Post on 05-Apr-2018
8/2/2019 G-Clare Matrix Converter
1/35
Matrix Converter Technology and
Applications
Jon Clare, Pat Wheeler, Lee Empringham,
Liliana de Lillo
Presented by
Jon Clare
Professor of Power Electronics
Head of PEMC Research Group
jon.clare@nottingham.ac.uk (+44 (0)115 9515546)
8/2/2019 G-Clare Matrix Converter
2/35
Presentation Outline
Basic Matrix Converter Concepts
Some Practical Issues
Applications
8/2/2019 G-Clare Matrix Converter
3/35
Matrix Converter Concept
Inputfilter
AC supply
Arbitraryfrequency
Bi-directional
switchLoad
Variable frequencyVariable voltage
output
SAaA
a
B
C
b c
8/2/2019 G-Clare Matrix Converter
4/35
Some Basic Ideas
Each output phase can be connected to any input phase atany time
Switching pattern and commutation control must avoid lineto line short circuits at the input
Switching pattern and commutation control must avoid opencircuits at the output (assuming inductive load)
Switch duty cycles are modulated so that the averageoutput voltage follows the desired reference (for example a
sinusoidal reference) Average input current is sinusoidal when the input voltage,
output reference and output current are sinusoidal
8/2/2019 G-Clare Matrix Converter
5/35
Example Switching Pattern
Tseq (sequence time)
SAb (on)
SBa
(on) SCa
(on)SAa
(on)
SBb (on) SCb (on)
SAc (on) SBc (on) SCc (on)
tAa tBa tCa
tAb tBb tCb
tAc tBc tCc
Outputphase a
Output
phase b
Outputphase c
Switching frequency = 1/Tseq
Simple illustration generally more sophisticated in practice
Modulation strategy ensures that tAa - tCc are generated so that theaverage output voltage during each sequence equals the target
output voltage. The sequence time is constant.
Repeats
8/2/2019 G-Clare Matrix Converter
6/35
Illustrative Output WaveformsFin > Fout
Output line to supply neutral voltage
Time (ms)
Volts
-360
-240
-120
0
120
240
360
0 20 40
Time (ms)
Volts
Output line to line voltage
-600
-400
-200
0
200
400
600
0 20 40
50Hz in - 25Hz outswitching frequency500Hz
Lo w sw i t ch i n gf requency
sh o w n f o rv i sua l cla r i t y
8/2/2019 G-Clare Matrix Converter
7/35
Illustrative Input Waveforms
Time(ms)-1.2
-0.8
-0.4
0
0.4
0.8
1.2
0 10 20 30 40
Time(ms)
Input current (unfiltered)50Hz in - 100Hz out
-1.2
-0.8
-0.4
0
0.4
0.8
1.2
0 5 10 15 20
Input current (unfiltered)50Hz in - 25Hz out
Lo w sw i t ch i n g
f requencysh o w n f o rv i sua l cla r i t y
8/2/2019 G-Clare Matrix Converter
8/35
Example Spectra
50Hz in - 25Hz out
2kHz switching
%
%
kHz
kHz
Output voltage
Input Current
25Hz
50Hz
Sidebands aroundmultiplesof the switching
frequency
Sidebands aroundmultiples
of the switchingfrequency
0
20
40
60
80
100
0 1 2 3 4 5
0
20
40
60
80
100
0 1 2 3 4 5
Exact nature of
spectra depends
on modulationmethod
8/2/2019 G-Clare Matrix Converter
9/35
Modulation Control
A number of modulation strategies have been proposed.
