large wind power design

8/6/2019 Large Wind Power Design

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A NOVEL THREE-PHASE RECTIFIER WITH HIGH POWER FACTOR FOR

WIND ENERGY CONVERSION SYSTEMS

C. E. A. Silva, D. S. Oliveira Jr., L. H. S. C. Barreto, R. P. T. Bascop.Federal University of Cear UFC, Department of Electrical Engineering - DEE,

Group of Energy Processing and Control GPEC, Fortaleza CE [email protected], [email protected], [email protected], [email protected]

Abstract In this paper it is proposed a new topology

of three-phase controlled rectifier feasible for high power

wind energy conversion systems (WECS). This rectifier is

based on the bridgeless rectifier, uses six wires of the

generator, and allows the operation with high power

factor, increasing the generator efficiency. One Cycle

Control (OCC), which avoids the need of sinusoidal

reference signals, was used in the rectifier control. This

study is then concerned with the operation principle and

experimental results obtained from a 5 kVA prototype.

Keywords - one cycle control, power factor correction,

three-phase PWM rectifiers, wind energy systems.

I.INTRODUCTIONAccording to the U. S. Department of Energy, through of

International Energy Outlook 2006 (IEO) report of EnergyInformation Administration (EIA), the global consumption ofenergy will grow at an annual average of 2% between theyears of 2003 and 2030. The forecast for the growth ofdemand for energy specifically in the electric form is even

greater i.e. 2.7% to the year [1].Either for ambient, strategical, or geographic questions,the generation of electric energy from wind energy systemshas grown quickly, changing from a global installed power of4.8 GW in 1995 to 58 GW in 2005, at annual average growthof 24% [2]. Considering the current estimations of increasein the demand for electric energy generation in the next few

years, one concludes that the growth of the electric energyobtained from wind systems tends to continue.

This worldwide context is challenging for all involved professionals in generation, distribution, and processing ofelectric energy. In energy processing power electronicspecialists and researchers are fundamental, constantly

searching the increase of the processed power with greaterefficiency and reduced weight and volume.

This paper intends to contribute with this researchconsidering a three-phase controlled rectifier with active power factor correction employing One Cycle Control(OCC), what allows obtaining high power factor withincreased simplicity of the circuit control when compared to

conventional techniques. This rectifier is feasible for highpower wind energy conversion systems (WECS).

II.WIND ENERGY CONVERSION PRINCIPLEThe wind turbine basic principle is to convert the linear

motion of the wind into rotational energy. This rotationalenergy is used to drive an electrical generator, allowing thekinetic energy of the wind to be converted to electric power.

The captured power of the wind (Pv) for a wind turbine isgiven by (1) [4].

1 3

2P A u

v a v= (1)

Where a is the wind density, u is the wind speed, and

Av is the area swept by the turbine. The mechanical power(Pm) generated by the wind turbine from captured power ofthe wind depends on the power coefficient (Cp) of the windturbine, as shown in (2).

( ),m p vP C P = (2)

According to (2), Cp is a function of tip-speed ratio andpitch angle . This function can be approached satisfactorilyby (3) [3].

( )5

21 3 4 6,

i

C

pi

CC C C C e C

= +

(3)

Where,

mr

u

= (4)

3

1 1 0.035

0.08 1i

=

+ +

(5)

Parameter r is the length of the wind turbine blade and

m is the angular rotor speed. Coefficients C1 to C6 dependon the aerodynamic characteristics of the wind turbinedesign. The typical values are given in Table I [3].

TABLE I

Typical values of coefficients C1 to C6

Coefficient Value

C1 0.5176

C2 116

C3 0.4C4 5

C5 21

C6 0.0068

III.WIND ENERGY CONVERSION SYSTEMSAny WECS is composed basically of three parts: wind

turbine, electrical power generator, and electronic powerprocessing system. The wind turbine and the electrical powergenerator compose the wind generator. Horizontal axis windturbines (HAWTs) with two and three blades are the onesthat allow the best exploitation of the available wind energy(Fig. 1) [4]. Three-bladed HAWTs are more commonly used

than two-bladed ones because they are less susceptible to thetower shadow effect. In Fig. 1 it is observed that the

maximum extraction of the wind energy is achieved whenthe rotational speed of the turbine varies with the wind speed,keeping a constant , implying a variable speed WECS.

