Prace Naukowe Instytutu Maszyn, Napdw i Pomiarw Elektrycznych

Nr 64 Politechniki Wrocawskiej Nr 64
Studia i Materiay Nr 30 2010
PWM rectifier, integrated power module,
hardware design, TMX320R2812, auto-code generation
Micha KNAPCZYK*, Krzysztof PIEKOWSKI**
THREE-PHASE PWM RECTIFIER BASED ON
INTEGRATED POWER MODULE AND FIXED-POINT DIGITAL
SIGNAL PROCESSOR FOR RAPID PROTOTYPING ISSUES
The paper presents a laboratory test-bench with a three-phase two-level PWM rectifier. The setup
is based on a 3.3 kW integrated power module and a 32-bit fixed-point digital signal processor with
a Simulink auto coder for rapid prototyping of control strategies. The setup has been diversified into
separate modules for different tasks: grid voltage and grid current measurement modules, hardware
dead-time block with IGBT gate signal inverted logic driver, analogue signal processing block for
sensor-to-processor interface, auxiliary control electronics and power circuits with overvoltage and
overload protections. These modules assembled in unit provide entire functionality of the laboratory
setup with the PWM rectifier for flexible and fast implementation of control strategies either for their
further development or for the purpose of didactics. In order to demonstrate the operation of the pro-
posed test-bench Sliding-Mode Voltage Oriented Control with -PWM has been implemented to
control the PWM rectifier. Numerous experimental results have been presented and discussed.
1. INTRODUCTION
Modern power electronics devices for commercial use are controlled by numerous
types of microcontrollers. A code of newly developed and thoroughly tested control
algorithms is next optimized to be run within a possibly lowest time-consuming mi-
croprocessor routine. However research and development phase of design of new
control schemes for power electronics equipment requires versatile and flexible con-
trol units usually based on fast fix-point or even floating-point digital signal proces-
sors. These are usually mounted on evaluation boards equipped with dedicated periph-
erals like PWM modules for control of power electronics devices, ADC converters,
__________
* 3cap Technologies GmbH, 85764 Oberschleiheim, Germany, michal.knapczyk@3cap.de
** Politechnika Wrocawska, Instytut Maszyn, Napedw i Pomiarw Elektrycznych, ul. Smoluchow-
skiego 19, 50-370 Wrocaw, Poland, krzysztof.pienkowski@pwr.wroc.pl
279
general purpose inputs and outputs, as well as RAM or EEPROM for flashing the
software and recording diagnostics alerts. They provide communication with PC usu-
ally via a standard serial or USB port. In field of high quality energy conversion inte-
grated power modules have recently revolutionized the design of modern power con-
verters. For high power conversion the semiconductor structures are designed as
integrated modules containing SCR or GTO legs. In range up to medium power rat-
ings complete IGBT- or MOSFET-based three-phase two-level and multi-level con-
verters are available. Further improvements in design of power modules have led to
integration of protective electronics with the semiconductor structure inside its pack-
age or outside it in case of its tiny dimensions [1, 2, 3]. Such intelligent power mod-
ules are protected against overloading, over/under-voltage and over-heating [6, 7, 8,
11]. This paper describes a design of a laboratory test-bench with the three-phase two-
level PWM rectifier based on 3.3 kW IGBT power module FS10R06VL4 with
EiceDRIVER 6ED003E06-F and evaluation board eZdsp R2812 with TMX320R2812
digital signal processor. The presented design process providing increased quality of
system performance has been significantly improved in comparison with the previous
hardware setup presented by authors in [4].
2. DESIGN OF LABORATORY SETUP WITH PWM RECTIFIER
The PWM voltage-source rectifier requires for its proper operation the exact infor-
mation about grid voltages, grid currents and the output DC voltage (Fig. 1).
Fig. 1. Diagram of proposed experimental setup of PWM rectifier
280
2.1. INTEGRATED POWER MODULE
The power unit of the proposed prototype of the PWM rectifier is based on the
3.3 kW IGBT power module by EUPEC/INFINEON with the electronic interface
EiceDRIVER 6ED003E06-F [11]. The reason of the widespread use of the IGBT
transistors is their voltage-based control because practically no power is taken during the
switching process unlike in case of SCRs or GTOs. The crucial problem in realization of
the driver system for the transistor-based two-level bridge is a floating reference voltage
for gate signals of the upper-side transistors. The problem has been overcome by the
application of a dedicated IGBT driver IR2136S of International Rectifier using the
boot-strap technique. Figure 2 presents the three-phase IGBT power module mounted on
a heat-sink with additional protective electronics.

