Design and Develop an IGBT Inverter

for AC Motor Drive Applications

Done By:
Ali Jumah 199900147
Mohammad Salem 199905041
Ahmad Al-Wahedi 200000137
Advisor:
Dr. Md Enamul Haque
Eng. Ahamd Abdrabou
Outline
Project title and objectives.
Introduction.
The Power Supply.
Implementation of Power
Supply.
PCB.
The Firing Circuit.
Implementation of Firing
Circuit.
dSPACE.
Opto-isolator.

Implementation of Opto-
isolator.
The IGBT module.
Implementation of IGBT
inverter.
The System Case.
The Simulation.
System Mechanism
Analyzing the results.
Conclusion.

Project Title and Objectives
Design and Development an IGBT Inverter for AC-
Motor Drive Applications.
Objectives:
Design and develop an IGBT inverter.
Improving the motor performance.
Simulating the circuit using any simulation software.
Prototyping and testing the circuit.
Participating in team work activities.
Implementing the theoretical background in real
applications.
Interacting with industry.
What is IGBT ?
The IGBT inverter (Insulated Gate Bipolar Transistor) main
component is the transistor.
It is a very fast switching inverter that is widely used in many
applications such as:
Refrigerators.
Electric vehicles.
Lifts.
Oil and petroleum industries.
UPS (Uninterruptible Power Supply).
IGBT Advantages
Low acoustic noise due to high switching frequency.
Low torque ripple.
Low losses associated with switching device.
Low cost driver circuits.
Variable speed operation over a wide speed range results in
significant energy savings.
High efficiency.
Smaller size.
Lower overall cost.
Introduction
The Schematic Diagram of an AC Motor Drive
Main Power Supply
It is a power supply that was used to feed the
IGBT module with 342Vdc.
Supplied by 2 phases line to line AC power
supply.
Rectified by a Full-Wave Rectifier.
Filtered by 4 capacitors.
Main Power Supply
Secondary Power Supply
It is a power supply that was used to feed the
Firing Circuit and the Opto-isolator circuit with
15Vdc.
Supplied by 1 phase AC power supply
(220Vac).
Transformed by step down transformer.
Rectified by a Full-Wave Rectifier.
Filtered by 2 capacitors.
Secondary Power Supply
PCB
PCB( Printed Circuit board).


Printed circuit boards, or PCBs, are used to
mechanically support and electrically connect
electronic components.

Circuit boards were created in the mid-1930s .


PCB
It consist of :

Base board.

An insulator (usually fiberglass).

Threads of conductive material serving as wires
on the base of the board .
PCB Manufacturing
Use a program to built the circuit.

Select each components place.

Print the circuit layout.

PCB Manufacturing
Paste the layout to a copper board.

Put it in closed box with a light source inside
for several minutes.

Replace the layout.
PCB Manufacturing
Put the board in solvent (Ferric Chloride) to
remove all copper except the circuit.

Drill the board.

Soldering the component to the board.
Firing Circuit

The firing circuit is a circuit that used to keep the
IGBT inverter safe from any fault. It also used to
control the input signal of the IGBT inverter so that
only 2 gates at the same time are working
Firing Circuit
dSPACE
Controlling system:
Controller board.
Software.
Connections.
Advantages:
Available.
Easy to handle based on software.
dSPACE
dSPACE
Opto-isolator
Helps cut down on ground loops.
Block voltage spikes.

6 opto-isolator chips were used to build the
opto-isolator circuit.
Opto-isolator
The IGBT Module
It consists of 6 IGBT inverters.
Each arm has two inverters.
Each arm has only one inverter working at a
time.
Its output is an AC three phase output.
The IGBT Module
The System Case
Selecting a flexible and quite hard material
(Plastic)
Cutting the plastic as the shape we want, in
out case in Cube.
Paste the edges together by using Cl-Acid
and angles.
Make a door in the front side or on the top of
the case.
Put the whole system inside the case.
The System Case
The Simulation
The Schematic diagram of the simulation
The Simulation Results
Rotor and Stator currents
Speed of the motor Torque of the motor
Simulation Results: Input AC voltage, DC voltage,
PWM signals and the Resultant Sine wave
The Spectrum analysis of the signals
using PowerGUI tool
The spectrum of the input voltage supply
of phase a and b with THD of 0.0%
The spectrum of the ripple of the DC
power supply comes out form the rectifier
The spectrum of the three level of PWM
signals
The spectrum of the resultant sine wave based
on the PWM signals with some distortion
System mechanism
1. An AC input supply of two phases is rectifier
through the power rectifier to get a DC
voltage goes to the inverter.

2. Before the DC output of the rectifier goes to
the inverter, it should first be filtered to pure
DC voltage through 4 parallel capacitors of
330F with rated voltage of 400VDC.

3. This DC voltage feeds the IGBT Module.
System mechanism
4. Then 6 PWM pulses will be generated form
the MATLAB through the DSpace device.

5. These 6 PWM pulses will go to the opto-
couplers then to the firing circuit which
controls the switching of the IGBT module
based on the PWM signal to get the desired
sine waves of phase a, b, and c at the
output of the inverter module which enters
to the motor
System mechanism
1. The secondary power supply with output voltages
of 5Vdc, 15Vdc, and -15Vdc was build to feed the
auxiliary circuits of the system such as: the firing
circuit and the opto-couplers.

2. The amplitude of the produced sine waves of
phases a, b, and c will depends on the modulation
index of the PWM signals. And their frequencies
will be equals to the frequency of the reference
signal used for modulation.
Testing Results
Theoretical result is


Experimental result =
By using a differential probe of scaling to 1/200
And oscilloscope scaling to 100

VDC
Vrms Vm
V
o
342
2 * 380 * 2 2 * * 2 * 2


Vdc 348 2 * 174
The Main Power Supply
Testing Results
The Secondary Power Supply
Testing Result
Comparison between Theoretical
and Experimental Results
Experimental Results
PWM signals out of the Opto-couplers Circuit
Testing Result
Out of three firing circuits, only channel of phase (b)
gives an acceptable output signals.
The output signal of phase b from the firing
circuit to the IGBT module (PWM-3)
The negative output signal of phase b from the
firing circuit to the IGBT module (PWM-4)
During Testing
Two of the firing circuits were burned.

By rebuilding the burned circuits and checking the
whole connections again it was found that one
channel of the IGBT Module was short circuited
which caused the burn of the two firing circuit.

The IGBT Module was changed, but still there were
no acceptable output signals.
Conclusion
Many problems were faced during implementation
and testing the system. However, these problems
build our personalities and developed our skills to
better level of experience.

Some of these problems are:
Out of stock components.
Slow computers with weak CPU processor.
Need to be careful for dealing with high power.
Stuck at the final stage of the project with unknown and
unsolved obstacle.



Conclusion
The project developed our skills in three
major subjects.

In Power Electronics field:
by designing an IGBT Inverter for AC Motor drive
application
In Control field:
Using PWM form controlling the frequency of the Motor
in Power Machinery field:
By learning the mechanism of work of the different
machinery such as generators, DC and AC induction
motors
Thank you for your listening
We are happy to answer your questions