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A
- VCE
CTIVE voltage control (AVC) has been shown to VREF/AFB 1+s/ωOP
provide an effective solution to the series connection of IGBT
LE
IGBTs. A high speed feedback loop is used to force the
collector-emitter voltage to follow a pre-defined reference. By
this means voltage sharing and dv/dt control are achieved Fig. 1. Chopper cell circuit used in simulation, showing the AVC control
without the need for bulky snubber networks [1-3]. model.
Investigations have shown that a complex series of trade- A. Device Models
offs are implicit in the design of the IGBT controller [4]. In this work the optimization algorithm runs within
Increased feedback loop gain and reduced gate resistance MATLAB, hence the Simulink models were used [7]. A
improve reference tracking but can result in oscillations and simplified block diagram of the IGBT model is shown in fig.
loss of voltage sharing. Diode power loss and over-voltage 2.
associated with IGBT turn-on can be reduced by slowing the The carrier storage region (CSR) is the heart of the non-
switching reference, at the cost of increased IGBT switching linear model. Its carrier dynamics are governed by the
losses. This last issue is particularly important for bridge leg ambipolar diffusion equation (ADE) describing the behaviour
applications where complementary IGBT voltage sharing must of the excess carrier density p(x,t):
be maintained [5].
Design of AVC by means of small signal models and ∂ 2 p ( x, t ) p ( x, t ) ∂p ( x, t )
D = + (1)
control theory is limited by the fact that linearised IGBT ∂x 2 τ ∂t
parameters are strongly operating point dependent. In this In the Fourier-based solution the excess carrier density is
paper these issues are addressed through the use of an expressed as a Fourier series in space, which transforms the
optimization approach that uses full non-linear models and ADE into a set of ODEs [6]. The boundary conditions of the
balances the conflicting system requirements. CSR – necessary to solve the ADE – are defined by other
II. CIRCUIT AND CONTROLLER MODELLING aspects of the device behaviour, for example the collector
current IC, the depletion layer width, the MOSFET current and
A chopper cell was modelled in order to evaluate the AVC
the P+ emitter recombination current. In turn, these depend on
performance, shown in fig. 1. The IGBT and diode models
the boundary values solved using the Fourier series, which are
are based on those developed using a Fourier-series-based
also used to determine the collector-emitter voltage VCE.
solution of the ambipolar diffusion equation (ADE) [6,7].
The device models used in this paper were based on a
These compact, physics-based models offer an accurate
1700V/400A NPT IGBT/diode pair, previously parameterized
solution of the device physics. They have been developed for
using methods described in [8,9].
use in both PSpice and MATLAB/Simulink.
f(u) f(u) The AVC gate drive is optimized using a formal numerical
PN jnc e- injection
pv ect optimization algorithm [7,9]. This finds the optimum design
Currents
px1
Saturation1 Ic W
Ic
W
Vbase 1
Vce by varying system parameters (e.g. component values,
pv ect
X2
px2 -K- Vd2 Wd2 Drift region resistance controller gains or reference waveform characteristics) and
Carrier storage region
Feedback
gain
Depletion
layer width evaluating the system performance. In addition to the
optimization algorithm, a suitable function must be found to
Vds
quantify the performance of the system to allow the evaluation
Id
Vgs to proceed automatically. Since the evaluation relies on
simulation of the system, this function must process the
MOSFET
f(u) s
1e-9s+1
simulation results to obtain the performance metric.
Displacement current
Miller cap
dVde/dt
Vmos
Vge
Cdg Cdg
Vge
Vge
2
A. Optimization Algorithm
dVde/dt
Optimization techniques rely on finding the minimum of an
Igc
4
Ig
Ig
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x2 Accepted increment A. Optimization of Power Dissipation and Diode Voltage
Rejected increment The profile P1 and the gate resistance RG were then optimized
Accepted pattern move
(optimization (1)) to minimise the power dissipation over the
Rejected pattern move
Base point
whole switching cycle, giving profile P2. Fig. 7 shows the
Pattern move point waveforms for profiles P1 and P2. The optimization has
effectively caused the devices to operate under hard switching.
The power dissipation values PDISS before and after
optimization are given in table II.
500
400 3 × IC
200
100
x1 V CE
Start point
0
Fig. 4. Example of the Hook & Jeeves direct search with two variables.
V REF
-100
C. Gate Drive Turn-On Optimization
-200
The gate drive optimization concentrated on optimizing the VAK
reference voltage (VREF) turn-on profile and gate resistance -300
(RG), both to reduce the total (IGBT+diode) power losses and -400
to minimise the peak snubberless diode recovery voltage -4 -3 -2 -1 0 1 2
Time (µs)
overshoot (VRM). The need to maintain low losses is important
Fig. 5. Experimental (dotted) and simulated (solid black) waveforms for turn-
since the turn-on of the IGBT may incur large losses. The on with the original profile (P1) at 290V and 113A.
requirement to reduce the diode peak recovery voltage is
necessary to reduce the tendency for the freewheel diode to 500
‘snap’ during turn-off; indeed it has been found 400 3 × IC
experimentally [5] that forcing slower VREF ramps during
VCE (V), VREF (V), VAK (V), 3 × IC (A)
-400
16 17 18 19 20 21 22
D. Implementation Time (µs)
MATLAB is an ideal environment in which to implement Fig. 6. Experimental (dotted) and simulated (solid black) waveforms for turn-
this algorithm. Objective function evaluation consists of off with the original profile (P1) at 290V and 113A.
running the simulation in Simulink (using a MATLAB
600
function call) and analysing the data within MATLAB. This
500
must occur each time the objective function is required, i.e.
