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TRENDS IN POWER TRENDS IN POWER ELECTRONICS AND DRIVESELECTRONICS AND DRIVES

Dr.V.KamarajProfessor

Electrical and Electronics EngineeringSSN College of Engineering

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IntroductionIntroduction

“Nearly 65% of the total electric energy produced in the USA is consumed by electric motors.”

- R. Krishnan, “Electric Motor Drives Modeling, Analysis, and Control” Prentice Hall,Inc.,2001

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Some Applications of Electric Some Applications of Electric DrivesDrives

Hard Disk Drive, Treadmill, Air conditionerPumps, fans, compressorsSpindles and servosAppliances and power toolsCement kilnsPaper and pulp mills; textile millsAutomotive applicationsConveyors, elevators, escalators, lifts

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Drive SystemDrive System

Four distinct elements of a drive system are :1. The load2. The motor3. The Power Electronic Converter4. The Control Electronics Drive system development challenges:1. Power Density2. Performance3. Energy Efficiency4. Cost5. Time to Market

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DRIVE SYSTEM TECHNOLOGIESDRIVE SYSTEM TECHNOLOGIES

I CONTROL ELECTRONICS

II SEMICONDUCTOR DEVICES TECHNOLOGY

III MATERIAL TECHNOLOGY

IV CAD TECHNOLOGY

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II CONTROL ELECTRONICSCONTROL ELECTRONICS

Functions to be implemented by Control Electronics

Monitoring and Diagnostics

Communication Interfaces

Real time PWM Control

Sensing

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Need for a ControllerNeed for a Controller

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System with ControllerSystem with Controller

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Analog ControllersAnalog Controllers

Advantages:1.Low cost if the controller is simple2.Easy InterpretationDisadvantages1.Reconfigurability of the control is not possible

without changing the hardware2.Number of passive components used are more3.More sensitive to variation in temperature4.Reliability is low

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Digital controllers using DSP and Digital controllers using DSP and MicrocontrollersMicrocontrollers

Advantages:1.Reconfigurability of the control without changing the

hardware2.Less passive components are used3.Less sensitive to temperature variationsDisadvantages:1.The hardware resources are fixed and it cannot be changed

once the particular DSP/Microcontroller is selected2.Design depends more on the hardware architecture of the

processor

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FPGA Based Digital ControllersFPGA Based Digital Controllers

Advantages:1.Reconfiguarabilty of the hardware2.The user is independent of the architecture of the

device

These two advantages makes Digital Controllers with FPGA a better choice

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Configuration of Cyclone FPGAConfiguration of Cyclone FPGA

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CONTROLLERS USING POWER CONTROLLERS USING POWER INTEGRATED CIRCUITS INTEGRATED CIRCUITS

PWM CURRENT REGULATING FECILITY

DECODING COMMUTATION LOGIC

HALL SENSOR

PROTECTIVE FEATURES

LM621,MC33034

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IIII SEMICONDUCTOR SEMICONDUCTOR DEVICES DEVICES TECHNOLOGYTECHNOLOGY

SEMICODUCTOR DEVICES ENHANCES

• PERFORMANCE

• RELIABILITY

• COST EFFECTIVENESS

OF

DRIVE SYSTEM

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SEMICONDUCTOR DEVICE SEMICONDUCTOR DEVICE TECHNOLOGY CHALLENGESTECHNOLOGY CHALLENGES

TERMINAL CHARACTERISTICS

MATERIAL PARAMETERS AND

AMBIENT CONDITIONS

DC I-V

AC STEADY STATE i,v

TRANSIENT i,v

GEOMETRY

ENERGYGAP

DOPING

MOBILITY

LIFETIME

DIELECTRIC CONSTANT

TEMPARATURE

ILLUMINATION

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ATLASATLAS

ATLAS enables device technology engineers to simulate the electrical, optical, and thermal behavior of semiconductor devices. ATLAS provides a physics-based, easy to use, modular, and extensible platform to analyze DC, AC, and time domain responses for all semiconductor based technologies in 2 and 3 dimensions.

