Goodman, Andrew Simon (2007) Direct energy converter controllers for switched reluctance motor ...

253 Pages·2016·16.84 MB·English

Direct Energy Converter Controllers for Switched
Reluctance Motor Operation
Andrew Simon Goodman, MEng(Honours)
SubmittedtotheUniversityofNottinghamforthedegreeofDoctorofPhilosophy,April
2007.
Abstract
Thereisincreasingdemandforsimplemotordrivesofferinghighreliabilityandfaulttoler-
anceinapplicationssuchastheaerospaceactuatorindustry,withthedevelopmentof‘more
electricaircraft’.
Thisthesispresentsamotordriveemployingaswitchedreluctancemotor,thenovelsingle
sidedmatrixconverter,andanoveldoublebandhysteresisbasedcontrolschemeforcontrol
oftheconverter,implementedusingafieldprogrammablegatearray(FPGA).
The single sided matrix converter is a direct energy converter, capable of supplying unidi-
rectional currents from a multiphase AC voltage source. It is suitable for driving motors
such as the switched reluctance motor and trapezoidal permanent magnet direct current
(PMDC) machine. The use of a direct energy converter removes the DC link energy stor-
age element usually found in switched reluctance motor drives, making practical imple-
mentation possible without the use of electrolytic capacitors. This is a requirement for
applicationsintheaerospaceindustry. Controllerimplementationwithouttheuseofadig-
ital signal processor (DSP) makes application of the converter in the aerospace industry
easyasspecificDSPapprovalisnotrequired.
Simulationsoftheconverteroperationarepresented,followedbyadescriptionoftheprac-
tical implementation of the novel converter and control schemes. Practical results demon-
strate the reliable operation of the converter, driving both switched reluctance and trape-
zoidalPMDCmachines.
The work has been published in three conference papers, presenting both the topology of
thedriveandtheappliedcontrolschemes,aswellasanalysingthefaulttolerantcapabilities
ofthedrive.
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ii
Acknowledgements
I would like to thank Dr Keith Bradley for his wide ranging expertise, encouragement
and trusting belief in me throughout this PhD. I would also like to thank Dr Pat Wheeler
for his assistance with the hardware design, Xiaoyan Huang for her help with the PMDC
machine, and Kevin Last, Colin Blackburn, Matt Cooper and the other workshop staff for
the mechanical and electrical help needed in producing and testing the single sided matrix
converterandsettingupthemotorloadingsystem.
I also have to thank my friends both within and outside the Electrical and Electronic En-
gineering Department of the University of Nottingham, especially Paul Robson, Graham
Stabler,RoderickMacKenzie,EdwardChristopher,RalphFeldman,LeeEmpringham,Lil-
iana de Lillio, Adam Docherty, Ashley Dobson and Ruth Staniforth, for their friendship,
supportandvitaltechnicalassistancethroughoutthedifferentstagesofthisresearch.
ThanksalsototheEPSRCforfundingme,andtoSwitchedReluctanceDrivesfortheloan
oftheswitchedreluctancemotorusedinthefinalstagesoftheSSMCtesting.
Finally, but most importantly i’d like to thank my family. Firstly my parents, Richard and
Rosemary Goodman, for providing me with a loving, stable and stimulating upbringing,
and for supporting me in many ways throughout my PhD. I could never have dreamt of
reaching this stage in my education without them. I am also very greatful to my sister,
EmilyGoodman,andherFiance´ SimonTalksfortheirsupport.
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KeytoAcronyms,Abbreviations&Terminology
Notation Meaning
ω RotationalSpeed
θ Angularposition
(V,I)A,B,C InputPhase(Voltages,Currents)
(V,I)u,v,w,x,y OutputPhase(Voltages,Currents)
A,B,C,U RequiredInputPhaseConnections
(A,B,C)withpolarity(U)
A/D AnaloguetodigitalConverter
AC AlternatingCurrent
CARAD CivilAircraftandTechnologyDemonstration
D CurrentDirectionofChange
DB DoubleBand
DC DirectCurrent
DSP DigitalSignalProcessor
DTI DepartmentofTradeandIndustry
EHA ElectrohydraulicActuator
EMA ElectroMechanicalActuator
EMF ElectroMotiveForce
EPSRC EngineeringandPhysicalSciencesResearchCouncil
FPGA FieldProgrammableGateArray
I,i Current
IC Integratedcircuit
IGBT InsulatedGateBipolarTransistor
IPC AssociationConnectingElectronicsIndustries
L Inductance
LinearSRM MagneticallyLinear,NonSaturating,
RotatingSwitchedReluctanceMotor
MOSFET MetalOxideSemiconductorFieldEffectTransistor
PCB PrintedCircuitBoard
ContinuedonNextPage...
