Ballard Power Systems

Using Simplorer and Maxwell Tools to Validate Electric Drives for EV Applications, and Interactions with Rapid Prototyping Tools
Roy I. Davis Ballard Power Systems Dearborn, Michigan

Automotive Electromechanical Simulation Workshop 9 October 2003

Electric Drives for EV Applications - Outline

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Brief Overview of Ballard Electric Drives Design Process How Ansoft Tools Fit In at Ballard PM Motor Design Evaluation Control Design Motor Design Inverter Design Custom Power Module Design Rapid Prototyping Control Design Testing Motor Design Evaluation

18 December 2003

Electric Drives Design Process

Customer Specification
Controller

VDC DC Supply ID C

V AC

MM

Inverter

IA C

Motor

NM

MT Transmission N T

Transmission Assumptions
Load

Motor Requirements
Motor Electromagnetic Design

Performance Evaluation

Motor Mechanical Design Motor Thermal Design

Inverter Requirements Cost Evaluation Volume Estimate Mass Estimate

18 December 2003

Custom Power Module Design Inverter Design

Transmission Requirements

How Ansoft Tools Fit in at Ballard

Customer Specification
Controller

Simplorer
Transmission Assumptions
Load

VDC DC Supply ID C

V AC

MM

Inverter

IA C

Motor

NM

MT Transmission N T

Motor Requirements
Motor Electromagnetic Design

Performance Evaluation

Motor Mechanical Design Motor Thermal Design

Maxwell 3D Simplorer
Cost Evaluation Volume Estimate Mass Estimate
18 December 2003

Inverter Requirements
Custom Power Module Design Inverter Design

RMxprt Maxwell 2D

Maxwell Thermal

Transmission Requirements

PM Motor Design Evaluation

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Maxwell 2D used to perform analysis

Calculation of Average Torque and Ripple Torque

Average value and peak-to-peak magnitude match well between test and FEA calculations. FEA Results (3.7 revs)
Maxwell 2D Torque vs. Time

Test Data (2.8 revolutions)

95

90

Torque, Nm

85

80

75

70 -0.10

-0.08

-0.06

-0.04

-0.02

0.00

0.02

0.04

0.06

0.08

Torque, Nm

Time, seconds
18 December 2003

Time, seconds
5

PM Motor Design Evaluation

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Maxwell 2D used to perform analysis

Calculation of Back EMF

Harmonic content and magnitude matches well with experiments. FEA Results

Test Data
40 30
Back-EMF (V)

20 10 0 -10 -20 -30 -40 -0.010 -0.008 -0.006 -0.004 -0.002 0.000 0.002 0.004 0.006 0.008

Time (s)

Equal time and voltage scales

18 December 2003 6

PM Motor Design Evaluation

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RMxprt used to enter motor design information Maxwell 2D used to perform analysis

Calculation of Ld and Lq (Energy or Vector Potential Method)

Flux Linkage Method:Ld versus Id

Flux Method: Lq versus Iq

4.50E-04 4.00E-04

2.5E-04 2.0E-04 1.5E-04 1.0E-04 5.0E-05 0.0E+00

3.50E-04 3.00E-04
Lq (H)

Ld(H)

2.50E-04 2.00E-04 1.50E-04 1.00E-04 5.00E-05 0.00E+00

100

200

300

400

500

600

100

200

300

400

500

600

700

Id(A) Ld (25 Turns) FEA

Iq (A)
Ld Test
18 December 2003

Lq (25 Turns) FEA

Lq,Test
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Control Design Motor Design - General

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Motor equivalent circuit parameters with saturation

Needed for control development Use Maxwell 2D to update estimates made earlier in design process Used to populate Simplorer model of PM motor PTPA (selection of id/iq trajectories) Maxwell & Simplorer Field weakening control Maxwell & Simplorer Interactions of control with dc bus variations due to load point changes (dynamic) - Simplorer Interactions of sensors and interface limitations on control performance Simplorer Etcetera

Ansoft tools are used to explore and understand:

Matlab/Simulink used as primary control development tool with autocode function for dSpace rapid prototyping hardware.

