Showing papers in "IEEE Transactions on Industry Applications in 2011"

An Industry-Based Survey of Reliability in Power Electronic Converters

Abstract: A questionnaire survey was carried out to determine the industrial requirements and expectations of reliability in power electronic converters. The survey was subjective and conducted with a number of high-profile semiconductor manufacturers, integrators, and users in the aerospace, automation, motor drive, utility power, and other industry sectors. According to the survey, power semiconductor devices ranked the most fragile components. It was concluded that main stresses were from the environment, transients, and heavy loads, which should be considered during power electronic system design and normal operation. This paper has also highlighted that there is a significant need identified by the responders for better reliability-monitoring methods and indicators.

Analysis, Design, and Implementation of Virtual Impedance for Power Electronics Interfaced Distributed Generation

Abstract: This paper presents a virtual impedance design and implementation approach for power electronics interfaced distributed generation (DG) units. To improve system stability and prevent power couplings, the virtual impedances can be placed between interfacing converter outputs and the main grid. However, optimal design of the impedance value, robust implementation of the virtual impedance, and proper utilization of the virtual impedance for DG performance enhancement are key for the virtual impedance concept. In this paper, flexible small-signal models of microgrids in different operation modes are developed first. Based on the developed microgrid models, the desired DG impedance range is determined considering the stability, transient response, and power flow performance of DG units. A robust virtual impedance implementation method is also presented, which can alleviate voltage distortion problems caused by harmonic loads compared to the effects of physical impedances. Furthermore, an adaptive impedance concept is proposed to further improve power control performances during the transient and grid faults. Simulation and experimental results are provided to validate the impedance design approach, the virtual impedance implementation method, and the proposed adaptive transient impedance control strategies.

A Survey of Condition Monitoring and Protection Methods for Medium-Voltage Induction Motors

Abstract: Medium-voltage (MV) induction motors are widely used in the industry and are essential to industrial processes. The breakdown of these MV motors not only leads to high repair expenses but also causes extraordinary financial losses due to unexpected downtime. To provide reliable condition monitoring and protection for MV motors, this paper presents a comprehensive survey of the existing condition monitoring and protection methods in the following five areas: thermal protection and temperature estimation, stator insulation monitoring and fault detection, bearing fault detection, broken rotor bar/end-ring detection, and air gap eccentricity detection. For each category, the related features of MV motors are discussed; the effectiveness of the existing methods are discussed in terms of their robustness, accuracy, and implementation complexity. Recommendations for the future research in these areas are also presented.

High-Bandwidth Sensorless Algorithm for AC Machines Based on Square-Wave-Type Voltage Injection

Abstract: This paper describes a new control algorithm which can enhance the dynamics of a sensorless control system and gives a precise sensorless control performance. Instead of the conventional sinusoidal-type voltage injection, a square-wave-type voltage injection incorporated with the associated signal processing method is proposed in this paper. As a result, the error signal can be calculated without low-pass filters and time delays, and the position estimation performance can be enhanced. Using the proposed method, the performance of the sensorless control can be enhanced; the bandwidth of the current controller was enhanced up to 250 Hz, and that of the speed controller was up to 50 Hz.

Open-Loop Control of Modular Multilevel Converters Using Estimation of Stored Energy

Abstract: The internal control of a modular multilevel converter aims to equalize and stabilize the submodule capacitor voltages independent of the loading conditions. It has been shown that a submodule selection mechanism, included in the modulator, can provide voltage sharing inside the converter arm. Several procedures for controlling the total stored energy in each converter arm exist. A new approach is described in this paper. It is based on estimation of the stored energy in the arms by combining the converter electromotive force reference, the measured alternating output current, and the known direct voltage. No feedback controllers are used. Experimental verification on a three-phase 10 kVA prototype is presented along with the description of the new procedure.

