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Transcript of Roy Davis Ballard
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Ballard Pow er Systems
Using Simplorer and Maxwell Tools to ValidateElectric Drives for EV Applications, and Interactions
w ith Rapid Prototyping Tools
Roy I. Davis
Ballard Power Systems
Dearborn, Michigan
Automotive Electromechanical Simulation Workshop
9 October 2003
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Electric Drives for EV Applications - Outline
n Brief Overview of Ballard
n Electric Drives Design Process
n How Ansoft Tools Fit In at Ballard
n PM Motor Design Evaluation
n Control Design Motor Designn Inverter Design Custom Power Module Design
n Rapid Prototyping Control Design
n Testing Motor Design Evaluation
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Electric Drives Design Process
Inverter
Controller
Motor TransmissionDC Supply LoadVDC V AC MM M T
IDC IAC NM NT
Customer Specification
Motor Requirements
Motor Mechanical Design
Motor Thermal Design
Inverter Requirements
Motor Electromagnetic Design
Cost EvaluationVolume EstimateMass Estimate
TransmissionAssumptions
Transmission Requirements
Custom Power Module DesignInverter Design
Performance Evaluation
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Inverter
Controller
Motor TransmissionDC Supply LoadVDC V AC MM M T
IDC IAC NM NT
Customer Specification
Motor Requirements
Motor Mechanical Design
Motor Thermal Design
Inverter Requirements
Motor Electromagnetic Design
Cost EvaluationVolume EstimateMass Estimate
TransmissionAssumptions
Transmission Requirements
Custom Power Module DesignInverter Design
Performance Evaluation
How Ansoft Tools Fit in at Ballard
Simp lo re r
RMxpr t
M ax w e ll 2 D
M ax w e l l The r m a l
M ax w e ll 3 D
S imp lo re r
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PM Motor Design Evaluation
n Maxwell 2D used to perform analysis
Calculation of Average Torque and Ripple Torque
Average value and peak-to-peak magnitude match well between test andFEA calculations.
70
75
80
85
90
95
-0.10 -0.08 -0.06 -0.04 -0.02 0.00 0.02 0.04 0.06 0.08
Time, seconds
Torque,
Nm
Maxwell 2D Torque vs. Time
Time, seconds
Torq
ue,
Nm
Test Data (2.8 revolutions)FEA Results (3.7 revs)
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PM Motor Design Evaluation
n Maxwell 2D used to perform analysis
Calculation of Back EMF
Harmonic content and magnitude matches well with experiments.
Test Data
-40
-30
-20
-10
0
10
20
30
40
-0.010 -0.008 -0.006 -0.004 -0.002 0.000 0.002 0.004 0.006 0.008
Time (s)
Back-E
MF(V)
FEA Results
Equal time and voltage scales
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PM Motor Design Evaluation
n RMxprt used to enter motor design information
n Maxwell 2D used to perform analysis
Calculation of Ld and Lq (Energy or Vector Potential Method)
Flux Linkage Method:Ld versus Id
0.0E+00
5.0E-05
1.0E-04
1.5E-04
2.0E-04
2.5E-04
0 100 200 300 400 500 600
Id(A)
Ld(H)
Ld (25 Turns) FEA Ld Test
Flux Method: Lq versus Iq
0.00E+00
5.00E-05
1.00E-04
1.50E-04
2.00E-04
2.50E-04
3.00E-04
3.50E-04
4.00E-04
4.50E-04
0 100 200 300 400 500 600 700
Iq (A )
Lq(H)
Lq (25 Turns) FEA Lq,Test
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Control Design Motor Design - General
n Motor equivalent circuit parameters with saturation
Needed for control development
Use Maxwell 2D to update estimates made earlier in design process
Used to populate Simplorer model of PM motor
n Ansoft tools are used to explore and understand:
PTPA (selection of id/iq trajectories) Maxwell & Simplorer Field weakening control Maxwell & Simplorer
Interactions of control with dc bus variations due to load pointchanges (dynamic) - Simplorer
Interactions of sensors and interface limitations on controlperformance Simplorer
Etcetera
n Matlab/Simulink used as primary control development tool withautocode function for dSpace rapid prototyping hardware.
