A NOVEL THREE-PHASE RECTIFIER WITH HIGH POWER FACTOR FOR WIND ENERGY CONVERSION SYSTEMS

C. E. A. Silva, D. S. Oliveira Jr., L. H. S. C. Barreto, R. P. T. Bascop.

Federal University of Cear UFC, Department of Electrical Engineering - DEE, Group of Energy Processing and Control GPEC, Fortaleza CE Brazil elmano@dee.ufc.br, demercil@dee.ufc.br, lbarreto@dee.ufc.br, rene@dee.ufc.br Abstract In this paper it is proposed a new topology of three-phase controlled rectifier feasible for high power wind energy conversion systems (WECS). This rectifier is based on the bridgeless rectifier, uses six wires of the generator, and allows the operation with high power factor, increasing the generator efficiency. One Cycle Control (OCC), which avoids the need of sinusoidal reference signals, was used in the rectifier control. This study is then concerned with the operation principle and experimental results obtained from a 5 kVA prototype. Keywords - one cycle control, power factor correction, three-phase PWM rectifiers, wind energy systems. I. INTRODUCTION According to the U. S. Department of Energy, through of International Energy Outlook 2006 (IEO) report of Energy Information Administration (EIA), the global consumption of energy will grow at an annual average of 2% between the years of 2003 and 2030. The forecast for the growth of demand for energy specifically in the electric form is even greater i.e. 2.7% to the year [1]. Either for ambient, strategical, or geographic questions, the generation of electric energy from wind energy systems has grown quickly, changing from a global installed power of 4.8 GW in 1995 to 58 GW in 2005, at annual average growth of 24% [2]. Considering the current estimations of increase in the demand for electric energy generation in the next few years, one concludes that the growth of the electric energy obtained from wind systems tends to continue. This worldwide context is challenging for all involved professionals in generation, distribution, and processing of electric energy. In energy processing power electronic specialists and researchers are fundamental, constantly searching the increase of the processed power with greater efficiency and reduced weight and volume. This paper intends to contribute with this research considering a three-phase controlled rectifier with active power factor correction employing One Cycle Control (OCC), what allows obtaining high power factor with increased simplicity of the circuit control when compared to conventional techniques. This rectifier is feasible for high power wind energy conversion systems (WECS). II. WIND ENERGY CONVERSION PRINCIPLE The wind turbine basic principle is to convert the linear motion of the wind into rotational energy. This rotational energy is used to drive an electrical generator, allowing the kinetic energy of the wind to be converted to electric power. The captured power of the wind (Pv) for a wind turbine is given by (1) [4]. 1 Pv = a Av u 3 (1) 2 Where a is the wind density, u is the wind speed, and Av is the area swept by the turbine. The mechanical power (Pm) generated by the wind turbine from captured power of the wind depends on the power coefficient (Cp) of the wind turbine, as shown in (2). Pm = C p ( , ) Pv (2) According to (2), Cp is a function of tip-speed ratio and pitch angle . This function can be approached satisfactorily by (3) [3].
C C p ( , ) = C1 2 C3 C4 e i + C6 (3) i Where, r m = (4) u 1 1 0.035 = 3 (5) i + 0.08 + 1 Parameter r is the length of the wind turbine blade and m is the angular rotor speed. Coefficients C1 to C6 depend on the aerodynamic characteristics of the wind turbine design. The typical values are given in Table I [3].
C5

TABLE I Typical values of coefficients C1 to C6

Coefficient C1 C2 C3 C4 C5 C6 Value 0.5176 116 0.4 5 21 0.0068

III. WIND ENERGY CONVERSION SYSTEMS Any WECS is composed basically of three parts: wind turbine, electrical power generator, and electronic power processing system. The wind turbine and the electrical power generator compose the wind generator. Horizontal axis wind turbines (HAWTs) with two and three blades are the ones that allow the best exploitation of the available wind energy (Fig. 1) [4]. Three-bladed HAWTs are more commonly used than two-bladed ones because they are less susceptible to the tower shadow effect. In Fig. 1 it is observed that the maximum extraction of the wind energy is achieved when the rotational speed of the turbine varies with the wind speed, keeping a constant , implying a variable speed WECS.

