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A Script Approach for Design of a Multi-Stage Computer Controlled Power Converter

A Script Approach for Design of a Multi-Stage Computer Controlled Power Converter . Raja Ayyanar , Xiaolin Mao, Sixifo Falcones , Lloyd Breazeale. Motivation Functionality details Example application Possible future developments Conclusion. Outline.

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A Script Approach for Design of a Multi-Stage Computer Controlled Power Converter

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  1. A Script Approach for Design of a Multi-Stage Computer Controlled Power Converter Raja Ayyanar, Xiaolin Mao, SixifoFalcones, Lloyd Breazeale

  2. Motivation • Functionality details • Example application • Possible future developments • Conclusion Outline

  3. Power converters are sometimes complicated. • The interaction of: • Energy storage elements • Software • Circuitry • Thermal • is an engineering challenge. Motivation

  4. Motivation A script solution is presented to assist in organizing the engineering of a multi stage power converter.

  5. The goals of the design script are: • To couple analysis with hardware • Enable accurate simulation of hardware • Documentation of design data • Ease of iterations • Generate firmware constants Motivation

  6. A main file declares globally visible variables and calls various functions located in separate files. • Each function is responsible for a specific scope of the circuit • Constants and transfer functions are loaded into the workspace for simulation. • Also two files are created by the script • Design data file • Code file Functionality

  7. This script evolved from the development of the two stage power converter: Example application Isolated boost LCL inverter

  8. Example application W5000B_code.txt W5000B_data.txt

  9. Example application

  10. Example application

  11. Example application

  12. Future developments Smart grid communication

  13. Future developments PWM networks

  14. Future developments MIMO control

  15. Questions?

  16. Supplementary slides

  17. W5000B DESIGN PARAMETERS 10-Sep-2012 ====================== AUXILIARY POWER SUPPLY ==================== **TRANSFORMER** Primary turns: 70 Primary gauge: 32 Secondary turns: 5 Secondary gauge: 20 Total wire area: 1.263177e+001 Fill ratio: 2.819591e-001 **LC FILTER** Ripple current frequency: 50000.00 Hz LC Resonant frequency: 716.94 Hz Total output capacitance: 8.800000e-005 Output inductance: 5.600000e-004 Max capacitor voltage ripple (p-p): 9.825487e-003 Max inductor current ripple (p-p): 3.458571e-001 **CONTROLLER** Frequency of poles: 13878.8 Hz Frequency of zeros: 288.2 Hz Bandwidth: 2000.00 Hz Phase Margin: 59.72 R1: 8250.00 R2: 806.00 R3: 174.00 R4: 6040.00 C1: 6.800000e-007 C2: 1.500000e-008 C3: 6.800000e-008 ====================== GATE DRIVE POWER SUPPLY ==================== Total wire area: 7.248157e+000 mm^2 Primary turns: 13 Secondary turns: 23 Fill ratio: 3.084322e-001 Ripple current frequency: 50000.00 Hz Output capacitance 1: 4.700000e-006 **TRANSFORMER** Primary turns n = 40 Secondary turns n = 25 Transformer transfer n = 6.250000e-001 ============================= DC-AC INVERTER ============================= **LCL OUTPUT FILTER** Grid side inductance: 0.000106 H Grid side inductor resistance: 0.035000 Ohm Inverter side inductance: 0.000210 H Inverter side inductor resistance: 0.048000 Ohm Capacitance: 0.000004 F Damping resistance: 3.000000 Ohm Resonant frequency: 9481.37 Hz Poles: 8845.94, -8845.94 0 Hz Zeros: 7385.79, -7385.79 Hz Attenuation at switch noise freq: -52.60 dB Data file

  18. Data file ================ ISOLATED BOOST CONVERTER ================ **CURRENT SENSOR LOW PASS FILTER** Corner frequency of first filter: 198.96 Hz Quality factor: 0.7060 Corner frequency of second filter: 207.64 Hz Stop frequency: 40000.00 Hz Stop attenuation: -137.8267 dB Total attenuation at Nyquist: -83.6488 dB Input currentsensorscale (Q22): 1920 DC gain: 0.1000 **VOLTAGE SENSOR LOW PASS FILTERS** Power dissipated in divider resistor: 0.3600 W Corner frequency of first filter: 104.42 Hz Corner frequency of second filter: 475.14 Hz Quality factor: 1.01 Total AC gain at inverter ripple freq: -128.6741 dB Input voltage sensor scale (Q21): 20786 DC gain: 0.00461857 **MSC INFO** PV Capacitance: 3.00e-006 F Boost inductance 1.70e-003 H Voltage trip threshold: 889.29 V Voltage trip filter Fc: 12392.53 Hz Settling time: 0.023500 s Current controller bandwidth: 314.16 Hz **DIGITAL CONTROLLER** Numerator: 0.00007590861 0.00007590861 Denominator: 1.00000000000 -1.00000000000 Numerator: 81506 81506 Denominator: 1073741824 -1073741824 =========================== DC LINK ========================== **VOLTAGE SENSOR** Corner frequency of first filter: 9490.46 Hz Corner frequency of second filter: 5695.50 Hz Corner frequency of third filter: 1876.83 Hz Quality factor: 1.8720 Total phase at 60 Hz: -1.9452 Degree Total AC gain at 120 Hz: 0.0279 dB Total phase at 120 Hz: -3.8957 degree Total AC gain at inverter ripple freq: -82.8800 dB DC link voltage sensor scale (Q22): 27273 DC gain: 0.00704000 Trip threshold: 448.37 V Total Capacitance: 4.230000e-003 Capacitor RMS rating (120 Hz) 1.566000e+001 Capacitor ESR (20kHz) 1.633333e-002 ** LINK VOLTAGE CONTROLLER** Coefficients: Numerator : -0.00000231022 -0.00000000192 0.00000230830 Denominator : 1.00000000000 -1.98820384754 0.98820384754 Numerator (Q30): -2481 -2 2479 Denominator (Q30): 1073741824 -2134817626 1061075802

