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A Modular Simulink-Based Controlled Three-Phase Switch Mode Inverter

Conference Paper · February 2000

DOI: 10.1109/PESS.2000.866971 · Source: IEEE Xplore

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 A Modular Simulink-Based Controlled Three- Phase Switch Mode
Inverter
Anawach Sangswang George Rest C.O. Nwankpa

Centerfor ElectricPowerEngineering
Departmentof Electricaland ComputerEngineering
DrexelUniversity
Philadelphia,Pennsylvania

Abstract: Theprimary goal ofthispaper istopresent the design overall design process. This method becomes ideally suitable
and construction of a Digital Signal Processor (DSP) controlled in today’s curricular agenda where limited time is allocated
three-phase inverter based on Simulink and Real Time Workshop for laboratory sessions. Commercial training laboratory
Toolbox from MathWorks. Traditionally various switching
systems available tend to be rather inflexible and expensive
schemes, such as Pulse Width Modulation (PWM) and Square
[2]. In recent years, many universities have developed
Wave Switching, in addition to, reduction ofharmonics through
power electronic switching are studied in class, however, their laboratory setups for power electronics courses directed
tangible effects cannot be seen without simulation and/or towards the use of computer simulation or computers
laboratory experiments .The purpose of this inverter is to provide a interacting with hardware. For example, a software tool for
modular educational platform with minimal setup time to study the power electronics circuits at Hong Kong Polytechnic has
operation of DC-AC converters. Access to the inverter is provided stressed the necessity for realistic time-domain simulations
through a variety of measurement sensors for data acquisition [3]. The University of Missouri-Rolls has implemented a
purposes, which emphasizes hands-on laboratory experience. An facility for computer control of electrical drives and
actual detailed setup and experimental procedure is presented that
machines [4]. Similar facilities have been set up at Montana
outlines the platform’s ease of use and accuracy.
State University [5]-[6].

1. Introduction
The primary goal of this paper is to present the design and
Because of enormous advances in semiconductor
construction of a Simulink-based digital signal processor
technology, power electronics devices with high power
controlled three-phase inverter. The purpose of this inverter
handling capabilities are commercially available and
is to provide an educational platform for students to study the
inexpensive, Power electronics are playing an important
operation of DC-AC Converters in a laboratory environment.
role in today’s technology; they have an increasing number
The Simulink-based controlled laboratory setup allows
of applications in the industrial and domestic areas. The
students to adjust parameters and quickly iterate to achieve
major fimction of power electronics is to control the flow of
required results. The Simulink toolbox in Matlab is used to
power by shaping the supplied power from the source.
simulate switching schemes and the C code for a DSP board
Power electronics also introduces distortion of the output
is generated by Real Time Workshop. Using these
waveform and injects harmonics into the supplier system.
technologies along with a readily available DSP board from
These harmonics can be reduced by using appropriate filter
Texas Instruments Inc. (TI), a customized code is directly
circuits. In addition, the advancement of computer
generated and downloaded to the control board. The marked
simulation and microprocessor technology makes various
differences between this three-phase inverter and commercial
control schemes involving power electronics to become
inverters are:
more flexible and easier. From educational side, computer
simulation has facilitated laboratory teaching in power
● Measurement sensors: Provide access to a diversity of
engineering related fields like, power electronics. The wide
measurements to basically every part of the inverter.
variety of computer simulation programs such as PSpice,
● Data acquisition: Measurements can be taken directly
Matlab, and Simulink allow students access to circuit
horn these sensors for analytical purposes.
waveforms, dynamic and steady-state behavior descriptions
among others [1]. In conjunction with this, laboratory setup ● Experimental Model: Assorted types of switching
in power electronics can also be a valuable experience, schemes and loads and can be easily added and tested.
which highlights what students have learned in class. ● Sirnulink-based control: It employs graphical user
interface (GUI) for building and simulating models
In general, with computer simulation it is much easier to stressing quick setup times.
study the inftuence of a parameter on system behavior than
a simulation through a hardware laboratory. While in With respect to the experiment discussed in this paper, it is
industry, combination between computer simulations and desirable to show how the inverter is used for the purpose of
hardware implementation has been used to shorten the demonstrating and analyzing the inverter waveforms and