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The main disadvantage of the PMSG is the high cost of permanent magnet material and power converter. The mathematical model of a PMSG and the main power processing topologies are presented as follows. A. PMSG mathematical model Using the torque definition, the mechanical torque (Tm) applied to the PMSG is given by (6). P Tm = m (6)

Fig. 1. Power coefficient vs. tip-speed ratio curves for HAWTs [4].

The possibility to control the frequency and the amplitude of the generated voltage through the excitement, independent of the speed rotation, made the doubly-fed induction generator (DFIG) the main choice in variable speed WECS of great size directly connected to grid (Fig. 2) [5]-[6].

Substituting (1), (2), and (4) in (6), the mechanical torque can be expressed according to (7). Cp ( ) 2 1 Tm = a r Av u (7) 2 Using the torque definition again, the electromagnetic torque (Te) of the PMSG is given by (8). E I + Eb I b + Ec I c Te = a a (8)

Where Ea,b,c are the induced instantaneous voltages across the PMSG windings and Ia,b,c are the induced instantaneous currents through PMSG windings. If friction is not considered, the variation of the angular mechanical speed of the rotor with the time is given by (9). 1 m = (Tm Te ) (9) J B. Power Processing Topologies Applied to PMSG The rectifier stage of the power converter used in systems such as that in Fig. 3 must present high power factor, otherwise harmonic distortion in the current and voltage of PMSGs may cause several undesirable effects to the generator, such as [10]: Increased heating due to iron and copper losses at the harmonic frequencies; Reduction in machine efficiency; Loss of the torque production; Increased audible noise emission; Eventual occurrence of mechanical oscillations; In order to avoid these problems, systems capable of emulating resistive loads for the PMSG must be used, resulting in low total harmonic distortion (THD). These systems can be implemented introducing a dc-dc stage between the conventional rectifier and the output stage, as shown in Fig. 4.

Fig. 2. Variable speed WECS directly connected to grid based in DFIG.

The WECS in Fig. 2 allows the processing of high power levels, since the power converter processes only about 30% of the rated power [7]. On the other hand, the reduced number of poles of the DFIG demands the use of gearbox between the wind turbine and the generator, implying bigger weight, size, and maintenance, reducing its efficiency and reliability [5]. An alternative to the DFIG is the permanent magnet synchronous generator (PMSG), which can be designed with higher number of poles to avoid the use of gearbox. Being a synchronous generator, all the generated power must be conditioned through a power converter before it can be used (Fig. 3), restricting the power of this type of WECS.

Fig. 3. Variable-speed WECS connected to grid based in PMSG.

The PMSG presents some advantages when compared with the DFIG [8]-[9]: External excitation current is not required; Light weight; Small size; High reliability; Low maintenance; High efficiency;

Fig. 4. WECS with power factor correction using intermediate dc-dc stage.

Any dc-dc converter with current source input characteristic can be used in the WECS of Fig. 4. The simplicity of control, the reduced number of components, and the predominant need to increase the generated voltage, make the boost converter the main choice [11]-[16] in this WECS, as shown in Fig. 5.

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Fig. 5. WECS with intermediate boost converter.

In Fig. 9 it is shown a WECS that uses a variation of the back-to-back converter [19] proposed in [20]. Only four semiconductors are used in the rectifier stage of this topology. Moreover, the voltage balance across the capacitors of dc link is not a trivial task, what is compromised by the low number of modulation freedom degrees of this converter.

It can be observed in Fig. 5 that there are always three power semiconductors in the rectifier stage operating at high frequency in the current path, reducing the efficiency of this topology. Another unidirectional topology proposed recently for WECS is shown in Fig. 6 [21].
Fig. 9. WECS with modified back-to-back converter.

IV. PROPOSED RECTIFIER

Fig. 6. WECS with semi-controlled rectifier.

