EP4111584A1 - Lastsimulationsumrichter und testvorrichtung - Google Patents
Lastsimulationsumrichter und testvorrichtungInfo
- Publication number
- EP4111584A1 EP4111584A1 EP22726377.9A EP22726377A EP4111584A1 EP 4111584 A1 EP4111584 A1 EP 4111584A1 EP 22726377 A EP22726377 A EP 22726377A EP 4111584 A1 EP4111584 A1 EP 4111584A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- simulation device
- load simulation
- phase
- control
- load
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
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- 238000012360 testing method Methods 0.000 title claims description 44
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Classifications
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
- H02M7/00—Conversion of ac power input into dc power output; Conversion of dc power input into ac power output
- H02M7/66—Conversion of ac power input into dc power output; Conversion of dc power input into ac power output with possibility of reversal
- H02M7/68—Conversion of ac power input into dc power output; Conversion of dc power input into ac power output with possibility of reversal by static converters
- H02M7/72—Conversion of ac power input into dc power output; Conversion of dc power input into ac power output with possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode
- H02M7/79—Conversion of ac power input into dc power output; Conversion of dc power input into ac power output with possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal
- H02M7/797—Conversion of ac power input into dc power output; Conversion of dc power input into ac power output with possibility of reversal by static converters using discharge tubes with control electrode or semiconductor devices with control electrode using devices of a triode or transistor type requiring continuous application of a control signal using semiconductor devices only
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
- G01R31/00—Arrangements for testing electric properties; Arrangements for locating electric faults; Arrangements for electrical testing characterised by what is being tested not provided for elsewhere
- G01R31/40—Testing power supplies
- G01R31/42—AC power supplies
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02M—APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF
- H02M1/00—Details of apparatus for conversion
- H02M1/0003—Details of control, feedback or regulation circuits
Definitions
- the invention is a load simulation device and a test device for electronic inverters.
- Inverters are electronic circuits that generate alternating current from direct current. They regularly generate multi-phase alternating current ("three-phase current"), for example three-phase or six-phase. Especially with regard to electromobility, such inverters for driving electric motors, even those with high electrical power, are becoming increasingly important. It is therefore also important to be able to test and inspect such inverters efficiently. On the one hand, efficiency includes the efficient handling of test routines and data management, but on the other hand it also includes energy efficiency and equipment that is as uncomplicated and inexpensive as possible.
- Simple chokes are known for this, which work as a passive, pure reactive power load.
- the electrical replica of the load is only approximate.
- the direct current path of the inverter is not actually loaded.
- the object of the invention is to specify a load simulation device and a test device for multi-phase inverters that can be built efficiently and operated in an energy-efficient manner.
- a load simulation device for simulating a three-phase load for a multi-phase inverter has several, preferably three or six phase connections for an inverter to be connected, one or more pairs of two DC outputs for a DC power supply to be connected to internal DC lines , Several, preferably three or six transistor bridges, each connected between the DC lines of a pair and each having at least two series-connected electronic scarf ter whose connection area are connected directly or indirectly to one of the phase connections, one for each of the electronic switches Control line for controlling the respective electronic switch, and a control circuit, which is connected to the control lines, for driving the electronic switches by means of respective control signals generated by it.
- the control circuit is designed to generate the control signals in timed coordination with control signals in an inverter to be connected.
- the load simulation device can generally simulate a multi-phase electrical load. In particular, it can simulate a synchronous electric motor or an asynchronous electric motor.
- the load simulation device can simulate an electric motor which has a plurality of phases, in particular three or six phases, and which are connected at a common neutral point. Motors with several mutually separate star points, e.g. B. two star points, each with three connected phases, the phases of which are offset by 2/3p from each other.
- the DC outputs are intended and designed to be connected to the DC inputs of the inverter or to the DC outputs of the DC source feeding the inverter under test.
- the control circuit is designed for the timing of the drive of the transistor bridges that is coordinated with the test object. In this way, it is caused/avoided that strong current ripples arise in the case of uncoordinated switching operation.
- the direct coupling of the DC paths of the inverter under test, the load simulation and the DC source ensures that the majority of the DC current flows between the load simulation and the inverter under test.
- the direct current source only has to make up for the unavoidable losses of the system and can accordingly be designed for a much lower output.
- the load simulation device can have one or more devices for generating one or more synchronization signals as a function of electrical variables at one or two or all phase connections and can supply the synchronization signals to the control circuit. There, the control signals for the transistors are generated based on the synchronization signals in a timely manner to the control in the test object.
- the device for generating a synchronization signal can have a delay device.
- the control timing in the inverter to be tested can be derived from the electrical quantities - current and/or voltage - which the load simulation device receives at its phase connections.
- the timing of control interventions or control steps of the control in the DUT can be determined directly or indirectly from these variables, so that the control in the load simulation device can then take place in a timely manner.