A High-Performance Single-Phase Bridgeless Interleaved PFC Converter for Plug-in Hybrid Electric Vehicle Battery Chargers

Abstract: In this paper, a new front end ac-dc bridgeless interleaved power factor correction topology is proposed for level II plug-in hybrid electric vehicle (PHEV) battery charging. The topology can achieve high efficiency, which is critical for minimizing the charger size, PHEV charging time and the amount and cost of electricity drawn from the utility. In addition, a detailed analytical model for this topology is presented, enabling the calculation of the converter power losses and efficiency. Experimental and simulation results are included for a prototype boost converter converting universal ac input voltage (85-265 V) to 400 V dc output at up to 3.4 kW load. The experimental results demonstrate a power factor greater than 0.99 from 750 W to 3.4 kW, THD less than 5% from half load to full load and a peak efficiency of 98.9% at 70 kHz switching frequency, 265 V input and 1.2 kW load.

Constant Power Control of DFIG Wind Turbines With Supercapacitor Energy Storage

Abstract: With the increasing penetration of wind power into electric power grids, energy storage devices will be required to dynamically match the intermittency of wind energy. This paper proposes a novel two-layer constant power control scheme for a wind farm equipped with doubly fed induction generator (DFIG) wind turbines. Each DFIG wind turbine is equipped with a supercapacitor energy storage system (ESS) and is controlled by the low-layer wind turbine generator (WTG) controllers and coordinated by a high-layer wind farm supervisory controller (WFSC). The WFSC generates the active power references for the low-layer WTG controllers according to the active power demand from or generation commitment to the grid operator; the low-layer WTG controllers then regulate each DFIG wind turbine to generate the desired amount of active power, where the deviations between the available wind energy input and desired active power output are compensated by the ESS. Simulation studies are carried out in PSCAD/EMTDC on a wind farm equipped with 15 DFIG wind turbines to verify the effectiveness of the proposed control scheme.

Torque Density and Efficiency Improvements of a Switched Reluctance Motor Without Rare-Earth Material for Hybrid Vehicles

Abstract: A machine design of a switched reluctance motor having competitive torque and efficiency as well as compactness with respect to an interior permanent-magnet (IPM) synchronous motor (IPMSM) in a hybrid electric vehicle (Toyota Prius 2003) has been investigated. A torque of 400 N·m is set as a target with an outer diameter of 269 mm with an axial length of 156 mm, including coil end lengths. In addition, a 50-kW field weakening capability must be competitive to the IPMSM. The highest efficiency of 95% is also aimed. Stator and rotor structures and iron material are investigated. Test machines are built. Static and light load tests are carried out.

New Bridgeless DCM Sepic and Cuk PFC Rectifiers With Low Conduction and Switching Losses

Abstract: New bridgeless single-phase ac-dc power factor correction (PFC) rectifiers based on Sepic and Cuk topologies are proposed. The absence of an input diode bridge and the presence of only two semiconductor switches in the current flowing path during each switching cycle result in less conduction losses and improved thermal management compared to the conventional Sepic and Cuk PFC converters. The proposed topologies are designed to work in discontinuous conduction mode (DCM) to achieve almost unity power factor in a simple and effective manner. The DCM operation gives additional advantages such as zero-current turn-on in the power switches, zero-current turn-off in the output diode and reduces the complexity of the control circuitry. The proposed rectifiers are theoretically investigated. Performance comparisons between the proposed and conventional Sepic PFC rectifiers are performed. Simulation and experimental results are provided for a design example of a 65-W/48-V at 100- Vrms line voltage to evaluate the performance of the proposed PFC rectifier.

A New Approach for Real-Time Multiple Open-Circuit Fault Diagnosis in Voltage-Source Inverters

Abstract: Practically all the diagnostic methods for opencircuit faults in voltage-source inverters (VSI) developed during the last decades are focused on the occurrence of single faults and do not have the capability to handle and identify multiple failures This paper presents a new method for real-time diagnostics of multiple open-circuit faults in VSI feeding ac machines In contrast with the majority of the methods found in the literature which are based on the motor phase currents average values, the average absolute values are used here as principal quantities to formulate the diagnostic variables These prove to be more robust against the issue of false alarms, carrying also information about multiple open-circuit failures Furthermore, by the combination of these variables with the machine phase currents average values, it is possible to obtain characteristic signatures, which allow for the detection and identification of single and multiple open-circuit faults