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characteristics. The problems that had to be resolved to
accomplish the goal, is discussed in the next section.
Section 3 presents the methodology to the solution for these
problems, Experimental set-up and results of Square Wave
and pulse-width modulation (PWM) switching schemes are
shown in section 4. Conclusion of this paper is in section 5.
2. Problem Formulation
The objective of the project was to design a three-phase
of the average current, rms current, peak current and peak
inverse voltage.
2.1.2 Filters
The only filter that will be used in this project is the rectifier
output filter. Since the output of the rectifier is dc, a low-pass
filter is desired. A dc filter is designed to smooth out the dc
output and filter out harmonic contents on the input of the
inverter.
L.

inverter as an educational platform to garner student I I

appreciation of inverter behaviors, applications and effects.
In order to realize the objective, it was necessary to build an I Rectifier
I XL = nwLa

, Lc.
I I 1
inverter that is able to run with different types of switching xc. — Inverter
circuit nuce
schemes and loads, A DSP board and computer interface
are required to accomplish control schemes and data T
acquisition.

Fig 2. Low-passfilter circuit

1-7
3-4$ 3-4 Drode DC Low ‘paSS DC 3-o Ftd/ AC
Load
AC Bridge Recifler Filter Bridge Irwerler 3-$ The figure above shows that the higher order harmonic
contents are attenuated by the inductor, while the capacitor
helps keeping the dc voltage constant, In addition, the
Fig.1 InverterSystemSetup
capacitor also acts as a snubber for switches in the inverter. It
is necessary to make the load impedance much greater than
As shown in figure 1, the overall system consists of a three-
the impedance of the capacitor; to allow the nth harmonic
phase input ~ower’ supply, rec&3er, filter, full bridge
current to pass through the filter capacitor.
inverter, and load. The three-phase input power supply is
fkom the utility. A diode rectifier converts an ac input to de
2.1.3 Inverter
output in an uncontrolled manner. A low-pass filter makes
The fimction of the inverter is to change a de input voltage to
the dc output to be as ripple free as possible. A three-phase
a symmetrical ac output voltage with controllable magnitude
full bridge inverter changes a dc input into a symmetrical ac
and fi-equency. The dc input of the inverter is obtained from
output. Since dc input is not controllable, the ac output of
output of the low-pass filter of the rectifier. Each switch of
the inverter is controlled by pulse-width-modulation
the inverter is operated by a small control signal. Switches in
(PWM) and fed to the load. From the inverter setup block
the same leg are not turned on at the same time, to prevent
diagrams, relevant hardware and software issues are
short circuit in a leg. Blanking time must be added to make
discussed as follows.
sure that there are no two switches in the same leg turning on
at the same time. Switches in this inverter are fully
2,1 Hardware Features
controllable power devices with fast switching speed,
There are seven main issues that are included in the
because this inverter is expected to handle various kinds of
hardware features.
switching schemes, including ones that require high
1) Obtaining dc input for the inverter by using a
switching speeds. High negative voltage blocking capability
rectifier circuit.
is also necessary for preventing the switch ffom damage. The
2) A filter circuit is used to reduce voltage ripple.
voltage and current rating of power devices in the inverter
3) Inverter
depends on the types of load and switching schemes. For
4) Measurement sensors
unidirectional switching, as in this inverter, an anti-parallel
5) Gate drive circuitry for controlling switching
connected diode is needed to provide a path for the current in
operation
the event that there is an inductive load. If an attempt is made
6) DSP controller
to open switch the energy stored in the inductor will be
transformed in order to maintain the direction of the current.
2.1.1 Rectifier Circuit
This may cause damages to the switch. Such a diode is called
The finction of a rectifier is to convert an ac signal into a
a fi-eewheeling diode.
unidirectional signal. The input is directly supplied from the
utility. The rectifier draws highly distorted current during
2.1.5 Drive circuits
turn off time in each diode and generates harmonics to the
The function of a drive circuit is to turn the switch from an
load at the same time. In order to obtain the dc input
off state to on state and vice-versa. The power rating of the
voltage, a three-phase diode bridge and a filter are used to
drive circuit may vary depending on the type of switches
achieve lower ripple content in the waveforms and higher
being used. A drive circuit also creates a blanking time for
power. The ratings of diodes are to be determined in terms
switches. Therefore, a high-speed drive circuit is desired for
such an inverter that is able to operate with various switching

