Prof. Slobodan N. Vukosavic

boban@ieee.org URL: vukosavic.etf.bg.ac.yu

DDC-LAB

DESIGN & Consulting in DSP, Power electronics, drives & controls

ddc@etf.bg.ac.yu URL: ddc.etf.bg.ac.yu

- White paper - What is DDC-Lab .................................................................................................................... 2 Products and services............................................................................................................. 2 Product areas.......................................................................................................................... 2 Why we're different ................................................................................................................. 2 Benefits to customers ............................................................................................................. 3 Our clients ............................................................................................................................... 3 About our manufacturing alliance network.............................................................................. 3 Key Phrases............................................................................................................................ 3 Specialties............................................................................................................................... 3 Software Tools at the DDC-Lab.............................................................................................. 4 Contact.................................................................................................................................... 4

- Some recent projects - (where permission to present relevant data has been granted by our clients)

1.. DSP-controller for the Electrostatic Precipitator........................................................ 5 2. Battery charger on board light electrical vehicles with PbS or NiCd........................ 7 3. Regenerative Power Supply & PFC - ARPS, Pnom=90kW.................................... 9 4. OEM – Kit for the IR: IRADK1.0 frequency inverter with IRAMS module. ............. 10 5. MFI: Miniature inverter for variable speed industrial AC drives ............................. 11 6. Washing machine: Sensorless AC motor drive for European-type washer............ 12 7. Thread-feed drive for the textile industry ................................................................ 14 8. Integral motor-drive concept for water circulation pumps. ...................................... 15 9. CIM – Compact traction drive with induction motor ................................................ 16

What is DDC-Lab

R/D Laboratory at the University of Belgrade with the goal of applying the DSP technology in power electronics and drives, with the motto to save on iron and copper by smart use of silicon and software. Design house with mature experience in developing, prototyping and manufacturing consumer, industrial, automotive and appliance products involving power electronics, electrical drives, digital controls and the DSP technology. Products and services

CONSULTING & DESIGN in Power electronics, drives & controls

DDC – Lab published a number of scientific articles in reference journals, books, invited papers and reports. Besides its academic activity, DDC-Lab provides consulting services, proposes and designs your product, provides reference designs and OEM kits, offers rapid prototyping, re-engineering, as well as pre- and post-production support. In an alliance with our manufacturing network, we produce, qualify, test and deliver small and medium series. We offer complete product development cycle from the concept, through the platform definition, risk assessment, product potential definition, identification of the system architecture, evaluation of alternative components, solutions and topologies, down to complete hardware, firmware and software design, rapid prototyping, sampling, testing, qualification and norm compliance verification, design and manufacturing documentation, production and delivery. Product areas

DSP-controlled power conversion, general purpose drives, Automotive, Military, Appliances, Electrical drives, Motion control systems, UPS, electrical traction, fork lifts, golf carts, alternative energy. Technical expertise includes long, mature experience in designing servo drives and motion control systems. Consulting in power electronics and industrial drives. Analytical studies, experimental and prototyping capability in building low-cost appliance drives designed to the norms. Complete product development cycle, potentials and risks, rapid prototyping, Compliance to applicable standards. Providing design and manufacturing documentation tested and qualified samples. Development and design of converter topologies, Hardware, software & firmware, Analog & digital, Circuit & PCB designs. Reliability, safety and compliance. Why we're different

Fresh ideas are generated from a synergy of DDC-Lab mature experience of our engineers and the energy brought in by our new University postgraduates. Experience and flexibility we gained over the years turned us into a cost-effective, one-stop service provider for your product design, prototyping, qualification and production needs. Our outsource design capacity and flexibility ensure correct product integration, technical and post-production support. Our technical expertise and references are the unique benefits, completing our service provider offer.

Benefits to customers

Quick and simple one-stop product design services, with both the cost and technical effectiveness. Along with the design, sampling and pre-production, we also perform product evaluation, schedule analysis, and ensure the compliance to the applicable standards. We deliver complete hardware, software, firmware and manufacturing documentation. Our clients are assured that no decision is made before a thorough analysis of all recent technologies, advances, solutions and options. Our clients

Sever-Subotica, Sprade-COM India, Serbain Railways, Nikola Tesla Power Plant, Zastava-automobili, Vickers-Electric, MOOG-Electric, International Rectifier, Lord-Baladyne Corp., Emerson Electric, Msemicon-IRL, GND-UPS Taiwan, Semicron, ELGE-Mi, Polimotor-GE, Iskra-avtoelektrika, Atech-SI, About our manufacturing alliance network

DDC Lab is founded 1998. in Belgrade, and by now it developed into the software and hardware design house, based on the knowledge and experience of its founder, Prof. Slobodan N. Vukosavic, numerous associates and postgraduate students. DDC-Lab offered the first job opportunity to the best graduate students, got involved in top R/D projects and mastered the recent DSP, power electronics and drives technologies. In cases when our clients desire us not only to conceive the product, design, document and provide samples; but also to provide the series production and supply quantities larger than 10-100, we rely on the local manufacturing alliance network. Our network includes the companies Tagor-Electronics, DKTS, Indel and Iritel, with more than 500 employees and with the quality process in place. Key Phrases

Industrial, automotive and appliance design, prototyping and consulting services. One-stop product development services. Using silicon & SW to save on iron & copper

Specialties

Industrial and servo drives, Control strategies, PWM application issues, Multilevel and multiphase drives, Magnetics and SMPS, EMI/EMC assessment, Embedded uC/DSP Safety and MTBF, Harmonics, power quality, Utility interface issues.

