant-type isolation DC-DC converter stage
• Boost-type rectifier• Isolated DC-DC converter• EMI Filter
EMI Filter:• Common-mode• Differential-mode
Boost Inductor:• DC-biased core losses• High-frequency copper losses
Boost Switch/Diode:• Hard-switching losses• Conduction losses
Isolation Transformer:• Non-sinusoidal core excitation• Litz wire high-frequency losses
DC-DC converter switches:• Soft-switching losses (ZVS/ZCS)• Conduction losses
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► Assessing System’s Performance- Translation of system requirements into components’ requirements- Example: boost-type PFC rectifier with resonant-type isolation DC-DC converter stage
• Boost-type rectifier• Isolated DC-DC converter• EMI Filter• Efficiency
- The performance of the complete system is defined by the performance of its individual components
Input power Output power
Power losses
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IntroductionPower electronics’ designer goalTypical and future power electronics measurement situations
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► Future Traction Vehicles Based on SST Technology- Typical measurements performed during testing and commissioning of power electronic converters
- Floating potentials: Up to tens of kilovolts and tens of kilovolts/microsecond- Voltages / currents: From millivolts to kilovolts, from amps to kiloamps, DC to tens of MHz
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► Future Micro Power Electronic Solutions- Vicor highly integrated power supplies- The little box challenge
- Big challenges during testing and debugging of the converter system!
Up to 1750W (!)Isolated DC-DC converter
www.vicorpower.com
www.littleboxchallenge.com
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Micro PowerElectronics
Smart microgridsDC Distribution
Microelectronics technologyPower supply on chip
MV / MF PowerElectronics
System Applications Standard / integratedsolutions
► Today, Soon, and Future of Power Electronics…- Today: System Applications Standard / integrated solutions
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► Today, Soon, and Future of Power Electronics…- Today: System Applications Standard / integrated solutions
- Future (Soon): Medium Freq. Medium Volt. Smart microgrids, DC distribution
Micro PowerElectronics
Smart microgridsDC Distribution
Microelectronics technologyPower supply on chip
MV / MF PowerElectronics
System Applications Standard / integratedsolutions
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► Today, Soon, and Future of Power Electronics…- Today: System Applications Standard / integrated solutions
- Future (Soon): Medium Freq. Medium Volt. Smart microgrids, DC distribution- Future: Micro Power Electronics Microelectronics technology, power supply on chip
Micro PowerElectronics
Smart microgridsDC Distribution
Microelectronics technologyPower supply on chip
MV / MF PowerElectronics
System Applications Standard / integratedsolutions
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…in power electronic systems:Passive componentsActive componentsSystem level
Today’s Measurement Concepts
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► Boost-type PFC with Isolated DC-DC Stage — Revisited- Passive Components: Inductors, transformers, capacitors
EMI Filter:• Common-mode• Differential-mode
Boost Inductor:• DC-biased core losses• High-frequency copper losses
Boost Switch/Diode:• Hard-switching losses
Isolation Transformer• Non-sinusoidal core excitation• Litz wire high-frequency losses
DC-DC converter switches:• Soft-switching losses (ZVS/ZCS)
Efficiency
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► Boost-type PFC with Isolated DC-DC Stage — Revisited- Passive Components: Inductors, transformers, capacitors- Active Components: Switches, diodes
EMI Filter:• Common-mode• Differential-mode
Boost Inductor:• DC-biased core losses• High-frequency copper losses
Boost Switch/Diode:• Hard-switching losses
Isolation Transformer• Non-sinusoidal core excitation• Litz wire high-frequency losses
DC-DC converter switches:• Soft-switching losses (ZVS/ZCS)
Efficiency
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► Boost-type PFC with Isolated DC-DC Stage — Revisited- Passive Components: Inductors, transformers, capacitors- Active Components: Switches, diodes
- System Level: Efficiency, EMI compatibility
EMI Filter:• Common-mode• Differential-mode
Boost Inductor:• DC-biased core losses• High-frequency copper losses
Boost Switch/Diode:• Hard-switching losses
Isolation Transformer• Non-sinusoidal core excitation• Litz wire high-frequency losses
DC-DC converter switches:• Soft-switching losses (ZVS/ZCS)
Efficiency
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…in power electronic systems:Passive componentsActive componentsSystem level
Today’s Measurement Concepts
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► Measurement of Core Losses- Datasheet provided parameters are only valid for sinusoidal excitation- Differences of up to two times in core losses with respect to calculated values have been reported
- Improved core loss estimation methods for non-sinusoidal excitation should be considered- … or a relatively simple core-loss estimation system can be built.