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schemes including high speed switching. A drive circuit I Identify algorithm I
must electrically isolate the control signal fi-om power
switch, for safety reason and undesirable interferences.
Overcurrent protection for the power switch is also
essential, in which a communication between a drive circuit
and control board is required.

2.1.6 Measurement sensors

* + 1‘at’absimu
Voltage and current sensors will be installed at the
following points. +
● Input of the rectifier
● Output of the rectifier (DC bus)
Real Time
● Output of the inverter Workshop

I I
Download to the \
The measurements are used for analytic and protection control board
purposes. Because this laboratory setup is designed for
students, the safety requirement with regard to isolation Fig 3. A modularSimulink-basedcontrolscheme
from high voltage equipments is an obligation. All voltage
and current measurements at each part must be accessible 2.2.2 Real-Time Workshop
through measurement point terminals. Measurement sensors Real-Time Workshop is a toolbox equipped in Matlab
must have excellent accuracy and high immunity to external Simulink. It allows C code to be generated from block
interference. Wide frequency bandwidth is also necessary diagrams in Simulink. Once a system has been designed and
for the sensors to handle dc signals in the dc link to ac simulated in Simuhnk, code for digital signal processors can
signals at the output of the inverter. Hall effect devices are be generated, compiled, linked, and downloaded to the DSP
perfectly fit for this setup. board. By providing a device driver block in Simulink, the
generated executable code will be able to run on a specific
2.1,7 DSP Controller hardware [8]. With Real-Time Workshop, various switching
This laboratory setup is designed for real-time control. This schemes can be easily added and implemented with a
requires such technology as a floating-point DSP, which minimal setup time.
offers opportunities to develop computationally intensive
applications that were previously not feasible by 3. Methodology
microprocessors. For flexibility reasons, a control board
must be a self-contained system, without occupying a host 3-4 3 - # Full Bridge
PC. The board can communicate with the host PC by using Diode Bridge IGBT-based Inverler

a standard RS232 serial port. This allows any set of readily 3-4 3-4
available computers in the laboratory to interface with the 208 V60HZ D,C. A. C. Voltage

control board. A

I /\
J ~ [, ),
2.2, Software Features w
As an educational platform, it is desired that this setup must
be able to demonstrate how a variety of switching signals 1
are generated. In order to appreciate the result of the Oscilloscope
Oscilloscope J Feedback
computer simulation, it must allow for implementation of
the generated signals on the real inverter. Gale Driver
Circuit
2,2,1 Matlab Simulink
Simulirik is a software package for creating, editing and
simulating dynamical systems on Matlab fkom Mathworks, I I
o I I

I
1/0 1/0
Inc [7]. It is widely used in industry and academic Personal
DSP Controller
institutions, Simulink utilizes a graphical user interface Computer

(GUI) for building models where models are created as

block diagrams. Simulink also allows complete models to
be simulated by a variety of integration solvers. In addition,
users can Ghange parameters and immediately see what
happens for “what it” exploration. While the simulation is
running, users can see the result via display blocks, such as
scopes.
Fig.4DSP ControlledThree-PhaseInverter
The experimental setup consists of a rectifier, full bridge
inverter, gate drive circuitry, control circuit, filtering and
protection circuits. Protection circuits sense overcument ffom
the switches and feedback a signal to the controller. The
inverter was designed to provide accessibility of sensors for

