The Design and Implementation of a Three Phase Power Converter in the Power Electronics and Drives Subject

Omar M F Muhialdin, Ahmad Nahas and Takyin Chan School of Electrical Engineering Victoria University PO Box 14428 MC, Melbourne VIC 8001, Australia o.muhialdin@gmail.com, ahmadnahas@gmail.com, taky.chan@vu.edu.au ABSTRACT
This paper describes the design and implementation of a Three Phase Power Converter (AC/DC/AC) as a fourth year group project for the Power Electronics and Drives B subject at Victoria University. The system implemented converts a three phase input voltage of 400 Vrms at a power rating of 500 W to DC by using a three phase diode bridge rectifier, and a Capacitive filter which assists in stabilising the output DC voltage produced. After that, the system provides the gate drive signal to a three phase pulse width modulated (PWM) inverter driving an induction motor. The pulse width modulation signal is generated by MATLAB using the Data Acquisition. The three phase MOSFET inverter uses the DC voltage supplied from the 3 phase bridge and the gate drive signals to produce a balanced three phase sinusoidal output which drives the induction motor. This project/paper can be useful for future power system students as more properties and specifications can be added to the designed product in order to investigate further issues and applications of Three Phase Power Converters. An AC voltage input that is fed to a three phase diode bridge rectifier to produce DC output voltages which across a C filter will feed the three phase PWM inverter. The PWM inverter is controlled by a three phase sinusoidal PWM signal generated by a control circuit. The PWM inverter will then convert the DC voltage at the input to AC output voltage. The AC output voltage can be controlled in both magnitude and frequency (V/F Open Loop Control). This control of voltage and frequency is required as it permits the user control the speed of an induction motor at different rates. The project utilised many electronic components such as; Diodes, MOSFETs, Capacitors, Optoisolators and Gate Drivers, to construct the full circuit. So, in order to achieve this, a full understanding of the characteristics and theory of each section had to be achieved, which assisted in completing the design and implementation of the product according to the required specifications.

2. PROJECT SPECIFICATIONS
The following specifications and objectives were set for the project: 2.1 Power Circuit Specifications: Input three-phase line voltage of 400 V to the three phase diode rectifier bridge at a power rating of 500 W. Output three phase voltage source PWM inverter, power rating 500 W. 2.2 Control Circuit Specifications: Carrier based pulse width modulation strategy. Control input: Digital TTL commands at 1-10 kHz (carrier frequency). Motor speed control from 10% to 100% of motor rated speed. Power supply to the control circuit: 12V and 5V supplies. Speed control: V/f control of induction motor, open loop.

1. INRTODUCTION
Over the past decade the field of power electronics has passed through rapid development due to the advancement of many modern technologies such as; DSP Cards, Data Acquisition Cards and Microprocessors. The aforementioned technologies made power electronics projects and applications easier to implement and more accessible. In this project we were to implement a Three Phase Power Converter (AC/DC/AC) to control the speed of an induction motor using Data Acquisition Cards. The complete system will consist of two sections; a Power Circuit and a Control Circuit. The power circuit consists of the three phase bridge rectifier, C Filter and Three Phase PWM Inverter. On the other hand, the control circuit consists of the Computer (Data Acquisition Card/PWM Program), Opto-Couplers and Gate Drivers.

Three Phase Diode Bridge Rectifier

C Filter

Three Phase PWM Inverter (MOSFET)

Induction Motor

Three Phase Power Supply DC Supply (5 V, 12 V)

Gate Drivers
Power Supplies

Opto-Couplers

Power Circuit Control Circuit Motor Circuit

Three Phase PWM Generator (DSP/Data Acquisition)

Figure 1: Complete System Block Diagram Switching signal implementation: Matlab to generate the real time code, and DSP or Data acquisition card. 2.3 PCB specifications: PCB dimensions: Max size of 200mm * 150 mm. Input/Output terminals to be mounted on the enclosure (4mm sockets). 2.4 Project Objectives: Gain understanding of the Power Converters (AC/DC/AC) concept. Gain understanding of the three phase PWM methodology. Calculating and simulating different sections of the circuit. Learning and programming the PWM methodology using MATLAB (Simulink/Data Acquisition). Researching appropriate high voltage components for each section of the circuit (MOSFET, Diodes and Capacitors). Researching appropriate components for the control circuit (Gate drivers, Opto-Couplers and fast recovery diodes). Designing the circuits PCB. Implementation of the power and control circuits on PCB. Testing of the full circuit.