Development and Validation of Model for 95%-Efficiency 220-W Wireless Power Transfer Over a 30-cm Air Gap

Abstract: Although 60-W wireless power transfer (WPT) was demonstrated in 2007, still there is no equivalent circuit model for a submeter air-gap, hundreds of watts, and high-efficiency wireless system A design-oriented circuit model is needed for this technology to evolve This paper proposes an equivalent circuit model for the wireless system and analyzes the system based on the proposed model The proposed model and its analysis are validated by means of finite-element analysis (FEA) and experimental results Furthermore, as a viable solution for high-power (multikilowatt) applications, losses in the WPT system are investigated in the following section Because of the high operating frequency (in megahertz), skin and proximity effects were shown to be dominant A new spatial layout of a coil is proposed that significantly reduces losses caused by skin and proximity effects With the new spatial layout, ie, the surface spiral layout, the efficiency and size of WPT system can be improved significantly in high-power applications The proposed coil design is evaluated by means of FEA

Deadbeat-Direct Torque and Flux Control of Interior Permanent Magnet Synchronous Machines With Discrete Time Stator Current and Stator Flux Linkage Observer

Abstract: This paper presents a discrete time deadbeat-direct torque and flux controller (DB-DTFC) for interior permanent magnet synchronous machines (IPMSMs). A Gopinath-style discrete time flux linkage observer is developed which contains two different flux estimation methods based on current and voltage models for flux linkage. This observer produces correctly estimated flux linkages needed for accurate DB-DTFC implementation. In order to eliminate the sampling delay due to a characteristic of digital control computation, a complex vector model-based rotor reference frame current observer is also developed. Combining the discrete time current and flux linkage observers, the correct single time step (deadbeat) air-gap torque and stator flux linkage control at the (constant) switching frequency is achieved and experimentally evaluated.

Analysis of the Effects of Solution Conductivity on Electrospinning Process and Fiber Morphology

Abstract: The electrospinning process and morphology of electrospun nanofibers depend on many processing parameters. These parameters can be divided into three main groups: 1) solution properties; 2) processing conditions; and 3) ambient conditions. In this paper, we report the results of a comprehensive investigation of the effects of changing the conductivity of polyethylene oxide (PEO)/water solution on the electrospinning process and fiber morphology. The effects of the conductivity of PEO solution on the jet current and jet path are discussed. Furthermore, the fiber diameter and fiber uniformity are investigated by using scanning electron microscopy techniques.

Impact of SiC Devices on Hybrid Electric and Plug-In Hybrid Electric Vehicles

Abstract: The application of silicon carbide (SiC) devices as battery interface, motor controller, etc., in a hybrid electric vehicle (HEV) will be beneficial due to their high-temperature capability, high-power density, and high efficiency. Moreover, the light weight and small volume will affect the whole powertrain system in a HEV and, thus, the performance and cost. In this paper, the performance of HEVs is analyzed using the vehicle simulation software Powertrain System Analysis Toolkit (PSAT). Power loss models of a SiC inverter based on the test results of latest SiC devices are incorporated into PSAT powertrain models in order to study the impact of SiC devices on HEVs from a system standpoint and give a direct correlation between the inverter efficiency and weight and the vehicle's fuel economy. Two types of HEVs are considered. One is the 2004 Toyota Prius HEV, and the other is a plug-in HEV (PHEV), whose powertrain architecture is the same as that of the 2004 Toyota Prius HEV. The vehicle-level benefits from the introduction of SiC devices are demonstrated by simulations. Not only the power loss in the motor controller but also those in other components in the vehicle powertrain are reduced. As a result, the system efficiency is improved, and vehicles that incorporate SiC power electronics are predicted to consume less energy and have lower emissions and improved system compactness with a simplified thermal management system. For the PHEV, the benefits are even more distinct; in particular, the size of the battery bank can be reduced for optimum design.