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data acquisition, Measurements can be taken at various
parts of the setup. All hardware and software tasks will be
discussed separately.
3.1 Hardware Features
The entire package was designed to handle 60A load
current, which gives it a three-phase power rating 20KVA.
The electrical design considerations and processes are given
as follows.
3.1.1 Measurement sensors
In order to obtain current signals, LA 1OO-P current
transducers from LEM are used with a 100A primary
current limit and a 1:2000 conversion ratio. These Hall
effect current sensors are installed at various points in the
inverter. A 12V dc power supply is required for these
current transducers. Their outputs are accessible through
measurement points placed on the extender of encased box,
which are clearly labeled. This setup does not require
special voltage sensor for voltage measurement, but a
voltage differential or high voltage probe is used to avoid
short circuit to mutual ground of the oscilloscope, Both
input and output voltages can be subsequently obtained
directly from their terminals.
3.1.2 Rectifier Circuit
A three-phase full bridge rectifier was chosen because of its
high power capability, lower ripple content and less
distortion compared to a single-phase rectifier. From
calculation with the line-to-line input voltage of 208 Volts
and input current of 60 Amps at the ffequency of 60 Hz, a
three-phase diode bridge rectifier with peak inverse voltage
of 300 Volts and average current limit through each diode
of 65 Amps was selected.
Fig. 5 RectifierCircuitrmdmeasurementsensors
There are 3 Hall-effect current sensors placed at the input of
the rectifier to measure input current in each line. At the
output of the rectifier also has a Hall effect current sensor
installed to obtain dc current waveforms. For voltage
measurement, each input terminal of the rectifier and both
dc output terminal of the rectifier are also connected to the
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measurement point. In the rectification, the rate of change of
the voltage across the diode (dv/dt) is not harmfid to the
diode and the rectifier noise is very small compared with
switching noise created by the inverter. Because of this
snubber circuits are not used.
3.1.3 Filter
The inverter is designed to handle a range of loads, therefore
only the relationship between the inductor and capacitor can
be determined[Rashid]. For our anticipated loads this
relationship is:
LX C=10.051X10-6
Since the inductors are not commercially available in a wide
range of properties, it is a good idea to acquire or build an
inductor fwst and then size the capacitor. An inductor was
wound and tested, using a steel core and #6 wire. It has an
inductance ranging fi-om 5 .5mH to 14.3mH over a varying
load current. Due to availability, a 450V, 1700uF capacitor
was chosen therefore, the Lx c relationship ranges from
9,35x 10-cto 24.31 x10-G ,
3.1.4 Inverter
The inverter consists of 2 switches in a phase. Its input is
from the rectifier output. Each switch is controlled by a gate
drive circuit.
Gate driver circuits
v~
cd’
I 6
c 3
c >
AO BCJ co
Fig,6Inverterand measurementsensors
Insulated gate bipolar transistors (IGBTs) are chosen because
of their high speed switching frequency and low switching
power loss. In addition, they do not require much power for
the gate drive circuits. Because IGBTs have high impedance
gates, a small amount of energy is sufficient to turn the IGBT
on. A 100A 600V P-Channel half-bridge IGBT with
antiparallel diodes inside is used as 2 switches in each phase.
They can handle up to 40kHz in hard switching and 200kHz
in resonant mode. Hall effect devices are mounted with the
inverter output to measure output current.
3.1.5 Gate driver
The major functions of gate drive circuits are to amplifi the
control signals fi-om the control board and electrically
isolate control signals from high voltage side of switches.
CAD, The diode bridge and the IGBTs are mounted on heat
sinks in order to help dissipate their heat. Two small fans are
also used to draw the hot air out of the box and keep all the
components cooled. The control board is mounted flat in an
isolated metal box to reduce electromagnetic interference.