2009 Brazilian Power Electronics Conference, Bonito (MS) - Brazil - ISSN 2175-8603 985


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Fig. 1. Power coefficient vs. tip-speed ratio curves for HAWTs [4].

The possibility to control the frequency and the amplitudeof the generated voltage through the excitement, independent

of the speed rotation, made the doubly-fed inductiongenerator (DFIG) the main choice in variable speed WECSof great size directly connected to grid (Fig. 2) [5]-[6].

Fig. 2. Variable speed WECS directly connected to grid based in

DFIG.

The WECS in Fig. 2 allows the processing of high powerlevels, since the power converter processes only about 30%of the rated power [7]. On the other hand, the reducednumber of poles of the DFIG demands the use of gearboxbetween the wind turbine and the generator, implying biggerweight, size, and maintenance, reducing its efficiency andreliability [5].

An alternative to the DFIG is the permanent magnet

synchronous generator (PMSG), which can be designed withhigher number of poles to avoid the use of gearbox. Being asynchronous generator, all the generated power must beconditioned through a power converter before it can be used(Fig. 3), restricting the power of this type of WECS.

Fig. 3. Variable-speed WECS connected to grid based in PMSG.

The PMSG presents some advantages when comparedwith the DFIG [8]-[9]:

External excitation current is not required; Light weight; Small size;

High reliability; Low maintenance; High efficiency;

The main disadvantage of the PMSG is the high cost of permanent magnet material and power converter. Themathematical model of a PMSG and the main powerprocessing topologies are presented as follows.

A.PMSG mathematical modelUsing the torque definition, the mechanical torque (Tm)applied to the PMSG is given by (6).

mm

m

PT

= (6)

Substituting (1), (2), and (4) in (6), the mechanical torquecan be expressed according to (7).

( ) 212

pm a v

CT r A u

= (7)

Using the torque definition again, the electromagnetictorque (Te) of the PMSG is given by (8).

a a b b c ce

m

E I E I E I T

+ + = (8)

Where Ea,b,c are the induced instantaneous voltages across

the PMSG windings and Ia,b,c are the induced instantaneouscurrents through PMSG windings. If friction is notconsidered, the variation of the angular mechanical speed ofthe rotor with the time is given by (9).

( )1

m m eT TJ

= (9)

B.Power Processing Topologies Applied to PMSGThe rectifier stage of the power converter used in systems

such as that in Fig. 3 must present high power factor,

otherwise harmonic distortion in the current and voltage of

PMSGs may cause several undesirable effects to thegenerator, such as [10]:

Increased heating due to iron and copper losses atthe harmonic frequencies;

Reduction in machine efficiency; Loss of the torque production; Increased audible noise emission; Eventual occurrence of mechanical oscillations;

In order to avoid these problems, systems capable ofemulating resistive loads for the PMSG must be used,resulting in low total harmonic distortion (THD). These

systems can be implemented introducing a dc-dc stage between the conventional rectifier and the output stage, as

shown in Fig. 4.

Fig. 4. WECS with power factor correction using intermediate

dc-dc stage.

Any dc-dc converter with current source input

characteristic can be used in the WECS of Fig. 4. Thesimplicity of control, the reduced number of components,

and the predominant need to increase the generated voltage,make the boost converter the main choice [11]-[16] in this

WECS, as shown in Fig. 5.



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Fig. 5. WECS with intermediate boost converter.

It can be observed in Fig. 5 that there are always three

power semiconductors in the rectifier stage operating at highfrequency in the current path, reducing the efficiency of thistopology. Another unidirectional topology proposed recentlyfor WECS is shown in Fig. 6 [21].

Fig. 6. WECS with semi-controlled rectifier.

