This paper presents a highly customizable 120kVA Power-Hardware-in-the-Loop test bench. The output stage consist of two identical Parallel Hybrid Converters each with a 17-level output voltage and an effective switching frequency of 1MHz. The Parallel Hybrid Converters can provide 3-phase AC or bipolar DC as output voltage. Thus, one 6-AC, 3-AC or DC system or two systems with 2x3-AC, 1x3-AC and 1xDC or 2xDC can be emulated

Bernet, D.

Braeckle, D.

Hiller, M.

Liske, A.

Schmitz-Rode, B.

Schwendemann, R.

Stefanski, L.

English

Hiller, Marc

KITopen

KIT – The Research University in the Helmholtz AssociationInstitute of Electrical EngineeringKaiserstraße 12, Bldg. 11.1076131 Karlsruhe, Germanywww.eti.kit.eduA novel high dynamic six phase 120 kW Power-Hardware-in-the-Loop Emulation Test Bench for emulating AC/DC Grids and Electrical MachinesL. Stefanski, R. Schwendemann, D. Bernet, D. Bräckle, B. Schmitz-Rode, A. Liske , M. HillerKarlsruhe Institute of Technology, Elektrotechnisches Institut, Karlsruhe, GermanyPower-Hardware-in-the-Loop (PHIL) test bench optional Coupling NetworkCentral Control Unit PHIL-System 1Grid 1Device under TestGalvanic IsolationParallel Hybrid Converter3ACDCPHIL-System 1PHIL Real-Time Simulation System (RTSS)Emulation-Model 1 & Emulation-Model 2DCDCActive-Front-End optional Coupling NetworkControl UnitGrid 2Galvanic IsolationParallel Hybrid ConverterDC3ACPHIL-System 2DCDCActive-Front-EndiDUT1uDUT1iDUT2uDUT2GTX GTXCentral Control Unit PHIL-System 2um,3um,2um,1Main Power Source(MPS) index mPHCOutputindex oCascaded H-Bridge (CHB) index cuc,1uc,2uc,3ic,1im,3im,2im,1ic,2 ic,3io,3io,2io,1uc,Cx8uc,Cx1LmRm uo,1uo,2uo,3DC-SupplyCc,CellCc,CellParallel Hybrid Converter OutputVoltage only defined by the low-power multilevel converter (CHB)→   Active power current only delivered by the high power two level converter (MPS )→ ,	  ,	  ,	  ,	with ,, 11%ic,123uc,C123 wc,123fo*uc,C,123* wc,123* wc,αβ0*wc,αβ0uo,123* uc,123,lim*pc,αβ0*γo*uc,0*uc,Cminpc,αβ0,lim*|uo,αβ|*ic,αβ*uc,C1,1-8uc,C2,1-8uc,C3,1-8a1,1-8a2,1-8a3,1-8DU-PD-PWMuc,123*s1,FB,1-8s2,FB,1-8s3,FB,1-8RTSS-ModelGTXPHIL-CCUARM-Core 1Energy Controller∑ C·u22123αβ0C·u22123αβ0minPower to Current calc.P → I [1]   αβ0123123αβαβ|x|,γPredictive Current Controler (PCC)w*-wp*plim*um,DCic,αβ*uc,αβk ∈ {1..8}ic,αβic,αβ*ec,αβec,maxum,k*s1s2s3MPSs1- s2- s3-s1 s2 s3uc,αβ*uc,αβ*Cell-Sort uC2uC3uC1uC4uC1uC2uC3uC4MPS-LCUUART-FOCDutycycle Calc.uC2uC3uC1uC4u*CHBCHB-CellΣ∆-ADCAMC1035uc,C1,1-8uc,C2,1-8uc,C3,1-8-iαβiαβeαβ*123αβ-imax|iαβ|emax*PHIL-CCUSAR-ADCLTC2325α jβ uc icicecjβ ec,maxic,maxα **Current error predictor and MPS switching state Selectorec,k=(uLm,k/Lm)∙∆tuLm,k=um,k-uc*[12,13]DAB with LLC transformerActive-Front-End No. 23ACDCDevice under TestDCDCActive-Front-End No. 13ACDCSolid-State-TransformerPHIL-System 1PHIL-System 2Parallel Hybrid Converter as PHIL output stageEnergy ControllerThree PI Controller balance the CHB cell capacitor voltagesPower reference values ∗ to current reference values ∗ calculation based on [1] depending on the operating pointPredictive Current ControllerDetermines the switching states of the MPS and therefore controls and limits the CHB currentsCHB ModulatorBalances the CHB cell voltages in each arm and determines which CHB cells are used to form the output Topology:Cascaded control