‘? ‘? c?

6 3 19
&
C2
20 v

~+
I ‘mB,dS- ~
Gate driver IC 2
tar m m
Capacitor ,s
P-J 00 0 0 a
15 14 5— :
R3 00 0 0
plTTl
z s. . . . . u
-~ ‘-’”“~ 1 L!u — U!uui
‘2 I
F-----4
1

! .!
+12V a Opto
p— coupler
Fig. 7 Gate drivercircuit
The control signal voltage is applied, at the point (a) in the
figure above, across the base-emitter of a switching
transistor, which then turns on and off creating a varying
switching signal. Output signals (c) and (d) are connected to
source (S) and gate (G) of the IGBT, respectively as shown
in figure 6. This signal is optically isolated from the control
signal to avoid unwanted interference. This gate drive
circuit also has built in overcurrent protection. It senses the
current from IGBT’s drain (D) through point (b), and
determines whether the inverter is handling too much
current or not. If overcurrent is sensed the gate driver turns
the IGBT off and then sends a control signal back to the
controller, Maintaining electrical isolation between systems,
and terminating signal interconnect shields correctly,
minimizes the possibility of electromagnetic compatibility
problems.
3.1.6 DSP board
The TMS320C31 DSP is used as a control board. This
board provides a high speed Harvard architecture designed
for fast execution of complex signal processing algorithms,
The board is supported by the following external
peripherals: three 82C54 16 bit timers, two 4:1 multiplexed
DSP 102 A/D converters, one Z80C30 serial controller
supporting 2 serial ports, two 82C55 parallel peripheral
interface supporting 48 bits of 1/0. Application of the DSP
and its accompanying peripherals can be programmed with
the help of C source code flashed onto an EEPROM chip
located on the board. Hardware configuration is further
facilitated by on board jumpers and external triggering
options [9].
3.1.7 Mechanical placement
Placement of the all circuits inside the laboratory setup is a
critical design consideration. Measurements were taken on
all of the major components and the layout was drawn up on
output voltages
II Inductor
1
b
b. Va w Vc ~
Measurement points
Fig, 8 Mechanicallayout
In addition to the metal box, the control board is mounted
away fi-om the inductor as far as possible. The gate driver
circuits are centrally located since it is wired to power
supplies, the control board and IGBTs. The three-phase input
and output terminals are compatible with the current
laboratory setup. There are measurement points at each
terminal so that the voltage can be probed. There are also dc
measurement points connected to Hall effect devices.
3.2 Software Features
Simulink-based software features are divided into 2 parts as
shown in the flow chart in Fig. 3. In addition, the
TMS320C3X code generation tools from TI and the SBC31
monitor program ffom Innovative Integration are needed to
successfully download the executable output file to the
control board.
3.2.1 Simulink
There are 2 switching schemes created in Simulink, three-
phase square wave and PWM switching schemes. A 3-phase
square wave is created by, using 3 pulse generators from the
source library in Simulink. Each pulse generator was set to a
50 percent of duty ratio and a phase of 120 degrees. The
tlequency of the square wave can be entered or changed by
users. Simulation results can be seen immediately, via the
scope or other display blocks, while the simulation is
mnning. A PWM signal is created by comparing a triangular
wave with a sinusoidal wave (sinusoidal PWM type). Since
Simulink does not provide a triangular signal generator, it
has to be created. Users can enter the modulating frequency,
tiequency modulation ratio ( m f ) and amplitude modulation
ratio (ma ). Moreover, an unlimited number of switching and
control schemes can be developed in Simuhnk.