- the control initially includes a frequency control to the effect that control clock frequencies in the load simulation device are the same as those in the DUT.
- Pulse width modulation hereinafter also referred to as "PWM” (“pulse width modulation”)
- PWM pulse width modulation
- the PWM pulse frequency in the load simulation device can be set to that in the DUT.
- the synchronization can, however, take place to the extent that the phase position within a cycle is also corrected.
- the synchronization can also have a delay after the clock in the DUT has been determined in such a way that the phase position in the load simulation device is delayed to the phase position in the DUT is provided.
- the PWM control can include the use of the rotating d/q coordinate system and the d component (direct component) and/or the q component (quadrature component) of the quantities to be controlled - phase current and/or or phase voltage - can be controlled to the desired values and, if necessary, also regulated with feedback.
- the rotational frequency of rotating d/q system is set or used in a known manner. It corresponds to the mechanical speed of the simulated electrical machine multiplied by the number of pole pairs of the same.
- the control circuit can be designed to generate the control signals in such a way that the sum of the currents it causes at the phase connections assumes a specific value or is within a specific range, in particular as small as possible and preferably 0.
- Real loads are regularly electric motors with windings connected at a star point. According to Kirchhoff's node rule, the sum of all currents at the neutral point is zero.
- the control or regulation of the load simulation device can understand this in terms of regulation, in that the sum of the currents is made as small as possible and is preferably brought/controlled/regulated to zero or approximately zero. This can be a regulation using feedback current signals from the phase connections. It can be subordinate to or superimposed on another regulation.
- controller in this specification is intended to address both open-loop and closed-loop/feedback devices, unless expressly stated otherwise.
- the load simulation device described can receive one or more of the voltage values at the phase connections and/or one or more of the current values at the phase connections as returned or fed back values.
- the control circuit of the load simulation device can also be designed to generate the control signals for the switches/transistors/transistor bridges in such a way that harmonics are at least partially compensated for.
- the Load simulation modulates the duty cycle at the transistor bridges for each motor phase, preferably in such a way that the phase current curve is as ideally as sinusoidal as possible.
- SVPWM space vector pulse width modulation
- THIPWM third-harmonics-injection pulse-width modulation
- harmonics from a possibly used in the DUT SVPWM or THIPWM or similar in the load simulation device causes the simulation to behave close to reality. Since the phases of a real load are coupled at a star point, harmonics compensate themselves there, since they are present in all phases in the same way. The active compensation in the load simulation device simulates this behavior.
- Both the switching on or omission of a compensating harmonic for the PWM in the load simulation device as well as its waveform (sine, triangle, ...), frequency and amplitude can be set as part of the configuration of the load simulation device and set via a user interface . However, this can also be done automatically by evaluating the voltages at the phase connections of the load simulation device, e.g. B. Deviations from an ideal sine wave can be examined. Correctly compensating values can then be determined and set automatically.
- the control circuitry of the load simulation device can further be designed to generate the control signals for the switches/transistors/transistor bridges in such a way that the load simulation device behaves like an electrical generator. This can be done, for example, by setting the q component of a variable to be controlled—phase current and/or phase voltage—to a negative value in the controller.
- the load simulation device can have a position transmitter simulation device that simulates a position transmitter signal of a sensor of a real three-phase load and makes it available at a connection.
- inverter-fed electric motors feed "position" signals back to the inverter. It is usually a pulse signal that provides information about the progression of the angle of rotation in the supplied motor and, for example, is integrated or extrapolated or interpolated into an angular position in the controller of the DUT.
- the load simulation device can be designed to simulate such a signal so that it can be fed back to the controller of the DUT via a signal output of the load simulation device.
- the design can be such that the signal is formed exactly like a signal from a real load, so that it can be fed directly to the DUT and no further modifications are necessary for the test mode. In the controller of the DUT, the signal can then be used to determine the virtual rotational speed of the simulated load.
- the control circuit of the load simulation device can have a pulse width modulation circuit for generating the control signals in accordance with desired values. It may also include vector control circuitry for generating current and/or voltage control setpoints.
- the transistors of the transistor bridges of the load simulation device can be driven using pulse width modulation (PWM) technology that is known per se.
- PWM pulse width modulation
- the necessary techniques, facilities and provisions can be used and provided for here.
- the control can include vector control, ie at least temporarily the representation of alternating currents and voltages in a rotating coordinate system, for example by means of d and q components. Feedback can also be provided in this domain and taken into account. For this purpose, phase voltages or currents measured for feedback can be converted into the dq system.
- the dq values determined in the control or regulator are transformed back into uvw values. Also on the input side (before dq) u-vw values can be used and/or specified and/or fed back.
- the load simulation device in particular its control circuit, can have an interface circuit for connection to a user interface and/or to a higher-level controller.
- the load simulation device may be desirable for the load simulation device to specify different target values for different behaviors.
