Airak, Inc.

Paul Grems Duncan

9058 Euclid Avenue

Manassas, Virginia 20110-5308

voice: [phone]

fax: [phone]

[e-mail]

An Optically Isolated HV-IGBT Based

Mega-Watt Cascade Inverter Building

Block for DER Applications

U.S. Department of Energy SBIR Grant

DE-FG02-01ER83142

August 27, 2001 – February 26, 2001

Project Goals

!

Primary:

Develop a new full-bridge, three phase,

megawatt inverter topology based upon HV-
IGBTs with optical current, voltage, and
temperature sensing in addition to
command/control interfacing.

!

Secondary:

Compare/contrast advantages of

optical sensor and control methodologies over
conventional methodologies (e.g. safety,
reliability, costs, response, efficiency, phase
margin, dynamic range, etc.).

Team Members

Power

Electronics

Subsystem

Design

- Dr. Jason Lai

Optical Sensor

and System

Design

- Paul Duncan

Technical

Management
- Stan Atcitty

Administrative

Management

&

Funding

- Dr. Imre Gyuk

Motivation

!

Optical Sensor Technologies + High Power
Systems => Tremendous Advantages

!

Commercial Point of View: “Dual Use” for
both Power Electronics and Utility Power
Industries (i.e. Potential Markets are Large)

System Configuration

Load

L

fa

i

der

i

L

i

s

v

as

S

1a

v

a

v

b

V

d1

S

2a

S

3a

S

4a

v

bs

v

cs

Transformer

v

C

v

S

L

fb

S

1b

V

d2

S

2b

S

3b

S

4b

L

fc

S

1ca

v

c

V

d3

S

2c

S

3c

S

4c

DER

sources

Cascaded inverter

Sensor & Control Configuration

Sensor

Conditioning

i

ac

v

dc

Fiber Optic

Sensors

HV-IGBTs

Interface

Circuit

DSP

Circuit

DER

Source

Gate Drivers

S

1a

S

2a

S

3a

S

4a

Optical
fiber links

Complete Module for Cascaded Inverter

v

ac

i

dc

Why HV-IGBTs?

!

Compared to GTO or other thyristor-based
devices…

–

Eliminate Current Snubbers and Voltage
Clamps

–

Simplify Gate Drive Circuitry and Isolation

–

Provide Cost Advantage at System Level

–

Increased Efficiency and Reliability

Implementation

IGBT Module Test Setup

L

o

2mH

V

dc

E2

G2

DUT

C2 E1

C1

G1

C

dc

10:1
Homemade
CT with
small toroid
ferrite core
µ=2600

Pearson 411 CT
1A:0.1V

To Scope
1A:0.01V

Busbar

High freq.
cap. 4.7uF

Bushing
– small

copper
tube

Pulse

Generator

Inductive
Load

2mF

0 ~ 650V

HV-IGBT Turn-on and Turn-off Waveforms

Voltage, Current and Switching Energy at 360 kW

V

CE

(200V/div)

E

on

= 120 mJ

Time (0.2us/div)

Time (0.2us/div)

I

C

(200A/div)

E

off

= 100 mJ

(a) Turn on

(b) Turn off

100 mJ

Current overshoot
due to diode reverse
recovery

Voltage overshoot
due to L

lk

(di/dt)

120 mJ

I

C

(200A/div)

V

CE

(200V/div)

IGBT Test Structure

Pulse Tester

IGBT

Liquid Cooled
Heat Sink

Bode Plots of the Control Loop

Transfer Function

65°
P.M.

K

i

/V

PWM

H

i

(s) G

id

(s)

0 dB line

8 kHz control bandwidth

Little phase shift at 60 Hz

Simulated Voltage and Current

Waveforms

V

dc

v

ab

v

an

i

a

0

50ms

40ms

30ms

20ms

10ms

0s

Time

Frequency Spectra of

Phase A Current

Har.

Freq

I

a

I

a

∠

I

a

#

(Hz)

(A)

(%)

(°)

1

60

127.6 100% 1.0

5

300

0.07

0.05% -97.9

7

420

0.07

0.05% -99.7

11

660

0.08

0.05% -98.1

13

780

0.06

0.04% -124.6

17

1020

0.06

0.00% -104.2

19

1140

0.07

0.00% -106.2

0.0

0.2

0.4

0.6

0.8

1.0

60

30

0

42

0

66

0

78

0

10

20

11

40

Frequency (Hz)

Phase

A Cur

rent (

pu)

THD = 0.14%

PWM

MC3315

3

12V

+

-

FLT

+15V

-5V

+15V

+15V

-5V

-5V

5

4

6

7

8

1

2

3

DC/

DC

DC/

DC

Optical Fiber

IGBT

Module

!

