500W Three Phase Inverter As an induction motor drive

ECE 345 Presentation April 30, 2003

Team Members: Dane Barhoover Brett Nee Paulus Yulianto

Motivation

Motors account for approximately 64% of the U.S. electrical use Approximately 1 billion motors in the U.S. use over 1700 billion kWh/yr 90% of the motors are less than 1 hp in size, and account for approximately 10% of the electricity consumed by the motor population This translates to 170 billion kWh/yr

Motivation

Each 1% Improvement in Motor and Drive Efficiency Results in : 17 billion kWh/yr of energy saved Over $1 billion energy cost saved/yr An equivalent of 6 10 million tons of displaced coal/yr 15 20 million tons less CO2 released into atmosphere/year

Specifications

Speed: 150RPM to 5000RPM Shaft Load: 50W to 500W @ 1500RPM Efficiency > 70% Three Phase Sinusoidal current to drive an induction machine

Low Cost

Implementation
DC Bus Voltage FET Hex Bridge Induction Motor

Gate Drive

Speed Command

Switching Signals

Hexbridge
+

Vdc -

A, B and C represent the three phase outputs to the motor

Switch Selection

Minimum ratings

400V, 10A device

Cost
IGBT (600 V, 15A) = $1.70 (1000 qty) MOSFET (400V, 10A) = $0.96 (1000 qty)

IGBT vs. MOSFET

IGBT : Vsat = 1.80 V Requiv = 0.07 FET : RDS(on) = 0.27

Switch Selection

MOSFET: FQP17N40

Low cost Better performance at operating current

Average Conduction Based Power Loss

20 FQP17N40 HGTG12N60B3D 15

10

0 0

10

RMS current (A) [Single Frequency Sinusoid]

Gate Drive

Interfaces the switching signals to the Hexbridge Concerns:

Dead time
To prevent shoot through Occasionally requires external circuitry to implement

Cost
Hexbridge requires six gate drive circuits Single hex-gate drive IC: IR21362 : $4.62 (1000 qty.) A single gate drive IC: IR2121, $1.75 (1000qty)

Keep the component count low

Gate Drive Selection

Single IC solution: IR21362 Provides six integrated gate drives on the IC Complementary Inputs for switching signal Takes 3.3V logic input Built in dead time to prevent shoot through (200ns) Over current protection Fault Clearing with RC time const Enable pin to shut off gate drive

Methods for Signal Generation

Space Vector PWM

Good dynamic performance Higher switching frequency ~20kHz Usually uses a control loop, increasing part count and complexity

Sine-Triangle PWM
Higher switching frequency ~20kHz Straightforward to implement Poor dynamic performance without a control loop

Methods for Signal Generation

Harmonic Elimination Low switching frequency

Depends on the number of harmonics eliminated Switching frequency = (n+2)*fundamental n = last harmonic eliminated Reduces the switching loss considerably

Difficult

to derive switching waveform Reduces switching frequency to audible range

Harmonic Elimination

Theory:

Take a square wave with 50% duty cycle and add or subtract subsequent square waves with varying duty cycles to eliminate harmonics Even harmonics are canceled due to waveform symmetry Triple (3*n) harmonics are eliminated in current due to balanced three-phase wye-connected load This results in solving the following transcendental equations:

Harmonic Elimination Equations

m 4 1 2sin(3 d 1 ) - 2sin(3 d 2 ) 2sin(3 d 3 ) - 2sin(3 d 4 ) 2sin(3 d 5 ) 0 1 2sin( d 1 ) 2sin( d 2 ) 2sin( d 3 ) 2sin( d 4 ) 2sin( d 5 ) 1 2sin(5 d 1 ) 2sin(5 d 2 ) 2sin(5 d 3 ) 2sin(5 d 4 ) 2sin(5 d 5 ) 0 1 2sin(7 d 1 ) - 2sin(7 d 2 ) 2sin(7 d 3 ) - 2sin(7 d 4 ) 2sin(7 d 5 ) 0 1 2sin(9 d 1 ) 2sin(9 d 2 ) 2sin(9 d 3 ) 2sin(9 d 4 ) 2sin(9 d 5 ) 0

3rd 9th harmonics eliminated Each additional harmonic eliminated results in another equation and has another term in each equation Solved using a Newton-Raphson approach implemented in MATLAB

Switching Waveform
Switching Function and the Fuction's FFT
1

Switching State

0.5

-0.5

-1 0 1 2 3 4 5 6

(radians)

Relative Magnitude of Frequency Content (abs(y)/yfundamental)

1

Magnitude

0.8 0.6 0.4 0.2 0 0 2 4 6 8 10 12 14 16 18 20

Harmonic Number

Switching Function Implementation

DSP: TMS320F2812 Cost $25 (1000 qty) Four independent timers Fast Clock (150 MHz) 6 PWM outputs 16 channel 12 bit A/D converter

Sine-Triangle PWM

ADC reads speed command Speed command determines the rate theta is integrated, which changes the fundamental frequency Compute for modulation depth from speed command (m) by keeping constant V/Hz ratio Evaluate K + m*sin(+) Load values into PWM compare registers Triangle generated by Timer1 counter at 20kHz

Sine-Triangle PWM Waveforms

Sine-Triangle PWM Waveforms

Harmonic Elimination

Switching angles, modulation depth and window are stored in a look-up table ADC reads speed command Speed command determines the rate of progression through the look-up table as well as the modulation depth, keeping V/Hz constant Harmonics eliminated: 3,5,7,9 31

Implementation issues

Large look-up tables ~20k Programming Flash Accessing ISR through Flash ADC noise and filtering

Arbitrary Waveform Generators

Used the Agilent 332508 Able to construct Harmonic elimination waveforms with use of a MATLAB script Allowed for testing while DSP code was in development

Harmonic Elimination Waveforms

Harmonic Elimination Waveforms

Harmonic Elimination Waveforms

350 W Load at 1500 RPM

Harmonic Elimination Waveforms

350 W Load at 1500 RPM

Efficiency Results

Results obtained at 1500RPM Shaft load varied from 50W to 500W

100

Inverter Efficiency (%)

95

90

85

80 0

100

200 300 Load Power (W)

400

500

Speed Control

A 0-3V command was used to adjust the speed with the DSP setup Speed control has been verified at no load conditions for a range 150RPM to 3800RPM Any speed greater that 3800RPM was unsafe with the test setup

Cost Summary
Component .022uF 47uF 1uF 0.1uF MUR160 LED 33kohm 500ohm 100ohm 25ohm 0.05ohm IR21362 FQP17N40 TMS320F2812 Description Cap Cap Cap Cap Diode Resistor Resistor Resistor Resistor Resistor Gate Drive MOSFET DSP Unit Cost $ 0.10 $ 0.16 $ 0.14 $ 0.10 $ 0.10 $ 0.10 $ 0.06 $ 0.06 $ 0.06 $ 0.06 $ 0.20 $ 4.33 $ 0.96 $ 25.00 Qty 1 1 2 3 3 1 1 1 1 6 1 1 6 1 Total Cost Cost $ 0.10 $ 0.16 $ 0.28 $ 0.30 $ 0.30 $ 0.10 $ 0.06 $ 0.06 $ 0.06 $ 2.57 $ 0.20 $ 4.33 $ 5.76 $ 25.00 $ 39.28

Summary

Inverter has very high efficiency (~97%) Harmonics Elimination proved very successful in removing specified harmonics Theoretically up to 5000 RPM can be achieved with our DSP code Continuing DSP code development for Harmonics Elimination for FEC

Questions?