- it can be connectable to a higher-order controller or a user interface, or it can have these itself.
- the load simulation device can be given different target values in order to simulate different behavior during the course of a more complex test program.
- target values for example for speed and/or torque and/or one or more phase currents and/or phase voltages, must also be specified for the DUT.
- the controller of the DUT can be designed to receive sensor signals, for example ambient temperature.
- the load simulation device or a higher-level controller that can be connected to it can be designed to serve such inputs of the DUT with simulated signals. This may be settable via an interface as part of the configuration of the load simulation device.
- the load simulation device can be designed to record electrical values that arise in combination with the DUT and to format, evaluate, log and thus make them available in a suitable scope and format. This can be done digitally and can also include communication with a higher-level controller.
- the load simulation device can have an inductance between each of the phase connections and each of the connection areas of the transistor bridges. Their inductances can be automatically or manually adjustable.
- the load simulation device can have a current and/or voltage detection device at one or more or all phase connections or behind the inductances and feedback of the detection values for the control.
- the inductances that may be provided at the phase connections contribute to a real simulation of the load by showing inductive switch-on and switch-off behavior.
- the inductances can be designed in such a way that the maximum current rise experiences a desired limitation, in particular to protect components and to avoid unwanted high-frequency current ripples on the motor phases.
- a test device for a multi-phase inverter to be tested has a load simulation device, which can be designed as described above and which has several, e.g. B. three or six, transistor bridges corresponding to the number of phases of the DUT. They can be connected parallel to one another between two direct current lines and each have at least two series-connected electronic switches whose connection area can be connected directly or indirectly to one of the phase connections. It is also conceivable that several, e.g. B. to define two sets of transistor bridges and to switch these different sets between tween different DC lines.
- the test device also has a DC voltage source with further DC outputs, which is designed to provide a DC voltage supply for the multi-phase inverter to be tested at its further DC outputs.
- a control device is provided, which is designed at least for driving the load simulation device and for driving the multi-phase inverter to be tested. The DC outputs of the load simulation device are connected to the corresponding further DC outputs of the DC voltage source.
- the load simulation device described so far can be built integrated with a superimposed controller and possibly also integrated with a direct current supply. They then form a test device overall as a single piece of equipment to which the DUT can be connected on the input side and on the output side.
- the test device then needs a certain power supply for the internal operation as well as for the operation of the DUT. It can be connected to a conventional power supply, such as 110 volts, 60 Hertz, or 230 volts, 50 Hertz, or in the case of power-intensive three-phase current can be connected to other equipment. It then generates the direct current internally, which is fed to the DUT on the input side.
- the load simulation device accepts three-phase current from the DUT and converts it back into direct current, which in turn can be fed to the DC voltage source.
- direct current which in turn can be fed to the DC voltage source.
- the test device can also be implemented without an integrated direct current source.
- the direct current source can then be switched on externally.
- the test device then has a DC output which can be connected to the corresponding DC output of the DC power source for the DUT.
- the control device of the test device can be designed to control or provide one or more of the following measures or devices:
- a DUT can go through a more or less detailed and complex test program that includes different operations, different operating modes, different power ranges, etc. pp. Such a test program can be defined using parameters so that these can then be implemented. Different operating times can be simulated, different load ranges, different modes (operation as a load, operation as a generator), different virtual speeds and so on.
- test program Once the test program has been defined, it can be processed according to the specifications. This can be done automatically and possibly without user intervention.
- Setpoint specification and parameter specification for the inverter to be tested The DUT is preferably "actually operated” so that it behaves as realistically as possible. In real operation, it receives setpoint specifications, for example for engine speed or engine torque, which can also be supplied in simulated operation. The same applies to parameters that may be expected, such as operating temperature, voltages and the like.
- the DUT can be equipped with sensors, such as temperature sensors, whose values can be fed back to the test device and evaluated or logged there.
- Setpoint specification for the load simulation device As explained above, the load simulation device must be specified with setpoint values for controlling its transistor bridges. This can be done according to different strategies.
- the load simulation device can log measured and generated variables and then provide them collectively or continuously as a data stream, so that the behavior of the DUT is logged. Evaluations can also be carried out here that deliver evaluation results that go beyond the individual values.
- Control of the DC voltage source According to the test program, the DC voltage source can be controlled at least to on/off and, where possible, to other states.
- a connection to a data network can be provided in order to collect or output data.
- a connection to a data network can be provided in order to collect or output data.
- it can be locally a bus or a storage medium.
- it can be a switchable network, such as a local switchable network, the Internet, or the like.
- User input is often required to carry out the test operation.
- a user interface can be provided in order to be able to provide the necessary information and, if necessary, also to be able to receive outputs.
- the load simulation device and overall test device are designed to handle the voltages in the DUT. These voltages can be 12V or 24V on the DC side, generally below 50V. However, they can also be higher and have values of up to 400 V, generally below 1,000 V.