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Control Design Motor Design - Simplorer
GND
MS3 ~BA
C
Viscous_Load
+
Omega_GND
+
Omega_Motor
Ballard_IPM
EQUBL
EQUBL
EQUBL
+
V
+
V
+
V
vdr
vqr
Rotor_Speed_MechVq_feedfwd
Vd_feedfwd
Vq_feedback
Vd_feedback
Q_reference
Q_feedback
D_reference
D_feedback
A_voltage_reference
B_voltage_reference
C_voltage_reference
Theta_Rotor_Mech
D_Q_Controller_Rotor_Frame
GAIN
Norm_to_DC_Bus_A
GAIN
Norm_to_DC_Bus_B
GAIN
Norm_to_DC_Bus_C
OMEGA
SINE
COSINE GAIN
NEG
P_over_2
IQ_Rotor
ID_Rotor
CONST
IQ_R_Ref
CONST
ID_R_Ref
+
V
EQUBL
Reciprocate
Lin_IPM_25kW.IQ_Rotor.VALIQ_R_Ref.VALLin_IPM_25kW.I1Lin_IPM_25kW.I1ID_R_Ref.VALID_Rotor.VALLin_IPM_25kW.I1IA_Filter.VAL
t [s]
0.4k
-0.3k
0
-0.2k
-0.1k
0.1k
0.2k
0.3k
0 5.6m1m 2m 3m 4m
A
A
Transform_ab_alphabeta
IA_Meas
IB_Meas
PHIMLOAD
LIMIT
LIMIT
LIMIT
Ibeta
theta_electrical
Ialpha
V1D
V1Q
GAIN
Half
I1D
I1Q
FA
FB
Falpha
Fbeta
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Control Design Motor Design Co-simulate
Kp
Ki R
1
S
1
S
1
L q
eL d
K p
K i
R
1
S
1
S
1
Ld
eL q
P M S M p h y s i c a l m o d e l
eL d
eL q
R
R
C ross-
Coup l ingI n p u t
Decoup l ing
Res is tance
Decoupl ing
Res is tanceDecoupl ing
e
pm e pm
B a c k - E M FDecoupl ing
S t a t e F e e d b a c kCur ren t Regu la to r
^
^
^
^
^
iq
*
id
*
-
-
--
+
+ +
+
+
++
++
++
+++
+-
-
iq
iq
id
id
v d
vq
Current Regulator/Motor Block Diagram Simulink Current Regulator
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Control Design Motor Design Co-simulate
n Space Vector Modulation (SVM) with Overmodulation Modes 1-2and Deadtime Compensation
Simulink Model of Modulation Systems
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Control Design Motor Design Co-simulate
GND
PHIDEGMS3 ~B
A
C
Viscous_Load+
Omega_GN
+
Omega_Moto
Ballard_IPM
EQUBL
EQUBL
EQUBL
+
V
+
V+
V
OMEGA
+
V
V_DC
IQ_Rotor.VALID_Rotor.VALLin_IPM_25kW.Viscous_Load.TLin_IPM_25kW.Lin_IPM_25kW.I-1 * Lin_IPM_25
t [s]
60
-0.12k
0
-0.1k
-80
-60
-40
-20
20
40
0 23m2.5m 5m 7.5m 10m 13m 15m 18m 20m
A
A
IA_Meas
IB_Meas
PHIMLOAD
LIMIT
LIMIT
LIMIT
Ballard Powe r Syste ms
Roy Davis
Simulation of IPM Drive
7 April 2003
SiM2SiMSIMPLORER Link Interface
SiM2SiM
SIM2SIM1
EQU
FML1
PHI_MOD:=MOD(Lin_IPM_25kW.PHIDEG,36
CONST
CONST1
CONST
CONST2
CONST
CONST3
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Control Design Motor Design Co-simulate
GND
PHIDEGMS3 ~B
A
C
Viscous_Load+
Omega_GN
+
Omega_Moto
Ballard_IPM
EQUBL
EQUBL
EQUBL
+
V
+
V+
V
OMEGA
+
V
V_DC
IQ_Rotor.VALID_Rotor.VALLin_IPM_25kW.Viscous_Load.TLin_IPM_25kW.Lin_IPM_25kW.I-1 * Lin_IPM_25
t [s]
60
-0.12k
0
-0.1k
-80
-60
-40
-20
20
40
0 23m2.5m 5m 7.5m 10m 13m 15m 18m 20m
A
A
IA_Meas
IB_Meas
PHIMLOAD
LIMIT
LIMIT
LIMIT
