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Fast development of a DSP-based control of

three-phase four-leg inverter for auxiliary power


supply converters using hardware-in-the-loop
Igor Musulin1, Josip Babi1 and eljko Jakopovi2
2

1 KonarElectrical Engineering Institute Inc., Zagreb, Croatia


Faculty of Electrical Engineering and Computing, Zagreb, Croatia
igor.musulin@koncar-institut.hr

Abstract This paper presents an easy and relatively fast way


to design and implement control system of three-phase four-leg
inverter in DSP (digital signal processor). The inverter model is
emulated using hardware-in-the-loop simulator and control
system is coded in TI DSP identical to the target system using
graphically based block-diagram programming environment. A
multi-loop cascade control is applied and two control strategies
are implemented: i) the PI (proportional-integral) controllers
with symmetrical sequence current and voltage decomposition
and ii) the PIR (proportional-integral-resonant) controllers.
Experimental results with symmetrical and single-phase loads
are presented. The control algorithms are evaluated based on the
execution time. Results show that PIR based control executes
roughly three times fasted that PI control.
Index Terms auxiliary power supply, carrier-based pulsewidth modulation, hardware-in-the-loop, proportional-integral
controller, proportional-integral-resonant controller, sequence
decomposition, three-phase four-leg inverter.

systems, power quality (FACTS) and energy transfer


(HVDC), but have not yet been extensively used for the
development of the power electronic systems. This is mainly
due to the inability to accurately simulate fast voltage-source
converters with high-frequency PWM controls and large
number of switches [2]. However, with the rapid development
of fast field-programmable gate array (FPGA) chips, a wide
range of commercially available HIL devices with low latency
are available.
This paper is organized as follows. Chapter II introduces
the problem of non-symmetrical loads in auxiliary power
supply converters in railway vehicles. Three inverter
topologies are presented, two of which are today considered
as standard solutions in auxiliary power supply converters in
railway vehicles. The last one, a three-phase four-leg inverter,
with its modulation technique and control strategy is described
in more details in Chapter III and Chapter IV. DSP and HIL
implementation are described in Chapter IV. Simulation and
experimental results, including the measurement of execution
time, (Chapter V) and conclusion (Chapter VI) are given at the
end.

I.
INTRODUCTION
When designing new power electronics converter two
different models are often used: time discrete model and
average model. In time discrete model current and voltage
waveforms are mathematically represented for each interval.
This model is mainly used for detailed converter analysis.
However, mathematical expressions can sometimes become
complicated and, since the model is nonlinear, it is not suitable
for the development of the control algorithm. For this reason,
a linear frequency domain model is used and an averaging is
done to get an average model. A control design engineer will
usually spend a lot of time and work hours on the
development, testing and optimization of a new design and/or
algorithm while working with one of the previously
mentioned off-line models. Furthermore, extensive
experiments and tests on target converter, which can often be
time and money consuming, can lead to new problems.
One promising alternative is using a digital real-time
simulator that is capable of emulating power electronics
hardware. Hardware-in-the-loop (HIL) simulation enables
testing of control software and hardware for power electronics
by replacing the real electrical system with a real-time
emulator. Analog and digital signals are replaced and
emulated using a virtual model. This accelerates the
development of control algorithms. Some of the advantages of
using hardware-in-the-loop simulators include safe testing
environment, ability to test the full operating range, including
failures test, repeatable testing, flexible reconfiguration and
automated testing [1]. Hardware-in-the-loop simulators are
already used in industries like automotive, aerospace, power

II. NON-SYMMETRICAL LOADS IN POWER SYSTEM


A recent survey has shown that today non-linear loads (e.g.
rectifiers, frequency converters, arc furnaces, controlled motor
drives, etc.) are approaching between 75 90 % of the loading
in electric utility distribution systems [3]. Non-symmetrical
loads (e.g. single- or two-phase loads in a three-phase system)
lead to current and voltage unbalance. A large number of nonlinear and non-symmetrical loads generate harmonics, cause
increase of neutral currents, overheating of drives and
equipment, reduction in the effective torque, etc.
While the problem is not so evident in low voltage electric
grid due to somewhat evenly distributed single-phase loads,
the influence of non-symmetrical loads is more apparent in
isolated systems like uninterruptible power supply, distributed
renewable energy sources operating in island mode and
auxiliary power supply for ships, airplanes and railway
coaches. For example, three-phase output inverter in an
auxiliary power supply for trains must generate three-phase
and single-phase output with grounded neutral wire. The
three-phase output is used for supplying air-conditioning units
and auxiliary inverter, main inverter and transformer fans.
Single-phase output supplies evaporators and condenser
blower fans, lighting and 230 V general purpose power
sockets for passenger use.

