Hardware-in-the-Loop Simulation of Power Electronics and ... · Hardware-in-the-Loop Simulation of...

Hardware-in-the-Loop Simulation of Power

Electronics and Electrical Drives SystemsMatthias Deter, Group Manager Engineer E-Drive HIL

dSPACE Technology Conference 2017

dSPACE GmbH · Rathenaustr. 26 · 33102 Paderborn · Germany

Introduction

Electric power generation and transportation are contributing substantially to the emission of

greenhouse gases.

Electric power generation and heat production is responsible for 25% (2010)

Transportation is responsible for 14% (2010)

Global warming and finite fossil fuel resources increase the

need for environmentally friendly energy systems

Human extract an energy feedstock of 521EJ (2015)

35% of the energy extracted by mineral oil (2015)

Mineral oil is the only energy feedstock where the growing need

within the coming decades presumably can be not satisfied.

Renewable energy sources and e-mobility are expected

to jump-start the reduction of emissions.

dSPACE Technology Conference 2017 (Plymouth, Michigan, USA)3

Source: IPCC (2014); based on global emissions from 2010.

https://www.ipcc.ch/report/ar5/wg3/

Electromobility – Domains and Components

New electric vehicle concepts and renewable energy sources are mega trends for future mobility.

Storage systems, power-electronics and electric drives will be the key players in powertrains.

POWER GRID CHARGING VEHICLE

4 dSPACE Technology Conference 2017 (Plymouth, Michigan, USA)

New electric vehicle concepts and renewable energy sources are mega trends for future mobility.

Storage systems, power-electronics and electric drives will be the key players in powertrains.

Electromobility – Domains and Components

Electric motor

Power electronics

Battery

High voltage and high

power

POWER GRID CHARGING VEHICLE

Charging station

Protocols

Power electronics

Standardization

Vehicle to grid

Renewable energy

Conventional power plants

Network control

Intelligent storage systems

Large variety of topologies


Challenges for the Automotive Industry

By 2021, the fleet average to be achieved by all new cars in the Europe union is 95 grams of CO2

per kilometer. Fuel consumption of around 4.1 l/100 km of gasoline or 3.6 l/100 km of diesel.

By 2018, the Chinese Ministry of Industry and Information Technology (MIIT) plan to establish a

point system for automotive manufacturers with an annual production capacity of at least 50,000

passenger cars

New vehicle concepts such as battery electric vehicles (BEV)

and plug-in hybrid electric vehicles (PHEV) are required.

Electrification of vehicle drive trains and auxiliary aggregates

New components such as power electronics and high voltage

batteries

Easy-to-use and high-performance charging interfaces


Challenges for the Overall Integration

dSPACE Technology Conference 2017 (Plymouth, Michigan, USA)

AC

AC

DC

AC

DC

AC

AC

DC

DC

DC

DC

DC

DC

AC

Power-electronic is the key technology in modern supply systems and electric vehicles

DC

AC

AC

DC

7

Electric Vehicle Supply Equipment

Electric vehicle supply equipment (EVSE) are produced by a wide range

of manufacturers world wide.

AC charging requires in vehicle rectification. Due to the limited power

its mainly applied in private and public sector.

DC charging is much quicker but require communication to handle the

energy exchange between grid and vehicle for power management,

smart metering and billing.

Charging infrastructures differ significantly depending on the use case

and the national standards, such as

CHAdeMO (Japan)

GB/T 20234.2. (China)

ISO 15118 (New Global Standard)


dSPACE Solution for Testing Charging Communication (1)

Basic charging

Communication via PWM signal and digital I/O

Available in engineering projects, has been used for many years

Smart charging

CHAdeMO

Communication via CAN

Dynamic model available for simulation of handshaking mechanism


GB/T 20234.2.