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 m
!.,

3.2,2 Real-Time Workshop (RTW)

Real-Time Workshop (RTW) generates source code as
Cl” RMS’
defined by the Simulink model. A device driver block must 174,8mV

be included in Simulink model in order to run with a

specific model, The following steps in RTW are needed:
1) Create main program for the control board to
execute the generated code.
2) Create a system target tile. This allows the Target
Language Compiler (TLC) to transform the model
into generated code.
3) Create a template make’iile to build the real-time
executable code.
4) Create device drivers to communicate between a ~
real-time program and an 1/0 device.
A main program and the generated model code are Fig, 10 Three-phase PWM
compiled and linked together with the device drivers by a
template makefile to build an executable code. This code is It makes such computational intensive algorithms as
downloaded to the control board. advanced real-time control of the inverter feasible, by use of
a DSP board. This setup was designed based on ease of use
4. Experimental setup and results and access for measurement data. In Simulink, students are
The entire system has a rating of 20kVA. It has been used introduced to an effective design process, which allows
as a three-phase inverter experimental setup for the power immediate results to be seen. Together with Real-Time
electronics course at Drexel University. During the Workshop, the computer simulation result can be easily
experiment, students create and edit the model and then run implemented with a minimal setup time.
an offline simulation for each switching scheme, in
Simulink. The simulation result can be seen via the scope 6. Acknowledgement
block. After the required simulation result is obtained, the This research was supported by the National Science
RTW is invoked to generate an executable code. This code Foundation under Project Number ECS-9453407. The
is downloaded to the control board via the monitor program. authors would also like to thank Dr. Amadi Nwankpa,
Students can change parameters in the model such as, University of Michigan, Ann Arbor, for his valuable
frequency and modulation ratio and then, see the result. suggestions on the software design of this setup.

7. References

[1] Mohan, Ned Power Electronics: Computer Simulation, Analysis and

;’
1“’””’’’;”” / [5]
,, ,.
I I
Fig. 9 Three-phase square wave
The plots in fig. 9 and 10 show the output screen shots of
the 3-phase square wave and PWM, respectively. The
square wave frequency is set to 60 Hz and the PWM setting
is Ma = 0.6 and Mf = 15. They are obtained from
measurement point terminals through the oscilloscope.
5. Conclusion
The proposed experimental setup emphasizes a correlation
among computer simulation and real-time data acquisition.
Education Using Pspice (Release 9), Minnesota Power Electronics
Research& Education, 1999,
[2] dSpaceInc., Solutionsfor control,Nortbville,Michigan,1999.
[3] K.Chauf, “A SoftwareTool for Learning the DynamicBehaviorof
Power ElectronicsCircuits” Vol. 39, No. 1, February 1996,pp. 50-
55.
[4] J, D, Morgan and M. H, Tranter, “Industry-Unh’ershyCooperation
with Emphasis on a Machines and Drives Laboratory”, IEEE
Transactions on Education, Vol. E-29, No, 2, May 1986, pp. 115-
119,
M. H. Nehrir,A. J. Odermann,and B. D. Bowen, “A Microcomputer-
Microprocessor-Based DC Motor Speed Controller for
Undergraduate Electric Machinery Laboratory”, IEEE Transactions
on Educafion, Vol. 33, No, 4, November 1990, pp. 341-345.
[6] M. H, Nehrir, V. Gerez, and A. J. Odermann, “A Microcomputer-
Controlled Thyristor Bridge Rectifier Experiment for Undergraduate
Electric Machinery Laboratory”, IEEE Transactions on Education,
Vol. 37, No. 1, February 1994, pp. 101-106,
[7] MathWorks Inc., Simulink, Dynamic System Simulation for Matlab,
Natick, Massachusetts, 1998.
[8] MathWorks Inc., Real-Time Workshop User’s Guide, Natick,
Massachusetts, 1998,
[9] Innovative Integration, SBC31 C Language Supplement, Westlake
Village, California, 1994,
[10] S.P, Carullo, R, Bolkus, J. Hartle, J. Fey, C.O. Nwankpa, and R.
Fischl, “Interconnected Power System Laboratory: Fault Analysis
Experiment”, IEEE Transactions on Power Systems, Vol. 11, No. 4,
November 1996, pp. 1913-1919.

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