Single-phase output can be obtained from a three-phase


inverter by:
an additional single-phase 400/230 V or delta/wye
three-phase transformer,
a split dc-linked capacitors and tying the neutral
grounded point to the midpoint of the dc-linked
capacitors
a four-leg inverter topology and tying the neutral
grounded point to the mid-point of the fourth leg.
Solution with a transformer is the most widespread, mainly
due to its simplicity and minimal changes in design and
control algorithm. Galvanic isolation and elimination of zero
currents are considered advantages, while transformer price
and weight are sometimes seen as disadvantages, mostly in
applications like train or tram converters where the total mass
of converter plays a significant role. Second solution, if
rearranged actually consists of three single-phase half bridge
inverters. This enables the independent control of the each leg
(i.e. phase). In case of unbalanced loads, neutral current flows
through the dc capacitors. Voltage oscillations across
capacitors are directly influenced by neutral current [4].
Therefore, high value capacitors or additional balancing
circuits must be used for voltage balancing.

switch ON time calculation can take up a lot of processor


calculation time and lead to digital delay.
On the other hand, carrier-based PWM algorithm [513] is
easy to implement since it uses only the comparison of
reference waveform with the triangular waveform. This
modulation technique is similar to sinusoidal PWM where
switching states are determined by comparing triangular
carrier and three sinus reference waveforms. The only
difference is in the reference waveform generation where
additional, so-called, offset voltage is added to sinusoidal
waveform. Best voltage synthesis (e.g. utilization of dc bus
voltage and low harmonic generation) can be achieved by
operating in the linear modulation region and selecting offset
voltage as shown in (1).

Vn0*

S7

S1

IV. DESIGN OF CONTROL SYSTEM


A multi-loop cascade control strategy is adopted in this
paper. An outer voltage control loop is used for voltage
reference tracking. Its output acts as a reference for the current
control loop. Current control loop is used for protection of the
inverter against overload and for the improvement of the
control system response.
Three-phase four-leg inverter control is based on dq0
coordinate transformation. However, with unbalanced load d
and q channel voltage and current oscillate with frequency 2,
while 0 channel voltage and current oscillates with .
Therefore the control bandwidth should be high enough to
attenuate disturbance caused by the unbalanced load. On the
other hand, high bandwidth can affect system stability.
Furthermore, since control values are oscillating classical PI
controller cannot achieve zero steady-state error.
As a solution, a transformation of current and voltage
waveforms to the symmetrical components (i.e. sequence
decomposition) is proposed in [1417]. From there, using
abc/dq coordinate transformation and standard PI controllers

S3

S5

VDC/2

Lf

L1

a
+
VDC

Lf

Vab

Lf

Vbc

c
Cf

VDC/2
S8

S2

(1)

where:
Vmin = min (Van, Vbn, Vcn), and
Vmax = max (Van, Vbn, Vcn).

III. THREE-PHASE FOUR-LEG INVERTER TOPOLOGY


AND MODULATION
A three-phase four-leg inverter topology show in Fig. 1,
although first mentioned in the literature in the early 90is, has
not been extensively used in commercial applications. The
neutral wire is connected to the neutral point of the added
fourth leg. Among main advantages are: i) higher utilization
of dc voltage (more than 15 % compared to conventional
three-phase three-leg inverter) and ii) neutral current flows
through the fourth leg and not through the dc capacitors, thus
minimizing dc input voltage oscillations. Complex
modulation scheme and large number of semiconductor
devices can be regarded as a disadvantage. Nevertheless, this
type of inverter presents an ideal solution for four-wire
systems for supplying non-symmetrical and single-phase
loads since it offers independent control of currents of each
phase.
Two modulation strategies for three-phase four-leg
inverters operating at constant switching frequency stand out:
carrier-based pulse-width modulation (PWM), and
three dimensional space vector PWM (3D SVPWM).
A 3D SVPWM is preferable for digital implementation,
but requires faster processors since sector determination and

