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I. I NTRODUCTION
Mechanical rotary systems have seen an increase in the use
of direct-driven and geared electrical machines in many industrial applications. For example, aero-engine starter/generator
operation with variable speed electrical machines are presently
being researched due to its potential to achieve reduced weight
and improved reliability of the mechanical-electrical power
conversion stage [1][4]. Aero-engine starter operation requires fault-tolerant characteristics and the permanent magnet
(PM) machine is found to be a candidate for such applications
due to its high power density and the operational capability
with fault-tolerance. A typical geared-drive aero-engine starter
operation may require motoring capability up to 30krpm [5]
and generating capability at even higher speeds. Conventional
method of PM motor control involves PWM inverters with
high switching frequency and is capable of instantaneous
control of the PM motor phase currents [6][8]. However,
as the PM motor electrical frequency is increased, a higher
switching frequency is required to provide the same level
of controllability of phase currents. This will increase the
power electronic losses in inverters designed with the present
generation of high-power semiconductor technology.
vdc
Phase - a
i2
Phase - a
H bridge
Fig. 1.
Phase - c
i3
i1
Phase -b
H bridge
Phase - b
Phase - c
H bridge
1902
Inverter
temperature
over-temperature shutdown
quasi-square wave mode
over-speed
shutdown
pm,n = 21
(3)
k=K1
electrical frequency f
Fig. 2.
K1
o
n
X
f,k ejk(e +n )
vn (t) =
K
X
1
2
{v n,k ejk(e +n ) }
(4)
k=K
1
2
K
X
{in,k ejk(e +n ) }
(5)
k=K
(7)
K
kpp X
2kf,k in,k
8
(9)
k=K
+ (Lq Ld ) in,k+2 in,k2 in,k
The nth -phase, k th harmonic real power (Pn,k ) and reactive
power (Qn,k ) components at the inverter AC side can be
written as,
1903
Pn,k =
1
Re v n,k in,k
2
and Qn,k =
1
Im v n,k in,k
2
(10)
Hysteresis controller
Speed controller
T*
PI
wr*
wr
PM machine
MTPA
input lookup
for THIPWM
un
Switching
waveform
generator
Current
waveform
generator
wr
d ( t )
d (t )
HIPWM
PI
in
a'
[ , ]
{
on+
off+
on
Current controller
in*
wr
off
Phase - a H bridge
+
+
Fig. 3.
Block diagram representation of the speed controller and per-phase mode controller.
phase voltage
{
{
on+
+
off+
back-EMF
on
off
electrical angle
vdc
+vdc
A. mode 1:
{un,k }
(11)
N
X
n=1
K
X
in,k in,k
k=1
)#
2
Ibase
Subject to
T
Nf
X
and
2
2
2
for all n and t
0
2 + v2
=
cos1
v1,q
(14)
1,d
4vdc
v1,d
= tan1
(15)
v1,q
n=1
1904
1
2
1
The dual mode operation for thermal protection is implemented via a hysteresis controller:
switch to mode 2 if < h
(18)
switch to mode 1 if > h
where and are the desired and actual temperatures
respectively. Parameter h represents the hysteresis band of the
controller.
1
0
1
2
1
1
0
0.5
0
0.5
(e) Torque demand [pu]
0.5
0
0.5
(f) Torque demand [pu]
0.5
0
0.5
(g) Torque demand [pu]
0.5
0
0.5
(b) Torque demand [pu]
0.5
0.5
0
(h) Torque demand [pu]
80
60
40
20
0.5
1
0
0.5
0.5
(c) Torque demand [pu]
0
1
0.5
100
50
0.5
1
TABLE I
M OTOR DRIVE SYSTEM PARAMETERS
0.5
1
0.5
0.5
1
1
C. Thermal protection:
0.5
0
0.5
(a) Torque demand [pu]
1.5
[deg]
[deg]
(17)
50
0
0.5
0.5
(d) Torque demand [pu]
4000rpm
1
10000rpm
100
1
16000rpm
20000rpm
Fig. 5. d-axis and q-axis voltage components for HIPWM and QSW modes
of operation with the MTPA optimization. (a) vd,1 , (b) vq,1 , (c) vd,3 , and (d)
vq,3 for HIPWM mode operation, (e) vd,1 , (f) vq,1 for QSW mode operation,
and the corresponding (g) , (h) in QSW mode.
Parameter
Value
Machine parameters:
kW rating
18kW
PM flux f,1
0.0645Vs
Maximum speed m
20krpm
Base speed m
10krpm
Rs
0.01
Lq
1.8mH
Ld
1.6mH
Pole pair number
2
DC-link voltage
135V
Inverter switching frequency 40kHz
H-bridge parameters (per-phase):
Maximum voltage
600V
Maximum current
260A
On-state resistance
5.3m (IGBT)
5.0m (Diode)
Forward voltage
2.4V (IGBT)
1.5V (Diode)
IGBT 10% fall time
500ns (Typical)
IGBT tail time
500ns (Typical)
A. MTPA optimization:
A 2-pole 18kW PM machine interfaced with a parallel Hbridge converter topology described by the parameters given
in table I has been simulated with the control system shown
in figure 3. The MTPA optimization is performed for a torque
demand variation T [1pu, 1pu] for the PWM and QSW
modes. In the former, harmonic injection PWM (HIPWM)
is considered with the fundamental and the third harmonic
voltages.
