Stig Munk-Nielsen

Power losses in PWM-VSI inverter using NPT or PT IGBT devices

This paper investigates the power losses for two different IGBT technologies (nonpunch through and punch through) for use in PWM-VSI inverters in order to choose the right device technology for a given application. A loss model of the inverter is developed based on experimental determination of the power losses. The loss model is used on two different modulation strategies which are a sine wave with a third harmonic added and a 60/spl deg/-PWM modulation where only two inverter legs are active at the same time. The two IGBT technologies are characterized on an advanced measurement system which is described. The total power losses in the inverter are estimated by simulation at different conditions and it is concluded that the nonpunch through (NPT) technology is most useful for higher switching frequencies, while the punch through (PT) technology is especially useful at lower switching frequencies and high load currents. It is also concluded that the 60/spl deg/-PWM modulation has the lowest power losses and the power losses are almost independent of phase angle cos(/spl phi/) for normal motor operation. >

Evaluation of modulation schemes for three-phase to three-phase matrix converters

This paper presents a method for evaluating different modulation schemes employed with three-phase to three-phase matrix converters. The evaluation method addresses three important modulator characteristics: the output waveform quality, the input waveform quality and the switching losses associated with the modulation schemes. The method is used to evaluate four different modulation strategies, all based on the direct space-vector modulation approach. Further, regarding the switching losses, the paper proposes a new space-vector approach by which the switching losses can be reduced by 15%-35%, depending on the output load angle. This new modulation approach is applicable whenever the output voltage reference is below half the input voltage and the output voltage quality is then superior to that of the conventional space vector modulation scheme. The functionality of the new modulation scheme is validated by both simulations and experimental results and compared to waveforms obtained by using exiting space vector modulation schemes. The output voltage of the proposed scheme turns out to be comparable to the best of the conventional schemes while the input current is more distorted.

An overview of the reliability prediction related aspects of high power IGBTs in wind power applications

Abstract Reliability is becoming more and more important as the size and number of installed Wind Turbines (WTs) increases. Very high reliability is especially important for offshore WTs because the maintenance and repair of such WTs in case of failures can be very expensive. WT manufacturers need to consider the reliability aspect when they design new power converters. By designing the power converter considering the reliability aspect the manufacturer can guarantee that the end product will ensure high availability. This paper represents an overview of the various aspects of reliability prediction of high power Insulated Gate Bipolar Transistors (IGBTs) in the context of wind power applications. At first the latest developments and future predictions about wind energy are briefly discussed. Next the dominant failure mechanisms of high power IGBTs are described and the most commonly used lifetime prediction models are reviewed. Also the concept of Accelerated Life Testing (ALT) is briefly reviewed.

Design of Neutral-Point Voltage Controller of a Three-Level NPC Inverter With Small DC-Link Capacitors

A neutral-point-clamped three-level inverter with small dc-link capacitors is presented in this paper. The inverter requires zero average neutral-point current for stable neutral-point voltage. The small dc-link capacitors may not maintain capacitor voltage balance, even with zero neutral-point current. This may happen due to nonlinearities present in the circuit. This requires a fast control of the neutral-point voltage. A simple carrier-based modulation strategy which allows modeling of the neutral-point voltage dynamics as a continuous function of power drawn from the inverter is proposed. This continuous model shows that the neutral-point current is proportional to the power drawn from the inverter, and it enables the use of a well-established classical control theory for the neutral-point voltage controller design. A simple proportional integral controller is designed for the neutral-point voltage control on the basis of the continuous model. The design method for optimum performance is discussed. The implementation of the proposed modulation strategy and the controller is very simple. The controller is implemented in a 7.5-kW induction machine-based drive with only 14 μF dc-link capacitors. Also, the experimental results show that fast and stable performance of the neutral-point voltage controller are achieved and thus verify the validity of the proposed control approach.

Simulation with ideal switch models combined with measured loss data provides a good estimate of power loss

Ideally, converter losses should be determined without using an excessive amount of simulation time. State-of-the-art power semiconductor models provide good accuracy; unfortunately they often require a very long simulation time. This paper describes how to estimate power losses from simulation using ideal switches combined with measured power loss data. The semiconductor behavior is put into a look-up table, which replaces the advanced semiconductor models and shortens the simulation time. To extract switching and conduction losses, converter is simulated and the semiconductor power losses are estimated. Measurement results on a laboratory converter are compared with the estimated losses and a good agreement is shown. Using the ideal switch simulation and the post processing power estimation program, a ten to twenty fold increase in simulation speed is obtained, compared to simulations using advanced models of semiconductors.