Vmax
Vmin 0
2 ,

V
min ,
Vmax 0
2
V

V
min
max
, otherwise

S4

Cf

Vca

L2
L3

Cf

S6

Ln

Figure 1. Three-phase four-leg inverter topology

one can easily control positive, negative and zero component


of a (now) symmetrical system.
Instantaneous positive, negative and zero sequence are
calculated using (2). Time domain implementation of an
operator a (= 1/2 + j 3/2) is shown in Fig. 2. It can be seen
that a 90 phaseshift associated with j is needed. This is done
using simple second-order low-pass filter tuned at the input
frequency in with a damping factor = 1 as shown in (3) and
further explained in [18]. Time domain implementation of a
secondorder lowpass filter is shown in Fig. 3. The operator
a2 can be implemented in a similar manner.

a2
1
a

a
a2

1
a
a2

a
a 2 va

1
1

a va
a 2

LPF

LPF
Figure 2. Implementation of operator a in time domain

LPF

in

in

vc T

vb

a vin

vabc zero

a 2
a va

vin

vabc negative

a
1
a2

vabc positive

a2

a
1

a
2
a

vb

vc T

vb

vc

(2)
Figure 3. Implementation of LPF in time domain

[12], [15], [1922]. PIR controller is represented by (5).


Resonant based controllers have an infinitive gain at resonant
frequency 0, the controller can successfully eliminate steadystate error when control values are oscillating with 0.
Another advantage of using resonant based controllers is the
simple control strategy, no additional coordinate
transformations and fastest time of execution. The last point
will be further explored in Chapter VI. It is important to note
that abc/dq0 coordinate transformation must be used here.

in2
s in 2

(3)

Subsequently, sequence composition (4) and dq/abc


transformation are used to get Va, Vb and Vc for PWM
modulation, Fig 4.
Another solution is using PR (Proportional-Resonant) or
PIR (Proportional-Integral-Resonant) controllers for control

vabc

a
a2

L1

L2

L3

a va positive va negative va zero


a 2

1
a
a2

VDC

Load

PI

PI

vdq load pos


idq load pos

vd neg*
vq neg*

PI

PI

+
C

idq inv pos

vq load vd load
+
+

vq pos*

vd pos*

iq load id load
iq inv id inv
+
+
+
+

vq load vd load

Vd pos

Vq pos

vd load vq load

id inv

iq inv

Va pos
Vb pos
Vc pos

Va pos
Va neg
Va zero

Sequence
composition

idq inv pos


idq inv neg
idq inv zero

dq control loop

Vd neg

Vq neg

idq inv neg

vdq load neg


idq load neg
vd zero*
vq zero*

dq/
abc

Vabc

PWM

Equ. 4

dq control loop

ic load
ib load
ia load

ic inv
ib inv
ia inv

vc load
vb load
va load

dq/
abc

Va neg
Vb neg
Vc neg

dq control loop

Vd zero
Vq zero

idq inv zero

vdq load zero


idq load zero

dq/
abc

Va zero
Vb zero
Vc zero

Figure 4. Control system of a three-phase four-leg inverter using symmetrical components

vdq load pos


vdq load neg
vdq load zero
idq load pos
idq load neg
idq load zero
vdq pos*
vdq neg*
vdq zero*

abc/dq
abc/dq

abc/dq
abc/dq
abc/dq

abc/dq
abc/dq
abc/dq

abc/dq
abc/dq
abc/dq

abc/dq

iabc inv pos


iabc inv neg
iabc inv zero

Sequence
decomposition

vabc load pos


vabc load neg
vabc load zero

Sequence
decomposition

iabc load pos


iabc load neg
iabc load zero

Sequence
decomposition

vabc pos*
vabc neg*
vabc zero*

Sequence
decomposition

Equ. 2

Equ. 2

Equ. 2

Equ. 2

ia inv
ib inv
ic inv
va load
vb load
vc load
ia load
ib load
ic load
va*
vb*
vc*

(4)