Ballard Powe r Syste ms
Roy Davis
Simulation of IPM Drive
7 April 2003
SiM2SiMSIMPLORER Link Interface
SiM2SiM
SIM2SIM1
EQU
FML1
PHI_MOD:=MOD(Lin_IPM_25kW.PHIDEG,36
CONST
CONST1
CONST
CONST2
CONST
CONST3
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Control Design Motor Design Co-simulate
GND
PHIDEGMS3 ~B
A
C
Viscous_Load+
Omega_GN
+
Omega_Moto
Ballard_IPM
EQUBL
EQUBL
EQUBL
+
V
+
V+
V
OMEGA
+
V
V_DC
IQ_Rotor.VALID_Rotor.VALLin_IPM_25kW.Viscous_Load.TLin_IPM_25kW.Lin_IPM_25kW.I-1 * Lin_IPM_25
t [s]
60
-0.12k
0
-0.1k
-80
-60
-40
-20
20
40
0 23m2.5m 5m 7.5m 10m 13m 15m 18m 20m
A
A
IA_Meas
IB_Meas
PHIMLOAD
LIMIT
LIMIT
LIMIT
Ballard Powe r Syste ms
Roy Davis
Simulation of IPM Drive
7 April 2003
SiM2SiMSIMPLORER Link Interface
SiM2SiM
SIM2SIM1
EQU
FML1
PHI_MOD:=MOD(Lin_IPM_25kW.PHIDEG,36
CONST
CONST1
CONST
CONST2
CONST
CONST3
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Inverter Design Custom Pow er Module Design
n Use Maxwell 3D to model power module layout Objective is to compute parasitic module inductance to support
module design layout decisions
2nd objective is to provide inductances for bridge circuit simulation
Presently developing this process difficult to get accurate resultsUppe
Lowe
E1
E2 S2
S14.7
3.3EMF := 17
EMF := 5
Switching
NEG
E3
-5
I1
Lstray
E4
n Also developing process for parameterizing the detailed modelsof IGBTs in Simplorer using this test circuit.
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Inverter Design Custom Pow er Module Design
n Simplorer model of inverter, dc source, and motor used to:
Evaluate component stresses under realistic conditions
Switches
Diodes
Capacitors
Investigate effects of different/variable PWM algorithms Determine losses
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Rapid Prototyping Control Design
n We use dSpace for rapid prototyping control design and motorperformance evaluations on the dyno
Clean interface to Simulink/RTW with Control Desk
n Simplorer model of motor and inverter easily integrated withSimulink model of control
Helps to debug any problems arising from interactions with inverter
PM motor model easily allows use of saturable inductances asfunctions of current
Easy to do what-if investigations
Much easier and seemingly more reliable than Matlab Power System
Toolbox to include detail model of inverter and PM motor.
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Testing Motor Design Evaluation
n Unexplained or different behavior that occurs during testing canbe examined in Maxwell or Simplorer to determine cause.
n Provides a feedback link to design tool usage that allowsrefinement of rules of thumb or development of design rules tobe applied with the numerical design tools.