Observer based dynamic adaptive cooling system for power modules

This paper presents an advanced dynamic cooling strategy for multi-layer structured power electronic modules. An observer based feedback controller is proposed to reduce a power device or module's thermal cycle amplitude during operation, with the aim of improving reliability and lifetime. The full-state observer design is based on a developed Cauer type thermal model. The observer enables estimation and control of the temperature at reliability critical locations only measuring one accessible location. This makes the method particularly powerful and suitable for application in power systems. The designed strategy is confirmed experimentally. Although the experiment is developed for a specific application scenario, the proposed strategy is of general validity

Reduced-order electro-thermal models for computationally efficient thermal analysis of power electronics modules

Silicon and Silicon Carbide-based power module are common in power electronic systems used in a wide range of applications, including renewable energy, industrial drives and transportation. Reliability of power electronics converters is very important in many applications. It is well known that reliability and ultimately the lifetime of power modules is affected by the running temperature during power cycles. Although accurate thermal models of power electronics assemblies are widely available, based e.g. on computational fluid dynamics (CFD) solvers, their computational complexity hinders the application in real-time temperature monitoring applications. In the thesis, geometry-based numerical thermal models and compact thermal models will be developed to address the fast thermal simulation in the electronic design process and real-time temperature monitoring, respectively. Accurate geometry-based mathematical models for dynamic thermal analyses can be established with the help of finite difference methods (FDM). However, the computational complexity result from the fine mesh and large dimension of ordinary differential equations (ODE) system matrix makes a drawback on the analysis in parametric studies. In this thesis, a novel multi-parameter order reduction technique is proposed, which can significantly improve the simulation efficiency without having a significant impact on the prediction accuracy. Based on the block Arnoldi method, this method is illustrated by referring to the multi-chip power module connected with air-force cooling system including plate-fin heatsink. In real-time temperature monitoring, more compact tools might be preferable, especially if operating and boundary conditions such as losses and cooling are now known accurately, as it’s often the case in practical applications. Compared with geometry-based model which is more suitable in the design of power modules, lumped parameter thermal compact model is simpler and can be applied in real-time temperature prediction during the power cycles of power modules. This thesis proposes a reduced order state space observer to minimize the error caused by air temperature and air flow rate. Additionally, a novel feedback mechanism for disturbance estimation is introduced to compensate the effect result from the error of input power loss, air flow and changes of other nonlinearities

Accurate Inverter Error Compensation and Related Self-Commissioning Scheme in Sensorless Induction Motor Drives

This paper presents a technique for accurately identifying and compensating the inverter nonlinear voltage errors that deteriorate the performance of sensorless field-oriented controlled drives at low speed. The inverter model is more accurate than the standard signum-based models that are common in the literature, and the self-identification method is based on the feedback signal of the closed-loop flux observer in dc current steady-state conditions. The inverter model can be identified directly by the digital controller at the drive startup with no extra measures other than the motor phase currents and dc-link voltage. After the commissioning session, the compensation does not require to be tuned furthermore and is robust against temperature detuning. The experimental results, presented here for a rotor-flux-oriented SFOC IM drive for home appliances, demonstrate the feasibility of the proposed solution

High Frequency Injection Sensorless Control for a Permanent Magnet Synchronous Machine Driven by an FPGA Controlled SiC Inverter

As motor drive inverters continue to employ Silicon Carbide (SiC) and Gallium Nitride (GaN) devices for power density improvements, sensorless motor control strategies can be developed with field-programmable gate arrays (FPGA) to take advantage of high inverter switching frequencies. Through the FPGA’s parallel processing capabilities, a high control bandwidth sensorless control algorithm can be employed. Sensorless motor control offers cost reductions through the elimination of mechanical position sensors or more reliable electric drive systems by providing additional position and speed information of the electric motor. Back electromotive force (EMF) estimation or model-based methods used for motor control provide precise sensorless control at high speeds; however, they are unreliable at low speeds. High frequency injection (HFI) sensorless control demonstrates an improvement at low speeds through magnetic saliency tracking. In this work, a sinusoidal and square-wave high frequency injection sensorless control method is utilized to examine the impact an interior permanent magnet synchronous machine’s (IPMSM) fundamental frequency, injection frequency, and switching frequency have on the audible noise spectrum and electrical angle estimation. The audible noise and electrical angle estimation are evaluated at different injection voltages, injection frequencies, switching frequencies, and rotor speeds. Furthermore, a proposed strategy for selecting the proper injection frequency, injection voltage, and switching frequency is given to minimize the electrical angle estimation error

Thermal Stress Based Model Predictive Control of Power Electronic Converters in Electric Drives Applications