1
s
Gc s K P K I K R 2
s
s 02

In Fig. 6 and 8 an output voltage and current response in


the case of switching a 12 kW single-phase load into already
symmetrical loaded three-phase output (Pthree-phase = Pmax) is
shown. Dashed vertical line represents the start of transition.
Both algorithms exhibit the similar behaviour regarding the
settling time. For the first controls strategy, before switching
a single-phase loads negative and zero sequence are equal to
zero or approximately zero due to non-ideal acquisition and
noise in measured channels. In the second algorithm, resonant
part is equal to zero and PIR controller behaves as PI. Zero (0)
part of abc/dq0 transformation is also equal or approximately
zero.
Output voltage and current response for a switching of a
24 kW single-phase load from a minimum load (Pthree-phase =
Pmin) is shown for two control strategies in Fig. 7 and Fig 9. It
is seen that both algorithms behave similar and produce
symmetrical output voltage in case of unsymmetrical loads.
The response time depends on the controller parameters.
While there is certainly a room for the further improvement,
three-phase output response in an auxiliary power supply for
trams and trains generally does not need to be a fast one. Loads
are quite robust and the settling time of up to two periods is
acceptable.

(5)

where:
0 = 2 for d and q frame, and
0 = for 0 frame.
V.

DSP AND HARDWARE-IN-THE-LOOP


IMPLEMENTATION
The control algorithm is coded using GRAP, graphical
block-diagram based programming environment [23], [24], so
there is no need for textual coding and the programming is
done relatively fast. Previously developed control algorithm
in Matlab/ Simulink environment is easily transferred using
corresponding optimized block elements.
The code itself is implemented in Texas Instruments
TMS320F28335 controlCARD with operating core frequency
of 150 MHz. Three different control tasks are used, namely
CT1, CT2 and CT3. The fastest control task is set at 20 kHz
and it is used for acquisition, A/D conversion and PWM
waveform generation. The second task at 5 kHz is used for
sequence
(de)composition,
control
sequence,
and
communication while the slowest task at 500 Hz is used for
monitoring and diagnostics.
Using the HIL simulator one can easily implement any
desired topology, as it is done with the three-phase four-leg
inverter topology. A total of four voltage measurements (input
dc voltage and three output ac phase voltages) and six current
measurements (three inverter line currents and three load line
currents) are used for control. Additional current and voltage
measurements can also be used. HIL simulation time step is
set to 1s. Experimental setup is shown in Fig. 5.

va load

400

vc load
vb load

Voltage, V

200

200

400
0,0

0,5

1,0

1,5

Time, ms
60

ia load ib load

40
Current, A

VI. HARDWARE-IN-THE-LOOP SIMULATION AND


EXPERIMENTAL RESULTS
Two control strategies from Chapter IV are used: PI
control with coordinate transformation and PIR control. An
input dc voltage is set to 700 V while output reference ac line
voltage is set to 230 V. The inverter switching frequency is 3
kHz. Maximum three-phase output power is Pmax is 24 kW
while minimum is Pmin 500 W and corresponds to the power
of main and auxiliary converter fans.

ic load

20
0

20
40
60
0,0

0,5

1,0

1,5

Time, ms

Figure 6. Voltage and current waveforms; PI control; Pthree-phase = Pmax

va load

400

vc load
vb load

Voltage, V

200

200

400
0,0

0,5

1,0

1,5

1,0

1,5

Time, ms
60

ic load

Current, A

40
20
0

20
40
60
0,0

0,5
Time, ms

Figure 5. HIL experimental setup with controller and interface board

Figure 7. Voltage and current waveforms; PI control; Pthree-phase = Pmin

va load

400

Table 1.

vc load
vb load

no
1
2
3
4
5

Voltage, V

200

200

400
0,0

0,5

1,0

1,5

Execution time
process
Sequence decomposition
Coordinate transformation
Control
Coordinate transformation
Sequence composition
Total (1+2+3+4+5)