In this topology there are only two semiconductors in the current path of each phase, increasing its efficiency. On the other hand, this structure allows the modulation of the positive half-cycle of the currents drained from the PMSG, resulting on a THD about 16% [21]. Than Systems in Fig. 5 and Fig. 6 are feasible for small WECS. Another option to achieve high power factor in the generator side is to use a PWM rectifier in the WECS, as shown in Fig. 7.

Fig. 7. with power factor correction using PWM rectifier.

The traditional topology applied in high power WECS is shown in Fig. 8 [6] and uses the back-to-back converter [17][18].

Fig. 8. WECS with back-to-back converter.

In the rectifier stage of this structure there are only two semiconductors in the current path of each phase and the current can be modulated in both half cycles. However, there are switches connected in series, complicating the command circuits.

The proposed topology is a novel unidirectional threephase PWM rectifier, based on the single-phase rectifier introduced in [23] and known in literature as bridgeless [22][26]. The proposed rectifier is recommended for applications where six wires are accessible and is composed by three single-phase rectifiers, as shown in Fig. 10, each one connected to one phase of the PMSG. This rectifier is fully controlled, being able to provide unity power factor and low harmonic content of the generator currents. In Fig. 10 Ea,b,c are the induced electromotive forces in each winding of the PMSG stator, inductors La,b,c represent the inductances of each winding of the PMSG stator and are coupled to each other, and L1,2,3 are boost inductors. Vdc is the voltage across the dc link capacitor. This capacitor decouples the rectifier and inverter stages. The main advantages of the proposed rectifier when compared to standard three-phase PWM rectifiers are: All switches are connected to the same reference, simplifying the command circuit; Depending of the operation mode, both switches of each leg receive the same drive signal; There are not switches connected in series, discarding the possibility of short circuit; For each leg there are only two semiconductors in the current path, increasing robustness with reduced losses; As the power of each phase is processed independently, for a same switch voltage stress, the current stress is 3 times less; The main disadvantage of the proposed rectifier is the great number of semiconductors, what is justified in high power applications.

Fig. 10. Schematic diagram of the proposed rectifier.

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A. Operation Principle of the Rectifier For each phase of the generator, there is a respective rectifier module that operates independently, analogously to the bridgeless converter. The stages of operation of each rectifier module are illustrated in Fig. 11.

the reverse conduction is not possible and the switch could be turned off. This mode simplifies the drive signal generation, but will lead to a little bit larger conduction losses than those in the first mode. B. Rectifier Control The control technique used in the rectifier is the One Cycle Control (OCC) [27]-[34]. The rectifier control schematic diagram is shown in Fig. 12.

Fig. 12. Block diagram of the rectifier control.

Fig. 11. Operation stages of the each rectifier module.

At the moment when switches S1 and S2 are turned on, the current flows through them and the boost inductor L1 stores energy, while diodes D1 and D2 are reverse biased. When S1 and S2 are turned off, diodes D1 and D2 are forward biased, and the current will flow through them, as the energy stored in the inductor will be transferred to the output stage. There are only two power semiconductors in the current path during all operating stages, reducing conduction losses. Depending on the modulation technique, two operating modes are available: 1) First Operation Mode Only one switch operates during a given half cycle of the line voltage, as the operation of a single boost converter results. Thus, switch S1 is turned off while S2 always remains turned on during the positive half cycle, and vice-versa during the negative half cycle. In a case where MOSFETs are used, the semiconductor that remains turned on during half line cycle will conduct the current through itself, and not through the respective antiparallel diode, reducing conduction losses. However, this operating mode increases the complexity in generating the drive signals. 2) Second Operation Mode Both semiconductors are driven with same gating signal. Thus, in the positive half line, when S2 is turned on, the current will flow in the reverse direction through itself and, when S2 is turned off the current will flow in the reverse direction through of the respect antiparallel diode. In the negative half cycle of the line voltage where S1 is turned on, the current will flow in the reverse direction through the switch itself, and when S1 is turned off, the current will flow in the reverse direction through the respective antiparallel diode. As well as in the previous mode, the switch reverse conduction is conditional to the use of MOSFETs, otherwise