- the load simulation device can have an exchangeable power semiconductor module, possibly with the connected inductances and possibly driver part, in order to quickly use different power semiconductor modules for different Use nominal voltages and thus be able to adapt to different operating voltages of different DUTs.
- a deployed module may be auto-detectable to recognize it as part of the existing configuration.
- the PWM clock frequency of the load simulation device can be at least a factor of 5 or 10 above the highest frequency of the AC voltage to be handled by the DUT. It can be over 5 kHz or over 10 kHz.
- Simulated engine speeds can range up to 10,000 or 20,000 or 50,000 or 100,000 rpm. For synchronous motors, it correlates directly to the frequency of the AC electrical voltage from the DUT.
- FIG. 3 schematically as a block diagram the control of the load simulation device
- Fig. 4 schematically as a block diagram the control of the test device
- FIG. 6 is a simplified schematic diagram of the test device.
- Figure 7 shows a block diagram of a control component
- Figure 8 shows various waveforms.
- Fig. 1 shows at the top a three-phase inverter 1, which is the device under test (DUT). It is not part of the invention, but here only to explain the environment Invention shown. It is shown only schematically as it is not part of the invention.
- DC inputs 5a and 5b for plus and minus the DC supply voltage are shown on the left.
- Three-phase current outputs 6u, 6v, 6w are shown on the right, at which the three-phase alternating current (three-phase current) supplied by the DUT can be tapped off.
- Internal transistor bridges 4U, 4V, 4W which generate the three-phase alternating current in a known manner, are only indicated.
- a PWM control 3 can be provided, which drives the transistor bridges 4 according to a control/regulation 2 .
- the DUT 1 With 7 different signal inputs and signal outputs of the DUT 1 are indicated, which are used in conventional operation. This can be setpoint specifications or feedback inputs, for example for position transmitters/pulse transmitters from the load to be controlled. It can also be sensor inputs, for example for a temperature sensor, or signal outputs. Generally speaking, the DUT 1 is constructed in a known manner and does not require any modification for testing by the test device.
- FIG. 1 shows a test device at 10 below. It has a load simulation device 10a, a control section 10b and a direct current generation section 10c. The areas are separated from one another by dashed lines lOx and lOy. This is intended to indicate that the test device 10 may, but need not, be broken up into different pieces of equipment at the dashed lines. Instead of continuous lines, respective connections are then to be provided in order to be able to produce appropriate connections across borders.
- the direct current source 10c, the higher-level controller 10b and the load simulation device 10a are accommodated in a single device 10.
- the direct current source 16 it is just as possible to provide the direct current source 16 separately and to integrate only the control part 10b and the load simulation device 10a as one device.
- the control part 10b it is also possible to design the control part 10b as a conventional PC equipped with appropriate software to implement the various components and having interfaces to the load simulation device 10a and the DUT 1 and possibly also interfaces to the DC power source 16 in order to be able to control them if necessary.
- the Lastsimulationsvor device 10a with all the necessary interfaces to the DUT 1 and, if necessary, to the power source, so that the PC can use one of its standard interfaces, e.g. B. USB or wireless z. B. by means of WiFi, communicates with the load simulation device 10a, which in turn then serves the other interfaces.
- the load simulation device 10a is shown to the right of the dashed line 10x in FIG. It comprises a power semiconductor block 11 which, when simulating a load, can be regarded as a controlled rectifier. It has three parallel transistor bridges llu, llv and llw, which are parallel to one another between direct current lines 14a and 14b.
- the examples of the invention described here and shown in the figures represent three-phase embodiments.
- the invention and in particular the load simulation device 10a can be designed more generally for handling multi-phase systems, ie for connecting multi-phase DUTs 1.
- the number of phases in the DUT 1 and in the load simulation device 10a can be three, as described. But she can also be six.
- the number of phases of the load simulating device 10a is at least the number of phases of the DUT 1.
- the load simulating device 10a can have more phases in the hardware layout, e.g. B. six, than the DUT 1. Only the smaller number of phases are then driven in the load simulation device 10a during operation.
- This may be selectably adjustable as part of the configuration or may be followed by automatic detection of which phase terminals have voltages from the DUT.
- a largely automatic configuration can be provided.
- a configuration mode can be provided before the simulation mode, which can last a few seconds and during which basic parameters can be determined, which can then lead to automatically settable configuring settings.
- the configuration mode can also include a specific type of control of the DUT. In the configuration mode, the voltages at the phase connections 17 can be observed and evaluated. One or more of the following parameters can be determined and then set if necessary:
- the configuration can also be carried out “manually”, for example via a graphical user interface.
- FIG. 2 shows in simplified form the structure of a single transistor bridge, such as can be used both in the load simulation device 10a and in the DUT 1.
- two transistor switches 21 and 22 which are regularly directly connected in series are connected, but sometimes also include other components between them.