It was then required to find a relationship that relates these frequencies to the modulation index (ma), as the program was specified to automatically change the modulation index value according the any given frequency. As can be seen from Figure 2, the relationship between the two parameters as follows; the maximum modulation index which occurs at maximum frequency of 50 Hz (100% motor speed) is at ma = 0.85, while the minimum modulation index which occurs at the minimum frequency (10% motor speed) occurs at approximately ma = 0.0167. The basic idea of the program is to compute three different sinusoids with the same triangular wave to produce the three phase PWM. As can be seen from Figure 2, a variable frequency block is fed into a saturation block, which in turn limits the input frequencies to the specified range of 5 50 Hz. For example; if the input frequency is below 5 Hz or larger than 50 Hz, then the saturation block would limit the input frequency to the upper or lower ranges of the frequency. After finishing the complier with the real time code, a sub system block was created for it. The sub system block was fed into a Digital Output block which represents the data acquisition interface of the computer. This outputs the three phase signal generated from the program to the Hardware PCB, which in turn controls the output and operation of the power circuitry, and as a result, it controls the speed of the motor. This program was very beneficial for students as it introduced new techniques of signal generation using Real Time Window Target and Data Acquisition Cards.

3. SOFTWARE (PWM GENERATION)

One of the main sections if this project was to construct a three phase PWM program which generates the appropriate pulses or signals that control the switching operations (On/Off) of the inverter circuit (MOSFETs). It was required to design the program in such a way that the generated PWM signals are able to produce an output which enables the power circuitry to control the motor within a speed of 10% - 100% (V/F open loop control). This implied that the range of frequency used to control the motor varies between 5 Hz 50 Hz.

0.016 Gain1 Freq Constant2 Saturation Scope

12:34 t

2*pi

pi/180

sin

>=

oolea Select1A

double

1 Pulses

[0 -2*pi/3 2*pi/3]

Triangle

Figure 2: Three Phase PWM Simulink Program

Pulses

Digital Output Digital Output

Discrete PWM Generator

Standard Dev ices Generic I8255 [90C0h]

Scope

Figure 3: PWM Output Signal at 50 Hz

Figure 4: PWM Subsystem

4. HARDWARE
The hardware section of this project was very challenging, as the design was dealing with high voltages and currents. Therefore, the calculations, simulations and component selection process of each section was very essential, in order to design the appropriate PCB. 4.1 Power Circuitry: 4.1.1 Three Phase Diode Bridge Rectifier: The rectifier circuit consists of six diodes where, theoretically, it can handle a minimum voltage of 566 Volts DC and a minimum direct current of a minimum 0.9A. However, taking a saftey factor of at least one the diodes where chosen to handle a minimum breakdown voltage of 1000V and a continuous direct current up to 3A. Where f: is the frequency between ripples = 300 Hz R: is the output resistance C: is the Filter capacitance

The capacitor was calculated to be 260F that is sufficient to filter out the 1 % ripple voltages. Another criterion required for the selection of the filter capacitor was its ability to withstand high voltages of at least 600V Dc.

4.1.2 Filter Design (Capacitive Filter): The filter situated after the rectifier circuit is connected across the 566 V DC and earth, in order to filter out the ripple voltages produced on the DC output.