Optical Fiber Link Used

! High Current Output Stage: >5A
! Desaturation Protection
! Low Component Count

R

on

R

off

Opto-Isolated Gate Driver Topology

HV-IGBTs & Gate Drivers

!

During the 2

nd

Phase

of this program intend
to move toward
Therma-Charge

TM

heat

pipe assemblies.

Therma-Charge

TM

technology allows the rejection of

multiple kilowatts of heat from power semiconductors
directly to ambient air. This is an important conclusion
considering the potential alternative is a liquid pumped
loop system that has inherent long-term reliability
(leaks), maintenance (pump failure, fluid cleanliness,
filtering) and corresponding cost issues.

Why Optical Sensors?

!

Intrinsic Safety

!

Intrinsic Isolation

!

Increased Reliability

!

Higher Response

!

Greater Dynamic Range

!

Small Size and Weight

Fundamentals:

Sensing with Crystals

Photodetector #1

Photodetector #2

Sensor

Material

Polarized

Laser Source

E or H

Applied

Magnetic or Voltage Field

φ

Polarization

Beamsplitter

Fundamentals:

Conversion to Current Measurements

The holy grail: I = total current flowing through a conductor

H=magnetic field intensity

∫

•

=

l

dl

H

i

r

B = magnetic flux density &

µµµµ

= permeability

µ

B

H

r

r

=

(a constant)

Vl

B

φ

=

(a constant)

φφφφ

=polarization rotation

Sensor and Power Conditioning

Function

Optical Sensors

&

OptoElectronics

IBM Compatible

Rack Mount Chassis

TMS320C6701 EVM

&

AED-106 A/D

Code

Composer

Studio

AED-106 A/D and

PWM Interface

PCB

FPGA

Foundation

To/From Gate Drivers

Optical Configuration (Voltage

or Current Sensor)

1310 Laser

1550 Laser

X

X

Fusion

Splices

p/o Front Panel

FC Connectors (2)

FC-FC

Bulkhead

Adapters (2)

SMOF

SMOF

Sensor

FC-FC Inline

Adapter

FC

Connectors

(4)

FC-FC Inline

Adapter

SMOF Fiber

Spool

Lo-Bi

Fiber Spool

Lo-Bi SMOF

FC Connector

SMOF

MMOF

MMOF

ST Connectors (2)

Coupler

Miniature

Polarizing

Beamsplitter

PIN

Photodiodes

Optical Sensor Analog Conditioning

Analog Interface Connector to

AED-106 Samtec FTSH-125-01-L-

MT (to/from AED-106-J14)

Buffer

Scaling

Amplifier

TransZ

Amplfier #2

TransZ

Amplfier #1

DC Restoration

Amplfier

Anti-Aliasing Filter

1v pp maximum

Mitel

Semiconductor

MF432 ST

Photodiode

C

AED-106 input channel

contains a series resistor of

4.32kOhms. Set low-

frequency pole IAW C=1/

(27143*fp)

(Optional)

Optical Current Sensor Sectional

Fundamentals:

Bragg Grating Temperature Sensor

///////

fiber

optic

coupler

wideband

optical

source

fiber

Bragg

grating

fiber

refractive index variation

λ − λ

λ − λ

λ − λ

λ − λ

B

λλλλ

λλλλ

B

Spectrometer

Bragg Temperature Sensor Data

Bragg Temperature Sensor

S/N: H0022014

y = 0.067x + 730.42

R

2

= 0.9944

730

731

732

733

734

735

736

737

738

739

0

20

40

60

80

100

120

Temperature [deg C]

W

a

v

e

le

ngt

h

[

n

m

]

Pending Milestones

!

Power Electronics Subsystem Integration (Dec ‘01)

!

Optical Subsystem Integration (Dec ’01)

!

Systems Integration (Jan ’02)

!

Systems Testing/Comparative Analysis (Jan/Feb ’02)

!

U.S. DoE Demonstration (Feb/Mar ’02)

!

U.S. DoE Follow-on Proposal (Mar ’02)

!

U.S. DoE 3-Phase System Development (Jun ’02+)

Next Steps

!

Demonstration of MW-Level HV-IGBT and
Optical Technologies for Industry Partners

!

Joint Collaboration and Development of
Technologies for Specific Power
Electronics and Utility-Scale Applications

Q&A / Discussion

For Further Information Contact:

Paul Grems Duncan

9058 Euclid Avenue

Manassas, VA 20110-5308

Voice: 703-330-4961

[e-mail]