Tape wound core
Ferrite core
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► Measurement of Core Losses- Increase of core losses due to misalignment of tape wound cores
- Core losses are extremely sensitive to horizontal misalignment
Tape wound core
Source: B. Cougo 2011“Increase of Tape Wound Core Losses due to Interlamination Short Circuits and Orthogonal Flux Components”
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► Core Loss Measurement Equipment- Characterization of the core losses in inductor for variable duty cycle - The losses based on the i2GSE match the measured losses for variable duty cycle
- Improved core loss estimation methods should be used for calculation of core losses in PE circuits- A simple testbench can be built in order to characterize core materials for a specific application
Source: J. Mühlethaler 2012“Improved Core-Loss Calculation for Magnetic
Components Employed in Power Electronic Systems”
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► Core Loss Measurement Equipment- Full-bridge structure generates typical excitations found in power electronic converters- External power supply adjusts the voltage amplitude
- Voltage and current are measured simultaneously to extract the core’s BH loop
Power stage based on full-bridge structure
Source: J. Mühlethaler 2010“Core Losses under DC Bias Condition based on
Steinmetz Parameters”
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► High Frequency Effects in Copper Conductors - Skin and proximity effects arise from the conduction of high-frequency currents in copper cond.
- Not accounting for high-frequency effects results in low accuracy in converter loss estimation- Manufacturing of high quality litz wire is complex and costly
Source: I. Villar 2010“Multiphysical Characterization of Medium-Frequency Power Electronic Transformers”
Skin effect Proximity effect Combined
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► Copper Loss Measurement Equipment- The transformer must be short circuited on its secondary terminal with a very low resistive path- An AC current source provides the high-frequency current with the required RMS value
- Since the power delivered is manly reactive a high power analyzer is utilized to measure the total losses
High-precisionpower analyzer
Transformer under testHigh-current high-frequencyAC source
!Short circuit
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► Copper Loss Measurement Equipment- The current source: 5-level NPC bridges feeding an inductive load through a step-down transformer- Mid-point voltage balancing required for stable operation
- Minimum THD modulation achieves low harmonic distortion in output current
Source: Ch. Gammeter 2012“Medium Frequency High Current Source for Testing
Interconnections in High-Power Converters”
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► Copper Loss Measurement — Litz Wire Bundles- Case study: Litz wire (tot. 9500 strands of 71µm each) with 10 sub-bundles - Current distribution in internal litz wire bundles depends strongly on interchanging strategy
- Total copper losses for 10bundles: 438W
10 bundles 950 with 71µm strands each
Source: G. Ortiz 2013“Medium Frequency Transformers for Solid-State
Transformer Applications — Design and Experimental Verification”
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► Copper Loss Measurement — Litz Wire Bundles- Case study: Litz wire (tot. 9500 strands of 71µm each) with 10 sub-bundles - Current distribution in internal litz wire bundles depends strongly on interchanging strategy
- Total copper losses for 10bundles: 438W- Total copper losses for 8 bundles: 353W
10 bundles 950 with 71µm strands each
Source: G. Ortiz 2013“Medium Frequency Transformers for Solid-State
Transformer Applications — Design and Experimental Verification”
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…in power electronic systems:Passive componentsActive componentsSystem level
Today’s Measurement Concepts
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► Switching Loss Measurement — Current Sensing- High bandwidth (tens of MHz) and (in most cases) isolated transducer
• Current transformer• Rogowski coil (PCB)
• High bandwidth coaxial current shunt (expensive, non-isolated)
Source: www.ib-billmann.de
PCB Rogowski coil
Planar current transformer Coaxial current shunt
Rogowski coilSource: www.pemuk.com
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► Switching Loss Measurement — Current Sensing- Current transformers:• High bandwidth isolated planar current transformer built in-house with standard components• Designed for pulse operation → small construction
- Very easy to manufacture!