4.1.3 Three Phase Power Inverter (MOSFETs): The three phase inverter has an input of 566Volts DC and consists of six MOSFETs. Similar to the diodes in the rectifier section, each MOSFET will be exposed to a maximum voltage of 566Volts and current of 1Amps. However, for safety purposes, the MOSFETs were chosen to handle a minimum breakdown voltage of 1000Volts DC and a maximum current of 3.1Amps. 4.2 Control Circuitry: 4.2.1 MOSFET Drivers: The overall circuit contains three MOSFET driver circuits operating the six MOSFETs of the three inverter circuit. Each gate driver circuit operates a single phase of the three phase power inverter legs. The main application of the gate drivers is that it converts the PWM signals produced from the Data Acquisition Card (5 V logic level signals) to a level where the MOSFETs can operate with. 4.2.2: Bootstrap Circuit: Each gate driver circuit contains a bootstrap circuit as it consists of a diode, capacitor and gate resistors. The bootstrap circuit is used to generate a voltage (VBS) between VB and VS (Refer to Figure 5). This circuit has the advantage of being simple and cost effective. However, it has some disadvantages; the duty cycle and on-time are limited by the requirement to refresh the charge in the bootstrap capacitor as long on-times and large duty cycles require a charge pump circuit.

4. .1: Bootstrap Diode: The diode should be able to block the full power rail voltage of a maximum of 566Volts DC. In addition, it needs to be a fast recovery device (trr > 100 ns) in order to minimise the amount of charge fed back from the bootstrap capacitor in the Vcc supply (10 to 15 V DC), and similarly the high temperature reverse leakage current is important if the bootstrap capacitor has to store charge for long periods of time. 4.2.2.2: Bootstrap Capacitor: The following equation details the minimum charge which needs to be suppled by the bootstrap capacitor:

Where: Qbs = Gate charge of high side fet ICBs(Leak) = Bootstrap capacitor leakage current Qls = 5 nC (500/600 V ICs) f = frequency of operation = 2 to 3 kHz

To calculate the minimum bootstrap capacitance value, the following equation is used:

Where: Therefore:

Figure 5: Bootstrap Supply Schematic In addition, the bootstrap supply is generated by the diode and capacitor combination. The bootstrap circuit operation begins when VS becomes 0V, the bootstrap capacitor between VB and VS starts to charge through the bootstrap diode from the DC power supply, which in turn supplies voltage to VBS. There are many considerations which need to be investigated and taken into account when choosing the appropriate components for the bootstrap circuit, which are explained as the following:

4.2.2.3: Bootstrap Resistor: A resistor is placed in series with bootstrap diode to limit the current when the bootstrap capacitor is initially charged. 4.2.2.4: Gate resistors: The switching speed of the output MOSFET can be controlled by using properly sized resistors controlling the turn-on and turn-off gate currents. To obtain the desired switching time, the gate resistance can be sized using the following equations:

And,

Where, RGon = Gate-on Resistor RDRp = Driver equivalent on-resistance

4.3 The overall circuit: Joining all the above sections together will form the overall circuit of the three phase induction motor controller. As shown in figure 4 below, the overall circuit schematic diagram contains three 230V AC inputs, three PWM inputs, a digital ground and a 10 to 15V DC input and its return path. Furthermore, there are three phase output were connected to the three phase induction motor. 4.4 PCB Design: One of the major components of the project is the PCB design. Since the circuit is operating a maximum DC voltage of 600Volts and currents up to 1Amp, the tracks had to set and positioned in a certain way to minimise the interferences between the high tension and digital controller circuits.

