Story Transcript
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3-Phase Power Inverter and Control Systems
© FTA & QTS LLC
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HEV Inverter and Controller Current Sensor Vehicle Sensors
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Gate Supply
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Power Inverter Section
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Induction/Permanent Magnet Electric Motor
Current Sensor
Field
(may or may not be included)
IGBT or MOSFET (Transistors)
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Power Inverter Control Unit
Engine Electronic Control Unit
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Current Sensor
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Power Inverter Systems
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Power Inverters “ ” or change the power output to perform opposite of the input
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If the input is , it is inverted (changed) to an ac sine, six-step, or square wave output
Inverter AC
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DC
Power
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• dc-ac conversion is used in Propulsion mode
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Power Inverter Systems
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Power Inverters “ ” or change the power output to perform opposite of the input
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If the input is , the sine wave is inverted (changed) to a dc output
Inverter AC
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DC
Power
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• ac-dc conversion is used in Regen mode
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Sine Wave
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Stator Winding Magnetic Field (1 of 24)
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Magnetic Attraction-Repulsion
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Stator Coil(s)
Direction
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IGBT
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PM Rotor (8 Magnetic Poles)
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Power Inverter with Integral dc-dc Converter System
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Lexus RX400h Hybrid – 3 Power Inverters in 1 Enclosure
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Power Inverter provides power for:
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Motor Generator 1
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Motor Generator 2 Motor Rear
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dc-dc Converter also resident
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inside of Power Inverter
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Prius
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3-Phase Power Inverter
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Power Lead Terminals for Motor
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ECU Connector High Voltage A/C Compressor Terminals
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Power Lead Terminals for Generator High Voltage Battery Terminals
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3-Phase Power Inverter - GM
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Ford Escape Power Inverter
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Battery Pack Connector
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Ford Hybrid Escape Power Inverter Assembly
Courtesy: Ford Motor Co.
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Power Transistor Power Module (IGBT / IPU)
Two IPMs: One each for
Drive Motor and Generator
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Electric Transaxle contains
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Insulated Gate
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BiPolar Transistor (IGBT)
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Power “Brick”
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(3-Phase Output Unit)
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IGBT Discrete Device Symbol Discrete IGBT
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Collector
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Drain
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Gate
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N-Channel MOSFET
Source
NPN Transistor
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Base
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Flywheel/Flyback Diode
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Emitter
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Automotive Electronic Devices
PNP
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NPN
BiPolar Transistor Basic Characteristics Transistor (Xsistor) means to Transfer Resistance
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BiPolar = 2 Polarities (Positive and Negative)
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Three Elements: Emitter (E), Base (B), and Collector (C)
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BiPolar Transistor is Current Controlled
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1.
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E-B Current Level Controls Current Level in the E-C Circuit
Current in E-C circuit is a ratio of the Current in the E-B Circuit
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Current Ratio is the GAIN or Beta of a BiPolar Transistor
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DC GAIN or Beta is termed the Hfe
Hfe = Hybrid Parameter Forward Current Gain, Common Emitter © FTA & QTS LLC
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Automotive Electronic Devices
P-Channel Enhancement
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N-Channel Enhancement
FET / MOSFET Transistor Basic Characteristics Transistor (Xsistor) means to Transfer Resistance
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BiPolar = 2 Polarities (Positive and Negative)
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Three Elements: Gate (G), Drain (D), and Source (S)
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Gate Voltage controls Current through Drain and Source
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N-Ch Enhc’mnt: 0V = 0 Current DS; 15V = Max Current DS
Gate Voltage controls Current through DS vis Electric Field
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FET / MOSFET Transistor is Voltage Controlled
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Gate = Base; Drain = Collector; Source = Emitter
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N-Channel = Low Side Drive; P-Channel = High Side Drive © FTA & QTS LLC
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Motor PE Devices
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Generator PE Devices
Cooling Ports
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Boost Converter PE Devices
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IGBT Internal Devices
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IGBT Internal Devices View
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IGBT (1 OF 6)
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Courtesy: Ford Motor Co.
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Rotor Assembly
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Stator Assembly
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Courtesy: Toyota Motor Co.