This control technique allows obtaining high power factor in continuous conduction mode without the need of a current reference signal. In PFC OCC control technique, the duty cycle of drive pulse depends on the input voltage, allowing the current loop to keep sinusoidal input current analogous in phase with the input voltage. The current feedback is used in the composition of the modulator signal, which is compared with a carrier whose inclination depends on the value of VT. Thus, it is possible to vary the current peak value drained from the PMSG by means of slope ramp integrator. In WECS the value of VT is determined through a maximum power point tracker (MPPT). In this work the value of VT is determined by voltage compensator, responsible for the regulation of Vdc. When the crossing between the carrier and the modulator signal occurs, the RS flip-flop is reset, commanding the switch to be turned off. A clock signal sets the flip-flop to a constant frequency, commanding the switch turning on ( Q ) and integrator reset ( Q ). Fig. 13 shows OCC modulation.

Fig. 13. One cycle control modulation.

V. POWER CIRCUIT DESIGN PROCEDURE The power circuit design of the proposed rectifier consists in determining the voltage and current stress of switches and diodes, and calculating the reactive elements (boost inductances and dc link capacitance). The control circuit design is not mentioned, since it is presented in [30]. Table II

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presents specifications and parameters used to design the prototype. TABLE II Rectifier specifications and parameters
Parameter Specification

(17) (1 Dmin ) 2.20 A 4 The maximum rms forward current (IDrms) through the rectifier boost diodes (D1,...,6) is given by (18).
I Davg = I Drms =

I ipk

Rms input voltage range (Vg) Frequency of the input voltage (fr) Output voltage (Vdc) Switching frequency (fs) Rated output power (Po) Efficiency () Output voltage ripple (Vdc) Current ripple through boost inductor (IL)

100 V 220 V 60 Hz 400 V 50 kHz 5 kVA 95% 1% 20%

1 2

(I
0

ipk

sin ( ) (1 Dmin ) sin ( ) d

2 (1 Dmin ) 4.59 A (18) 3 Consequently, the average (ISavg) and rms (ISrms) values of the current through the switches (S1,...,6) are given by (19) and (20), respectively. (19) I Savg = I RSavg I Davg 1.53 A I Drms = I ipk
2 2 I Srms = I RSrms I Drms 3.28 A

The maximum voltage across the switches and diodes is the dc link voltage, as shown in (10). VS max VD max Vdc = 400V (10) The peak of the maximum generated voltage (Vgpk) is given by (11). Vgpk = 2 220 311V (11) Defining the duty cycle as the ratio between the on-time of a switch (Ton) and the respective switching period (TS), and since the static gain of the proposed rectifier is equivalent to that of the boost converter, the minimum duty cycle is given by (12). Vgpk Dmin = 1 0.22 (12) Vdc The peak of the maximum input current through each phase is given by (13). Po I ipk = 2 11.28 A (13) 3 Vg The maximum average reverse current through the switches (IRSavg) is given by (14).
I RSavg 1 = I ipk sin ( ) d 2

(20)

From the ratio between voltage and current through an inductor, the boost inductances L1,2,3 is given by Eq. (21). Vgpk Dmin L1,2,3 = 612 H (21) I L I ipk f s Similarly, the dc link capacitance that guarantees the maximum specified ripple is given by (22). Po Co = 2.17 mF (22) 2 2 2 6 f r Vdc (1 + Vdc ) (1 Vdc ) VI. EXPERIMENTAL RESULTS The proposed rectifier prototype was built and tested. Table III lists the semiconductor and reactive devices used to implement the prototype.
TABLE III Rectifier semiconductors and reactive devices
Parameter Specification

I RSavg =

I ipk

3.59 A

(14)

Boost inductors (L1,2,3) Output capacitance Switches (S1,,6) Diodes (D1,,6)

600H 2400F IRGP50B60PD1 (600 V/50 A) HFA25TB60 (600 V/25 A)

The maximum rms reverse current through the switches (IRSrms) is given by (15).
I RSrms = 1 2

Fig. 14 shows prototype picture.