Fig. 2. EiceDRIVER 6ED003E06-F: overview (left); block diagram [11] (right)
The FS10R06VL4 power module presented in Fig. 3 provides the maximal DC-link
voltage U
dcmax
= 300 V and the maximal DC-link current I
dcmax
= 10 A. The minimum
dead-time for the IGBT transistors in each leg of the converter is T
dead
= 1.8 s.
Fig. 3. EUPEC module FS10R06VL4 consisting of six IGBTs integrated in gel-filled package
281
Figure 4 presents the detailed functional diagram of the proposed laboratory setup of
the PWM rectifier with the FS10R06VL4 integrated power module containing six IGBT
transistors with respective shunt diodes, the IR2136S IGBT driver and the LM393M
voltage comparators. The on-board electronics is supplied with 15VDC. This electronic
interface provides short-circuit, under/over-voltage and over-current protection by
a shunt resistor, the IR driver and comparators. In case of power modules which are
equipped with NTC temperature sensor in their internal structure EiceDRIVER can also
provide an over-temperature protection [11].
U
W
V
G1 G2 G3 G4 G5 G6
EU EV EW
15k 15k 15k
82
82
15k 15k 15k
82
82
82
82
COM LO3
VSS
RCIN
EN
ITRIP
FLT
LIN3
LIN2
LIN1
HIN3
HIN2
HIN1
VCC VB1
HO1
VS1
VB2
HO2
VS2
VB3
HO3
VS3
LO2
LO1
2
1
3
4
5
6
7
8
9
10
11
12
13 14
15
16
18
19
20
22
23
24
26
27
28
IR2136S
+
-
LM393M
+-
NTC
(optional )
1 2 3 4 5 6 7 8 9
NC
P1/CON9 - CONTROL
1
2
P2/CON2
LM393M
P
N
(+)
(-)
10u
10u
10u
BYG20J BYG20J BYG20J
560k 100k
MCL4148
MCL4148
0.1u 10n
10n 0.1u
0.1u
0.1u
10n
270 120
47u
MCL4148
68k
2.2k
0.1u
33k
560k 0.1u
100k 2.2k
0.1u
15k
10n
0.1u
33k 8.2k
33m
SUPPLY
15V
FS10R06VL4
Fig. 4. Detailed diagram of EiceDRIVER 6ED003E06-F with FS10R06VL4 6-pack module [11]
Table 1 presents selected electrical characteristics of the proposed FS10R06VL4
power module with its driver circuit 6ED003E06-F.
Table 1. Selected parameters of EiceDRIVER 6ED003E06-F with FS10R06VL4 6-pack module
DC-link voltage U
dc
: 360 V
DC-link current I
dc
(@T
C
= 25 C) 10 A
Collector-emitter voltage U
CE
600 V
Maximal switching frequency f
switch
15 kHz
Minimal PWM ratio 0.1
Total power dissipation P
tot
(@T
C
= 25 C) 78 W
Minimal dead-time for IGBTs in one leg T
dead
1.8 s
Driver supply voltage U
in
15 V
282
2.2. VOLTAGE AND CURRENT SENSORS
In the proposed laboratory setup with the PWM rectifier voltage and current trans-
ducers offered by LEM have been applied. The operation of these sensors is based on
Hall-effect to provide galvanic separation between the microprocessor and the power
module, as well as to provide high linearity and accuracy of voltage and current sensing
[9]. Figure 5 presents prototype boards with LV25-P sensors for grid and DC-link volt-
age measurement and grid current transducers LA50-P. The voltage measuring range in
case of LV25-P is set up using carefully selected shunt power resistors. The current
measuring range for LA50-P can be easily adjusted by setting an appropriate number of
turns of a current cable round a transducers core.

Fig. 5. Prototype boards with transducer for AC-DC voltages (left) and ac currents sensing (right)
Figure 6 shows a coupling and scaling interface for the transducers and the DSP.
Since the analog-to-digital converter (ADC) of the DSP requires positive input signals in
range from 0 to 3V the offset signals have been added to the scaled output signals of the
proposed transducers. The matching circuit is based on inverting operational amplifiers
TL074 and RC low-pass filters for the anti-aliasing purpose. For the maximum protec-
tion of the DSP the inputs of the ADC channels have been equipped with the 1N5711
Schottky barrier diodes operating as voltage limiters.
Fig. 6. Scaling interface between voltage and transducers and analog-to-digital converter of DSP
283
2.3. OPTOCOUPLERS, DEAD TIME AND POSITIVE-TO-NEGATIVE LOGIC CONVERTER
For galvanic separation between the power module with its interface electronics and
the microprocessor-based control system fast logic gate opto-couplers HCPL-2211 have
been applied. The hardware dead-time module has been designed using SN7414
Schmitt-trigger inverters, SN5406 buffers with open-collector outputs and the RC
branches. Besides providing blinking time the proposed circuit inverses control signal to
negative logic routine. Despite its sensitiveness to changes of ambient temperature the
circuit shown in Fig. 7 provides satisfactorily stable functionality at typical laboratory
conditions. There are six independent circuits for each of six IGBTs.
+15V
TMX320R2812
SN7406D SN7414D
+5V
ACTIVE HIGH
ACTIVE LOW
A1 B1 C1
HCPL-2211
GPIO
(PWM)
to IGBT
7805
SN7414D

Fig. 7. Opto-coupler, dead time and positive-to-negative logic converter (left); signal routine (right)
Figure 8 (left) presents the prototype board with the complete set of circuits presented
in Fig. 7 for one IGBT. The parameters of the RC branch have been tuned in order to
make signals reach a Schmitt-triggers threshold in 2 s as shown in Fig. 8 (right).