18 December 2003

Control Design Motor Design - Simplorer

Omega_Motor Viscous_Load
+

IA_Meas
A

OMEGA

Omega_GND

+
V

Ballard_IPM IB_Meas
A
I1Q
A B C 3~

MS

+
V

+
V V
LOAD

I1D V1Q V1D PHIM

T ransform_ab_alphabeta GND
0.4k 0.3k 0.2k
EQUBL

0.1k 0

Lin_IPM_25kW.MI [Nm] IQ_Rotor.VAL IQ_R_Ref.VAL Lin_IPM_25kW.I1Q Lin_IPM_25kW.I1D ID_R_Ref.VAL ID_Rotor.VAL Lin_IPM_25kW.I1A [A] IA_Filter.VAL

FB FA

Fbeta Falpha

GAIN

EQUBL

-0.1k -0.2k -0.3k 0 1m 2m 3m 4m 5.6m t [s]

COSINE

Half
EQUBL

P_over_2
GAIN

Norm_to_DC_Bus_C
LIMIT GAIN CONST

theta_electrical
SINE

ID_R_Ref IQ_R_Ref
CONST

Ibeta

Norm_to_DC_Bus_B
LIMIT GAIN

D_Q_Controller_Rotor_Frame
Vd_feedback Vq_feedback

NEG

Ialpha

Reciprocate
EQUBL

Vd_feedfwd Vq_feedfwd vdr Rotor_Speed_Mech Theta_Rotor_Mech D_feedback D_reference Q_feedback Q_reference

IQ_Rotor

Norm_to_DC_Bus_A
LIMIT GAIN

vqr C_voltage_reference B_voltage_reference A_voltage_reference

ID_Rotor

18 December 2003

Control Design Motor Design - Simplorer

10
GAIN

Ld
GAIN

Vq_feedfwd Rs1

10

NEG

GAIN

Q_feedback
10

q_integral
GAIN

CONST

Lamda_PM Q_reference q_proportional

10

Rotor_Speed_Mech
10
GAIN

Vq_feedback Rs
GAIN

10

Vd_feedfwd

Poles_over_21 Lq

10

NEG

GAIN GAIN

D_feedback
10

d_integral
GAIN

D_reference

d_proportional
10

Vd_feedback vd r
10 10

Poles_over_2
10
GAIN COSINE

vqr Cos
SINE

B_voltage_reference sqrt_3_over_2
GAIN

Theta_Rotor_Mech

10

Sin
NEG

v_beta

NEG

v_alpha

C_voltage_reference
10

10

GAIN

NEG

A_voltage_reference

one_half

18 December 2003

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Control Design Motor Design Co-simulate

iq
Back-EMF Decoupling

PMSM physical model

e ^ m p 1 Ki S +
Resistance Decoupling

e pm

R + + + + -

iq *

+ Kp +

vq

1 Lq

1 S

iq

State Feedback Current Regulator

^ eL d
C rossCoupling Input Decoupling

eL d

1 Ki S

eL q

^ eL q
+ + R
Resistance Decoupling

id *

Kp

+ +

vd

+ + -

1 Ld

1 S

id

id

Current Regulator/Motor Block Diagram

Simulink Current Regulator

18 December 2003

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Control Design Motor Design Co-simulate

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Space Vector Modulation (SVM) with Overmodulation Modes 1-2 and Deadtime Compensation

Simulink Model of Modulation Systems

18 December 2003 12

Control Design Motor Design Co-simulate

Omega_Motor Viscous_Load IA_Meas
A

+ +

OMEGA

Omega_GND

+
V

IB_Meas
A

Ballard_IPM
A B C 3PHIDEG ~

MS

+
V

+
V

+
V
LOAD
EQU

V_DC

PHIM

FML1
PHI_MOD:=MOD(Lin_IPM_25kW.PHIDEG,360)

GND

60 40 20 0
EQUBL

-20 -40 -60

IQ_Rotor.VAL ID_Rotor.VAL SIMPLORER Link Interface Lin_IPM_25kW.MI [Nm] Viscous_Load.TORQUE [Nm] SIM2SIM1 Lin_IPM_25kW.OMEGA Lin_IPM_25kW.I1D -1 * Lin_IPM_25kW.I1Q

SiM2SiM SiM2SiM

EQUBL

-80 -0.1k -0.12k 0 2.5m 5m 7.5m 10m 13m 15m 18m 20m 23m t [s]