- the transistors can be field effect transistors, such as MOSFETs, or IGBTs.
- Freewheeling diodes 24, 25 can be present, which can be provided as separate semiconductors or integrated with the transistors 21, 22.
- a driver section with analog driver circuits 26, 27 can be provided which, from the PWM pulses up ...wn supplied by the controller, generate suitable drive signals for the individual control terminals of the individual transistors 21, 22 in terms of level and power.
- a transistor bridge as shown in FIG. 2 is provided for each phase u, v, w of the connected three-phase current.
- Each transistor 21, 22 of the three transistor bridges llu, llv, llw has a control input up, vp, wp for the transistors 21 of the individual phases u, v, w on the positive side of the DC voltage supply, and un, vn, wn for the transistors 22 of phases u, v and w on the negative side of the supply voltage.
- the phase u, v, w respectively connected to the connection area 23 can be applied either to plus or to minus the DC supply voltage.
- the transistors 21 and 22 of the transistor bridges can be driven using PWM technology, which has various control and regulation strategies. One of them is that the transistors 21 and 22 must not be closed (low impedance) at the same time, since this would be a short circuit between the DC voltage lines.
- the load simulation device 10a to the left of the power semiconductor block 11 shows a controller 13 which is designed to control the transistors 21, 22 to drive the transistor bridges llu, llv, llw in a suitable manner in order to also control them with either high resistance or low resistance.
- the load simulation device 10a has phase connections 17u, 17v, 17w to which the corresponding outputs 6u, 6v, 6w of the DUT 1 can be connected.
- the DUT 1 will regularly be a power source and consequently the load simulation device 10a will simulate a consumer.
- the operating conditions can also be reversed, in real terms, for example, when braking or when driving an electrically powered motor vehicle downhill.
- the previously consuming motor or simulated load 10a acts as a generator and the DUT 1 can feedback act as a controlled rectifier and feed DC voltage back to the DC voltage source.
- the load simulation device 10a can map these operating cases accordingly through suitable control.
- the load simulation device 10a regularly also has inductances 12 in the form of coils.
- a coil 12u, 12v, 12w is provided for each phase u, v, w and looped into the current path.
- the coil value can be set manually or automatically. It can be greater than 1 pH or 2 pH or 5 pH or 10 pH. It can be less than 5 mH or 2 mH or 1 mH or 500 pH. It can be between 20 pH and 100 pH.
- the phase terminals 17u, 17v and 17w are connected to the connecting portions 23u, 23v, 23w directly or through the coils 12u, 12v, 12w, respectively.
- the DC lines 14a and 14b in the power semiconductor block 11 are either led out via lines 14 to a plug connection 14p, 14n, or they are led directly to the DC voltage source 16 with line 14 in a fully integrated device 10 .
- the direct current source 16 generates direct current with which the DUT 1 is powered. This generates alternating current, which is fed to the load simulation device 10a. This in turn generates direct current which is fed back to the direct current source 16 . If the test device 10 is constructed as a unit of 10a, 10b and 10c, this feedback takes place inside the device by means of line 14 and can otherwise be produced via plug-in connections.
- the DUT 1 on the left supplies AC power via the phase lines u, v, w and via the inductances 12 to the controllable rectifier 11 of the load simulation device 10a, where it is rectified and fed back via lines 14n, 14p to the DC voltage input of the DUT 1 or to the DC voltage output of the DC voltage source 16 is performed. Except for losses, power is fed back so that the load simulation device works together with the DUT in an energy-saving manner.
- FIG. 6 shows with the thick arrow 61 how current can actually flow.
- the u-phase bridge in the DUT 1 is shown, on the right the u-phase bridge in the load simulation device 10a. It is assumed that in the DUT 1 the upper transistor 21 is closed (never derohmic). If at the same time in the load simulation device in the connected transistor bridge of the corresponding phase u the lower transistor is closed (low resistance), current can flow through the inductor 12u.
- the switching operation of the transistor bridges in the load simulation device 10a takes place in a timely manner with the switching operation of the transistor bridges in the DUT 1 .
- the latter can be determined in particular in the frequency of the PWM pulses in the DUT 1 and in their phase position from the electrical values at the input 17 of the load simulation device, since these were generated by the switching operations in the DUT and reflect them.
- the timing may include frequency matching of the PWM pulse frequencies and possibly also phase matching of the individual pulses. Since the output signals of the DUT 1 (voltages and currents at the outputs 6u, 6v, 6w) correspond to the currents and voltages at the phase terminals 17u, 17v,
- 17w of the load simulation device 10 are not pure sinusoidal oscillations, but rather reflect the switching activity of the transistors of the transistor bridges, the switching operation in the DUT 1 can be read from the electrical values present at the load simulation device 10a. Voltage values and voltage curves can be evaluated.