  19. **CURRENT SENSOR** Output currentsensorscale (Q22): 5517 DC gain: 0.03480000 Corner frequency of first filter: 9773.12 Hz Corner frequency of second filter: 4681.03 Hz Quality factor: 2.0878 Max current limit: 34.02 Min current limit: -34.18 **VOLTAGE SENSOR** Output voltage sensorscale (Q22): 61975 DC gain: 0.00309804 Corner frequency of first filter: 17987.67 Hz Corner frequency of second filter: 9773.12 Hz Quality factor: 2.0878 Corner frequency of third filter: 4681.03 Hz **PR CURRENT CONTROLLER** Generalized integrator gain: 150.00 Proportional gain: 1.20 Phase margin: 55.98 Bandwidth: 600.00 Hz **VOLTAGE FILTER** Pass frequency: 60.00 Hz Stop frequency: 40000.00 Hz Pass attenuation: -0.0005 dB Pass phase: -1.0940 degrees Pass phase: -0.0191 radians Stop attenuation: -50.4482 dB **CURRENT FILTER** Pass frequency: 60.00 Hz Stop frequency: 40000.00 Hz Pass attenuation: -0.0004 dB Pass phase: -0.9028 degrees Pass phase: -0.0158 radians Stop attenuation: -42.7066 dB **DIGITAL CURRENT CONTROLLER** Coefficients: Numerator : 1.20985497083 -2.40300487973 1.19485852363 Denominator : 1.00000000000 -1.99857894528 1.00000000000 Numerator: 1299071883 -1290103421 1282969571 Denominator: 1073741824 -2145957802 1073741824 **3rd Harmonic Compensator** Coefficients: Numerator: 0.00498934764 0.00000000000 -0.00498934764 Denominator: 1.00000000000 -1.98722262104 1.00000000000 Numerator (Q30): 5357271 0 -5357271 Denominator (Q30): 1073741824 -2133764042 1073741824 **5th Harmonic Compensator** Coefficients: Numerator: 0.00497044374 0.00000000000 -0.00497044374 Denominator: 1.00000000000 -1.96457450146 1.00000000000 Numerator (Q30): 5336973 0 -5336973 Denominator (Q30): 1073741824 -2109445809 1073741824 **7th Harmonic Compensator** Coefficients: Numerator: 0.00494216846 0.00000000000 -0.00494216846 Denominator: 1.00000000000 -1.93076327767 1.00000000000 Numerator (Q30): 5306613 0 -5306613 Denominator (Q30): 1073741824 -2073141283 1073741824 Data file

  20. Data file **PHASE-LOCKED LOOP** Filter corner frequency: 3.000 Hz Filter coefficients: Filter numerator: 0.00094159037 0.00094159037 Filter denominator: 1.00000000000 -0.99811681926 Filter numerator (Q30): 1011025 1011025 Filter denominator (Q30): 1073741824 -1071719774 Integrator coefficients: Integrator numerator: 0.00000000000 0.00010000000 Integrator denominator: 1.00000000000 -1.00000000000 Integrator numerator (Q30): 0 107374 Integrator denominator (Q30): 1073741824 -1073741824 Two pie (Q22): 26353589

  21. Code file W5000B CONTROLLER AND FILTER COEFICIENTS 10-Sep-2012 #define BSTCOEF_a 81506 #define BSTCOEF_b 81506 #define BSTCOEF_d -1073741824 #define BSTFORM_a 30 #define BSTFORM_b 30 #define BSTFORM_d 30 #define LINKCOEF_a -2481 #define LINKCOEF_b -2 #define LINKCOEF_c 2479 #define LINKCOEF_e -2134817626 #define LINKCOEF_f 1061075802 #define LINKCOEF_Q 30 #define PRCOEF_a 1299071883 #define PRCOEF_b -1290103421 #define PRCOEF_c 1282969571 #define PRCOEF_e -2145957802 #define PRCOEF_f 1073741824 #define PRFORM_a 30 #define PRFORM_b 29 #define PRFORM_c 30 #define PRFORM_e 30 #define PRFORM_f 30 #define HC3COEF_a 5357271 #define HC3COEF_c -5357271 #define HC3COEF_e -2133764042 #define HC3COEF_f 1073741824 #define HCCOEF_Q 30 #define HC5COEF_a 5336973 #define HC5COEF_c -5336973 #define HC5COEF_e -2109445809 #define HC5COEF_f 1073741824 #define HC7COEF_a 5306613 #define HC7COEF_c -5306613 #define HC7COEF_e -2073141283 #define HC7COEF_f 1073741824 #define PLLCOEF_a 1011025 #define PLLCOEF_b 1011025 #define PLLCOEF_d -1071719774 #define TS 107374 #define PLLCOEF_Q 30 #define TWOPIE 26353589

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