Beruflich Dokumente
Kultur Dokumente
Annual Meeting
New Orleans, Louisiana, October 5-9, 1997
Modeling and Analysis of DC Link Bus Capacitor and Inductor Heating Effect on
AC Drives (Part I)
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Ajith. H. Wijenayake, Dennis H. Braun, Michael L. Gasperi, Tom P. Gilmore, Dan C. Pixler
* **
Rockwell Automation Rockwell Automation
Adv. Tech Labs Standard Drives
1201 S. Second Street West Enterprise Drive
Milwaukee, WI 53154 Mequon, WI 53092
(414) 382-5798 382-2508 (414) 242-8292 242-8261 242-7096
ABSTRACT- The overall performance and efficiency of to be predicted. In order to accomplish such performance
a voltage source inverter (VSI) can be improved by prediction, the design engineer should be able to accurately
selecting a combination of DC link capacitance and model and simulate the entire drive/motor system. In such
DC link inductance based upon a weighted systems, the modeling of inverter power devices and motor
can be accomplished within a reasonable accuracy.
optimization criterion. Developments of
semiconductor technology have enabled present The accurate modeling of capacitor and inductor, to reflect
semiconductor devices to operate with improved power their actual performance and power losses, is difficult due to
losses, to a great extent. However, still there is a so many dependencies. In capacitor modeling, it is very
considerable amount of power loss in the DC link important to include its parasitic elements such as equivalent
capacitor bank and DC link inductor. These loss series resistance (ESR), and actual variation of capacitance, if
components are normally ignored to a certain level in correct performance over the life span is to be investigated.
However, this is complicated by the fact that ESR, and actual
terms of design/efficiency optimization, in the design
capacitance are frequency, temperature and life time
phase of the drive. Therefore, there are additional dependent [1].
opportunities to optimize the design by selecting the
capacitor/inductance combination for minimum Presently, the DC link inductors function in the drive is to
power losses or for any other any other optimum such meet the input power factor and harmonics requirements. The
as size and weight or cost. This paper describes the value of this inductor can be selected to optimize power losses
modeling of the PWM AC drive, AC motor and (i.e. capacitor losses, inductor copper losses and core
special modeling of the DC bus capacitor and DC link losses), and hence the efficiency of the overall system. This
necessitates an accurate inductor model which will represent
inductor, using SABER simulator. The paper the copper and core losses separately, as a function of core
compares the Saber simulation results with the operating temperature flux density, current ,frequency
experimental data to verify the accuracy of the model, (frequencies), and other physical parameters of the inductor.
for given values of DC link inductance and bus
capacitance, as the first step towards modeling the Due to the complexity of the total VSI model with the nonlinear
overall system for accurate prediction of the drive effects of the power semiconductor switches, the different time
performance. constants and dependencies of the power components such as
the DC link inductance and DC bus capacitance, analysis of
the detailed behavior at the system level as well as at the
1.0 INTRODUCTION device level can be quite challenging.
Modeling and simulations of power converter circuits have Thermal management of the DC link inductance and DC bus
been an enormous aid in forecasting circuit performance and capacitance is a major concern and must be included in the
improving cycle time from circuit design to manufacturing by overall system model of the VSI.
eliminating most of the prototype iterative testing needed.
Figure 2. SABER system model for the adjustable speed drive system.
Most simulation programs, with integrated circuit emphasis, do 2.0 MODELING OF THE ADJUSTABLE SPEED DRIVE
not provide the capability to effectively analyze many of these SYSTEM
aspects of power electronics systems. SABER, [2], a
simulation package based on analog hardware descriptive The SABER system model for the drive system is a
language (AHDL) is well suited for such power electronic combination of three system modules and the load profile. The
circuit simulations, due to its device modeling features as well three system modules include a converter model with pre-
as thermal modeling capabilities, and other functional features. charge control ,an IGBT inverter model with PWM controller,
SABER simulator is capable of simulating entire power and induction motor model.
electronics system in a single simulation environment, since
its thermal analysis capabilities can be readily incorporated
into the overall analysis and design of the drive system.