- the load simulation device 10a has suitable devices to derive the switching frequency and possibly also the phase angle from the electrical values present and then to take them into account when driving the transistors of the transistor bridges 111, 11v, 11w. Current sensors and/or voltage sensors and/or current returns and/or voltage returns can be provided for this purpose.
- the current and/or voltage of one phase or two phases or all phases can be detected at the respective phase input 17u, 17v, 17w or behind it and can be fed to the controller.
- the determination of the switching frequency in the DUT 1 and the determination If necessary, the phase position can be digital if the input values at the phase terminals 17u, 17v, 17w are converted to digital quickly, ie at a high clock frequency, and then evaluated.
- the sampling frequency can be over 100 or 200 or 500 kHz or over 1 or 2 or 5 MHz.
- both the DUT 1 and the load simulation device 10a work on a PWM basis.
- the pulse frequency of the PWM in the DUT can then be determined from the returned signals.
- the phase position can then also be determined. Referring to Fig. 5, qualitative explanations are given on this.
- diagram 51 shows a pulse 51a to d which is intended to be the idealized clock which prevails in the DUT 1. It should be noted that this pulse as shown in FIG. 5 may not actually exist. It is used in the figure only to illustrate the basic ideas.
- Diagram 52 in FIG. 5 shows a pulse as initially determined by load simulation device 10a. For its part, it has idealized pulses 52a, 52b, 52c, 52d. Since there are processing times due to systematic reasons, it cannot be determined at the same time as pulse 51 in DUT 1, but is determined with a time delay of dt.
- the delay time dt includes the delay within the load simulation device 10a and as such can be determined and is known since it is a constant, determinable system parameter.
- the individual pulses 52a, 52b show the same interval tp as the idealized pulse 51 in the DUT 1, so that the time interval between the determined idealized pulse 52 corresponds to the interval in the idealized pulse 51.
- the controller 13 generates control signals up, un, vp, vn, wp, wn for each of the two transistors of the three bridges llu, llv, llw of the power semiconductor block 11. They are used to control the transistor switch to either on (low resistance) or off ( high impedance).
- the tapping off of optionally returned variables in the load simulation device 10a can take place directly at the phase connections 17 or can take place between the inductances 12 and the power semiconductor block 11 . For the currents it makes no difference.
- the voltages can differ according to the voltage drop across the inductances. 1 also shows that the controller 13 operates an output 18 of the load simulation device 10a.
- a position signal or position pulse of the virtually rotating load is generated here and output for use in the DUT 1 .
- a signal present in real devices is thus simulated in order to supply the DUT 1 with the input variables required for operation.
- control devices control aspects and control components are addressed. As mentioned, they can be divided into different real devices. However, it is just as possible to implement them in an integrated manner in just a single device, which is then programmed appropriately, is capable of multitasking if necessary and has sufficient power to be able to carry out the individual measures and activities.
- the controller 13 can have a digital circuit, for example in the form of a small computer with CPU, RAM, ROM, bus, registers and other usual components of a computer. If necessary, A/D converters operated in multiplex mode can be available on the input side and D/A converters on the output side. In addition, the controller can have analog circuit components, for example to generate the PWM control signals in a suitable manner and for communication purposes.
- the hardware implementation can have an FPGA ("Field Programmable Gate Array") for fast digital processing.
- FPGA Field Programmable Gate Array
- the controller 13 can be designed for quasi-simultaneous execution of several programs/tasks in multitasking.
- Suitable signals for driving the transistors of the power semiconductors are generated here in accordance with the pulse width modulation technique in terms of timing, duration and amplitude. This can include digital and analog components, the latter primarily on the output side.
- the 32 addresses the general control of the power semiconductors, which outputs current and/or voltage specifications according to input setpoint values, which can then be fed to the pulse width modulation control 31 so that they can be converted into corresponding pulses there.
- the various control measures as have already been explained and as will be explained further below, can be implemented in the controller 32 .
- the controller 32 may have one or more of the following inputs:
- the controller 32 Depending on the entered values, the controller 32 generates the current pulse duty factor, which is passed on to the PWM controller, as outputs to the PWM controller 31 .
- the device 34 is used to generate one or more synchronization signals or information as already described with reference to FIG. It can receive returned signals via lines 13u, 13v, 13w of the individual phases and determine the information described therefrom after rapid A/D conversion and digital evaluation. These can then be made available in particular to the pulse width modulator 31 in order to generate drive signals for the transistors 21, 22 of the transistor bridges with the correct frequency and phase.
- An FPGA can be used to implement this device.
- threshold switches can also be used for the feedback, which switch at about half the DC voltage, with a certain switching hysteresis for interference suppression.
- the simulator indicates the simulator for the position signal or for the position pulse, which generates the simulated position signal that is output at the output 18 . It is formatted so that the DUT 1 can use it directly.
- the formatting of these pulses can be set via an interface or user interface and thus be adaptable to the need of the DUT 1.
