Matrix Converter Technology and Applications

Jon Clare, Pat Wheeler, Lee Empringham, Liliana de Lillo

Presented by

Jon Clare
Professor of Power Electronics Head of PEMC Research Group jon.clare@nottingham.ac.uk (+44 (0)115 9515546)

Presentation Outline

Basic Matrix Converter Concepts Some Practical Issues Applications

Matrix Converter Concept

Input filter AC supply Arbitrary frequency

A B C
Bidirectional switch

SAa

b
Load

c
Variable frequency Variable voltage output

Some Basic Ideas

Each output phase can be connected to any input phase at any time Switching pattern and commutation control must avoid line to line short circuits at the input Switching pattern and commutation control must avoid open circuits at the output (assuming inductive load) Switch duty cycles are modulated so that the average output voltage follows the desired reference (for example a sinusoidal reference) Average input current is sinusoidal when the input voltage, output reference and output current are sinusoidal

Example Switching Pattern

Simple illustration
SAa (on) tAa SAb (on) tAb SAc (on) tAc tBb SBc (on) tBc Tseq (sequence time) Switching frequency = 1/Tseq
Modulation strategy ensures that tAa - tCc are generated so that the average output voltage during each sequence equals the target output voltage. The sequence time is constant. generally more sophisticated in practice

SBa (on) tBa SBb (on)

SCa (on) tCa SCb (on) tCb SCc (on) tCc

Output phase a Output phase b Output phase c

Repeats

Illustrative Output Waveforms

Fin > Fout
Output line to supply neutral voltage

360 Volts 240 120 0 -120 -240 -360 0

50Hz in - 25Hz out switching frequency 500Hz

20

Time (ms)

40

Low switching frequency shown for visual clarity

600 Volts 400 200 0 -200 -400 -600 0

Output line to line voltage

20

Time (ms)

40

Illustrative Input Waveforms

1.2 0.8

Input current (unfiltered) 50Hz in - 25Hz out

0.4 0 -0.4

Low switching frequency shown for visual clarity

Input current (unfiltered) 50Hz in - 100Hz out

-0.8 -1.2 0 10 20 30 Time(ms) 40

1.2 0.8 0.4 0 -0.4 -0.8 -1.2 0 5 10 15 Time(ms) 20

Example Spectra
100 % 80

Output voltage
25Hz Sidebands around multiples of the switching frequency

50Hz in - 25Hz out 2kHz switching

60 40 20 0 0 1 2

kHz

Exact nature of spectra depends on modulation method

100 % 80 60 40 20 0 0 1 50Hz

Input Current
Sidebands around multiples of the switching frequency

kHz

Modulation Control
A number of modulation strategies have been proposed. All of them allow flexible control with the following features:
Continuous control of output voltage amplitude from zero up to a maximum limit (typically 87% of input) Continuous control of output frequency up to a maximum feasible limit of approximately 1/10 of the switching frequency Control of input displacement factor: unity, leading and lagging regardless of output power factor

DC-AC and AC-DC conversion is an inherent feature by setting either the input or output frequency to zero

Matrix Converter Features

Direct conversion - No DC link - all silicon solution No restriction on input and output frequency within limits imposed by switching frequency Inherent bi-directional power flow (can be disabled) Sinusoidal input and output currents Potential for high power density if switching frequency is high enough Output voltage limited to 87% of input voltage (for most modulation schemes)

Switch Configurations
Back to Back Switch
Can Control Direction of Current Flow within each Switch
Useful (required) for most current commutation strategies

Common Emitter
Pair of switching devices arranged with emitters connected Both devices can be gated from the same isolated power supply

Common Collector
Pair of switching devices arranged with collectors connected

A Bi-directional Switch in a Single Package

Dynex 200Amp Bi-directional Module

DIM200MBS12-A

Nine packages for a 3-phase to 3-phase Matrix Converter Used for larger converters, say >200Amps

Common Emitter

A Matrix Converter Output Leg in a Single Package

600V, 300A (SEMELAB)

1700V, 600A

Three packages for a 3-phase to 3-phase Matrix Converter Used for medium converters, say 50Amps to 600Amps

(DYNEX)

A Complete Matrix Converter in a Single Package

EUPEC 35 Amp Matrix Converter Module

One package for a 3-phase to 3-phase Matrix Converter Used for small converters, say <50Amps

7.5kW from a 230V (phase) supply

Safe, Snubberless Current Commutation

Example of one method based on output current direction sensing
SA1 SA1 SA1

SA2 SB1

IL

SA2 SB1

SA2 SB1

SB2 SA1

SB2

SB2 SA1

SA2 SB1

SA2 SB1

SB2

SB2

Current commutates from A to B with no short circuit of input or open circuit of output