Figure 1 shows the block diagram of the modeling scheme A. Modeling of DC Bus Capacitor
required to analyze and predict the overall system
performance. The DC bus capacitor bank is made up of normally, eighteen,
high ripple current rated, aluminum electrolytic capacitors. In
ESR T( )
1 ( )
T1 T0 /F The corresponding equation for the ESR variation with
= D + Ye (1)
ESR T( )
0
temperature was obtained using the test data, and is shown in
equation (2). This equation can be implemented in SABER
capacitor thermal model to reflect the actual ESR variation
with the temperature.
150
DC Bus Capacitance @20,700 uF 1 L=53.5uH- Sim
4 2 L=107uH- Sim
5
9 4 L=53.5uH- Mes
125 5 L=107uH- Mes 50
6 L=214uH- Mes 200 400 600 800 1000 1200 1400 1600 1800
7 L=53.5uH-SESR
Speed ( RPM )
8 L=107uH- SESR
4
100 6
9 L=214uH- SESR
Figure 10. Total power dissipation in the DC link components for
1
5 different combination of DC link component values.
23
75 Figure 10 clearly indicates that the total power dissipation of the
DC link components has a maximum value for certain
combination of DC link inductor and DC bus capacitor values.
This peak occurs around 40 Hz, due to pulse dropping of the
50 PWM operation. However, the capacitor loss peaks around 30
200 400 600 800 1000 1200 1400 1600 1800 Hz as shown in figure 9. As seen by the simulation data at
Speed ( RPM) higher DC link inductance values, and at higher frequencies, the
power dissipation of the inductor is the dominating part of the
Figure 9. Comparison between measured and simulated power losses total loss component. Therefore, total power loss increases as
for the DC bus capacitor bank. the operation frequency is increased. Figure 11 shows the
comparison between the measured total power loss data and that
Figure 10 shows the total power dissipation in the DC link of the simulated data.
inductor and DC link bus capacitor bank. In calculating DC link
inductor total losses the core losses were neglected due to
inaccurate measurements. Therefore, only the copper losses are 250 1
L=53.5uH-Simu
counted towards the total losses of the inductor. The modeling
225 2 L=53.5uH- Meas
of the inductor in SABER was also not possible due to 3 L=107uH-Simu
unavailability of the physical and magnetic parameters of the 200 4 L=107uH- Meas
Power Dissipation ( Watts )
75
Total power dissipation @ 20,700 uF
50
200 400 600 800 1000 1200 1400 1600 1800
Speed ( RPM )
Figure 11. Comparison between measured and simulated total power
loss of the DC link components.
140
120
7.0 ACKNOWLEDGEMENTS
100
0 8.0 REFERENCES
1 2 3 4 5 6 7 8 9
Case Number
Min L Min L Min L Nom L Nom L Nom L Max L Max L Max L [1] John D. Prymak, Spice Modeling of Capacitors, 15th
Min C Nom C Max C Min C Nom C Max C Min C Nom C Max C
Capacitor and Resistor Technology Symposium, March 1995,
Figure 12. Cost Comparison of DC Link Inductor & DC Bus pp 39-46.
Capacitor Components. [2] SABER designer and applications reference, ANALOGY,
Inc.,
Referring to Figure 12, the minimum cost function as case # 1 [3] Ned Mohan, Power Electronics: Computer Simulations,
of minimum inductance and minimum capacitance is the Analysis, and Education Using Pspice, Minnesota Power
obvious choice, as is the worst case of both maximum values. Electronics Research & Education, University of Minnesota.
Of particular interest is case #3, of minimum inductance and [4] M. Bartoli, A. Reatti, M. K. Kazimierczuk, Minimum
maximum capacitance since this is the case that produces Copper and Core Losses Power Inductor Design, IEEE-IAS
maximum efficiency. This case results in a relative cost Annual Meeting, 1996 October, pp1369-1376.
increase of 14 percent higher than nominal cost. Since no total [5] Michael L. Gasperi, Life Prediction Model for Aluminum
cost analysis of the drive product is included, further detailed Electrolytic Capacitors, IEEE-IAS Annual Meeting, 1996
work would be required to produce conclusive impact on the October, pp 1347-1351.
product considering weighted optimization of one index to [6] Michael L. Gasperi, Gollhardt, M. L., Sladky, R., A
another. model for Equivalent Series Resistance in Aluminum
Electrolytic Capacitors, CARTS 97, Components Technology
6.0 CONCLUSIONS Institute, Inc., Huntsville, Al. March, 1997, pp 71-75.