Software Tools at the DDC-Lab

uC and DSP development tools, most analog/digital simulation tools, schematics and PCB CAD tools, Math tools, VHDL, compilers and code generators, documentation tools.

Contact

Prof. Slobodan N. Vukosavic boban@ieee.org (enlisted at the IEEE list of consultants) .

1.. DSP-controller for the Electrostatic Precipitator

Customer: Nikola Tesla Power Plant, Serbia

Product description: DSP-based controller for the electrostatic precipitator cleaning the output gasses and reducing emission in thermal power plant. The DSP technology helps detect the back-corona effect, identifies accumulation of the dust layers on the positive filter plates/electrodes, controls the corona and regulates the voltages and currents so as to obtain the optimal extraction of fine particles. DDC-Lab involvement: Consultancy in concept, design and software of the DSP-based controller.

The new system is based on Digital Voltage Controller ETF-2005 with twin DSP core technology. This device has fully autonomy and flexibility, but his main feature are built in adaptive algorithm of control the electrostatic precipitators. All in purpose of achieving the maximum collection efficiency for both large and small electrostatic precipitators.

ETF-2005, twin DSP core digital voltage controller

Digital Voltage Controller ETF-2005, comprises a number of operating modes. With adaptive intermittent control, significant increase in the collection and energy efficiency is offered. When handling high resistivity dust produced by combustion of low sulphur coal, this agorithm meets the highest emission standards. Intermittent control represents precipitation with modulated power, where the thyristor firing is held off for specific period of time, based on feedback from opacity meter, and hence suppress a certain number of

half cycles of the primary current within each intermittence period. As a result, savings in electrical power and improvement in the collection efficiency of precipitations are achieved. This algorithm cuts down the back corona phenomenon, and re-entry of collected particles.

Very fast DSP cores provide real time parameter estimation of the DC-current spectrum, which allows back corona detection, the estimation of the dust layer thickness, early corona detection and prevention of arcing. Hence, de-ionization intervals are rarely used, and the precipitation efficiency increases. DC-current contens-namely, the corona parameters. This eliminates the need for the operator to adjust the references manually in cases when the coal/fuel parameters change.

2. Battery charger on board light electrical vehicles with PbS or NiCd

Customer: Zastava Automobili, Kragujevac

Product description:

FAST_CHARGE is a family of battery charges dedicated to fast-charging of the traction PbS and NiCd batteries in small (P

i) pulsed charging controlled by the uP, increasing the average charging current without the plates deterioration and with the unity power factor towards the utility network.

ii) digital charge process control, with the advanced battery monitoring

iii) flexibility of the microprocessor control permitting an easy customization of the unit to various battery technologies, voltages and [Ah] capacities.

DDC-Lab involvement:

Concept, design and manufacturing of the complete product.

3. Regenerative Power Supply & PFC - ARPS/ADP2000

Product description: ARPS/ADP2000 is a compact size, DSP controlled DC/AC power converter with CAN-communication, designed to receive the power from a 500V DC-bus and convert this power back to the 3-phase mains. Having a rated power of 90 kW at 3x460V, regenerative power supply ARPS is designed to be attached to the common DC-bus of a multiaxis/multimotor drive systems encountered in robotics & general automation, and to recuperate back to the mains the power generated in the braking phases of the robot/machine. The ARPS regenerating power Typical application: Plastics-injection molding machines, where the stamps and moulds weighing over a ton have to be moved swiftly, and where large amounts of braking power is generated; processes where carbon powder and textile dust prevent the use of braking resistors due to the risk of fire.

DDC-Lab involvement: Concept, hardware design, safety and EMC norms, DSP-control software design and communication software design, pre-series production and customer support.

4. OEM – Kit for the IR: IRADK1.0 frequency inverter with IRAMS module. Customer: International Rectifier, El Segundo,

Product description: IRADK1.0 is a RISC-controlled miniature frequency inverter designed to demonstrate the features of IRAMS family of intelligent power modules, promoted by IR. The hardware and software features of the IRADK are compatible with the needs and norms of the appliance market. PC-based GUI is designed to bring the IRAMS features to the potential IR-customer closer look. DDC-Lab involvement: Concept, design of al the aspects of the product (hardware, software, mechanics, marketing issues).

5. MFI: Miniature inverter for variable speed industrial AC drives

Customer: GND-UPS Taiwan.