All of them allow flexible control with the followingfeatures:
Continuous control of output voltage amplitude from zero up
to a maximum limit (typically 87% of input)
Continuous control of output frequency up to a maximumfeasible limit of approximately 1/10 of the switching
frequency
Control of input displacement factor: unity, leading and
lagging regardless of output power factor DC-AC and AC-DC conversion is an inherent feature by
setting either the input or output frequency to zero
8/2/2019 G-Clare Matrix Converter
10/35
Matrix Converter Features
Direct conversion - No DC link - all silicon solution
No restriction on input and output frequency withinlimits imposed by switching frequency
Inherent bi-directional power flow (can be disabled)
Sinusoidal input and output currents
Potential for high power density if switchingfrequency is high enough
Output voltage limited to 87% of input voltage (formost modulation schemes)
8/2/2019 G-Clare Matrix Converter
11/35
Switch Configurations
Back to Back Switch
Can Control Direction of Current Flow within each Switch
Useful (required) for most current commutation strategies
Common Emitter
Pair of switching devices arrangedwith emitters connected
Both devices can be gated from thesame isolated power supply
Common Collector
Pair of switching devicesarranged with collectorsconnected
8/2/2019 G-Clare Matrix Converter
12/35
A Bi-directional Switchin a Single Package
Dynex 200Amp Bi-directional ModuleDIM200MBS12-A
CommonEmitter
Nine packages for a 3-phaseto 3-phase Matrix Converter
Used for larger converters,say >200Amps
8/2/2019 G-Clare Matrix Converter
13/35
A Matrix Converter OutputLeg in a Single Package
Three packages for a 3-phaseto 3-phase Matrix Converter
Used for medium converters,say 50Amps to 600Amps
600V, 300A
(SEMELAB)
1700V, 600A
(DYNEX)
8/2/2019 G-Clare Matrix Converter
14/35
A Complete Matrix Converterin a Single Package
One package for a 3-phaseto 3-phase Matrix Converter
Used for small converters,
say
8/2/2019 G-Clare Matrix Converter
15/35
SA1
SA2
SB2
SB1
SA1
SA2
SB2
SB1
SA1
SA2
SB2
SB1
SA1
SA2
SB2
SB1
SA1
SA2
SB2
SB1
IL
Safe, Snubberless
Current CommutationExample of one method based on output current direction sensing
Current commutates from A to B with no short circuit of input or open circuit of output
8/2/2019 G-Clare Matrix Converter
16/35
Matrix Converter Protection
To matrixconverteroutputs
Input toswitchmatrix
Voltage Clamp (typical approach)
Capacitor is small
depends on nature of load For the Matrix Converter based EHA (shown later)
machine inductance = 1.15mH
maximum output current is, say, 30Amps
capacitor required is 2 F2 F
8/2/2019 G-Clare Matrix Converter
17/35
Input Filter Design
R
L
C
MatrixConverter
C chosen to limit voltage distortion at converter terminals
L chosen to limit current distortion at supply
R chosen to give adequate damping Limit overshoot on turn-on
Avoid excitation of resonance by supply or converter
Power quality specification has strong influence on filter size
8/2/2019 G-Clare Matrix Converter
18/35
Smiths Aerospace EHA
A320 Aileron EHA
Full Stroke - 44mm
Max Force - 44500N
Typical rate 35mm/s
Frequency response 2Hz
Hydraulic RamHydraulic Ram
M
MatrixConverter
Accumulator
Bypass valve
M
MatrixConverter
Pump
Bypass valve
8/2/2019 G-Clare Matrix Converter
19/35
EHA Control Loops
MatrixConverter
PMMotor Actuator
Control
Ram Position250Hz sampling rate2Hz bandwidth
Motor Current12.5kHz
sampling rate200HzBandwidth
Motor Speed
1.25kHz sampling rate20Hz bandwidth
Supply
LVDTResolverLEMs
Supply
Voltage
Ram Position Demand
Voltagetransducers Filter
8/2/2019 G-Clare Matrix Converter
20/35
Prototype EHA Converter
Control Card withFPGA and A/Ds
Gate Drives
for IGBTs
Power Circuitand sensors
Air-cooledHeatsink
Cable toPM Motor
DSP Card
8/2/2019 G-Clare Matrix Converter
21/35
Loading Rig
8/2/2019 G-Clare Matrix Converter
22/35
Speed reve rsal a t 960 0r pm
Speed Control Results
-15000
-10000
-5000
0
5000
10000
15000
0.00 0.05 0.10 0.15 0.20 0.25 0.30
Speed[rpm]
-12
-10
-8
-6
-4
-2
0
2
4
0.00 0.05 0.10 0.15 0.20 0.25 0.30
Iqref[Amps]
-15
-10
-5
0
5
10
15
0.00 0.05 0.10 0.15 0.20 0.25 0.30
Io1[Amps]
-15
-10
-5
0
5
10
15
0.00 0.05 0.10 0.15 0.20 0.25 0.30
Io2[Am
ps]
-15
-10
-5
0
5
10
15
0.00 0.05 0.10 0.15 0.20 0.25 0.30
Time [secs]
Io3[Amps]
Motor shaft speed (rpm)
q-axis current (torque) demand
Phase A current
Phase B current
Phase C current
8/2/2019 G-Clare Matrix Converter
23/35
Ram Position
(Unloaded)
Position Control Results
-20
-10
0
10
20
Position[mm]
Position Position ref.