A new modular multilevel converter with integrated energy storage

This paper introduces a new modular converter with integrated energy storage based on the cascaded half-bridge modular multilevel converter with common DC bus. It represents a complete modular solution with power electronics and energy storage building blocks, for medium and high voltage applications. Furthermore, this solution can interconnect a DC and AC grid with bidirectional power flow, where both of them can receive or generate excess power to the third source integrated in each converter sub-module. This particularity enables the converter usage as a high voltage UPS system in the future HVDC meshed grids. Its functionality and flexibility makes the converter independent on the energy storage unit characteristic. The converter concept with its basic functions and control schemes are described and evaluated in this paper.

An Active Damping Technique for Small DC-Link Capacitor Based Drive System

A small dc-link capacitor based drive system shows instability when it is operated with large input line inductance at operating points with high power. This paper presents a simple, new active damping technique that can stabilize effectively the drive system at unstable operating points, offering greatly reduced input line current total harmonic distortion. The proposed method requires only a first-order, high-pass filter with a gain. Active damping voltage terms, linked directly to the dc-link voltage ripple through gain units, are injected to the drive machine for stabilizing the operating points. The stabilizing effect of the active damping terms is demonstrated for an induction machine based drive system. The effects of the added damping terms on the machine current and dc-link voltage are analyzed in detail. A design recommendation for the proposed active damping terms is given. Experimental results verifying the effectiveness of the new active damping method are presented.

Converter Structure-Based Power Loss and Static Thermal Modeling of The Press-Pack IGBT Three-Level ANPC VSC Applied to Multi-MW Wind Turbines

Wind turbine converters demand high power density due to nacelle space limitation and high reliability due to high maintenance cost. Depending on the converter structure, the converter thermal performance determines the converter power density and reliability. To estimate the converter thermal performance, the converter structure-based power loss and thermal models are developed in this study for the medium-voltage (MV) three-level active neutral-point-clamped voltage source converter (3L-ANPC-VSC) utilizing 4500 V-1800 A press-pack insulated-gate bipolar transistor-diode pairs and interfacing a 6 MW wind turbine to a MV grid. The switching power loss models are built using the experimental switching power loss data acquired via the double-pulse tests conducted on a full-scale 3L-ANPC-VSC prototype. The converter static thermal model is developed based on the double-sided water-cooled press-pack switches. Via a single-phase test setup with two full-scale 3L-ANPC-VSC legs, the developed power loss and thermal models are validated experimentally. Employing the validated models, the 3L-ANPC-VSCs thermal performance is demonstrated on simulation for a 6 MW wind turbine grid interface. Hence, these converter structure-based models developed and validated in this study are proven to be suitable for the converter power density and reliability studies based on converter thermal performance.

Improving Power Converter Reliability: Online Monitoring of High-Power IGBT Modules

The real-time junction temperature monitoring of a high-power insulated-gate bipolar transistor (IGBT) module is important to increase the overall reliability of power converters for industrial applications. This article proposes a new method to measure the on-state collector-emitter voltage of a high-power IGBT module during converter operation, which may play a vital role in improving the reliability of the power converters. The measured voltage is used to estimate the module average junction temperature of the high and low-voltage side of a half-bridge IGBT separately in every fundamental cycle of the current by calibrating them at load current. The measurement is very accurate and also measures the voltage at the middle of a pulse-width modulation (PWM) switching. A major objective is that this method is designed to be implemented in real applications. The performance of this technique is measured in a wind power converter at a low fundamental frequency. To illustrate more, the test method as well as the performance of the measurement circuit are also presented. This measurement is also useful to indicate failure mechanisms such as bond wire lift-off and solder layer degradation. The measurements of and rise in the junction temperature after five million cycles of normal operation of the converter are also presented.

A review on real time physical measurement techniques and their attempt to predict wear-out status of IGBT

Insulated Gate Bipolar Transistors (IGBTs) are key component in power converters. Reliability of power converters depend on wear-out process of power modules. A physical parameter such as the on-state collector-emitter voltage (Vce) shows the status of degradation of the IGBT after a certain cycles of operation. However, the Vce mainly shows the wear-out of bond wire lift-off and solder degradation. The Vce is normally used to estimate the junction temperature in the module. The measurement of Vce is sensitive to the converter power level and fluctuations in the surrounding temperature. In spite of difficulties in the measurement, the offline and online Vce measurement topologies are implemented to study the reliability of the power converters. This paper presents a review in wear-out prediction methods of IGBT power modules and freewheeling diodes based on the real time Vce measurement. The measurement quality and some practical issues of those measurement techniques are discussed. Furthermore, the paper proposes the requirements for the measurement and prognostic approach to determine wear-out status of power modules in field applications. The online Vce measurement for a selected topology is also shown in the paper.