Communication via CAN J1939 (Trailer CAN)




dSPACE Solution for Testing Charging Communication (2)

Smart charging

ISO15118

TCP/IP-based powerline communication using the

HomePlug GreenPhy standard

Wireless communication in case of inductive charging

Current dSPACE solution based on PLC <==> CAN converter

CAN interface used for controlling

DIN 70121 compliant

AC and DC charging supported

Dynamic parameter manipulation not possible


Available in engineering projects since 2016


On Board Energy Systems

System power and energy density makes the difference

Increasing DC voltages for high power and quick charging

Enhanced energy storages based on modern cell types and super caps

Continues miniaturization of power electronics

Increasing switching frequencies

DC/DC Converter fSW > 100kHz

Drive Inverters fSW > 20kHz

Increasing complexity of applied topologies

Parallel & Interleave structures

Multi Level architectures

Increasing complexity of controller

Raising fail safe requirements

Fail back routines e.g. „Limp Home“ mode


Battery Management Systems (BMS)

BMS Function

Battery management on cell and system level

Power flow management for hybrid battery stacks

Control of the thermal and electric behavioral

State Of Charge (SOC) management

SOC is used to monitor the health of a battery and

calculate e.g. the remaining range of an electric car.

SOC balancing for enhanced battery life time

Handle the interplay with peripheral cooling systems

Control of pre-charge relays

Isolation monitoring

dSPACE Battery Simulators provide the necessary precision,

flexibility and safety for an entire HIL laboratory test.


Vehicle Electrical Network and Power Converters

Power electronic devices

On Board Charger (PEV/PHEV)

DC/DC-Converter

Motor Inverter

Established topologies available as predefined library blocks

dSPACE ASM Electric Components (Processor Based)

dSPACE XSG Electric Components (FPGA Based)

Specific model topologies require a flexible modelling approach

DC/DC converter topologies or motor filter

circuits differ from application to application.

An automatic transfer from the circuit diagrams to real-time capable models is essential


Three-phase power converter

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Power Electronics Simulation

Scalable real-time performance due to parallelization

Multi-Core for low latency high performance parallel computation

Multi-Processor for scalable computation environment

Multi-FPGA for apportion of high dynamic tasks and I/O

Modelling

Oversampling strategy provides highest fidelity

Real-time simulation in regards to the specific eigen-value

Optimal utilization of available real-time hardware

Task separation for performance optimized application embedding

Interface functions enable easy signal linking between sub models

The Electrical Power Systems Simulation (EPSS) Package enables the real-time simulation of

SimPowerSystemsTM models on dSPACE Processor and FPGA platforms


MATLAB

Simulink

- …

- SimPowerSystems

Electrical Power Systems Simulation (EPSS) Package


FPGA

~2.5µs

IOCNET

Multi-Core/Processor

Multi-FPGA

Circuit diagram

SimPowerSystemsTM model

Processor

~25µs

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Basic Considerations for Electric Drive Simulation

Requirement Identification

Motor specific characteristics

Control specific model demands

Application specific precision demands

The Challenges

Find the right degree of precision

for your drive virtualization

Balance real-time performance,

flexibility and simulation fidelity

Optimal cost-benefit outcome

Ready to use model libraries

dSPACE ASM Electric Components (Processor Based)

dSPACE XSG Electric Components (FPGA Based)


Preconditions for Simulation on Signal Level

Internal signals of the ECU have to be accessible

Current Sensor Feedback Signals (e.g. ADC measures the Hall Transducer feedback voltage)

Power Electronic Control Signals (e.g. Gate Driver PWM signals)

Processor-based Simulation

For Drives that operate at low switching frequencies (< 25kHz, typical: 16-20kHz)

Are running on moderate speeds (< 2kHz fund. elec. frequency)

The additional delay of the average model can be neglected

FPGA-based Simulation

For Drives that operate at higher switching frequencies

Are running on high speeds

A quasi continuous current simulation is required for the control algorithms of the DUT


Simulation on Electric Power Level (Emulation)