Primary
Planar core
Secondary
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► Switching Loss Measurement — Current Sensing- Rogowski Coils• High bandwidth, isolated Rogowski coil built with standard PCB• For switching loss measurement, the integration is preferably done in post-processing
• Extremely low effect on power circuit • Very well suited for measurement in IGBT modules
PCB Rogowski coil placed on an IGBT module
Resulting voltage output and integrated signal
Source: Y. Lobsiger 2011“Decentralized Active Gate Control for Current
Balancing of Parallel Connected IGBT Modules”
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► Switching Loss Measurement — Current Sensing- Current shunt• Exceptionally high bandwidth (in the GHz range) and direct voltage output• PCB soldered shunts offer the possibility to measure switches with virtually any package
• Typically expensive and non-isolated → requires an oscilloscope with isolated channels• Alternative constructions with SMD resistors also possible
Source: R. Burkart 2013“Comparative Evaluation of SiC and Si PV Inverter Systems
Based on Power Density and Efficiency as Indicators of Initial Cost and Operating Revenue”
Source: www.ib-billmann.deCoaxial current shunt
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► Switching Loss Measurement — Deskew- MOSFET and SiC technology feature ultra high switching speeds in the tens of nanoseconds range- Light takes about 3.3ns to travel 1 meter → different cable lengths can lead to meas. inaccuracies
- Specially critical if the voltage/current measurement is not done passively (e.g. diff probes)
Source: R. A. Friedemann 2012“Design of a Minimum Weight Dual Active Bridge Converter
for an Airborne Wind Turbine System”
1.7kV SiC JFET turn-off:drain current
drain-source voltage
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► Switching Loss Measurement — Deskew- Simplified example case:
• Switching 100A with a 1000V DC-link • Unipolar-type semiconductor, i.e. no tail current with a
linear parasitic capacitance and ideal circuit layout(no parasitic stray inductance, hence no switching overshoot)
• Switching time: 100ns
• Deviations of ±25% on measured energy withonly a 12ns deskew
Voltage lagging 12ns
Current lagging 12ns
Nominal
5mJ of energy
6.25mJ of energy(+25%)
3.75mJ of energy(-25%)
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► Switching Loss Measurement — Deskew- Correcting deskew mismatch can be done directly in modern oscilloscopes- Example: Lecroy Wavesurfer MXs-B oscilloscope
- Or in post-processing (e.g. with Matlab)- In all cases, the deskew must be properly measured beforehand
Source: www.teledynelecroy.com
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…in power electronic systems:Passive componentsActive componentsSystem level
Today’s Measurement Concepts
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► Assessing System’s Performance — Efficiency- Efficiency constitutes one of the systems primary performance indices- The measurement of efficiency is typically done in one of two ways:
• Measurement of input and output power• Measurement of input or output power and power losses
- The desired accuracy of the efficiency measurement will determine which method should be used
Input power Output power
Power losses
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► Assessing System’s Performance — Efficiency- Input and output power measurement
• Power analyzer: Yokogawa WT3000• Reading accuracy: 0.02%• Range accuracy: 0.04%
• Table multimeter: Agilent 34401• Reading accuracy: 0.005% @ 100mV• Range accuracy: 0.0035% @ 100mV
www.yokogawa.com
www.agilent.comSource: Th. Schröter 2011“Aspects and Considerations for Accurate Measurement of Very High Efficiency”
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► Assessing System’s Performance — Efficiency- Input and output power measurement
• Handheld multimeter: Fluke 80 series V• Reading accuracy: 0.3% @ 600mV
• Shunt resistor (curr. meas.): Burster 1282• Shunt resistance: 1mΩ (1mV/A)• Resistance tolerance: 0.02%• Temperature coefficient: 0.001 %/°K
www.fluke.com
www.burster.comSource: Th. Schröter 2011“Aspects and Considerations for Accurate Measurement of Very High Efficiency”
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► Assessing System’s Performance — Efficiency- Measurement situation example: • Input power (AC side): Yokogawa WT3000• Output power (DC side): Agilent 34401 (voltage)
Burster 1282 & Agilent 34401 (current)
• Achieved power measurement accuracy: ±0.107%
Yokogawa WT3000
Agilent 34401
Burster 1282
Source: Th. Schröter 2011“Aspects and Considerations for Accurate
Measurement of Very High Efficiency”
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► Assessing System’s Performance — Efficiency- Maximum permissible relative error in the power measurement for the determination of the losses with
a max. relative error of in dependence on the efficiency
- The power measurement accuracy must be extremelly high when an accurate efficiency meas. isdesired
Source: J.W. Kolar 2012“Extreme Efficiency Power Electronics”
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► Assessing System’s Performance — Efficiency- Calorimetric direct power loss measurement• Converter placed in a controlled-temperature double-jacketed chamber • A water-cooled heat exchanger extracts the heat generated by the converter• The power extracted through the water-cooling circuit corresponds to the losses gen. by the conv.
