Large Converters and Motor Drives

Eaton Navy Controls DivisionRob Cuzner

Jim Ulrich

Large Converters and Motor Drives Navy Power Conversion Applications

• Electric Propulsion

• Shipboard Power Distribution

• Power Electronic Modules

Large Converters and Motor Drives Electric Propulsion

M ediumV oltageInverter

C ontactor

D B R es is to rD B R esis tor

C ontactor

D B R es is to rD B R esis tor

Turb ineG enera tor

Turb ineG enera tor

DCPowerSource

H ighFrequency

D C /D CC onverter

DCPowerSource

Port SS

ST BD SS

H ighFrequency

D C /D CC onverter

M ediumV oltageInverter

Large Converters and Motor Drives Shipboard Power Distribution

D C Loads

Tu

rbin

eG

en

era

tor

A C S hore P ower

V ariab leS peedD rive

A ctiveR ectifie r

Tu

rbin

eG

en

era

tor

M o to rLoads

D C B us

D C /D CC onverte r

V ariab leV o ltage

C onverte r

Large Converters and Motor Drives Power Electronic Module

Large Converters and Motor Drives System Design

MASTERCONTROL :

H M I, P LC , S h ipC om m . IF , S ystem

C ontro l, P EC om m . IF

PEM:G ate D rives,

P ower D evices,Loca l S nubbers,

C o ldp la te orH eats ink

PEM CONTROL:P E C om m . IF ,P ower Logic

C ontro l, Loca lC ontro l

DC Link:C apacito rs,R esisto rs,B uswork

Output Filter:Inductors,C apacito rs

POW ERSUPPLY :Iso la tion ,

D istribu tion

COOLINGSYSTEM:

Fans, P lum bing

S igna ls

A ir

A ir, W ater

S igna ls

C ontro lP ower

L ink V o ltage

LOCALSENSORS

S igna ls

B uswork

C ab ling

SYSTEMSENSORS

S igna ls

MECHANCICAL PACKAGING : S upportS tructures, S ound A ttenuation ,

M ain ta inab ility

Large Converters and Motor Drives System Design Tools

MASTERCONTROL :

C adence C apture ,A llegro , Software

D eve lopm entToo ls

PEM:P S pice, A C S L,

M atLab/S im ulink,S D R C Ideas,

A nsoft

P E M C O N TR O L:C adence C apture ,A llegro , Software

D eve lopm entToo ls DC Link:

P S pice, A C S L,M atLab/S im ulink

Output Filter:P S pice, A C S L,

M atLab/S im ulink,A nsoft

POW ERSUPPLY :P S pice ,

C adenceC apture ,A llegro

COOLINGSYSTEM:M athC ad,F lo therm

LOCALSENSORS

SYSTEMSENSORS

MECHANCICAL PACKAGING : S D R CIdeas

Large Converters and Motor Drives CAD Experience - System Simulation

• Complete System Simulation using PSpice• Devices for Power Circuit Modeling, ABM for

Control Circuit Modeling• Common Mode, Differential and Averaging

Models Have Been Developed• Models Validated on Actual Equipment• Simulation Provides Risk Mitigation and Reduces

Development Cycle Time

Large Converters and Motor Drives CAD Experience - System Simulation

• Transient and Steady State Component Stress Levels

• Power Device Losses

• Conducted Emissions Per MIL-STD-461D

• System Stability with Dynamic Loads

• Control Circuit Design and Gain Optimization

• Predict Output Voltage/Input Current Harmonic Performance

• Impact of Digital Control System Loop Time and Latency

• Predict Behavior When Paralleled with Other Converters or Utility Power

Large Converters and Motor Drives System Simulation - Simulated Motor Soft Start (Stable)

Time

0s 1.0s 2.0s 3.0s 4.0s 5.0s 6.0s 7.0s 8.0sV(HS100:TORQUE)

-100V

0V

100V

200V

300V

Torque

V(HS100:SPEED)0V

2.0KV

4.0KVSpeed

-I(R614)

-500A

0A

500A Current

V(R541:2,R542:2)

0V

500V

-700VSEL>>

Voltage

Large Converters and Motor Drives System Simulation - Simulated Motor Soft Start (Unstable)

Time

0s 1.0s 2.0s 3.0s 4.0s 5.0s 6.0s 7.0s 8.0sV(HS100:TORQUE)