Product description: Miniature, DIN-rail format industrial drive for AC motors and brushless DC motors with the rated power up to 500W is designed, documented, produced and shipped to the client along with the documentation related to the production technology.

DDC-Lab involvement: Power section design, analog and digital controls, control and communication embedded software design and documentation. Production of the first prototype, production of production technology documentation.

6. Washing machine: Sensorless AC motor drive for European-type washer

Customers:

designed for: Sever-Corporation (recently acquired by ATB)

Product description: Electronic controller for the 3-phase induction motor with no sensors is designed for the European-type washer, having the drum speeds up to 1500 RPM. Controller is based on a low-cost RISC microprocessor, passive utility interface, and includes the communication support to the machine controller, as well as the motor control features such as the shaft speed estimation, the torque / unbalance detection, wash, distribution and spin modes and active braking. It is designed to comply to the applicable safety and EMC norms, having the overall cost as the primary goal. Motor is designed for 1.5 Nm torque at the low-speed mode, while reaching 20.000 RPM in the field weakening. Extremely large tope speed – to – rated speed ratio and a wide field weakening range called for particular care in designing the motor magnetic circuit, the form of the rotor slots and the winding scheme.

DDC-Lab involvement: Electronics: Complete hardware and software design, manufacturing of prototypes. Power section concept & design, designing the power and control hardware, design of the RISC processor control & communication software, norms issues. Motor: Consultancy and support in the motor design.

7. Thread-feed drive for the textile industry

Customers: Designed for: Sprade Electro Controls

Product description: 3-phase, 200W induction motor feeds the thread, while the dancing-arm with the proximity sensor determines the tension. The process controller is adjusting the motor speed and torque so as to achieve the same tension of the thread at various speeds of the feeder. The unit operates on 300V DC, where the DC voltage comes from the rectifier common to 500-1000 drives. Wireless communication provides low-speed serial-link connection to the host, made in such a way that the failure of any out of 500-1000 modules does not impair the communication of functional modules and the host.

DDC-Lab involvement: Hardware and software design, power section concept & design, motor control software, process controller.

8. Integral motor-drive concept for water circulation pumps.

Customers:

Electronics designed for: Sever-Subotica

(Recently acquired by ATB, Austria)

Product description:

Miniaturized, motor-integrated, RISC-processor controlled IGBT-based single phase 220V AC supplied drive for 3-phase 200/370W induction motors driving water circulation pumps, servo valves and HVAC loads.

WPD family of miniaturized inverters is dedicated to low power (200/370W) 3-phase induction motors and designed to be integrated within the motor/pump body or the connection box. The WPD family makes use of the latest RISC processor technology; recent high frequency IGBT developments, a proprietary power converter topology and control algorithm focused on the passive components minimization. In such a way, a complete frequency inverter with a minimum of necessary command and communication channels is designed in a very small size The WPD family of drives is mounted on standard 200W and 370W induction motors; under the on the aluminum cover of the connection box. DDC-Lab involvement: Complete hardware and software design, manufacturing of prototypes. Power section concept & design, designing the power and control hardware, design of the RISC processor control & communication software, norms issues.

9. CIM – Compact traction drive with induction motor

DSP-controlled MOSFET-based 42V battery supplied 2.2 kW induction motor traction drive for golf-car and manipulator applications

CIM_TD is the drive dedicated to low voltage, battery supplied traction drives using the squirrel cage induction motor for the electric propulsion. The inverter is based of Semicron MOSFET transistors, while the control executes on TMS320F243 digital signal processor. The options include

o sensorless operation, wherein the tractive force is controlled down to the standstill without the shaft sensors attached to the motor; and also

o the sensored operation, wherein the shaft sensors such as the optical encoders or electromagnetic resolvers give the possibility to keep the vehicle steady (in position) when stopped at a steep slope, or to perform various specific positionning of the vehicle, frequency required in the case of the warehouse manipulators.

The CIM_TD is mounted on the aluminum heatsink and protected by the aluminum metal IP54 case. The unit has a unique power connector (for battery and the motor connections) and a dedicated signal connector (for commands and feedback signals). The drive, its control board and the Semicron MOSFET power switches are shown in Figs.

TECHNICAL CHARACTERISTICS:

• Input voltage (battery) from 32V to 60V • Output voltage 3 x (0 - 28.3V) 0-250 Hz • Maximum RMS line-to-line output voltage Ul = 28.3V with 42V DC battery • Rated continuous duty output RMS current Is = 90A • Peak stator current Imax = 165 A • Rated continuous duty motor power Pnom = 2.2 kW • Rated torque with 4-pole induction motor Tnom = 14 Nm • Operating temperature from - 25° C do +60° C • Isolation level between all the nodes 500V 50Hz, 60 sec. test

PROTECTIONS:

• Battery overvoltage and undervolage • Short circuit between the motor phases • Ground fault (phase wire to ground) • Excessive slip frequency • Overspeed (speed > MAX limit) • I2T protection based on the motor thermal model • I2T protection based on the heatsink thermal model • Protection against interruption or short circuit between the command wires. • Overtemperature (PTC)