iv
Notation Meaning
PMDC PermanentMagnetDirectCurrent
PWM PulseWidthModulation
R Resistance
RL ResistiveandInductive
rms RootMeanSquare
rpm RevolutionsperMinute
SAa,SBa,SCa SSMCOutputCurrentHighSideSwitchesconnectingto
inputphaseA,B,Crespectively
SAb,SBb,SCb SSMCOutputCurrentLowSideSwitchesconnectingto
inputphaseA,B,Crespectively
SATOW SurfaceActuationofThinandOptimisedWings
SB SingleBand
sec Seconds
Scope Oscilloscope
SR SwitchedReluctance(Motor)
SSMC SingleSidedMatrixConverter
SVM SpaceVectorModulation
t Time
U1,U2,U3,U4 OutputCurrentwithrespecttoHysteresis
BandLogicSignals
V Voltage
V+3,V+2,V+1 PositiveInputVoltageLevelBands
V0 VoltageLevelzero
V-1,V-2,V-3 NegativeInputVoltageLevelBands
V1,V2,V3 RequiredVoltageLevel(withoutpolarity)
VHDL Very-High-SpeedIntegratedCircuit
HardwareDescriptionLanguage
X,Y,Z,A,B,C InputVoltageStateLogicSignals
x-x SwitchedReluctanceMotorPoleNumbers
Contents
1 Introduction 1
1.1 ThesisStructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 PowerElectronicConvertersincludingtheMatrixConverter 6
2.1 PowerElectronicConvertersOverview . . . . . . . . . . . . . . . . . . . . 6
2.1.1 ThePWMCurrentSourceRectifier . . . . . . . . . . . . . . . . . 8
2.2 DirectPowerConverters(ACInput) . . . . . . . . . . . . . . . . . . . . . 9
2.2.1 TheCycloconverter . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2.2 TheMatrixConverter . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.3 TheConventionalMatrixConverter . . . . . . . . . . . . . . . . . . . . . 12
2.3.1 CircuitStructure . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.3.2 MathematicalModelandModulationStrategies . . . . . . . . . . . 14
2.3.2.1 TheModulationProblemandBasicSolution . . . . . . . 18
v
CONTENTS vi
2.3.2.2 TheOptimumAmplitudeAlgorithm . . . . . . . . . . . 20
2.3.2.3 ScalarModulationApproach . . . . . . . . . . . . . . . 22
2.3.2.4 SpaceVectorModulationApproach . . . . . . . . . . . . 24
2.3.2.4.1 SpacePhasors . . . . . . . . . . . . . . . . . . 24
2.3.2.4.2 MatrixConverterOutputSpacePhasors . . . . 25
2.3.2.4.3 SelectionofSwitchingStates . . . . . . . . . . 25
2.3.2.5 IndirectModulationApproach . . . . . . . . . . . . . . 30
2.4 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3 SingleSidedMatrixConverterDCDrive 33
3.1 TheSingleSidedMatrixConverter . . . . . . . . . . . . . . . . . . . . . . 33
3.1.1 Topology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.1.2 Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.1.2.1 ControlPlatform . . . . . . . . . . . . . . . . . . . . . . 35
3.1.2.2 ControlApproach . . . . . . . . . . . . . . . . . . . . . 37
3.1.2.2.1 SingleBand . . . . . . . . . . . . . . . . . . . 37
3.1.2.2.2 DoubleBand . . . . . . . . . . . . . . . . . . 37
3.1.3 AdvantagesoverotherPowerConverters . . . . . . . . . . . . . . 40
3.2 SuitableMotors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
CONTENTS vii
3.2.1 SwitchedReluctance . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.2.2 TrapezoidalPermanentMagnetDC . . . . . . . . . . . . . . . . . 45
3.3 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4 SingleSidedMatrixConverterSimulation 52
4.1 SwitchedReluctanceMotorModel . . . . . . . . . . . . . . . . . . . . . . 53
4.2 TrapezoidalPMDCMotorModel . . . . . . . . . . . . . . . . . . . . . . . 59