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Polarity Changes = Rotation
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PM Rotor (8 Magnetic Poles)
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Stator Winding Magnetic Field (1 of 24)
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Direction
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Polarity Changes = Rotation
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Direction
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Stator Winding Magnetic Field (1 of 24)
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PM Rotor (8 Magnetic Poles)
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Stator Self-Induction = Rotor Rotation
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P O W E R
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Basic Motor Magnetic Circuit
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Stator Self-Induction = Rotor Rotation
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Basic Motor Magnetic Circuit
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Stator -Rotor
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Commutation Waveforms
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6 - Step
Trapezoidal
Electrical Degrees
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Sinusoidal
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Traditional Six (6) Step Waveform
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+ 400 Volts dc
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0 Volts dc
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Gen 1 - Honda Insight 6 Stepped Waveform
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• • • • •
3-Phase Propulsion Systems (early) Fuel Pumps Cooling Fans Blower Motors etc………
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Trapezoid Waveform
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Time
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Sinusoidal (Sine) Waveform
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3-Phase Electric Machine Sine Waves
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Sine Wave
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Sine and Trapezoid Waveform
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Trapezoid Wave
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Automotive 6 Cylinder Engine Typical Firing Order: 165432 Companion Cylinders:
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Traditional Six (6) Step Waveform
4 3 2
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Exhaust
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360 Crankshaft Degrees
4 3 2
Compression
360 Crankshaft Degrees
Electric Machine Motor Companion Six Step IGBT Firing Order: 2&4 2&6 1&6 1&5 3&5 3&4
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466
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1 6 5
Exhaust
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Compression
1 6 5
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Basic Power Inverter – 6 Step Hard Switching Pattern
Q2
Q3
IGBTs (6 total)
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B+ Bus
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Phase B
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Q6
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Q4
Phase C
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Phase A
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- Bus 40
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Q2
Q3
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B+ Bus
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Phase B
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Q5
Q6
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Q4
Phase C
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Phase A
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Typically, Six IGBT Power Transistors are used in a 3 Phase motor drive system © FTA & QTS LLC
- Bus
B
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Phase B
Phase A
Phase B
Phase A
Phase B
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Phase A
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Traditional Six (6) Step Waveform – Using 2 Phases
Phase C
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Phase B
Phase A
Phase B
Phase A
Phase B
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Phase A
Phase C
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Phase C
Phase C
Phase C
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Phase C
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Six (6) Step Waveform
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6-Step
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Legend:
6 -
Negative ON
Positive ON © FTA & QTS LLC
OFF
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Six (6) Step
“0” Ref Line
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Phase “A”
“0” Ref Line
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Phase “B”
“0” Ref Line
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Phase “C”
60°
120°
180°
240°
© FTA & QTS LLC
300°
360°
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Phase B
Phase A
Phase B
Phase A
Phase B
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Phase A
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Alternate Six (6) Step Waveform – Using 3 Phases
Phase C
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Phase B
Phase A
Phase B
Phase A
Phase B
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Phase A
Phase C
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Phase C
Phase C
Phase C
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Phase C
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Alternate Six (6) Step Waveform – Using 3 Phases Phase B
Phase A
Example: Switching Cycle #1
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Power Inverter holds 2 IGBTs High & 1 Low
Phase C
B
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Instead of holding only 1 High & 1 Low
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3-Phase Electric Machine Sine Waves
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550 foot-pounds by the 0.10472 radians per second (engine speed) = 550/0.10472 or 5,252.
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Synthesizing a Sine Wave 300
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AC waveform delivered to motor by varying pulse width
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V O L T S
TIME
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0
100%
50%
5%
50%
IGBT PWM Signal
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50%
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Sine Wave and Stator Winding Polarity Changes Polarity changes in the Stator windings, due to from self-induction generated in the Stator windings (polarity change locations are approximated)
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V O L T S
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300
TIME
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0
100%
50%
5%
50%
IGBT PWM Signal
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50%
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Waveform Amplitude and Hz
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-Amplitude U = Torque N AU TH O R IZ ED
V O L T S
Hz = rpm
TIME
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0
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Power Inverter Sine Wave Output Amplitude of Current Waveform = Torque
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• Higher Amplitude = Increased Electric Machine Torque
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• Lower Amplitude = Decreased Electric Machine Torque
Frequency of Waveform = Speed
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• Higher Frequency = Increased Electric Machine Speed
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• Lower Frequency = Decreased Electric Machine Speed
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PWM Control of IGBTs determines Amplitude while the
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Frequency of the PWM determines Speed (rpm)
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Sine Waveform Calculations
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Root Mean Square Defined
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Root Mean Square (RMS) = Amount of AC power that produces the same heating effect as an equivalent DC power or equivalent DC effective power value
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Provides a method to convert AC to a unit for objectively comparing AC to DC power
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To Calculate RMS:
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The RMS is a measure of the magnitude of a set of numbers.