• Accuracy higher than ±1W up to 100W of losses (e.g. for a 1kW converter → ± 0.1% accuracy)
Source: D. Christen 2010“Calorimetric Power Loss Measurement for
Highly Efficient Converters” www.enertronics.ch
Calorimeter manufactured by enertronics GmbH
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► Assessing System’s Performance — EMI Compatibility- The performance of the EMI filter is split into:• Differential-mode rejection and• Common-mode rejection
• These two parameters must be separated by a dedicated circuit• This allows to identify and correct possible incompatibilities with the respective EMI directives
Differential-mode filter
Common-mode filter
Source: M. Hartmann 2010“EMI Filter Design for High Switching Frequency Three-Phase/Level PWM Rectifier Systems”
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► Assessing System’s Performance — EMI Compatibility- Simple active circuit for separation of CM and DM noise- Requires 4 OP-amps and passive components
- Achieves DMTR/CMRR > 51 dB and CMTR/DMRR > 47dB for frequencies up to 10MHz
Source: S. Schroth 2014“Analysis and Practical Relevance of CM/DM EMI Noise Separator Characteristics”
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Smart Grid / DC Distribution Highly Integrated Microelectronics
Future Technologies
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► Future Traction Vehicles Based on SST Technology- Typical measurements performed during testing and commissioning of power electronic converters
- Floating potentials: Up to tens of kilovolts and tens of kilovolts/microsecond- Voltages / currents: From millivolts to kilovolts, from amps to kiloamps, DC to tens of MHz
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► State-of-the-Art Isolated Voltage Measurement- Basic types• Differential probes
• Optically isolated systems(analog link / digital link)
- Drawback: probe combines isolation and measurement
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► State-of-the-Art Isolated Current Measurement- Basic types• Current transformers
• Current compensated transformers(clamp-on current probes)
• Rogowski coils
- Drawback: combination of isolation and measurement
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► Wireless Oscilloscope – Basic Idea- Provide the isolation at a different position in the measurement chain
• Separate data acquisition (channels) and user interface• No need for isolated probes / sensors• No need for an additional oscilloscope
- System overview of a 100MHz wireless channel oscilloscope
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► Isolated Voltage Measurement - Setup consist of measurement of high side gate signal on a half-bridge-type structure• The differential probe exhibits strong CM error during high dv/dt
• The Wireless Scope feautres no visible CM error
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► Isolated Current Measurement
MOSFET drain current• Floating reference voltage• High bandwidth current transients
(turn-on / turn-off)
Measurement setup• 0.1 Ohm shunt & Wireless Scope• Current transformer• Rogowski coil
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► Isolated Current Measurement 2 — Results
Rogowski Coil• Delay• Limited bandwidth• Ringing due to CM transients• Limited isolation voltage
Current Transformer• High bandwidth• No apparent CM error• High-pass characteristic (no DC)• Limited isolation voltage
Shunt & Wireless Scope• High bandwidth• No apparent CM error• DC – 100 MHz• No intrinsic limitation
on isolation voltage
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Smart Grid / DC Distribution Highly Integrated Microelectronics
Future Technologies
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► Example Microelectronics Highly Integrated Converter - Isolated (4kV) DC-DC converter with power
output up to 1.7kW
- How to test the circuit? How to measure internal signals? How to characterize switching performance? How to characterize magnetics performance?
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► Example of Power Supply on Chip- Switched capacitor converter with 4.6W/mm2 and 86% efficiency
- How to test the circuit? How to measure internal signals? How to characterize switching performance? How to characterize capacitor performance?
Source: T. Andersen 2013“A 4.6 W/mm2 Power Density 86% Efficiency On-Chip
Switched Capacitor DC-DC Converter in 32nm SOI CMOS”
(!)
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► Future Micro Power Electronic Solutions- Merge simulation and measurement to create a "simulation-augmented" environment
- Link between these two enables to supervise internal quantities of the experimental hardware
Simulationmodel
Measurementquantities
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Summary / Outlook
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► Measurement in Today’s Power Electronics- Design of power electronics circuit that fulfills given specifications• Components: Passives, Actives• System: Efficiency, EMI
► Measuring Future Power Electronics- High-power medium-frequency electric power systems-oriented• High common-mode, high isolation, high bandwidth• Wireless measurement systems
- Microelectronics, highly integrated solutions:• Simulation augmented measurement concepts
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Thank You!Questions?