Power electronics is used increasingly in a wide range of application fields such as variable speed drives, electric vehicles and renewable energy systems. It has become a crucial component for the further development of emerging application fields such as lighting, more-electric aircrafts and medical systems. The reliable operation over the designed lifetime is essential for any power electronic system, particularly because the reliability of power electronics is becoming a prerequisite for the system safety in several key areas like energy, medicine and transportation. The thermal stress of power electronic components is one of the most important causes of their failure. Proper thermal management plays an important role for more reliable and cost effective energy conversion. As one of the most vulnerable and expensive components, power semiconductors, are the focus of this thesis. Active thermal control is a possibility to control the junction temperatures of power semiconductors in order to reduce the thermal stress. For this purpose the finite control-set model predictive control (FCS-MPC) is chosen. In FCS-MPC the switching vector is selected using a multi-parameter optimization that can include non-linear electric and thermal stress related models. This switching vector is directly applied to the physical system. This allows the direct control of the switching-state and the current through each semiconductor at each time instant. For cost-effective control of the thermal stress a measure for the degradation of the semiconductor's lifetime is necessary. Existing lifetime models in literature are based on the thermal cycling amplitudes and maximum values of recorded junction temperature profiles. For online estimation of the degradation, a method to detect the junction temperatures of the semiconductors during operation is designed and validated. An existing and proven lifetime model is adapted for online estimation of the thermal stress. An algorithm for the FCS-MPC is written that utilizes this model to drive the inverter with reduced stress and equalize the degradation of the semiconductors in a power module. The algorithm is demonstrated in simulation and validated in experiment. A technique to find the optimal trade-off between reduction of the thermal stress and allowing additional losses in the system is given. The effect of rotor flux variation of the machine on the junction temperatures of the driving inverter is investigated. It can be used as another parameter to control the junction temperature. This allows increasing the maximal thermal cycling amplitude that can be compensated by an active thermal controller. A suitable controller is proposed and validated in experiment. The integration of this technique into the FCS-MPC is presented

Design of an electric drivetrain for the Formula Student-class vehicle

Hlavním úkolem této diplomové práce bylo navrhnout a postavit funkční prototyp frekvenčního měniče pro použití ve vozidlech týmu eForce FEE Prague Formula, soutěžícího v mezinárodní inženýrské soutěži Formula Student. Práce je členěna do několika kapitol, kdy je nejdříve prozkoumán již minule provedený vývoj v týmu. Dále je vystavěna potřebná teorie pro vývoj frekvenčního měniče. Další kapitola detailně popisuje provedený vývoj zařízení. Poslední kapitoly se věnují zhodnocení navrženého měniče. Diplomová práce také prozkoumala nové možnosti v měření fázových proudů, umožňující vysokou přesnost při zachování nízké ceny a kompaktních rozměrů. Celkovým cílem bylo navrhnout jednoduché a robustní zařízení s nízkou výrobní cenou. Ověřování návrhu bylo provedeno v laboratořích fakulty pro ujištění připravenosti navrženého měniče pro nasazení do vozidla. Práce bude pokračovat na vylepšování řídícího algoritmu a postupné integraci do týmových vozidel.This thesis' main objective was to design and develop a functional motor controller for usage in a Formula Student competition vehicle of the eForce FEE Prague Formula team. Work is split into several chapters. Exploring a drivetrain development progression in the team, presenting a needed theory for a motor controller development and giving a detailed overview of the designed device. The last chapters are dedicated to evaluation of the design. Thesis had explored a new methodology in a phase current sensing, providing a significant precision while allowing for a low cost and compact design. Overall aim was to create a simple, robust and cheap solution. Verification of the design was performed in the laboratory environment of the faculty in order to ensure preparedness for integration into the vehicle. Further work will focus on control strategy improvements and final integration into the team's vehicles

Application of Fuzzy control algorithms for electric vehicle antilock braking/traction control systems

Abstract—The application of fuzzy-based control strategies has recently gained enormous recognition as an approach for the rapid development of effective controllers for nonlinear time-variant systems. This paper describes the preliminary research and implementation of a fuzzy logic based controller to control the wheel slip for electric vehicle antilock braking systems (ABSs). As the dynamics of the braking systems are highly nonlinear and time variant, fuzzy control offers potential as an important tool for development of robust traction control. Simulation studies are employed to derive an initial rule base that is then tested on an experimental test facility representing the dynamics of a braking system. The test facility is composed of an induction machine load operating in the generating region. It is shown that the torque-slip characteristics of an induction motor provides a convenient platform for simulating a variety of tire/road - driving conditions, negating the initial requirement for skid-pan trials when developing algorithms. The fuzzy membership functions were subsequently refined by analysis of the data acquired from the test facility while simulating operation at a high coefficient of friction. The robustness of the fuzzy-logic slip regulator is further tested by applying the resulting controller over a wide range of operating conditions. The results indicate that ABS/traction control may substantially improve longitudinal performance and offer significant potential for optimal control of driven wheels, especially under icy conditions where classical ABS/traction control schemes are constrained to operate very conservatively