-15000
-10000
-5000
0
5000
10000
15000
MotorSpeed[rpm]
Speed Speed ref .
-15
-10
-5
0
5
10
15
0 1 2 3 4 5 6 7 8 9 10
Time [secs]
Iq[Amps]
Iq
Motor Speed
q-axis currentdemand (torque)
8/2/2019 G-Clare Matrix Converter
24/35
Motor speed
Ride-Through Operation
Torque Producing Current, Iq
Input supply voltages (400Hz)showing a 50msec period ofsupply interruption
7000
7500
8000
8500
0 .0 0 .1 0 .2 0 .3 0 .4 0 .5 0 .6 0 .7 0 .8
MotorSpe
ed[rpm]
-5
0
5
10
15
20
25
0 .0 0 .1 0 .2 0 .3 0 .4 0 .5 0 .6 0 .7 0 .8
Iq[Amps]
-200
-150
-100
-50
0
50
100
150
200
0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8
Time [secs]
InputSupply[Volts]
8/2/2019 G-Clare Matrix Converter
25/35
EHA Converter driving IM Load
-8
-4
0
4
8
12
16
20
24
0.001 0.0015 0.002 0.0025 0.003 0.0035 0.004
-30
-25
-20
-15
-10
-5
0
5
10
A
A
M at r i x co n v er t e r d r i v i n g t w o 4 0 0 H z i n d u ct i o n m o t o r f a n s, V/ f m o d e
Outputcurrent(400Hz)
Inputcurrent(360Hz)
8/2/2019 G-Clare Matrix Converter
26/35
Prototype Size Reduction
Examples of size reduction opportunities
Bespoke FPGA/DSP board
prototype uses evaluation DSP board
Heatsink and Input filter inductors
currently rated for continuous 150% overload in 70OCambient
optimised designs for realistic duty/environment needed
Input filter capacitors
selected on delivery time for prototype
different vendors parts < 50% volume
Voltage and current transducers
Easily obtainable parts selected for prototype
Much smaller replacements are available
Bespoke silicon/silicon packaging
8/2/2019 G-Clare Matrix Converter
27/35
A 130kW Matrix Converter Vector ControlledInduction Motor Drive
PC Controller
Gate
Drivers
FiberOptic
Links
(27)
Current Direction Sensor
Desired
voltage, freq.
Serial
Link
Input
voltageD/A
PWM
FPGAMicroContr.
BidirectionalSwitches
Controller Board
(6)
(6)
(6)
Current
Direction
(3)
MotorSpeed
Encoder PC Controller
Gate
Drivers
FiberOptic
Links
(27)
Current Direction Sensor
Desired
voltage, freq.
Serial
Link
Input
voltageD/A
PWM
FPGAMicroContr.
BidirectionalSwitches
Controller Board
(6)
(6)
(6)
Current
Direction
(3)
MotorSpeed
Encoder
Work done in collaboration with the US Army
Research Labs
Design and construction of a large MatrixConverter power circuit
Results from 150kVA tests with anInduction Motor Load under v/f control
Closed loop vector control of a 150HPInduction Motor
Control Platform Infineon C167 control platform
FPGA based Current Commutationcontrol
Fibre-optic connections from control cardto to gate drives
Power Circuit Water cooled heat sinks
Laminated input power planes
8/2/2019 G-Clare Matrix Converter
28/35
A 130kW Matrix Converter Vector ControlledInduction Motor Drive
Resu l t s f r om a 600 Am p, 120 0VI GBT
Mat r i x Conver t e r
Test a t US Arm y ResearchLabora to r ies
150HP Induction Motor Load, 480Volt
supply
Output Power 129kW (156kVA)
Switching Frequency: 4kHz
(Limited by processor)
Output Currents
Output Voltages
-1750
-1500
-1250
-1000
-750
-500
-250
0
250
500
750
1000
1250
1500
1750
0 5 10 15 20 25 30 35 40 45 50
Time, milliseconds
Volts
- 5 0 0
- 4 0 0
- 3 0 0
- 2 0 0
- 1 0 0
0
1 0 0
2 0 0
3 0 0
4 0 0
5 0 0
0 5 10 1 5 2 0 25 3 0 3 5 4 0 45 5 0
Amps
8/2/2019 G-Clare Matrix Converter
29/35
A 130kW Matrix Converter Vector ControlledInduction Motor Drive
vc
va
vbv
vvd
*
vq*
Rotor Speed
Flux Current DemandCompensation terms
iq*
sl e