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SQUARE all the values measured under Sine Wave
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Take the average (MEAN) of the squares
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Take the square ROOT of the average
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Measurements Under Sine Wave (Curve) = RMS
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More Sinewave Ordinates = More accurate conversion © FTA & QTS LLC
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Triangle Waveform Creates Sine Wave (Comparators)
Courtesy: Worcester Polytechnic Institute, 2007
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Triangle Waveform Creates Sine Wave (Comparators)
Courtesy: Worcester Polytechnic Institute, 2007 © FTA & QTS LLC
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Courtesy: Texas Instruments, 2017
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Triangle Waveform Creates PWM (Sine Wave Creation)
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Triangle Waveform Creates Sine Wave (Comparators)
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Courtesy Worcester Polytechnic Institute, 2007
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Advanced Power Inverter Controls Advanced Power Inverter Controls will:
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• Adjust Carrier Frequency to increase efficiency & reduce noise
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• Be designed as 2 or 3 Level System
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• Example: 2kHz – 20kHz operating range
• 2 Level System = Connected to Positive & Negative Bus
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• Multi-Level (Voltage) Systems are:
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• Connected to Positive & Negative Bus
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• But also……will apply different voltages to motor to apply
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appropriate torque ranges to enhance efficiency, reducing
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temps, and reducing overall noise (acoustic and electrical)
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IGBT Sine Wave Switching in Stator Windings
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Rising Currents from IGBT
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Through Stator causes magnetic
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poles in Stator windings that
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Interact with Rotor Magnets / Bars
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IGBT Sine Wave Switching in Stator Windings Changes in IGBT Current direction in
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Stator causes changes in magnetic poles
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in Stator windings which cause
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winding polarity changes that
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Interact with Rotor Magnets / Bars
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Cartesian Plane = Creating Motor Control System y
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U
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+3 +2
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-1 +1 +2 +3 +4 +5 +6 +7 +8 -2
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x
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Control System will plot Torque and Speed based On Cartesian plane x,y coordinates
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90°
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Cartesian Plane = Creating Motor Control System y
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Direction
+2
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+1 -1
-1
+1
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+4 +5
+6 +7
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0
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x
Vectors determine
0° (360°)
Magnitude of Current & Direction (Hz) of the Waveform
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270°
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180°
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+3
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Quadrant 2
y
Quadrant 1
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90°
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Cartesian Plane = Creating Motor Control System
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+2 +3
+4 +5
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x +8
0° (360°)
x, y Coordinates in Quadrants 1-4
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Quadrant 3
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180°
+1
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Quadrant 4
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90° x axis Determines Electric Machine Speed-rpm (Hz)
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Cartesian Plane = Creating Motor Control System y
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+8
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+7
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+6 +5
+3 +2
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+1
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+4 +5
+6 +7
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x
0° (360°)
x axis determines machine Speed (Hz) & y axis determines machine Torque (current)
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+2 +3
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-8
y axis Determines Amplitude or Electric Machine Torque (Current)
270°
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180°
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90° Quadrant 2
y
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Cartesian Plane = Creating Motor Control System Quadrant 1
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+8
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+7 +6
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+5
+3 +2
-5 -4
-3 -2
-1
+1 -1 -2
+1
+4 +5
+6 +7
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-3
+2 +3
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-7 -6
+8
x
Lower amplitude & Hz
0° (360°)
means Lower machine speed and torque
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-4
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-5 -6
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Quadrant 3