-200V

0V

200VTorque

V(HS100:SPEED)0V

2.0KV

4.0KVSpeed

-I(R614)

0A

500A

-600ASEL>>

Current

V(R541:2,R542:2)

-500V

0V

500V Voltage

Large Converters and Motor Drives System Simulation - Simulated Motor Hard Start

Time

0s 0.5s 1.0s 1.5s 2.0s 2.5s 3.0s 3.5sV(HS100:TORQUE)

250V

500V

-100VSEL>> Torque

V(HS100:SPEED)0V

2.0KV

4.0KV

Speed

-I(R614)-2.0KA

0A

2.0KA

Current

V(R541:2,R542:2)-1.0KV

0V

1.0KV

Voltage

Large Converters and Motor Drives System Simulation - Simulated RDCL Inverter Voltage

Frequency

0Hz 1KHz 2KHz 3KHz 4KHz 5KHz 6KHz 7KHz 8KHz 9KHz 10KHz100*V(L218:1,E17:2)/622.161

0V

100mV

200mV

300mV

SEL>>

Time

20.00ms 25.00ms 30.00ms 35.00ms 40.00ms 45.00ms 50.00ms16.67msV(L218:1,E17:2)

-500V

0V

500V

-700V

700V

Large Converters and Motor Drives System Simulation - Simulated Hard-Switched CE101 Results

Frequency

100Hz 1.0KHz 10KHz30Hz-I(R597)

10uA

100uA

1.0mA

10mA

100mA

1.0A

10A

100A

Limit

48.5 dB Relaxation

Large Converters and Motor Drives System Simulation - Actual Hard-Switched CE101 Data

Large Converters and Motor Drives System Simulation - Simulated Hard-Switched CE102 Results

Frequency

10.0KHz 100.0KHz 1.00MHz 6.55MHzV(R598:2)*3

1.0uV

10uV

100uV

1.0mV

10mV

100mV

1.0V

12db Relaxation

Limit

Large Converters and Motor Drives System Simulation - Actual Hard-Switched CE102 Data

Large Converters and Motor Drives System Simulation - Simulated RDCL CE102 Results

Frequency

10KHz 100KHz 1.0MHz 10MHzV(R1481:2)*3

1.0uV

10uV

100uV

1.0mV

10mV

100mV

1.0V

Limit

12 dB Relaxation

Large Converters and Motor Drives System Simulation - Simulated LISN Voltage

Time

71.400ms 71.450ms 71.500ms 71.550ms 71.600ms 71.650ms 71.700ms 71.750ms 71.800ms71.364ms 71.844msV(R598:2)

-4.0V

-2.0V

0V

2.0V

-5.6V

Large Converters and Motor Drives System Simulation - Actual LISN Voltage

Large Converters and Motor Drives System Simulation - Digital Control Loop Time and

Latency

Time

24.240ms 24.280ms 24.320ms 24.360ms 24.400ms24.214msV(HS419:Output) V(HS476:OUT)

-240.0V

-230.0V

-220.0V

-210.0V

-200.0V

-249.1V

Large Converters and Motor Drives Simulation Program Needs

• PSpice Advantages– Fast Model Development– Large Circuit Library– Accuracy– Easy Configuration Management– Wide Industry Use– Cost

Large Converters and Motor Drives Simulation Program Needs

• PSpice Needs– Native Programming Environment– Control Over Simulation Routine– Improved Convergence with “Stiff” Systems– Improved Speed and Performance– Expanded Analog Behavioral Library– Standardization of Models– User control of Y-axis units

Large Converters and Motor Drives Simulation Program Needs

• Saber Advantages– Fast Model Development– Large Circuit Library– Electro-Mechanical Component Library– Easy Configuration Management– Control Over Simulation Routines– Native Programming Environment

Large Converters and Motor Drives Simulation Program Needs

• Saber Needs– Cost– Improved Speed and Performance– More Choices and Control Over Simulation

Routines– Standardization of Models

Large Converters and Motor Drives Simulation Program Needs

• ACSL, MatLab/Simulink Advantages– Native Programming Environment– Speed of Simulation– Large Circuit Library– Control Over Simulation Routines– Choice Of Simulation Routines– Cost

Large Converters and Motor Drives Simulation Program Needs

• ACSL, MatLab/Simulink Needs– Model Development– Configuration Management– Component Libraries