In this topology there are only two semiconductors in thecurrent path of each phase, increasing its efficiency. On theother hand, this structure allows the modulation of thepositive half-cycle of the currents drained from the PMSG,resulting on a THD about 16% [21]. Than Systems in Fig. 5and Fig. 6 are feasible for small WECS.

Another option to achieve high power factor in thegenerator side is to use a PWM rectifier in the WECS, asshown in Fig. 7.

Fig. 7. with power factor correction using PWM rectifier.

The traditional topology applied in high power WECS isshown in Fig. 8 [6] and uses the back-to-back converter [17]-

[18].

Fig. 8. WECS with back-to-back converter.

In the rectifier stage of this structure there are only twosemiconductors in the current path of each phase and thecurrent can be modulated in both half cycles. However, there

are switches connected in series, complicating the commandcircuits.

In Fig. 9 it is shown a WECS that uses a variation of the back-to-back converter [19] proposed in [20]. Only foursemiconductors are used in the rectifier stage of thistopology. Moreover, the voltage balance across thecapacitors of dc link is not a trivial task, what iscompromised by the low number of modulation freedom

degrees of this converter.

Fig. 9. WECS with modified back-to-back converter.

IV.PROPOSED RECTIFIERThe proposed topology is a novel unidirectional three-

phase PWM rectifier, based on the single-phase rectifierintroduced in [23] and known in literature as bridgeless [22]-

[26]. The proposed rectifier is recommended for applications

where six wires are accessible and is composed by three

single-phase rectifiers, as shown in Fig. 10, each one

connected to one phase of the PMSG. This rectifier is fully

controlled, being able to provide unity power factor and low

harmonic content of the generator currents.

In Fig. 10 Ea,b,c are the induced electromotive forces in

each winding of the PMSG stator, inductors La,b,c representthe inductances of each winding of the PMSG stator and arecoupled to each other, and L1,2,3 are boost inductors. Vdc isthe voltage across the dc link capacitor. This capacitor

decouples the rectifier and inverter stages. The mainadvantages of the proposed rectifier when compared to

standard three-phase PWM rectifiers are:

All switches are connected to the same reference,simplifying the command circuit;

Depending of the operation mode, both switches ofeach leg receive the same drive signal;

There are not switches connected in series, discardingthe possibility of short circuit;

For each leg there are only two semiconductors in thecurrent path, increasing robustness with reduced

losses;

As the power of each phase is processedindependently, for a same switch voltage stress, thecurrent stress is 3 times less;

The main disadvantage of the proposed rectifier is thegreat number of semiconductors, what is justified in highpower applications.

Fig. 10. Schematic diagram of the proposed rectifier.



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A.Operation Principle of the RectifierFor each phase of the generator, there is a respective

rectifier module that operates independently, analogously tothe bridgeless converter. The stages of operation of eachrectifier module are illustrated in Fig. 11.

Fig. 11. Operation stages of the each rectifier module.

At the moment when switches S1 and S2 are turned on, the

current flows through them and the boost inductor L1 stores

energy, while diodes D1 and D2 are reverse biased. When S1

and S2 are turned off, diodes D1 and D2 are forward biased,

and the current will flow through them, as the energy stored

in the inductor will be transferred to the output stage.

There are only two power semiconductors in the currentpath during all operating stages, reducing conduction losses.

Depending on the modulation technique, two operating

modes are available:

1)First Operation ModeOnly one switch operates during a given half cycle of the

line voltage, as the operation of a single boost converter

results. Thus, switch S1 is turned off while S2 always remains

turned on during the positive half cycle, and vice-versa

during the negative half cycle.

In a case where MOSFETs are used, the semiconductorthat remains turned on during half line cycle will conduct the

current through itself, and not through the respectiveantiparallel diode, reducing conduction losses. However, this

operating mode increases the complexity in generating thedrive signals.

2)Second Operation ModeBoth semiconductors are driven with same gating signal.