C1
C2
Fig. 8. Evaluation board with optocouplers and hardware dead-time (left);
measured control signals for one leg of IGBT module (right)
284
2.4. FAULT PROTECTION SYSTEM AND LINE POWER ADAPTER
The proposed prototype of the PWM rectifier has been equipped with software and
hardware protection systems against hazardous effects of any possible faults or power
overshoots. As it is shown in Fig. 9, in case of short-circuit or overvoltage the power
module should be cut off from the supply line throughout respectively varistors, fuses
and a relay. Moreover a brief unexpected collapse of the low DC voltage supplying the
DSP and control electronics causes the cut-off of the power module and safe discharge
of the DC-link capacitor thru a discharging resistor.
Fig. 9. Overview of protective equipment of proposed setup of PWM rectifier
In order to provide a low DC input voltage for auxiliary electronics and sensors
a power adapter has been designed. Figure 10 presents its application with a wiring dia-
gram. For safety reasons the power module supply voltage of 15VDC is provided sepa-
rately.

Fig. 10. Power adapter for DC low voltage: front view (left); schematic diagram (right)
285
2.5. TMX320R2812 DIGITAL SIGNAL PROCESSOR
For the realization of the control tasks in the experimental setup of the PWM rectifier
an evaluation board eZdsp R2812 by Spectrum Digital based on TMX320R2812
Digital Signal Processor by Texas Instruments has been chosen. Fig. 11 presents the
front view of the DSP applied in the proposed setup of the PWM rectifier. The block
diagram beside shows the DSPs internal functionality.

Fig. 11. eZdsp board based on TMX320R2812 DSP by Texas Instruments [10]
The TMX320R2812 is the fixed-point, 32-bit data word microprocessor with two
overlapping data and program address spaces, 18 K words on-chip RAM, 128 K
words on-chip FLASH, 64 K words off-chip SRAM, 30 MHz clock (maximal rate
up to 150 MHz), 56 multiplexed digital inputs/outputs, 12-bit 16-channel analog-to-
digital converter (80 ns), 45 interrupts divided into 8 levels of priority, 5 V supply
voltage and two Event Managers including a hardware 2-level/3-level PWM modu-
lator.
The DSP is embedded on an evaluation board presented in Fig. 12 with the interface
electronics for the transducers and two external 8-bit digital-to-analog converters (DAC)
for monitoring of inner control variables direct on an oscilloscope.

Fig. 12. DSP socket with interface electronics (Fig. 6) (left); pin layout for PWM and DACs (right)
286
2.6. OVERVIEW OF PWM RECTIFIER PROTOTYPE
The complete laboratory setup of the PWM rectifier consists of the six component
boards presented in the previous sections assembled one on another and connected as
shown in Fig. 13 to provide the functionality depicted in Fig. 1.

Fig. 13. Overview of assembled prototype of PWM rectifier on test-bench
3. SIMULINK MODEL FOR AUTO-CODE GENERATION
The idea of Sliding-Mode Voltage Oriented Control (SM-VOC) for the PWM recti-
fier described in details in [5] is the decomposition of the grid current vector i
g
based on
the Park transformation into the two rectangular components i
gd
and i
gq
in the (dq) co-
ordinate frame oriented with the grid voltage vector as depicted in Fig. 14 (left). Figure
14 (right) presents a block diagram of the proposed control method.