scheme and CHB modulation:Two three phase PHIL systems, each with an 60 kVA output stage, capable of emulating a DC or an AC system Output stages with a highly dynamic 17-level output voltage and an effective switching frequency of 1 MHzAbstract: This paper presents a highly customizable 120kVA Power-Hardware-in-the-Loop test bench. The output stage consist of two identical Parallel HybridConverters each with a 17-level output voltage and an effective switching frequency of 1 MHz. The Parallel Hybrid Converters can provide 3-phase AC or bipolar DC asoutput voltage. Thus, one 6-AC, 3-AC or DC system or two systems with 2x3-AC, 1x3-AC and 1xDC or 2xDC can be emulated.a) Control structure of PHIL-System 1; b) laboratory prototype; c) Signal processing system (CCU & RTSS); d) CHB phase with four double H-bridge cells; e) 30kVA single-board converter with SiC-B6-bridge (AFE, MPS)Active pre-charge of the CHB cell capacitors to an arm voltage of ,,∗  480V with a ∗  500Hz and !,∗  325V[1] L. Stefanski, D. Bernet, M. Schnarrenberger, C. Rollbühler, A. Liske, and M. Hiller, “Cascaded h-bridge based parallel hybrid converter—a novel topology for perfectly sinusoidal high power voltage sources,” in IECON 2019 - 45th Annual Conference of the IEEE Industrial Electronics Society, pp. 1639–1646.Each of the two PHIL systems emulates an ideal 50 Hz 400 V grid. A 30kVA solid-state transformer (SST) is connected to the PHIL test bench as a DUT. At t = 1.2 ms, the SST performs a load step from 0 kW to 29 kW.The line to line output voltage of PHIL-System 1, is depicted in blue and is only defined by thelow power high dynamic CHB. The grey curve isthe CHB output voltage filtered in post-processingwith a 1µs wide MA-Filter.The 29 kW load step does not effect the armvoltage , of the CHB or its output voltage ,nor is it visible in the CHB current ,.The fundamental output current of the PHIL systemis fully supplied by MPS a the high power two levelconverter regardless of the operating point, therebylimiting the CHB output current to the MPS currentripple.The output voltage and current of the PHC/PHILare not affected by the switching 2-level voltage ofthe MPS and the current ripple of the PHC/PHILoutput current is only caused by the AFE1 andAFE2 switching with 50 kHz.The low power CHB has a effective switchingfrequency of 1 MHz (̅,%&,'(%)*+  63.8 kHz) andthe high-power 2-level MPS has a low averageswitching frequency of ̅,%&  6.2 kHz.Conclusion: Due to advantageous converterconfiguration, the Parallel Hybrid Converter has thesame output voltage characteristics as full-powermultilevel converters previously used as PHIL outputstage, but has inherently higher power density andlower costs compared to them. The low power CHBonly has to carry the current ripple of the 2L-VSCused as Main Power Source (MPS), however itdefines the output voltage of the PHC.Measurements result active CHB pre-chargeGrid emulation measurements result

A novel high dynamic six phase 120 kW Power Hardware in the Loop Emulation Test Bench for emulating AC/DC Grids and Electrical Machines

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A novel high dynamic six phase 120 kW Power Hardware in the Loop Emulation Test Bench for emulating AC/DC Grids and Electrical Machines

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