Thus, in the positive half line, when S2 is turned on, the

current will flow in the reverse direction through itself and,

when S2 is turned off the current will flow in the reverse

direction through of the respect antiparallel diode.

In the negative half cycle of the line voltage where S1 is

turned on, the current will flow in the reverse direction

through the switch itself, and when S1 is turned off, the

current will flow in the reverse direction through the

respective antiparallel diode.As well as in the previous mode, the switch reverse

conduction is conditional to the use of MOSFETs, otherwise

the reverse conduction is not possible and the switch could be turned off. This mode simplifies the drive signalgeneration, but will lead to a little bit larger conductionlosses than those in the first mode.

B.Rectifier ControlThe control technique used in the rectifier is the OneCycle Control (OCC) [27]-[34]. The rectifier control

schematic diagram is shown in Fig. 12.

Fig. 12. Block diagram of the rectifier control.

This control technique allows obtaining high power factor

in continuous conduction mode without the need of a currentreference signal. In PFC OCC control technique, the duty

cycle of drive pulse depends on the input voltage, allowing

the current loop to keep sinusoidal input current analogous in

phase with the input voltage.

The current feedback is used in the composition of the

modulator signal, which is compared with a carrier whose

inclination depends on the value of VT. Thus, it is possible to

vary the current peak value drained from the PMSG by

means of slope ramp integrator. In WECS the value of VT is

determined through a maximum power point tracker

(MPPT). In this work the value of VT is determined by

voltage compensator, responsible for the regulation of Vdc.

When the crossing between the carrier and the modulator

signal occurs, the RS flip-flop is reset, commanding theswitch to be turned off. A clock signal sets the flip-flop to a

constant frequency, commanding the switch turning on ( Q )

and integrator reset ( Q ). Fig. 13 shows OCC modulation.

Fig. 13. One cycle control modulation.

V.POWER CIRCUIT DESIGN PROCEDUREThe power circuit design of the proposed rectifier consists

in determining the voltage and current stress of switches and

diodes, and calculating the reactive elements (boostinductances and dc link capacitance). The control circuitdesign is not mentioned, since it is presented in [30]. Table II



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presents specifications and parameters used to design theprototype.

TABLE II

Rectifier specifications and parameters

Parameter Specification

Rms input voltage range (Vg) 100 V 220 V

Frequency of the input voltage (fr) 60 Hz

Output voltage (Vdc) 400 V

Switching frequency (fs) 50 kHz

Rated output power (Po) 5 kVA

Efficiency () 95%

Output voltage ripple (Vdc) 1%

Current ripple through boost inductor (IL) 20%

The maximum voltage across the switches and diodes is

the dc link voltage, as shown in (10).

max max 400S D dcV V V V = (10)

The peak of the maximum generated voltage (Vgpk) isgiven by (11).

2 220 311gpkV V= (11)

Defining the duty cycle as the ratio between the on-time

of a switch (Ton) and the respective switching period (TS),and since the static gain of the proposed rectifier isequivalent to that of the boost converter, the minimum dutycycle is given by (12).

min 1 0.22gpk

dc

VD

V= (12)

The peak of the maximum input current through eachphase is given by (13).

2 11.283

oipk

g

PI A

V=

(13)

The maximum average reverse current through theswitches (IRSavg) is given by (14).

( )0

1sin

2RSavg ipk I I d

=

3.59ipk

RSavg

II A

= (14)

The maximum rms reverse current through the switches(IRSrms) is given by (15).

( )( )2

0

1sin

2RSrms ipk I I d

=

5.642

ipk

RSrms

II A= (15)

The duty cycle (D) varies with the input voltage accordingto (16).

( ) ( )min1 sinD D = (16)

The maximum average forward current (IDavg) through of

the rectifier boost diodes (D1,...,6) is given by (17).

( ) ( ) ( )min0

1

sin 1 sin2Davg ipk I I D d

=

( )min1 2.204

ipk

Davg

II D A= (17)

The maximum rms forward current (IDrms) through therectifier boost diodes (D1,...,6) is given by (18).