(I
0

ipk

sin ( )

5.64 A (15) 2 The duty cycle (D) varies with the input voltage according to (16). D = (1 Dmin ) sin ( ) (16)

I RSrms =

I ipk

The maximum average forward current (IDavg) through of the rectifier boost diodes (D1,...,6) is given by (17).
I Davg = 1 I ipk sin ( ) (1 Dmin ) sin ( ) d 2

Fig. 14. Prototype photography.

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Fig. 15 shows the voltage and current waveforms of phase a for an input voltage of 100 Vrms, approximately, and output power of 500 W, as the power factor is 0.985. The voltage THD is about 4.3% and current THD is about 13.6%.

Fig. 18 shows the harmonic spectrum of the input current through phase a for rms input voltage of 220 Vrms and output power of 5 kW. The total harmonic distortion is about 6.2%.

Fig. 15. Voltage (1) and current (2) of phase a for Vin=100 Vrms (100V/div 5 A/div 5 ms).

Fig. 18. Harmonic spectrum of the input current (Vin=220 Vrms and Pout=5kW).

Fig. 16 shows the voltage and current waveforms of phase a for an input voltage of 220 Vrms, approximately, and output power of 5 kW, as the power factor is 0.997. The voltage THD is about 4.0% and current THD is about 6.25%.

Fig. 19 presents the power factor versus output power curve, where high power factor along the load range can be observed.

Fig. 16. Voltage (1) and current (2) of phase a for Vin=220Vrms (100V/Div - 10A/Div 5 ms).

Fig. 19. Power factor vs. output power.

Fig. 17 presents the line current waveforms of phases a, b, and c for an input voltage of 220 Vrms and output power of 5 kW.

Fig. 20 presents the efficiency curve for rms input voltage range shown in Fig. 21, as the average efficiency is about 96%.

Fig. 17. Current waveforms in phases a, b, and c for input voltage of 220 Vrms (5 A/Div 5 ms).

Fig. 20. Efficiency versus output power curve.

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Fig. 21. Rms input voltage vs. output power.

VII. CONCLUSION A novel three-phase PWM rectifier has been presented. The main advantage, when compared to a conventional three-phase controlled rectifier are the use of switches with the source terminal connected to the same point, robustness due to the absence of controlled switches in the same leg, and reduced current stress through the switches. Moreover, the control implementation through OCC allowed great simplification of the control circuit. With this control technique the current drained follows inherently the input voltage waveform, without the need of synchronism techniques. This characteristic is very important for wind energy conversion applications due to the amplitude and frequency variation of the generated voltage. The experimental results validate the effectiveness of the considered system, which presents the relevant results from a experimental prototype of 5kW, with average efficiency of 96% and power factor bigger that 0.98 along the load range. ACKNOWLEDGEMENT The authors would like to thank FUNCAP, CNPq and CAPES for the financial support and incentive the scientific research, ENERSUD for the donation of a wind generator, FINEP and ELETROBRAS for the financial incentive. REFERENCES [1] International Energy Outlook 2006. Energy Information Administration, Washington, jun. 2006. Available in <http://www.eia.doe.gov/oiaf/archive/aeo06/index.html> . Had access in 11 jun. 2007. [2] Global Wind Energy Outlook 2006. Global Wind Energy Council, Bruxelas, 2006. Available in < http://www.gwec.net/fileadmin/documents/Publications/ Global_Wind_Energy_Outlook_2006.pdf>. Had access in 11 jun. 2007. [3] Siegfried Heier, Grid Integration of Wind Energy Conversion Systems. Jhon Wiley & Sons Ltd., 1998. [4] T. Burton, D. Sharpe, N. Jenkins, E. Bossanyi, Wind energy handbook, John Wiley & Sons, Ltd, Nova York, USA, 2001. [5] J. M. Carrasco, L. G. Franquelo, J. T. Bialasiewicz, E. Galvan, R. C. Portillo Guisado, M. A. M. Prats, J. I.

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