- the simulation can simulate a SIN/COS encoder, possibly with magnetoresistive sensors, or a resolver, which can have inductively coupled coils, or a pulse encoder as the encoder. It can be switchable between different simulations of different encoders in order to be able to serve different requirements of different DUTs.
- 35 is a summation current setting device for superimposed or subordinate control of the power semiconductors such that the sum of the currents at the phase connections 17 assumes a specific value or is within a specific range of values, preferably smaller than a threshold value or as small as possible overall, and preferably becomes zero.
- This component can be interwoven with other control components and can be implemented digitally and arithmetically. It is only shown in isolation in FIG. 3 for visualization purposes. It can be subordinate in the sense that superimposed components generate setpoints in the u/v/w system that would lead to specific currents. If the sum were not the desired value, e.g.
- corrections can be made such that the currents in all phases are changed by the same values, in the example given by 5 A, if 0 is desired as the sum.
- the controller can be designed to specifically set the sum of the currents to values not equal to 0 if simulation of the load is advantageous.
- An error simulation can be implemented by e.g. B. an open line or a short circuit between lines is simulated.
- the cumulative current setting device 35 can also be designed to control or regulate a plurality of separate cumulative currents, in particular star points with a total current of 0, for a plurality of phases.
- a plurality of separate cumulative currents in particular star points with a total current of 0, for a plurality of phases.
- the individual control components can exchange information with one another in order to ensure that all control components that may be working in separate locations can always set their outputs depending on the same input values.
- two control components can exchange information about the currently simulated position for three phases each.
- 36 symbolizes a harmonic suppression component, which ensures that harmonics are at least partially compensated. It causes the phase current to develop a sinusoidal curve that is as ideal as possible.
- Certain types of modulation in the DUT 1 can cause harmonics to form on the generated voltage or current waveforms.
- FIG. Fig. 8A shows the so-called "space vector PWM” (SVPWM).
- SVPWM space vector PWM
- the inverter superimposes a triangular oscillation 82 of three times the frequency on an ideal nominal sinusoidal oscillation 81. In total, this leads to an overall oscillation that is no longer sinusoidal.
- 8B shows the so-called "third harmonics injection PWM” (THIPWM).
- THIPWM third harmonics injection PWM
- the inverter superimposes a sinusoidal oscillation 84 of three times the frequency on an ideal setpoint sinusoidal oscillation (not shown). All in all, this leads to a calculated total target oscillation 85 that is no longer sinusoidal, on the basis of which the pulse duty factors of the signals up, un, vp, vn, wp, wn are determined.
- the harmonics suppression component 36 for the PWM in the load simulation device 10a superimposes the ideal sine setpoint on the ideal sine wave target, compensating for the influence of the curves 82 or 84, which regularly corresponds to the frequency, phase position and amplitude of the superimposed component from the DUT 1. It can be manually or automatically configurable.
- 37 symbolizes an interface for data input and data output. The data input is desirable for the flexible control of the load simulation device, ie ultimately parameters for the specification of higher-level control and regulation parameters, test modes and the like.
- the data output is desirable for the output of measured values and values derived from them. Basically, it can be said in this respect that it is not the load simulation device 10a that is tested, but a DUT 1 that may be connected to it became. If desired, they can be processed, evaluated, passed on and stored. This can also be done through the interface 37 .
- the controller 32 can also bring about a switchover between behavior as a load and behavior as a generator by giving appropriate specifications to the PWM controller 31 .
- this can mean setting a q target component in the d/q system to a negative value if inverted load operation (load as a generator, as is the case in regenerative braking or when driving downhill) is to be simulated.
- a higher-level controller 15 can be provided in the integrated or separately provided control part 10b. It can be connected to a memory 19 of sufficient volume.
- the higher-level control can have various connections, namely in particular to the load simulation device 10a via lines 15b, to the memory 19, to the DUT 1 via lines 15a and possibly also to the direct current source 16 via lines 15c. Not shown as separate lines are connections to a user interface that is intended to be included in the higher-level controller 15 .
- the user interface may include a screen, possibly a graphical user interface, or input masks to make the desired entries or queries.
- the higher-level controller 15 can also be suitable for receiving signals from the DUT 1, for example if it has been equipped with additional sensors in order to record these signals and be able to manage, evaluate and store them in an assignable manner.
- FIG. 4 shows a schematic block diagram of the higher-level controller 15. It can also be or have a computer or small computer or PC. It can have the usual computer components CPU, RAM, ROM, bus, . . .
- A/D converters or D/A converters possibly an FPGA and analog components, can be provided. It can be designed for quasi-simultaneous execution of several programs/tasks in multitasking.
- target value specifications can be generated here and output to the load simulation device 10a, and values can be received from it, in particular measured values, processed values or the like.
- the interface to the DUT 1 is indicated at 45 . It generates the signals required for DUT 1 to operate, so that the DUT 1 appears to operate normally on the input side.