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TECHNOLOGYTECHNOLOGY

ENERGY/MATERIAL/INFORMATION

PRODUCT

PROCESSING CONDITIONS

PRECISE CONTROL

• HIGH PERFORMANCE

• HIGH RELIABILITY

• LOW COST

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PWM SWITCHING FREQUENCIES ABOVE THE AUDIBLE FREQUENCIES

CONVERTER EFFICIENCY AND RELIABILITY

IGBT

DEMISE OF GTO’S AND SCR’S

SILICON CARBIDE TECHNOLOGIES

POWER SEMICCONDUCTOR DEVICES

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III NEW MAGNETIC MATERIALSIII NEW MAGNETIC MATERIALSSMC (Somaloy500) Material PropertiesSMC (Somaloy500) Material Properties

1.1E-3Damping Factor (1/Q)

1 JImpact Energy

0.18Poisson’s Ratio

117 GpaYoung’s modulus

23 MpaFatigue Strength

340 MpaCompressive Strength

Mechanical

70 uΩ*m Resistivity

11E-6 m/m*KThermal expansion

450 J/kg*KSpecific heat

7.37 g/cm3Density

Physical

270 A/mHc

1.51 TB@10000A/m

1.26 TB@4000A/m

Magnetic

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Soft Magnetic Composite (SMC)Soft Magnetic Composite (SMC)

Soft Magnetic Composites (SMC) are composed of surface-insulated iron powder particles.

SMC can be compressed to form uniform isotropic components with complex shapes in a single step.

SMC makes it possible to define a magnetic field in three dimensions, thereby permitting the designer to build an electric motor beyond the restrictions set by the traditionallamination technology.

Electrically Insulated Fe-powder Particles

Typical SMC micro-structure

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SMC Parts ManufacturingSMC Parts Manufacturing

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Technology improvement narrows the gap between steel and SMC.

Soft Magnetic Composite (SMC) Magnetic PropertySoft Magnetic Composite (SMC) Magnetic Property

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AdvantagesAdvantages

Reduced eddy current lossIncreased efficiencyReduction in materialsPotential for reduced air gap length as a result of the tight tolerances maintained in manufacturing SMC materialPotential elimination of the ground wall insulation since the SMC stator itself acts as an insulatorReduced conducted EMI when machine is used with inverter supplies since the stator SMC body acts as an insulator and does not conduct current to ground,Reduced bearing currents in the presence of PWM waveforms again because of the use of SMC which acts as insulation against this type of current flow,Modular construction allows the possibility of easy removal of an individual modular unit for quick repair or replacement,Stator is easily recyclable since the stator can again be compressed back into powered form with pressure and the copper windings readily removed.

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DisadvantagesDisadvantages

Relatively high hysterisis loss (low frequency loss),Slight penalty a result of smaller saturation flux density,Relatively brittle material,Lower relative permeability (700 vs roughly 3000)

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IVIV CAD TECHNOLOGYCAD TECHNOLOGY

Computer Aided Design is the technology concerned with the use of computer systems in the

» CREATION» MODIFICATION» ANALYSIS » OPTIMIZATION

OBJECTIVES» Improve the performance» Improve the power density» Improve the reliability

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CADCAD ADVANTAGESADVANTAGES1. CAD methods doesn't require assumed flux paths or

Empirical factor

2. Complex geometries can be designed

3. Design improvement is possible in the design stage itself.

4. Weight of the material can be greatly minimized.

5. Design validation without resorting to expensive field tests.

CAD PACKAGESCAD PACKAGES

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ORGANIZTION OF A CAD PACKAGE

Three identifiable Modules

1. Preprocessor

2 Solver

3. Post Processor

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PREPRE--PROCESSINGPROCESSING

ModelingMesh GenerationMaterial Properties SpecificationBoundary Condition ApplicationExcitationModel Validation

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POST PROCESSINGPOST PROCESSING

Flux plotsNumerical valuesAnimation

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MagNetMagNet

MagNet gives complete and accurate electromagnetic field simulations. Engineers can design, analyze and optimize motors transformers actuators or any electric or electromechanical components regardless of how complex.

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MAXWELLMAXWELL

Ansoft offers the Maxwell SV to help engineering students visualize electromagnetic fields and broaden their understanding of electromagnetic physics. The Maxwell SV is a subset of Ansoft'scommercially distributed Maxwell 2D. Students can perform AC/DC electromagnetic and electrostatic-field simulation without limitation

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ANSYSANSYS

ANSYS Emag software addresses the analysis needs of the low-frequency electromagnetics industry, including electric motors, relays, solenoids, toroids, induction heating, accelerators,medical instruments and magnet design.