4.3 SingleBandControllerModel . . . . . . . . . . . . . . . . . . . . . . . . 61
4.4 DoubleBandControllerModel . . . . . . . . . . . . . . . . . . . . . . . . 65
4.5 Inductive/ResistiveLoad . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4.5.1 PulsedOutputCurrent . . . . . . . . . . . . . . . . . . . . . . . . 69
4.5.2 ContinuousOutputCurrent . . . . . . . . . . . . . . . . . . . . . . 72
4.5.3 FourierAnalysisofPulsedCurrentinRLLoad . . . . . . . . . . . 74
4.5.3.1 SingleBandControl . . . . . . . . . . . . . . . . . . . . 75
4.5.3.2 DoubleBandControl . . . . . . . . . . . . . . . . . . . 83
4.5.3.3 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . 86
4.5.4 DeviceLossEstimationandComparison . . . . . . . . . . . . . . 91
4.6 SwitchedReluctanceMotorLoad . . . . . . . . . . . . . . . . . . . . . . 92
4.6.1 Speed-530rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
CONTENTS viii
4.6.2 Speed-3080rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
4.7 PMDC(SATOW)MotorLoad . . . . . . . . . . . . . . . . . . . . . . . . 101
4.8 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
5 PrototypeDrive-ConstructionandControlImplementation 107
5.1 ConverterHardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
5.1.1 FPGAControllerPCB . . . . . . . . . . . . . . . . . . . . . . . . 109
5.1.2 ResolverInterfacePCB . . . . . . . . . . . . . . . . . . . . . . . . 111
5.1.3 CurrentMirrorsPCB . . . . . . . . . . . . . . . . . . . . . . . . . 112
5.1.4 VoltageTransducersandClampPCB . . . . . . . . . . . . . . . . 114
5.1.4.1 ClampVoltageMonitoringCircuit . . . . . . . . . . . . 115
5.1.5 MatrixPowerPCB . . . . . . . . . . . . . . . . . . . . . . . . . . 116
5.1.5.1 HighVoltage/HighCurrentAreas . . . . . . . . . . . . . 117
5.1.5.1.1 HighVoltageImplications . . . . . . . . . . . 121
5.1.5.1.2 HighCurrentImplications . . . . . . . . . . . 122
5.1.5.1.2.1 CopperAreaRequired . . . . . . . . . 123
5.1.5.2 GateDriveCircuit . . . . . . . . . . . . . . . . . . . . . 126
5.1.5.3 LowVoltageControlandMeasurementSignals . . . . . 128
5.1.5.4 MechanicalConsiderations . . . . . . . . . . . . . . . . 128
CONTENTS ix
5.2 FPGAControllerDesign . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
5.2.1 FPGADesignConsiderations . . . . . . . . . . . . . . . . . . . . 130
5.2.1.1 DataValidity . . . . . . . . . . . . . . . . . . . . . . . . 131
5.2.1.2 NumericalManipulation . . . . . . . . . . . . . . . . . . 131
5.2.1.3 StateMachines . . . . . . . . . . . . . . . . . . . . . . . 132
5.2.2 ControlStructure . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
5.2.2.1 TransducerDataAcquisitionandProcessing . . . . . . . 134
5.2.2.2 InputVoltageStateDetermination . . . . . . . . . . . . 136
5.2.2.3 Resolver Data Processing, Filtering and Current Refer-
enceCreation . . . . . . . . . . . . . . . . . . . . . . . 136
5.2.2.4 PhaseCurrentControllers . . . . . . . . . . . . . . . . . 139
5.2.2.4.1 SingleBandCurrentController . . . . . . . . . 140
5.2.2.4.2 DoubleBandCurrentController . . . . . . . . 143
5.2.2.5 TripHandling . . . . . . . . . . . . . . . . . . . . . . . 145
5.2.2.6 DataExtraction . . . . . . . . . . . . . . . . . . . . . . 146
5.3 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
6 PrototypePracticalResults 149
6.1 BasicControlDataRequiredforBothControlSchemes . . . . . . . . . . . 149