r
id
iq
i
i ic
ia
ib
SpeedControl
Id CurrentControl
ej
e-j
Timers
3/2
2/3
Iq CurrentControl
*
*
d
q
i
i
dt
r
ref id*
Speed Demand
inputvoltages
MatrixConverter
ControlAlgorithm
PWM
MICRO-CONTROLLERInfineon SAB80C167
motor
3-Phase Supply
InputFilter
MatrixConverter
Power Circuit
FPGA
CurrentA to D
GateDrives
Voltage
A to D
FPGA
Encode
A B
A B
Up/Down
vAB
vBC
Closed Loop Vector Scheme applied to theMatrix Converter Induction Motor Drive
0
200
400
600
800
1000
Speed[rpm]
-400
-200
0
200
400
600
800
Id,
Iq[Amps]
-600
-400
-200
0
200
400
600
0 1 2 3 4 5Time [secs]
OutputCurrents[Amps]
0
200
400
600
800
1000
Speed[rpm]
-400
-200
0
200
400
600
800
Id,
Iq[Amps]
-600
-400
-200
0
200
400
600
0 1 2 3 4 5Time [secs]
OutputCurrents[Amps]
Closed Loop Vector Control of a150HP Induction Machine
Control Platform (old!)
Closed Loop Motor Control
Fi ld P S l U i F O L
8/2/2019 G-Clare Matrix Converter
30/35
Field Power Supply Using a Four-Output LegMatrix Converter
collaborative proj ect wit h t he US Arm y Research Labs
LoadMatrix10kWGenDIESEL
ENGINE
FILTER
Engine
Speed Control
Modulation
D,Q, Control
and Engine Demand
MATRIX
CONVERTER
FILTER
Space
Vector
ModulatorInput Voltage
Output Voltage
Output Current
-250
-200
-150
-100
-50
0
50
100
150
200
250
0.000 0.001 0.002 0.003 0.004 0.005 0.006 0.007 0.008
Time [s]
OutputLinetoLineVo
ltages[V]
Field power supply
Matrix Converter Power Circuit
Variable Speed Diesel Engine Permanent Magnet Generator
Designed for 10kVA Load
50Hz, 60Hz or 400Hz Output Frequency
IGBT based Matrix Converter
25kHz Sampling Frequency DSP/FPGA Control Platform
LC Output Filter
Output Voltage Control Loop designedusing a Genetic Algorithm Optimisation
400Hz Output Voltage Waveforms
8/2/2019 G-Clare Matrix Converter
31/35
MotorMotor
Electronics
MotorMotor
Electronics
Integrated EMATechnology demonstrator
To design and build an Integrated Electro Mechanical Actuator (EMA) intendedas a technology demonstrator for a rudder actuator on a large, twin-engined,civil aircraft.
Need to continuously deploy rudder under some flight conditions drives thermal
design (stationary motor with high torque) Natural cooling considered
8/2/2019 G-Clare Matrix Converter
32/35
Integrated EMATechnology demonstrator
Gate Drive Circuits
Ballscrew housing
Input Filter Capacitors
Switching Signals
Voltage Clamp DiodesVoltage Clamp Capacitors
30kW matrixconverter integratedwith ballscrew-heatsink
d
8/2/2019 G-Clare Matrix Converter
33/35
Integrated EMATechnology demonstrator
Bespoke PM motor designed
and constructed Speed limited to 4950rpm by
use of existing actuator fordemonstrator
I d EMA
8/2/2019 G-Clare Matrix Converter
34/35
Integrated EMATechnology demonstrator
Initial dynamic tests on unloaded motor (speed reversal)
Motor current (A) vs time Motor speed vs time
8/2/2019 G-Clare Matrix Converter
35/35
Conclusions
Matrix converters are a reality
Matrix converters can be constructed at 100kW+
Matrix converters are interesting for aerospace applications
Potential for high power density
Power quality
New devices and device technology (Silicon Carbide, reverseblocking IGBTs?) will increase attractiveness
Research now needs to be applications focussed
Continue better understanding of application issues
Optimised design
Realise potential
Other direct converter structures also interesting
eg Sparse 2-stage direct converter