A Low-Voltage Ride-Through Technique for Grid-Connected Converters of Distributed Energy Resources

Abstract: With more and more distributed energy resources (DERs) being installed, the utility requires these generation systems and their interface converters to remain grid connected during voltage sags to ensure the operating stability of the ac power system. These low-voltage ride-through (LVRT) requirements also suggest that the DER generation system injects real power and reactive power to support grid voltages. In this paper, a positive- and negative-sequence current injection method is proposed to meet the LVRT requirement. The proposed method imposes a predefined ampere constraint in its current injection to reduce the risk of overcurrent during the LVRT operation. Its operation principle and control method are explained and analyzed. Experimental results are presented to validate the effectiveness of the proposed method. Comparisons of the proposed method and other LVRT techniques are also presented.

Automatic Tracking of MTPA Trajectory in IPM Motor Drives Based on AC Current Injection

Abstract: This paper deals with a novel approach for the real-time tracking of the maximum-torque-per-ampere (MTPA) trajectory of an interior permanent-magnet (IPM) motor drive. The proposed approach is based on the injection of proper test signals and allows the MTPA trajectory to be learned and updated in the drive during steady-state conditions. The analytical development of the estimation algorithm, which is supported by a complete validation by simulation, is given in this paper. Finally, experimental results are presented based on a prototype IPM drive system.

Vector Control of Single-Phase Voltage-Source Converters Based on Fictive-Axis Emulation

Abstract: This paper presents an alternative way for the current regulation of single-phase voltage-source dc-ac converters in direct-quadrature (dq) synchronous reference frames. In a dq reference frame, ac (time varying) quantities appear as dc (time invariant) ones, allowing the controller to be designed the same as dc-dc converters, presenting infinite control gain at the steady-state operating point to achieve zero steady-state error. The common approach is to create a set of imaginary quantities orthogonal to those of the real single-phase system so as to obtain dc quantities by means of a stationary-frame to rotating-frame transformation. The orthogonal imaginary quantities in common approaches are obtained by phase shifting the real components by a quarter of the fundamental period. The introduction of such delay in the system deteriorates the dynamic response, which becomes slower and oscillatory. In the proposed approach of this paper, the orthogonal quantities are generated by an imaginary system called fictive axis, which runs concurrently with the real one. The proposed approach, which is referred to as fictive-axis emulation, effectively improves the poor dynamics of the conventional approaches while not adding excessive complexity to the controller structure.

A Comparison of Control and Modulation Schemes for Medium-Voltage Drives: Emerging Predictive Control Concepts Versus PWM-Based Schemes

Abstract: Control and modulation schemes for ac electrical drives synthesize switched three-phase voltage waveforms that control the electrical machine. Particularly in medium-voltage applications, the aim is to minimize both the switching losses in the inverter and the harmonic distortions of the stator currents and the torque. For a given modulation scheme, lower switching losses usually imply higher distortion factors and vice versa. This tradeoff can be described by a hyperbolic function, as shown in this paper for pulsewidth modulation (PWM). A number of predictive control concepts are rapidly emerging. Their characteristic hyperbolic tradeoff functions are derived, compared with each other, and benchmarked with respect to PWM and offline optimized pulse patterns (OPPs). It is shown that predictive schemes with long prediction horizons shift the performance tradeoff curve toward the origin, thus lowering both the switching losses and the harmonic distortions. As a result, at steady-state operating conditions, these predictive schemes achieve a performance similar to OPPs, while providing a superior dynamic performance during transients.

Monitoring Solder Fatigue in a Power Module Using Case-Above-Ambient Temperature Rise

Abstract: Condition monitoring is needed in power electronic systems as a cost-effective means of improving reliability. Packaging-related solder fatigue has been identified as one of the main root causes of power electronic module failures. This paper presents a method to monitor solder fatigue inside a module by identifying the increase of internal thermal resistance due to that solder fatigue, taking account of the masking effect of the variable operating point. It is assumed that the total loss in the module increases as junction temperature rises, causing an increase in case-above-ambient temperature rise, which can be measured. A dynamic thermal model of the heat sink is utilized to estimate the power loss from temperature measurements, while a device power loss model is developed to estimate the internal thermal resistance by considering the converter electrical loading. Experiment and simulation are used to demonstrate the concept and verify the method.