1905
v1
iph ,1[A]
200
Torque
v1
2
0
iph ,1[A]
4
(c) Time [ms]
100
6 0
100
100
4
(d) Time [ms]
Torque
100
100
0
[V] and
200
v1
Phase current
Torque
100
[V] and
15
10
(b) Time [ms]
200
Torque
v1
100
100
iph ,1[A]
15
10
(a) Time [ms]
[V] and
iph ,1[A]
200
100
100
[V] and
10
iph ,1[A]
[V] and
100
Torque
v1
iph ,1[A]
v1
100
[V] and
10
200
Torque
200
60
40
20
0
3 4 5 6 7 8 9
(g) Operating point number
3 4 5 6 7 8 9
(h) Operating point number
3 4 5 6 7 8
(i) Operating point number
3 4 5 6 7 8
(j) Operating point number
60
40
20
0
60
40
20
0
60
40
20
0
Fig. 6. Current, voltage and torque waveforms in PWM and QSW modes for the operating points 3, 6 and 9, and H-bridge IGBT power losses comparison
for all the nine operating points given in table II. (a), (c) and (e) PWM mode waveforms and (b), (d) and (f) QSW mode waveforms for operating points 3,
6 and 9. PWM and QSW modes power losses in the (g) upper IGBT-1, (h) upper IGBT-2, (i) lower IGBT-1 and (j) lower IGBT-2.
Speed
[rpm]
Torque
[Nm]
1
2
3
4
5
6
7
8
9
4000
4000
4000
10000
10000
10000
16000
16000
16000
5.1
8.5
11.9
5.1
6.8
8.5
1.7
3.4
5.1
Total loss
HIPWM
mode [W]
107.0
187.7
259.1
110.8
163.8
231.5
61.0
108.0
176.4
Total loss
QSW
mode [W]
50.8
119.4
182.6
87.2
120.7
154.3
37.5
75.2
117.5
Reduction
in losses %
52.5
36.4
29.5
21.3
26.3
33.4
38.5
30.4
33.4
1906
70
60
50
40
0
10
15
(a) Time [mins]
20
25
30
100
80
70
60
50
40
0
10
15
20
25
(b) Time [mins]
30
90
80
70
60
50
40
0
10
15
20
25
(d) Time [mins]
30
80
90
100
90
Heat-sink Temperature 0C
100
100
110
100
90
80
70
60
50
40
0
25
10
20
15
(c) Time [mins]
30
10
15
20
25
(e) Time [mins]
30
90
80
70
60
50
40
0
Fig. 7. Thermal simulation results for the H-bridge module and heat-sink. (a) Heat-sink temperature during PWM mode, QSW mode and hysteresis controlled
mode, and (b)-(e) IGBT junction temperatures in one H-bridge module.
C. Thermal simulation:
The QSW mode loss mitigation capability is considered
for the regulation of converter temperature during a cooling
failure. To investigate this possibility, a thermal model of
the H-bridge converter is simulated with steady-state power
loss information. The H-bridge module thermal model is
12
16000
Speed [rpm]
presented elsewhere.
It can be observed from figures 6 (g) to (j) that during all
the nine operation points considered, the IGBT losses during
PWM mode operation are higher than that in QSW mode
operation. The IGBT switching and conduction losses are a
function of the commutated current magnitude and the DClink voltage. Hence, high losses can be seen during high torque
conditions where a high current is fed to the motor. Figures 6
(g) to (j) also reveal that the relative difference in overall power
losses in the upper IGBTs are lower than that of the lower
IGBTs during QSW mode operation. This is mainly due the
high duty of the lower IGBTs during one cycle, i.e., the upper
IGBT current commutation occurs only during the positive
and negative voltage pulses while the lower IGBT current
commutation occurs during the zero-voltage free-wheeling
periods in addition to the positive and negative voltage periods.
In QSW mode field-weakening ( = 0) operation, the upper
and lower IGBTs have equal duty and incur similar losses.
However, the total losses remain lower than that of PWM
mode operation. Evaluation of the total losses (as shown in
table II) reveals that a higher level of loss mitigation can be
expected during low-speed low-load conditions, e.g., 52.5%
in operation point 1. At high loads and high speeds, the loss
mitigation is in the neighbourhood of 30%.
10
12000
8
6
8000
Torque
Speed
4000
2
0
5
4
Time [s]
1907
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1908