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CAD OF SWITCHED CAD OF SWITCHED RELUCTANCE MACHINERELUCTANCE MACHINE

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Torque RippleTorque Ripple

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Proposed Method to Reduce Proposed Method to Reduce Torque RippleTorque Ripple

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Acoustic NoiseAcoustic Noise

Source of the Problem

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Effect of Skewing on Acoustic NoiseEffect of Skewing on Acoustic Noise

Max:59.845Min :0.134

0.624Skewed rotor structure

Max:31.477Min :0.233

0.589Standard Structure

Stress Kg/m2Displacement in μmGeometry

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A Method to Reduce Acoustic A Method to Reduce Acoustic NoiseNoise

POWDER MIX

COMPACTION

CURING OR HEAT TREATMENT

NET SHAPE

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Future ScenarioFuture Scenario

Technology advancement, cost and size reduction are promoting extensive application of drive system in residential, Industrial and Transportation SystemsBoost in global industrial automationHigher cost of energy and environmental regulation will promote energy saving by Power ElectronicsWide growth of environmentally clean wind and PV Energy Wide growth of Electric and Hybrid Vehicles as fuel cost increasesPower Electronics will be a key technology like computers

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REFERENCESREFERENCESM. Balaji, S. Ramkumar and V. Kamaraj"Performance evaluation of switched reluctance machine using finite element analysis"Proceedings of the 2nd National Conference on Cutting Edge Technologies In Power Conversion And Industrial Drives, Sathyamangalam, India, 24 - 25 March, 2006, Paper No. PE72.R.T. Naayagi and V. Kamaraj"Shape optimization of switched reluctance machine for aerospace applications"Proceedings of IECON '05, the 31st Annual Conference of the IEEE Industrial Electronics Society, Raleigh, NC, USA, 6 - 10 November, 2005, pp 1748 - 1751.R.T. Naayagi and V. Kamaraj"Optimum pole arcs for switched reluctance machine with reduced ripple"Proceedings of PEDS '05, the 6th IEEE International Conference on Power Electronics and Drive Systems, Kuala Lumpur, Malaysia, 28 November - 1 December, 2005, Vol. 1, pp 761 - 764.R.T. Naayagi and V. Kamaraj"Minimization of torque ripple in switched reluctance machine for direct drive applications"Proceedings of IEEE Symposium on Emerging Technologies, Islamabad, Pakistan, 17 - 18 September, 2005, pp 388 - 392. R.T. Naayagi and V. Kamaraj"Modeling and design of shape optimized SRM with reduced ripple"Proceedings of the IEEE Symposium on Emerging Technologies, Islamabad, Pakistan, 17 - 18 September, 2005, pp 399 - 404.R.T. Naayagi and V. Kamaraj"Optimal design of switched reluctance machine"Proceedings of ROVISP '05, International Conference on Robotics, Vision, Information and Signal Processing, Penang, Malaysia, 20 - 22 July, 2005, Paper No. B3-5.

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ReferencesReferencesR.T. Naayagi and V. Kamaraj"Optimal design of switched reluctance machine using genetic algorithm"Proceedings of EDPE 2005, International Conference on Electrical Drives and Power Electronics, Dubrovnik, Croatia, 26 - 28 September, 2005, Paper No. E05-11.R.T. Naayagi and V. Kamaraj"Optimal design of switched reluctance machine using genetic algorithm"Proceedings of AEE '05, the WEAS 4th International Conference on Applications of Electrical Engineering, Prague, Czech Republic, , 2005.R.T. Naayagi and V. Kamaraj"Torque ripple minimization of switched reluctance machine (3 phase) using genetic algorithm"Proceedings of SOSM 2005, the 15th International Conference on Soft Computing, Optimization, Simulation and Manufacturing Systems, Cancun, Mexico, , 2005.R.T. Naayagi and V. Kamaraj"A comparative study of shape optimization of SRM using genetic algorithm and simulated annealing"Proceedings of INDICON 2005, IEEE India Annual Conference, Chennai, India, 11 - 13 December, 2005, pp 596 - 599.M. Balaji, C.A. Vaithilingam and V. Kamaraj"Torque ripple minimization in switched reluctance motor drives"Proceedings of PEMD '04, the 2nd International Conference on Power Electronics, Machines and Drives, Edinburgh, UK, 31 March - 2 April, 2004, Vol. 1, pp 104 - 107.K. Sivaprasad, P. Naveenkumar, M. Balaji and V. Kamaraj"Performance prediction of switched reluctance machine using multilevel simulation"Proceedings of EPE-PEMC 2004, the 11th International Power Electronics and Motion Control Conference, Riga, Latvia, 2 - 4 September, 2004, CDROM Paper No. A52627.V. Kamaraj and C.A. Vaithilingam"Modeling and simulation of switched reluctance machine (SRM) using MagNet6.0"Proceedings of PEDS '03, the 5th IEEE International Conference on Power Electronics and Drive Systems, Singapore, 17 - 20 November, 2003, Vol. 1, pp 480 - 484.