Online Identification of PMSM Parameters: Parameter Identifiability and Estimator Comparative Study

Abstract: In this paper, a model-reference-based online identification method is proposed to estimate permanent-magnet synchronous machine (PMSM) parameters during transients and in steady state. It is shown that all parameters are not identifiable in steady state and a selection has to be made according to the user's objectives. Then, large signal convergence of the estimated parameters is analyzed using the second method of Lyapunov and the singular perturbations theory. It is illustrated that this method may be applied with a decoupling control technique that improves convergence dynamics and overall system stability. This method is compared with an extended Kalman filter (EKF)-based online identification approach, and it is shown that, in spite of its implementation complexity with respect to the proposed method, EKF does not give better results than the proposed method. It is also shown that the use of a simple PMSM model makes estimated parameters sensitive to those supposed to be known whatever the estimator is (both the proposed method and EKF). The simulation results as well as the experimental ones, implemented on a nonsalient pole PMSM, illustrate the validity of the analytic approach and confirm the same conclusions.

Effect of Eddy-Current Loss Reduction by Magnet Segmentation in Synchronous Motors With Concentrated Windings

Abstract: In this paper, we investigate the effect of eddy-current loss reduction by the magnet segmentation in synchronous motors with concentrated windings in order to understand appropriate segmentation methods. The loss-reduction effects in each harmonic eddy current in the magnets are analyzed by both the theoretical solution and the three-dimensional finite-element analysis with Fourier transformation. The basic experiments using magnet specimens are carried out in order to support the calculated results. It is clarified that the loss-reduction effect varies with the harmonic orders and that the effect depends on the types of the rotors, for instance, interior and surface permanent-magnet rotors.

Performance Improvement of Sensorless IPMSM Drives in a Low-Speed Region Using Online Parameter Identification

Abstract: This paper describes an approach in improving the performance of the position sensorless control of an interior permanent-magnet synchronous motor using parameter identification. The model-based sensorless method requires accurate motor parameters. At low speed, the resistance variation degrades the accuracy of position estimation. The identified parameter is used in the sensorless drive system to improve the accuracy of position estimation. In this paper, the resistance is identified online, but the offline identified value of the q-axis inductance is used. The experimental results reveal the effectiveness of applying parameter identification to the sensorless drive system.

Evaluating the Practical Low-Speed Limits for Back-EMF Tracking-Based Sensorless Speed Control Using Drive Stiffness as a Key Metric

Abstract: Although it is widely known that back-electromotive-force tracking has a low-speed limit, there is very little published literature evaluating this limit. This paper shows that the low-speed limit is mainly a function of the amplitude of the inverter harmonics and that theory and simulation will provide erroneous results when inverter harmonics are not incorporated. This paper will also provide a method for evaluating this low-speed limit using drive stiffness as the metric. The experimental results show quantitatively how the drive stiffness suffers as speed decreases, which ultimately sets the practical low-speed limit.

Real-Time Selective Harmonic Minimization for Multilevel Inverters Connected to Solar Panels Using Artificial Neural Network Angle Generation

Abstract: This work approximates the selective harmonic elimination problem using artificial neural networks (ANNs) to generate the switching angles in an 11-level full-bridge cascade inverter powered by five varying dc input sources. Each of the five full bridges of the cascade inverter was connected to a separate 195-W solar panel. The angles were chosen such that the fundamental was kept constant and the low-order harmonics were minimized or eliminated. A nondeterministic method is used to solve the system for the angles and to obtain the data set for the ANN training. The method also provides a set of acceptable solutions in the space where solutions do not exist by analytical methods. The trained ANN is a suitable tool that brings a small generalization effect on the angles' precision and is able to perform in real time (50-/60-Hz time window).

A Novel E-Core Switched-Flux PM Brushless AC Machine

Abstract: A novel E-core switched-flux permanent-magnet (SFPM) brushless machine is proposed, and its electromagnetic performance is compared with that of the conventional SFPM brushless machine. The operation principle of the E-core SFPM machine will be first described, and the influence of stator and rotor pole number combinations is investigated, while the electromagnetic performance of the optimized E-core SFPM machine is predicted by finite-element analyses and validated by experiment. It is shown that the number and volume of magnets in the E-core SFPM machine is significantly reduced, only half of that in the conventional machine, while the phase back electromotive force and torque of the E-core machine are ~15% larger than those of the conventional machine.