- the DUT interface 45 can also receive sensor signals from the DUT 1 .
- the interface to the DC voltage source 16 is indicated at 44 . It may in any event include an on/off control and possibly other components.
- BO 43 indicates the user interface already described, by means of which a user can make the desired inputs and outputs.
- a sequence planning and sequence control is indicated with 46 . It can be used to determine and define test programs. It can then also control the implementation of the test programs determined in this way. Inputs and/or outputs and/or storage of data and/or processing or pre-processing of data can also be initiated in the desired manner, if necessary also alarms or the like.
- FIG. 7 schematically shows as a block diagram a component for specifying the desired value for the load simulation device 10a. It can be implemented in the controller of the load simulation device 10a or in the higher-level controller of the test device or distributed between the two.
- a first control mode 71 is pure current control or regulation at the phase connections 17 of the load simulation device 10a.
- a second control mode 72 is voltage control or regulation at the phase terminals 17 of the load simulation device 10a, e.g. B. can be selected if the DUT 1 itself carries out current regulation.
- a third control mode 73 is the use of a previously stored motor model which mathematically simulates a motor as a load and from which setpoints for current and/or voltage at the phase terminals are derived.
- the feedback of the driven mechanical load on the electrical circuit can also be simulated, for example by a vehicle. The feedback can be simulated as time-varying
- Bl are calculated according to real load cycles, for example driving uphill, driving straight, driving downhill, accelerating, braking, stop-and-go and the like in a vehicle.
- Choices 74 if any, including possible setpoint inputs for current and/or voltage and/or simulated speed may be part of the user-accessible configuration. It can also be automatically selectable and/or switchable as part of a test program during the execution of the program. As far as a specification of a simulated speed is mentioned, this can also mean the specification of a simulated acceleration, i.e. changing simulated setpoint speed values from an actual speed, e.g. B. 0, include the predetermined number of revolutions.
- target values for the load simulation device can go hand in hand with and correlate in terms of content with the specification of target values for the operation of the DUT 1.
- Target values for the load simulation device can be set according to target values for the operation of the DUT 1 and/or vice versa.
- 10c in Fig. 1 symbolizes the DC part. It can be a conventional direct current source, which has, for example, a mains connection 16a in order to be connected to a conventional alternating current mains. It can then generate direct current, which provides the input power for the DUT 1 at outputs 16b. However, it also has feed points 16c, at which the DC power obtained from the load simulation device 10 is fed back into the DC circuit or from where, in the case of the inverted behavior—load as a generator—power for the load simulation device 10a. If, as shown in FIG. 1, the described components 10a, 10b and 10c are integrated with one another, the feed points 16c can be inside the device.
- the DC part 10c is provided separately, ie is separated along line 10y, the DC power can also be supplied from the load simulation device 10a on the outside and/or via the terminals 16b. It then does not have to take place through the control part 10b.
- Connection lines between the higher-level controller 15 and the DC voltage source are indicated at 15c. On the one hand, they can be used, if necessary, to supply the higher-level controller 15 with energy, but they can also be used for control and, in any case, monitoring.
- All of the power semiconductors of the load simulation device i.e. the power semiconductors 21, 22 of the transistor bridges, possibly with freewheeling diodes and with the closed inductances and upstream driver part with driver circuits, can be designed as an electrically and mechanically detachable built-in module. It can then be exchanged for another module with other semiconductor types and possibly other inductances. Power semiconductor blocks with different electrical dimensions can then simply be used for different nominal voltages of different DUTs 1, so that adaptations to different operating voltages of different DUTs can be made quickly. An inserted module can be automatically recognizable in order to be able to recognize it as part of the existing configuration.
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Abstract
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DE102021113004.2A DE102021113004B3 (de) | 2021-05-19 | 2021-05-19 | Lastsimulationsvorrichtung, testvorrichtung |
PCT/EP2022/062303 WO2022243067A1 (de) | 2021-05-19 | 2022-05-06 | Lastsimulationsumrichter und testvorrichtung |
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DE102023102270A1 (de) | 2023-01-31 | 2024-08-01 | Dspace Gmbh | Testanordnung zum Test eines leistungselektronischen Steuergeräts |
CN117783757B (zh) * | 2024-02-23 | 2024-05-14 | 山东华天电气有限公司 | 一种模块化模拟装置及其控制方法 |
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US7439753B2 (en) | 2005-11-23 | 2008-10-21 | Zippy Technology Corp. | Inverter test device and a method thereof |
US8587322B2 (en) * | 2010-10-27 | 2013-11-19 | E & M Power, Inc. | Methods and apparatus for motor emulation |
EP3196713B2 (de) | 2016-01-19 | 2024-06-26 | dSPACE GmbH | Simulationsvorrichtung zur simulation |
KR102427488B1 (ko) * | 2018-01-23 | 2022-08-02 | 주식회사 플레코 | 전동기 모의 장치 |
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