Emulator Demands

Handling of full energy flow in & out of the device under test

Highest dynamics to assure realistic current shapes

Powerful software environment for flexible application

DUT Preconditions

Electrical interface for DC-Link coupling required

Electrical interface for position sensor simulation must be accessible

Special Demands

Proper cooling of all power components

Assuring health and safety requirements

Assuring Electro Magnetic Compliance (EMC)

Precise virtualization of E-Motor based on FPGA technology


dSPACE Approach for Simulation on Power Level

Basics

Direct DC-link coupling

FPGA based real-time simulation

Injection of realistic phase currents

fSW_ECU << fSW_ELE & LMOTOR >> LELE

Advantages

High dynamic current injection

Simulation of variable inductances

Energy recovering possible

Customer Benefit

Flexible emulator hardware

Reduced operation costs

ELE

ECU

iA

iB

iC

A

B

C

MDL

iA

*

iB*

iC*

uA uB uC

ω

T



Low-Voltage Electronic Load Modules

DS5380 Low Power E-Load

Linear controlled transistors

UDC_MAX = 30V; IMAX = 30A

Parallel connection supported

Typical Applications

AMT (automated transmission)

EKP (fuel pump)

SCR (SCR pump)

DS5381 Mid Power E-Load

Switched MOSFET stage

UDC_MAX = 60V; IMAX = 50ARMS / 100APEAK

Parallel connection supported

Supports power recovery


EPS (electric power steering)

Starter and Generator Systems

Mild HEV (48V)

High-Voltage Electronic Load Module

Key Features

Modular hardware with parallel multilevel inverter topology

Low THD due to patented switching technology

Observer based Model Predictive current Controller (MPC)

Liquid cooled hardware with integrated protection

UDC_MAX = 700V; IMAX = 75ARMS / 100APEAK

Designed for parallel operation

Supports power recovery


Automotive motor controllers

Industrial servo controllers

DC/DC, AC/AC and AC/DC converters


New

High-Voltage Electronic Load Module

Emulation Capabilities

High dynamic motor emulation with DC-Link voltages up to 700V

AC grid emulation (e.g. 400V/3~/50Hz, aerospace 115V/1~/400Hz)

DC sink/source emulation (e.g. battery, photovoltaic panel)

Enhanced Control Characteristic

Slew rates up to 5A/µs & 10V/µs*

Set-value to output latency (settling time) < 5 µs

Load disturbance reaction time < 5 µs

Precise emulation of fundamental frequencies up to several kHz (@2kHz: THD<1%)

Supports higher order harmonic current emulation of nonlinear motor characteristics

Emulation of real current slew-rates and ripples with the DUT switching frequency (typ. 20kHz)


New

*depending on DUT input capacitance

High-Voltage Electronic Load Module – Performance


Example 1: Changing Motor Inductance

DUT Control

UDC = 400V

fPWM = 10kHz

fFUNDAMENTAL = 1kHz

Emulator Output

Plant: Linear PMSM model

RWINDING = 1Ω

LWINDING #1 = 0.75mH

LWINDING #2 = 3mH

23

New

High-Voltage Electronic Load Module – Performance


Example 2: Current Amplitude Step

DUT Control

UDC = 600V

fPWM = 10kHz

fFUNDAMENTAL = 1kHz

Emulator Output

Plant: Linear PMSM model

cos φ = 1

Amplitude step from 10 to 100A

24

New

Summary

Cutting-edge simulation platforms (FPGA and Processor)

Solutions for the complete electric vehicle domain

Ready to use open models (can be modified or partly replaced by users)

Required signal conditioning

Preprogrammed off-the-shelf solutions

Convenient user programming of the FPGA

dSPACE is your one-stop supplier for

all electric motor and power

electronic simulation needs


Thank you for listening!



Important Information

© 2016, dSPACE GmbHAll rights reserved. Written permission is required for reproduction of all or parts of this publication. The source must be stated in any such reproduction.This publication and the contents hereof are subject to change without notice. Benchmark results are based on a specific application. Results are generally not transferable to other applications.Brand names or product names are trademarks or registered trademarks of their respective companies or organizations.

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