Analysis of PWM Frequency Control to Improve the Lifetime of PWM Inverter

Abstract: Studies show that the power cycling mean time to failure (MTTF) of the insulated-gate bipolar transistor (IGBT) bond wire in an adjustable speed drive may be very short under some very common conditions. This paper proposes a switching frequency reduction method based on the junction temperature variation (ΔTj) of an inverter IGBT. It has the following advantages. First, it reduces the pulsewidth-modulation frequency under low-speed higher torque condition. Second, the inverter is started more smoothly and safely under higher command switching frequency and high-torque condition. Third, the overall MTTF of the inverter IGBT can be improved. The theory analysis, simulation, and experimental result are provided to show these advantages.

A Simple Digital DCM Control Scheme for Boost PFC Operating in Both CCM and DCM

Abstract: Digital average current controllers for boost power factor correctors (PFCs) are usually designed for continuous conduction mode (CCM). However, discontinuous conduction mode (DCM) appears in the inductor current near the zero crossings of the input current at light loads, resulting in input current distortion. It is caused by inaccurate average current values obtained in DCM and by the linear CCM PFC controller that is unable to ensure input current shaping in DCM whereby the converter exhibits nonlinear characteristic. This paper proposes a simple digital DCM control scheme that is achieved with minimal changes to the CCM average current control structure. It is mathematically and computationally simple. The result of all arithmetic operations in the proposed current control loop to obtain the desired control output can be achieved in a single clock cycle, whereas other DCM control schemes require multiple clock cycles. Good input current shaping is achieved in both CCM and DCM with the proposed CCM-DCM digital controller.

A New DC-Voltage-Balancing Circuit Including a Single Coupled Inductor for a Five-Level Diode-Clamped PWM Inverter

Abstract: This paper proposes a new dc-voltage-balancing circuit for a five-level diode-clamped inverter intended for a medium-voltage motor drive with a three-phase diode rectifier used as the front end This circuit consists of two unidirectional choppers and a single coupled inductor with two galvanically isolated windings The inductor produces no net dc magnetic flux because the individual dc magnetic fluxes generated by the two windings are canceled out with each other This makes the inductor compact by a factor of six, compared with the balancing circuit including two noncoupled inductors Moreover, introducing phase-shift control to the new balancing circuit makes it possible to adjust the midpoint voltage As a result, the dc mean voltages of all the four split dc capacitors can be balanced, independent of inverter control Experimental results obtained from a 200-V 55-kW downscaled model verify the effectiveness of the new balancing circuit

Finite-Element Analysis of Short-Circuit Electromagnetic Force in Power Transformer

Abstract: Transient electromagnetic forces in radial and axial directions induce critical mechanical stress on windings and transformers. In this paper, short-circuit electromagnetic forces that are exerted on transformer windings are investigated. A 3-D transformer model is considered to calculate the transient electromagnetic forces. The magnetic vector potential, magnetic flux density, and electromagnetic forces due to the short-circuit transient currents applied to the power transformer are analyzed by a coupled electromechanical finite-element method. The results obtained are compared with the analytical results and show good agreement. The numerical modeling technique dealt with in this paper is expected to be useful in the design of power transformers.

Unified Direct-Flux Vector Control for AC Motor Drives

Abstract: This paper introduces a unified direct-flux vector control scheme that is suitable for sinusoidal ac motor drives. The ac drives considered here are induction motor, synchronous reluctance, and synchronous permanent-magnet (PM) motor drives, including interior and surface-mounted PM types. The proposed controller operates in stator flux coordinates: The stator flux amplitude is directly controlled by the direct voltage component, while the torque is controlled by regulating the quadrature current component. The unified direct-flux control is particularly convenient when flux weakening is required since it easily guarantees maximum torque production under current and voltage limitations. The hardware for control is standard, and the control firmware is the same for all the motors under test with the only exception of the magnetic model used for flux estimation at low speed. Experimental results on four different drives are provided, showing the validity of the proposed unified control approach.