PI control
50,88 s
9,36 s
18,36 s
2,88 s
7,41 s
88,89 s

PIR control

4,84 s
19,37 s
1,35 s

25,56 s

Time, ms
60

Current, A

complex control structure as an obvious disadvantage over PR


or PIR based control. In this paper, apart from testing different
control strategies, the execution time is measured for each one.
Five distinctive parts of control algorithm are selected:
sequence decomposition, sequence composition, coordinate
transformation (abc/dq(0)and dq(0)/abc) and control. Other
parts like system definition, A/D conversion, scaling, PWM
and recorder are the same for each algorithm and are not
measured. Execution times are given in Table 1.
PI based control strategy (Fig. 5) has only four sequence
decomposition calculations (12,72 s 4 = 50,88 s) and one
sequence composition calculation. In Table 1 it can be seen
that the sequence (de)composition takes roughly 65 % of total
execution time. There are also twelve abc/dq and three dq/abc
coordinate transformations per task. Although single abc/dq
transformation last only 0,78 s compared to 1,21 s for
abc/dq0, a total coordinate transformation time is two times
larger due to number of calculations. Also, control is executed
three times per task, once for each system (i.e. positive,
negative and zero). It is interesting to note that the control
itself is executed faster (18,36 s compared to 19,37 s). This
leads to conclusion that digital implementation of resonant
part of PIR controller used in this example takes a lot of
computing time. For PIR control strategy there is no sequence
(de)composition and coordinate transformation is executed
just five times (4 abc/dq0 + 1 dq0/abc) per task. The
control is done only once per task, but there are three frames
to control (d, q and 0), opposite to previous case where there
are only two (d and q frame).
Comparing the total execution time for PI and PIR based
control strategies, from Table 1 it can be seen that PIR
executes roughly 60 % faster than PI. This means that a
control task CT2 in PIR control strategy can be set to higher
sampling rate to achieve better stability, among others.
Additional optimization regarding the PI control strategy
can be done by transferring sequence (de)composition

ic load
ia load ib load

40
20
0

20
40
60
0,0

0,5

1,0

1,5

Time, ms

Figure 8. Voltage and current waveforms; PIR control; Pthree-phase = Pmax

va load

400

vc load
vb load

Voltage, V

200

200

400
0,0

0,5

1,0

1,5

1,0

1,5

Time, ms
60

ic load

Current, A

40
20
0

20
40
60
0,0

0,5
Time, ms

Figure 9. Voltage and current waveforms; PIR control; Pthree-phase = Pmin

The identical waveforms can be seen on the HIL analog


outputs, Fig. 10 and Fig 11. HIL input/output is 5 V so
appropriate scaling must be done. In this case, voltage and
current scaling factor is set to 100 V = = 1 V and 100 A = = 1
V, respectively.
Many papers dealing with the control of a three-phase
four-leg inverter using coordinate transformation refer to

Figure 10. Voltage and current (Ch4: ic load) waveforms corresponding to


test case in Fig. 7; 1 V = = 100 V (A)

Figure 11. Voltage and current (Ch4: ic load) waveforms corresponding to


test case in Fig. 9; 1 V = = 100 V (A)

calculations to dedicated chips (e.g. FPGA) or implementing


own digital integrators (e.g. Firs-Order IIR Digital Integrator
based on backward rectangle method) instead of using builtin elements.

[13]

VII. CONCLUSION
In this paper a new way of developing control algorithm
using hardware-in-the-loop has been investigated. Two
different control strategies have been implemented and tested.
Special emphasis is given to measuring the execution time.
PIR controller has the advantage compared to PI controller
mainly due to lack of sequence (de)composition calculation
and less coordinate transformation calculations.
Using this way of design, the process of prototyping and
testing of complex control systems is simplified. Control is
coded on the same TI controlCARD used in the target
converter. This enables user to easy implement desired control
strategy, test various control algorithms, compare overall
exection time and load and, if necessary, further optimize
algorithm, all before actually beginning to work on a target
model.

[14]

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[16]

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[18]
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Vehicles and Power Generation Units, PhD thesis, University of
Zagreb, 2011.

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