EQUBL

LIMIT

CONST

CONST1
LIMIT CONST

CONST2
LIMIT CONST

Ballard Pow e r Sys t e m s Roy Davis Simulation of IPM Drive 7 April 2003

CONST3
18 December 2003 13

Control Design Motor Design Co-simulate

Omega_Motor Viscous_Load IA_Meas
A

+ +

OMEGA

Omega_GND

+
V

IB_Meas
A

Ballard_IPM
A B C 3PHIDEG ~

MS

+
V

+
V

+
V
LOAD
EQU

V_DC

PHIM

FML1
PHI_MOD:=MOD(Lin_IPM_25kW.PHIDEG,360)

GND

60 40 20 0
EQUBL

-20 -40 -60

IQ_Rotor.VAL ID_Rotor.VAL SIMPLORER Link Interface Lin_IPM_25kW.MI [Nm] Viscous_Load.TORQUE [Nm] SIM2SIM1 Lin_IPM_25kW.OMEGA Lin_IPM_25kW.I1D -1 * Lin_IPM_25kW.I1Q

SiM2SiM SiM2SiM

EQUBL

-80 -0.1k -0.12k 0 2.5m 5m 7.5m 10m 13m 15m 18m 20m 23m t [s]

EQUBL

LIMIT

CONST

CONST1
LIMIT CONST

CONST2
LIMIT CONST

Ballard Pow e r Sys t e m s Roy Davis Simulation of IPM Drive 7 April 2003

CONST3
18 December 2003 14

Control Design Motor Design Co-simulate

Omega_Motor Viscous_Load IA_Meas
A

+ +

OMEGA

Omega_GND

+
V

IB_Meas
A

Ballard_IPM
A B C 3PHIDEG ~

MS

+
V

+
V

+
V
LOAD
EQU

V_DC

PHIM

FML1
PHI_MOD:=MOD(Lin_IPM_25kW.PHIDEG,360)

GND

60 40 20 0
EQUBL

-20 -40 -60

IQ_Rotor.VAL ID_Rotor.VAL SIMPLORER Link Interface Lin_IPM_25kW.MI [Nm] Viscous_Load.TORQUE [Nm] SIM2SIM1 Lin_IPM_25kW.OMEGA Lin_IPM_25kW.I1D -1 * Lin_IPM_25kW.I1Q

SiM2SiM SiM2SiM

EQUBL

-80 -0.1k -0.12k 0 2.5m 5m 7.5m 10m 13m 15m 18m 20m 23m t [s]

EQUBL

LIMIT

CONST

CONST1
LIMIT CONST

CONST2
LIMIT CONST

Ballard Pow e r Sys t e m s Roy Davis Simulation of IPM Drive 7 April 2003

CONST3
18 December 2003 15

Inverter Design Custom Power Module Design

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Use Maxwell 3D to model power module layout

Objective is to compute parasitic module inductance to support module design layout decisions 2nd objective is to provide inductances for bridge circuit simulation Presently developing this process difficult to get accurate results
Upper I1 E3 -5 Switching Lstray S1

4.7

Lower

E4

E1 EMF := 17 3.3

E2
NEG

S2 EMF := 5

Also developing process for parameterizing the detailed models of IGBTs in Simplorer using this test circuit.
18 December 2003 16

Inverter Design Custom Power Module Design

Simplorer model of inverter, dc source, and motor used to:

Evaluate component stresses under realistic conditions

Switches Diodes Capacitors

Investigate effects of different/variable PWM algorithms Determine losses

18 December 2003

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Rapid Prototyping Control Design

We use dSpace for rapid prototyping control design and motor performance evaluations on the dyno

Clean interface to Simulink/RTW with Control Desk

Simplorer model of motor and inverter easily integrated with Simulink model of control

Helps to debug any problems arising from interactions with inverter PM motor model easily allows use of saturable inductances as functions of current Easy to do what-if investigations Much easier and seemingly more reliable than Matlab Power System Toolbox to include detail model of inverter and PM motor.

18 December 2003

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Testing Motor Design Evaluation

Unexplained or different behavior that occurs during testing can be examined in Maxwell or Simplorer to determine cause. Provides a feedback link to design tool usage that allows refinement of rules of thumb or development of design rules to be applied with the numerical design tools.

18 December 2003

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