( )( )

( ) ( )2

min0

1sin 1 sin

2Drms ipk I I D d

=

( )min2

1 4.593

Drms ipk I I D A

=

(18)

Consequently, the average (ISavg) and rms (ISrms) values ofthe current through the switches (S1,...,6) are given by (19) and

(20), respectively.

1.53Savg RSavg Davg I I I A= (19)

2 2 3.28Srms RSrms DrmsI I I A= (20)

From the ratio between voltage and current through aninductor, the boost inductances L1,2,3 is given by Eq. (21).

min1,2,3 612

gpk

L ipk s

V DL HI I f

=

(21)

Similarly, the dc link capacitance that guarantees themaximum specified ripple is given by (22).

( ) ( )2 22

2.176 1 1

oo

r dc dc dc

PC mF

f V V V =

+

(22)

VI.EXPERIMENTAL RESULTSThe proposed rectifier prototype was built and tested.

Table III lists the semiconductor and reactive devices used toimplement the prototype.

TABLE III

Rectifier semiconductors and reactive devices

Parameter Specification

Boost inductors (L1,2,3) 600H

Output capacitance 2400F

Switches (S1,,6) IRGP50B60PD1 (600 V/50 A)

Diodes (D1,,6) HFA25TB60 (600 V/25 A)

Fig. 14 shows prototype picture.

Fig. 14. Prototype photography.



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Fig. 15 shows the voltage and current waveforms of phasea for an input voltage of 100 Vrms, approximately, and

output power of 500 W, as the power factor is 0.985. Thevoltage THD is about 4.3% and current THD is about 13.6%.

Fig. 15. Voltage (1) and current (2) of phase a for Vin=100 Vrms

(100V/div 5 A/div 5 ms).

Fig. 16 shows the voltage and current waveforms of phasea for an input voltage of 220 Vrms, approximately, and

output power of 5 kW, as the power factor is 0.997. Thevoltage THD is about 4.0% and current THD is about 6.25%.

Fig. 16. Voltage (1) and current (2) of phase a for Vin=220Vrms

(100V/Div - 10A/Div 5 ms).

Fig. 17 presents the line current waveforms of phases a,b, and c for an input voltage of 220 Vrms and output powerof 5 kW.

Fig. 17. Current waveforms in phases a, b, and c for input voltage

of 220 Vrms (5 A/Div 5 ms).

Fig. 18 shows the harmonic spectrum of the input currentthrough phase a for rms input voltage of 220 V rms and

output power of 5 kW. The total harmonic distortion is about6.2%.

Fig. 18. Harmonic spectrum of the input current (Vin=220 Vrms

and Pout=5kW).

Fig. 19 presents the power factor versus output powercurve, where high power factor along the load range can beobserved.

Fig. 19. Power factor vs. output power.

Fig. 20 presents the efficiency curve for rms input voltagerange shown in Fig. 21, as the average efficiency is about

96%.

Fig. 20. Efficiency versus output power curve.



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Fig. 21. Rms input voltage vs. output power.

VII.CONCLUSIONA novel three-phase PWM rectifier has been presented.

The main advantage, when compared to a conventionalthree-phase controlled rectifier are the use of switches with

the source terminal connected to the same point, robustness

due to the absence of controlled switches in the same leg, and

reduced current stress through the switches.

Moreover, the control implementation through OCC

allowed great simplification of the control circuit. With this

control technique the current drained follows inherently the

input voltage waveform, without the need of synchronism

techniques. This characteristic is very important for wind

energy conversion applications due to the amplitude and

frequency variation of the generated voltage.

The experimental results validate the effectiveness of theconsidered system, which presents the relevant results from aexperimental prototype of 5kW, with average efficiency of96% and power factor bigger that 0.98 along the load range.

ACKNOWLEDGEMENT

The authors would like to thank FUNCAP, CNPq andCAPES for the financial support and incentive the scientific

research, ENERSUD for the donation of a wind generator,FINEP and ELETROBRAS for the financial incentive.

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