Fig. 14. Sliding-Mode Voltage Oriented Control:
vector decomposition (left); block diagram (right)
287
Fig. 15 demonstrates the Simulink model of Sliding-Mode Voltage Oriented Control
presented in Fig.14 (right) realized with help of Target for TI C2000 toolbox including
C28x IQmath Library for fast fixed-point arithmetic.
SM-VOC
voltage
egAB
egBC
angle
egd
egq
udc*
820
switching fcn
for q -axis
iq*
iq
sq
switching fcn
for d -axis
id*
id
sd
signal offset
cancelation
A5
A4
A0
A1
A3
egAB
egBC
igA
igB
udc
scaling
Input1
Input2
left
right
reference currents
id*, iq*
computation
egd
egq
phi*(rad)
u0*
i_load
id*
iq*
phi *
0
current
angle
igA
igB
igd
igq
analog -to
-digital
converter
C281 x
ADC
A5
A4
A0
A1
A3
To switches
s1*
s2*
s3*
u0
to IGBTs
d
q
angle
a
b
c
R2812 eZdsp
PI
Out to SCOPE
DACleft
DACright
Digital Output
C281 x
GPIO DO
Fig. 15. Target for TI C2000 model of Sliding-Mode Voltage Oriented Control for auto-coding
Figure 16 presents one of applications of the fixed-point IQmath arithmetic
model of selected parts of Sliding-Mode Voltage Oriented Control for real-time
auto-coding.
iq*
2
id*
1
reference currents
id*, iq*
computation
egd
egq
phi*(rad)
u0*
i_load
id*
iq*
IQN x IQN2
A
B
Y
IQNmpy
IQmath
IQN x IQN 1
A
B
Y
IQNmpy
IQmath
IQN x IQN
A
B
Y
IQNmpy
IQmath
IQN / IQN1
A
B
Y
IQNdiv
IQmath
IQN / IQN
A
B
Y
IQNdiv
IQmath
i _load
5
u0*
4
phi *(rad)
3
egq
2
egd
1
Fig. 16. Target for TI C2000 model of Sliding-Mode Voltage Oriented Control for auto-coding
Texas Instruments IQmath Library is set of highly optimized and high precision
mathematical function library to port the floating-point algorithm into fixed-point code
on TMS320C28x devices. These routines are typically used in computationally inten-
sive real-time applications where optimal execution speed and high accuracy is criti-
cal. The TI IQmath library shortens significantly the time of DSP application devel-
opment [10].
288
4. SELECTED EXPERIMENTAL RESULTS
The experiments have been carried out using the parameters presented in Table 2.
Due to the properties of the power module of the PWM rectifier presented in Table 1 the
experimental verification has been performed at a reduced grid voltage.
Table 2. Parameters of experimental setup
with PWM rectifier
Grid phase voltage e
g
: 38 V
Grid voltage frequency f
g
: 50 Hz
Grid resistance R
g
: 100 m
Choke inductance L
g
: 11.3 mH
DC-link capacitance C
d
: 1000 F
DC-link nominal voltage U
dc
: 100 V
Load resistance R
load
: 35
SM-VOC sampling rate: 35 s
Figure 17 (left) presents a measured phase grid voltage and three-phase sinusoidal
grid currents at step change of a converter load (R
load
= 35 ) and at unity power
factor condition (UPF). Figure 17 (right) shows the grid currents in the (dq) coordinate
frame at step change of converter load derived with help of DACs.
igA
igB
igC
egA

Fig. 17. Experimental results of Sliding-Mode Voltage Oriented Control for proposed PWM rectifier:
phase grid voltage and three-phase grid currents at step load change and unity power factor (left);
grid currents in (d-q) coordinate frame at step change of converter load (right)
The transient of the DC-link voltage at step change of converter load is shown in
Fig. 18 (left). Since the measured phase grid voltage is corrupted with low-order harmon-
289
ics (mainly the third), this grid voltage distortion is also penetrating into the DC-link volt-
age making it oscillate. However there is no fourth wire in the system and the influence of
the third harmonic is thus cancelled and the grid currents remain sinusoidal. Figure 18
(right) presents the rectifier input line-to-line PWM voltage produced with help of the
delta-modulation (-PWM) for SM-VOC. Since the grid voltage is reduced the presence
of voltage drops over IGBTs is thus distinct.

Fig. 18. Experimental results of Sliding-Mode Voltage Oriented Control for proposed PWM rectifier:
transient of DC-link voltage (left); rectifier input PWM voltage under delta-modulation (right)
5. CONCLUSIONS
The paper presents a thorough design of the experimental setup of the PWM rectifier
based on a DSP control unit. For the proper operation the PWM rectifier requires feed-
back information about all state variables. Hence the voltage and current sensors with its
auxiliary electronic have been constructed and examined. The real-time application of
the Sliding-Mode Voltage Oriented Control (SM-VOC) for the PWM rectifier requires
a faster and more efficient digital signal processor than in case of its linear counterpart
(VOC) to achieve the comparable quality of the control process. This is due to the fact
that Sliding-Mode Control of the PWM rectifiers uses the delta-modulation that is real-
ized on-line at each calculation step of the control algorithm. In contrary, SV-PWM is
realized in a separate hardware module (Event Manager) at a definable rate regardless of
a control algorithm rate. However as it was shown in this paper it is possible to imple-
ment the proposed sliding-mode-control technique in TMX320R2812 DPS which is
dedicated for power electronics applications. The proper selection of values of the choke
inductance and the DC-link capacitor, as well as neglecting a sensorless control in the
algorithm provide the satisfactory performance of the sliding-mode-based control tech-
niques using the proposed digital controller.
290
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