VCE (V), VREF (V), VAK (V), 3 × IC (A)
400 VREF
once for every point in the search space. Errors in simulation 3 × IC
are ignored; these generally involve lack of convergence or 300
VCE
excessive simulation times (indicating that the particular 200
simulation is unlikely to produce a result). This is achieved by 100
setting their objective function evaluations to infinity. 0
IV. RESULTS -100
Figs. 5 and 6 show experimental waveforms from the AVC -200
gate drive and corresponding simulation waveforms. These -300
VAK
demonstrate the action of the controller during turn-on and -400
turn-off respectively. The feedback gain AFB was set to 1/30.
-500
The supply voltage was 290V and the load current was 113A. -1 0 1 2 3 4 5
Time (µs)
The controller uses the original profile P1 as given in table I.
Fig. 7. Optimization (1): simulation waveforms for optimized and original
profiles (P2, solid, and P1, dotted, respectively).
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TABLE I
PROFILE PARAMETERS 600
Profile tFALL tON VFALL RG 500
P1 3.5µs 1.1µs 185V 3.9Ω
200
150
600
100
500
V REF 50
VCE (V), VREF (V), V AK (V), 3 × IC (A)
-300
VAK
-400 Figs. 12 and 13 show the experimental and simulation
-500
waveforms for turn-on and turn-off respectively for profile P5.
-1 0 1 2 3 4 5 The supply voltage VDC is 283V and the load current is 100A.
Time (µs)
Similar waveforms are shown for the reduced load current of
Fig. 8. Optimization 2: simulation waveforms for the further optimized
profile P3 (including diode voltage, solid), compared with those for profile P2 50A, with a supply voltage of 290V and profile P6, in figs. 14
(dashed). and 15 for turn-on and turn-off respectively.
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500 500
VREF
400 400
3 × IC
300 300
VCE
200 200
0 0
VCE
-100 -100
-400 -400
-4 -3 -2 -1 0 1 2 18 19 20 21 22 23 24
Time (µs) Time (µs)
Fig. 12. Experimental (dotted) and simulated (solid black) waveforms for Fig. 15. Experimental (dotted) and simulated (solid black) waveforms for
turn-on with the practical profile (P5) at 283V and 100A. turn-off with the practical profile (P6) at 290V and 50A.
V. DISCUSSION
The results shown in section IV show that the simulation
500 captures the behaviour of the AVC gate drive correctly. The
turn-on waveforms in fig. 5 and the corresponding turn-off
400
3 × IC waveforms in fig. 6 exhibit the expected characteristics of the
VCE (V), VREF (V), VAK (V), 3 × IC (A)
300 AVC gate drive, including the preconditioning step and good
voltage following during switching. The two stage turn-on
200
profile results in the diode switching off significantly before
100 VREF the IGBT collector voltage has reached its on-state value.
0 A. Optimization of Power Dissipation and Diode Voltage
VCE
-100 Optimization (1) varies the reference voltage turn-on profile
to obtain the minimum overall power dissipation (diode and
-200 V AK
IGBT combined throughout one switching cycle). As
-300 expected this effectively removes active control of the gate,
-400 forcing the IGBT into hard switching. The peak diode reverse
17 18 19 20 21 22 23
recovery voltage thus becomes large in magnitude, as is
Time (µs)
Fig. 13. Experimental (dotted) and simulated (solid black) waveforms for
evident from fig. 7. This shows that the optimization correctly
turn-off with the practical profile (P5) at 283V and 100A. determines that hard switching produces the minimum losses.
However, the loss of control over the IGBT is not attractive
when switching series-connected devices, because they may
switch at different times and cause a severe voltage imbalance.
The reintroduction of a large diode peak reverse recovery
500 voltage is also unattractive.
400 V REF Optimization (2) improves on this by reducing the diode
VCE (V), VREF (V), VAK (V), 6 × IC (A)
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performance. However, it should be stressed that the choice factor has the disadvantage of increasing the tracking error
of weighting between power dissipation and diode peak between VCE and VREF during switching. In such cases, the
reverse recovery voltage depends ultimately on the optimization algorithm could be used to improve the tracking
application. Different weightings would give rise to (by reducing the mean error) and to decrease the chance of
correspondingly different optimum profiles. oscillation (by reducing the variance of the error). Using the
It should be noted from table I that the gate resistance RG mean squared error as the objective function in this case
also increases from 3.9Ω to 10.9Ω in the optimizations. The would be suitable.
principal effect of this is to delay the onset of turn-off during In practical systems, there is a string of series-connected
the pre-conditioning step, shown in figs. 6, 13 and 15. During IGBTs. Since there will always be an inherent variation in
this period the collector voltage is in the range of at least tens IGBT parameters, such as leakage current and threshold
of volts, with the full load current flowing through the device, voltage, the ability of a gate drive to maintain control of the
contributing significantly to the power dissipation. Delaying device may vary across the string. Simulation of a whole
the increase in VCE with larger values of RG therefore reduces series string and the subsequent application of robust
PDISS. An increased value of RG also improves stability. optimization methods would be a valuable asset in
These waveforms may be considered ideal. determining the reliability of the system performance.
B. Effects of Optimization at Reduced Load Current VI. CONCLUSIONS
Unfortunately the operation of the controller optimized for The numerical optimization method outlined in this paper
113A varies noticeably at the reduced load current of 50A; the has been shown to be an effective method of improving the
smaller current allows switching to occur more quickly. performance of the AVC gate drive. The gate resistance and
Therefore the diode has recovered before the IGBT collector voltage reference profile during turn-on were varied to
voltage reaches its on-state value, as is shown in fig. 9. improve the performance of the controller during IGBT turn-
Nevertheless, it is still an improvement on the original profile, on.
also shown in fig. 9.
Optimization (3), shown in fig. 10, further improves the REFERENCES
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required for low-voltage operation. Increasing the damping
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