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180°
0
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+4
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Quadrant 4
-8
270° © FTA & QTS LLC
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90° Quadrant 2
y
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Cartesian Plane = Creating Motor Control System Quadrant 1
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+8
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+7 +6
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+5
+3 +2
-7
-6
-5
-4
-3
-2
-1
+1
-2
+2 +3
+4 +5
+6 +7
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-3
+8
x
0° (360°)
Higher amplitude & Hz means Higher machine speed and torque
N
-4
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-5 -6
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Quadrant 3
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-8
-1
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0
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180°
+1
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Quadrant 4
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270° © FTA & QTS LLC
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3 Separate Cartesian Vectors to Create 3 Phase Control
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+150
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Virtual
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Rotating vectors (x;y coordinates) create the 3φ waveforms
+50
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C U R R E N T -
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V +200 O L T +150 A G E +100 +50 0
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-150
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Phase A
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+50 Virtual
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0
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V +200 O L T +150 A G +100 E
Electrical Degrees
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+300
+50
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-100
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Phase C
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Phase B
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+150
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3-Phase Sine Wave Current Waveforms
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50A
86.6A
50A
100A
60°
C
A
A 86.6A
50A
100A
210°
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180°
100A
C
A 86.6A
86.6A
C
A
100A
50A
A
86.6A
50A
86.6A
B
B
120°
150°
C
A 50A
100A
C
A
86.6A
86.6A
50A
50A
B
B
B
240°
270°
300°
B
330°
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90°
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C
86.6A
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0° (360°)
A
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B
B
C
50A
86.6A
100A
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3-Phase Sine Wave 360° Electrical Switching Cycle
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Sin Generator
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Q3
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Q2
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Q1
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Propulsion Mode @ 180° of Sine Wave Cycle: PWM Control of Q1, Q5 and Q6
_
Phase A
Phase B
_
Battery Pack
Q6
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Q5
PWM
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PWM
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Phase C
PY C O
Q4
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PWM
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Q3
PR
Q2
+
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Q1
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Propulsion Mode @ 180° of Sine Wave Cycle: PWM Control of Q1, Q5 and Q6
_
Phase A
Phase B
_
Battery Pack
Q6
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N
Q5
PWM
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PWM
-
R
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+
Phase C
PY C O
Q4
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TH O
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PWM
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H IB IT ED
Advantages & Disadvantages of 6-Step/Trapezoid Control
Advantages:
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• Control Algorithms are simple (hard switching pattern)
U
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• Only 2 Phases required are required to active at one time (although 3 could be used)
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• Less switching losses (compared to traditional Si IGBT)
AU N
Disadvantages
TH O
• Higher average battery terminal voltages
-U
• Torque ripple at every commutation point
H
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• Less torque is produced
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• Higher acoustic and electrical noise
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Advantages & Disadvantages Sine Control
PR
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• Maximum torque production
U
• Smooth motion rotation
SE
• No torque ripple in commutation
O
Advantages:
TH O
Disadvantages
AU
• 3-Phases are used at same time
N
• Higher Switching losses (when creating waveform)
-U
• Higher Switching Frequencies
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• On-the-fly Carrier Frequency Changes
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• Control Algorithms are complex and mathematical
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Power Inverter ECU
(ABS, ECM, Trans, Battery etc.)
Resolver
PR Current Sensors
Tables to Shape Waveforms
X
AU
Position Information
Waveform Generator Phases U,V,& W
Six-Pack Motor Drive IGBTs
Current Sensor To Motor 1 of 3 Ø
Power Computation
Phase U,V or W Current
Signal from Resolver
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Torque Computation
Voltage & Waveform Control Provide control of waveform type and amount of voltage boost to the motor(s)
-U
N
PI
Torque Achieved
TH O
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Sensor Inputs
6-Pack Motor Drive (IGBTs)
SE
I/O
Voltage & Waveform Control
U
HV ECU
O
µC Unit
CAN
Torque Request
H IB IT ED
Propulsion Control Block Diagram
Sensor Inputs
Other System ECUs
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Creation Process
PR
∫
.9 .8 .7 .6 .
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1 2 3 4 .