Matrix Converter Protection

Voltage Clamp (typical approach)

To matrix converter outputs

Input to switch matrix

Capacitor is small
depends on nature of load

For the Matrix Converter based EHA (shown later)

machine inductance = 1.15mH maximum output current is, say, 30Amps capacitor required is 2F

Input Filter Design

R L C

Matrix Converter

C chosen to limit voltage distortion at converter terminals L chosen to limit current distortion at supply R chosen to give adequate damping
Limit overshoot on turn-on Avoid excitation of resonance by supply or converter

Power quality specification has strong influence on filter size

Smiths Aerospace EHA

M
Matrix Converter

Pump

Bypass valve

Accumulator

Hydraulic Ram

A320 Aileron EHA

Full Stroke - 44mm Typical rate 35mm/s Max Force - 44500N Frequency response 2Hz

EHA Control Loops

Voltage transducers Filter

Supply

Matrix Converter

LEMs

PM Motor

Resolver

Actuator

LVDT

Supply Voltage

Motor Current 12.5kHz sampling rate 200Hz Bandwidth

Motor Speed 1.25kHz sampling rate 20Hz bandwidth

Control
Ram Position 250Hz sampling rate 2Hz bandwidth

Ram Position Demand

Prototype EHA Converter

Control Card with FPGA and A/Ds DSP Card

Gate Drives for IGBTs

Power Circuit and sensors Air-cooled Heatsink Cable to PM Motor

Loading Rig

Speed Control Results

15000 10000

Speed reversal at 9600rpm

Motor shaft speed (rpm)
0.05 0.10 0.15 0.20 0.25 0.30

Speed [rpm]

5000 0 -5000 -10000 -15000 0.00

4 2 0 -2 -4 -6 -8 -10 -12 0.00

15 10

Iq ref[Amps]

q-axis current (torque) demand

0.05 0.10 0.15 0.20 0.25 0.30

Io 1 [Amps]

5 0 -5 -10 -15 0.00

15 10

Phase A current
0.05 0.10 0.15 0.20 0.25 0.30

Io 2 [Amps]

5 0 -5 -10 -15 0.00 15 10 0.05 0.10 0.15 0.20 0.25 0.30

Phase B current

Io 3 [Amps]

5 0 -5 -10 -15 0.00 0.05 0.10 0.15 0.20 0.25 0.30

Phase C current

Time [secs]

Position Control Results

20 Position Position ref.

Position [mm]

10 0 -10 -20

Ram Position (Unloaded)

15000
Motor Speed [rpm]

Speed

Speed ref.

10000 5000 0 -5000 -10000 -15000

15 10 5 0 -5 -10 -15 0 1 2 3 4 5 Time [secs] 6 7 8 9 10 Iq

Motor Speed

Iq [Amps]

q-axis current demand (torque)

Ride-Through Operation

8500 Motor Speed [rpm]

Motor speed
8000

7500

7000
0 . 0 0 . 1 0 . 2 0 . 3 0 . 4 0 . 5 0 . 6 0 . 7 0 . 8

25 20 Iq [Amps] 15 10 5 0
0 . 0 0 . 1 0 . 2 0 . 3 0 . 4 0 . 5 0 . 6 0 . 7 0 . 8

Torque Producing Current, Iq

-5 200 150 100 50 0 -50 -100 -150 -200 0.0 0.1 0.2 0.3 0.4 T ime [secs] 0.5 0.6 0.7 0.8

Input Supply [Volts]

Input supply voltages (400Hz) showing a 50msec period of supply interruption

EHA Converter driving IM Load

Matrix converter driving two 400Hz induction motor fans, V/f mode
24 20 16 12 8 4 A 0 -4 -8 0.001 10 5 A 0 -5 -10 -15 -20 Input

Output current (400Hz)

current -25 (360Hz)

0.0015 0.002 0.0025 0.003 0.0035 -30 0.004

Prototype Size Reduction

Examples of size reduction opportunities
Bespoke FPGA/DSP board
prototype uses evaluation DSP board

Heatsink and Input filter inductors

currently rated for continuous 150% overload in 70OC ambient optimised designs for realistic duty/environment needed

Input filter capacitors

selected on delivery time for prototype different vendors parts < 50% volume

Voltage and current transducers

Easily obtainable parts selected for prototype Much smaller replacements are available

Bespoke silicon/silicon packaging

A 130kW Matrix Converter Vector Controlled Induction Motor Drive

Control Platform
Infineon C167 control platform FPGA based Current Commutation control Fibre-optic connections from control card to to gate drives

Power Circuit
Water cooled heat sinks Laminated input power planes
Controller Board
D/A Gate Drivers Input voltage

(6)

PWM Micro Contr.