5. TESTING
After completing the hardware and software sections, it was required to test the final product. The testing procedure involved four different sections as follows: Figure 6: RGon Sizing The worst case of sizing is when the MOSFET is turned off (turn-off resistor RGoff). If the voltage drop at the gate exceeds the threshold voltage of the MOSFET, the device may self turn on causing large oscillations and relevant cross conduction. 5.1 Insulation Test: This test is done by applying 500 V DC to the circuit to test the DC and 3 phase input sides of the circuit. 5.2 DC to AC Test: By applying 12 V DC to the DC side of the circuit, and inputting the three phase PWM signals to the circuit, it was required to observe the behaviour of the PWM signal generated and the output of the inverter circuit under low voltage with no load. 5.3 AC to DC Test: Injecting 400 V AC at the input of the circuit to test the DC output with different load conditions. Moreover, it was required to observe the effect of the ripple of voltage in the DC output voltage. The circuit perfectly managed to reduce the ripple voltage to a very low percentage of 1 % under all loads. 5.4 Functionality Test: After successfully passing the aforementioned tests it was finally time to test the full circuit together. The circuit successfully managed to control the speed of the induction motor at speed ratings that vary between 10 100 %, and at a frequency range of 5 to 50 Hz. The PWM program managed to provide the open loop voltage to frequency control. Moreover, the ripple voltages were reduced to a very low level of 1 %.

Figure 7: RGoff Sizing (when low side is off and high side is on) The following equation relates the MOSFET gate threshold voltage to the collector:

4.2.3 High Tension Isolation Circuit: In order to isolate the high tension circuit from the digital control PWM signals, an isolation circuit was implemented at the digital inputs of the PWM signals. The selected isolation is an optically coupled isolator phototransistor output.

Fuse

D1 1N5408 Phase A PhaseB PhaseC

D3 1N5408

D5 1N5408

C filter 1 470uF

RA1 100

Q1 IRFBG30

RB1 100

Q3 IRFBG30

RC1 100

Q5 IRFBG30 Phase A PhaseB

C filter 2 470uF D2 1N5408 D4 1N5408 D6 1N5408 RA2 100 Q2 IRFBG30 RB2 100 Q4 IRFBG30 RC2 100 Q6 IRFBG30 PhaseC

R Gnd

DG1 Diode HO VB VS NC DG2 7 8 6 5

PWM1

R1 100 OptoCoupler1

R4 100 12V C11 10uF 2 1 3 4

Gate1 IN VCC COM LO IR2111

PWM Gnd

C12 Cap 220pF

PWM2

R2 100 OptoCoupler2

R5 100 12V C21 10uF 2 1 3 4

Gate2 Diode IN VCC COM LO IR2111 DG3 HO VB VS NC

7 8 6 5

C22 Cap 220pF

PWM3

R3 100 OptoCoupelr3

R6 100 VCC C31 10uF 2 1 3 4 Gate3 Diode IN VCC COM LO IR2111 HO VB VS NC 7 8 6 5

C32 Cap 220pF

Figure 8: Overall Circuit

6. CONCLUSION
The project was a very useful introduction for students at Victoria University to the world of power electronics applications. The project involved many aspects which needed scrupulous attention to detail. The circuit design managed to perform perfectly under all testing procedures, and managed successfully to drive and control the speed of the induction motor at the required ratings. Finally, the project assisted students in learning new tools and design methodologies.

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Q. Jiang, Lecture Notes for the Subject Power Systems 3.2, School of Electrical Engineering, Victoria University. O.M.F Muhialdin, A. Nahas, A. Massaud, Three Phase Power Converter Project (AC/DC/AC) Report, School of Electrical Engineering, Victoria University.

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7. ACKNOWLEDGMENT
We would like to thank the subject supervisor Dr. Qin Jiang for the opportunity on working on such a beneficial project. And special thanks to Mr. Taky Chan, the lab supervisor for his guidance, advice, and continuous support for the duration of this project.

REFERENCES
[1] N Mohan, T.M. Undeland and W.P. Robbins, Power Electronics: converter, applications and design, Media Enhanced third edition, 2002. A. Merello, A. Rugginenti and M. Grasso, Using monolithic high voltage gate drivers, Reference: DT04-4 revA, www.irf.com. J. Adams, Bootstrap Component Selection for Control ICs, Reference: DT98-2a, www.irf.com.

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