y
O
∫
x
Sine Wave
U
SE
∑
Torque Model Algorithm
Rotating Vector
Torque Model Computation (Current) Vector Calculation & Integrator
R IZ ED
Electric Machine
AU
TH O
IGBT Modules
Integrator
CAN Message
0101100110010101
-U T H
R PY C O
8 Bit Sine Table Lookup
N
IGBT Gate Drive
IG
Fault Status’ • Over Current • Under Current • Over Temp • Input/Output PWM
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
μPU Port
Analog to PWM Converter
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High Speed Digital to Analog Conversion 1,2,3,4,5 …
0 1 0 1…
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C O
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TH O
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O
H IB IT ED
GM 2-Mode 3 Phase Current Waveforms
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Upper Current Regulation Band
H IB IT ED
2ΔI
+I
O
Reference Current Waveform (i.e., Desired Current)
R IZ ED
U
SE
PR
or I*
Tolerance Band
-I
-I = *I – ΔI is lower Current boundary +I = *I + ΔI is upper Current boundary
IG
H
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-U
N
AU
TH O
Lower Current Regulation Band
C O
PY
R
I = Current
PWM % © FTA & QTS LLC
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C O
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N
-U TH O
R IZ ED
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U
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H IB IT ED
C O
H IB IT ED N
PY
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-U
Current Regulation At Low Current Level
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TH O
R IZ ED
U
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PR
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Current Regulation at High Current Level
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C O
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-U TH O
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PR
H IB IT ED
H IB IT ED O PR SE U R IZ ED
Cruising
C O
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-U
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AU
TH O
Energy Lost = Not Recoverable
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H IB IT ED
Regenerative Electric Machine Braking Controls and Circuits
SE
PR
O
There are numerous strategies for controlling electric machine regenerative braking such as:
R IZ ED
U
1. Single Switch – One IGBT Control 2. Two Switch – Two IGBT Control
AU
TH O
3. Three Switch – Three IGBT Control
-U
N
IGBT control can be implemented using or Sine Wave controls Six-Step (6-Vector)
C O
PY
R
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H
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Although 1 or 2 Switch strategies can be used to control Regen at various road speeds, the Examples in this presentation will use 3-Switch IGBT control
© FTA & QTS LLC
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Regenerative Electric Machine Braking Controls and Circuits: Modulating Regen
PR
O
To safely control the vehicle Regen braking must be controlled or
R IZ ED
U
SE
“modulated” to ensure that directional stability of the vehicle is maintained
Therefore, the Hybrid and Motor Controllers will modulate (via 0 – 100% PWM)
AU
TH O
the electric machine output to increase Battery Pack SOC%
-U
N
One method of the PWM modulation method is for the controls to oscillate
T
between Coasting and Flywheel Diode (100%) feedback – resulting in an
C O
PY
R
IG
H
“average” current transmitted to the battery pack
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H IB IT ED
IGBT Flywheel / Flyback Diodes
Q2
Q3
R IZ ED
U
SE
Q1
PR
O
B+ Bus
TH O
Phase B
AU
Q5
Q6
H
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-U
N
Q4
Phase C
R
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Phase A
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-
B Bus © FTA & QTS LLC
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Coasting: No Regen – Q4 Flywheel Diode and PWM of Q5 & Q6 Controls Coasting
Q2
Q3
+
+
Phase A
Phase B
N
PWM
-U
PWM
Battery Pack
Q6
T
Q5
PWM
_
Phase C
-
C O
PY
R
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H
Q4
+
AU
TH O
R IZ ED
U
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Q1
PR
O
H IB IT ED
(Example illustration of only one (1) of the possible switching cycles)
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Modulated Regen Control: 100% Regen using Flywheel Diodes
O
H IB IT ED
Diode Operation is Controlled by PWM control of IGBTs
+
PR
Q2
Q3
+
Phase A
Phase B
Battery Pack
Q6
T
-U
N
Q5
-
R
IG
H
_
Phase C
PY C O
Q4
+
AU
TH O
R IZ ED
U
SE
Q1
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H IB IT ED
Regenerative Braking Waveform
Vehicle Placed in Neutral (No Regen Commanded) Vehicle in Drive during Braking (Regen is Commanded)
C O
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-U
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AU
TH O
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O
Vehicle Placed back in Drive for Acceleration
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H IB IT ED
Regenerative Braking Waveform Video
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Regenerative Braking Diagnostic Concerns
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C O
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Toyota Gen 1 Prius Hybrid Power Inverter
Courtesy: Toyota Motor Co.
© FTA & QTS LLC
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H IB IT ED
Power Inverter Bus Capacitors
PR
O
Why Use Large Capacitors in the Power Inverter?
SE
• Reduce “Harmonics” (electrical noise within waveform)
R IZ ED
U
• Reduce Electric Machine Heat caused by Harmonics
TH O
• Increase Power Factor (not Efficiency)
AU
• A measure of how efficiently the load current is being converted into
-U
N
useful work output
H
T
• As Capacitors Age: Power Factor decreases and Harmonics
C O
PY
R
IG
(Heat) increase….reducing machine life
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TH O
R IZ ED
U
SE
PR
O
X Capacitor(s)
H IB IT ED
Power Inverter Bus Filtering
AU
Common Mode Choke - an Inductor used in electronic circuits that is utilized to block high-frequency, alternating current (AC) in a circuit while allowing lower frequencies, or direct current (DC), to pass through.