FPGA

Work done in collaboration with the US Army Research Labs Design and construction of a large Matrix Converter power circuit
Results from 150kVA tests with an Induction Motor Load under v/f control Closed loop vector control of a 150HP Induction Motor
Motor
Speed Encoder

(6)

Bidirectional Switches
Current Direction Sensor

(6)

Current Direction Fiber (3) Optic Links (27)

Desired voltage, freq.

Serial Link

PC Controller

A 130kW Matrix Converter Vector Controlled Induction Motor Drive

Output Currents
500 400 300 200 100

0 -1 0 0 -2 0 0 -3 0 0 -4 0 0 -5 0 0
0 5 1 0 1 5 2 0 2 5 3 0 3 5 4 0 4 5 5 0

Results from a 600Amp, 1200V IGBT Matrix Converter

Amps

Output Voltages
1750 1500 1250 1000 750 500 250

Test at US Army Research Laboratories

150HP Induction Motor Load, 480Volt supply Output Power 129kW (156kVA) Switching Frequency: 4kHz (Limited by processor)

Volts

0 -250 -500 -750 -1000 -1250 -1500 -1750 0 5 10 15 20 25 30 35 40 45 50

Time, milliseconds

A 130kW Matrix Converter Vector Controlled Induction Motor Drive

Speed Demand MICRO-CONTROLLER Infineon SAB80C167 Compensation terms Id Current Control input voltages 3-Phase Supply

ref

Flux Current Demand

id*

vAB vBC
Voltage A to D Input Filter

vd*

e
Speed Control

v v 2/3

va vb vc
Matrix Converter Control Algorithm

Closed Loop Vector Control of a 150HP Induction Machine

iq*

Iq Current Control

vq

Gate Drives

Matrix Converter Power Circuit

r
* iq * id

sl

dt

PWM

FPGA

id iq

e-j

i i 3/2

ia ib ic

Current A to D

1000

Rotor Speed

AB Timers
Speed [rpm]

Up/Down

FPGA

800 600 400 200 0

Closed Loop Motor Closed Loop Vector Scheme applied to the Matrix Converter Induction Motor Drive

Control

motor
Encode

800 600
Id, Iq [Amps]

400 200 0
-200 -400

600 Output Currents [Amps] 400 200 0 -200 -400 -600 0 1 2 Time [secs] 3 4 5

Control Platform (old!)

Field Power Supply Using a Four-Output Leg Matrix Converter

collaborative project with the US Army Research Labs
250

Field power supply

Output Line to Line Voltages [V]

200 150 100 50 0 -50 -100 -150 -200

Matrix Converter Power Circuit Variable Speed Diesel Engine Permanent Magnet Generator Designed for 10kVA Load 50Hz, 60Hz or 400Hz Output Frequency
DIESEL ENGINE

Gen

Matrix 10kW

Load

-250 0.000

0.001

0.002

0.003

0.004 Time [s]

0.005

0.006

0.007

0.008

400Hz Output Voltage Waveforms

FILTER
Input Voltage

FILTER

MATRIX CONVERTER

IGBT based Matrix Converter 25kHz Sampling Frequency DSP/FPGA Control Platform LC Output Filter Output Voltage Control Loop designed using a Genetic Algorithm Optimisation

Space Vector Modulator

Output Current

Engine Speed Control

Modulation D,Q, Control and Engine Demand

Output Voltage

Integrated EMA Technology demonstrator

Electronics

Motor

To design and build an Integrated Electro Mechanical Actuator (EMA) intended as a technology demonstrator for a rudder actuator on a large, twin-engined, civil aircraft.
Need to continuously deploy rudder under some flight conditions drives thermal design (stationary motor with high torque) Natural cooling considered

Integrated EMA Technology demonstrator

30kW matrix converter integrated with ballscrewheatsink
Switching Signals Gate Drive Circuits Voltage Clamp Capacitors Voltage Clamp Diodes Input Filter Capacitors

Ballscrew housing

Integrated EMA Technology demonstrator

Bespoke PM motor designed and constructed Speed limited to 4950rpm by use of existing actuator for demonstrator

Integrated EMA Technology demonstrator

Motor current (A) vs time

Motor speed vs time

Initial dynamic tests on unloaded motor (speed reversal)

Conclusions
Matrix converters are a reality Matrix converters can be constructed at 100kW+ Matrix converters are interesting for aerospace applications
Potential for high power density Power quality

New devices and device technology (Silicon Carbide, reverse blocking IGBTs?) will increase attractiveness Research now needs to be applications focussed
Continue better understanding of application issues Optimised design Realise potential

Other direct converter structures also interesting

eg Sparse 2-stage direct converter