-U
N
Decoupling Capacitors - are used to filter out voltage spikes and pass through only the DC component of the signal. The idea is to use a capacitor in such a way that it shunts or absorbs the noise making the DC signal smooth.
IG
H
T
Y Capacitor - is a bypass capacitor that is used to reduce Electromagnetic Magnetic Interference(EMI). The Y capacitor also can be called a filter capacitor.
C O
PY
R
DC link capacitors - are commonly used as an intermediary buffer between an input source to an output to help offset the effects of inductance in inverters, motor controllers, and battery systems. They also serve as filters that protect EV subsystems from voltage spikes, surges, and electromagnetic interference (EMI). © FTA & QTS LLC
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DC Input Capacitors and Inductors to reduce IGBT Module electrical (EMC) noise by using bus bar in lieu of cables or shortening cables
N
AU
TH O
R IZ ED
U
SE
PR
O
H IB IT ED
Example: Sine Wave Input Filter
H
T
-U
Common Mode Choke shown
C O
PY
R
IG
Courtesy: EPCOS
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TH O
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H IB IT ED
2001 IPM Waveform with Distortion
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TH O
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H IB IT ED
2001 IPM Waveform with Distortion
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C O
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H IB IT ED
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TH O
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H IB IT ED
Power Inverter & Controls Analysis
© FTA & QTS LLC
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H IB IT ED O •
Waveform widths identical?
PR
Waveform peaks (+ and -) identical?
C O
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R
IG
H
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-U
N
AU
TH O
R IZ ED
U
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•
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H IB IT ED O
2. Is there waveform symmetry?
Waveform peaks (+ and -) identical?
•
Waveform widths identical?
C O
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IG
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-U
N
AU
TH O
R IZ ED
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•
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H IB IT ED
Waveform peaks (+ and -) identical?
•
Waveform widths identical?
IG
H
T
-U
N
AU
TH O
R IZ ED
U
SE
PR
•
O
3. Is there waveform symmetry?
C O
PY
R
Oscillating waveforms can be caused by worn bearings or low battery capacity (low battery causes reduced performance mode) © FTA & QTS LLC
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H IB IT ED SE
Symmetrical upper and lower boundary amplitudes? Regulation only in the waveform cresting areas?
C O
PY
R
IG
H
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-U
N
AU
TH O
R IZ ED
• •
PR
Distributed winding machines:
U
O
4.
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Concentrated winding machines:
O
PR
(boundaries are much higher and lower than Distributed winding machines)
Regulation only in the waveform cresting areas?
(regulation will be in majority of waveform because of parallel winding connections of concentrated design)
PY
R
IG
H
T
-U
N
AU
TH O
R IZ ED
U
•
Symmetrical upper and lower boundary amplitudes?
SE
•
C O
H IB IT ED
5.
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Distributed Winding Waveform
SE U R IZ ED
TH O
Example Apps: Ford, GM, Lexus, Toyota
PR
Appearance is very symmetrical and Current Regulation is less aggressive (smoother)
AU
Concentrated Winding Waveform
T
-U
N
Appearance is less symmetrical and Current Regulation is more aggressive (choppy)
C O
PY
R
IG
H
Example Apps: Honda, Hyundai
© FTA & QTS LLC
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H IB IT ED
Basic Power Inverter Diagnostic Codes Drive Motor Inverter Temp High/Low
Drive Motor Performance
Drive Motor Inverter Performance
Controller Performance/Error
Generator Inverter Temp High/Low
Controller Communication
Inverter Cooling System Performance
SE
U
Isolation Fault
R IZ ED
Generator Inverter Performance
PR
O
Generator Performance
Accelerator Pedal Sensor
TH O
Regenerative Braking
AU
Battery Pack Voltage Correlation
Cruise Control PRND Switch
N
IGBT Enable Fault
Direction/Speed Sensor
-U
High Voltage Interlock Loop
Brake Torque Control Correlation
Controller Hardware Failure
C O
PY
R
IG
H
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Battery Pack Pre-charge
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