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Abstract− Power semiconductor switches that include integrated as the load power rating increases and lack of isolation can
pilot current sensors create opportunities to eliminate external lead to performance compromises.
current sensors in three-phase inverter applications. Each of the
three conventional low-side power switches in a three-phase Estimation approaches to reduce the number of current
inverter can be replaced by one of these special devices that is sensors are also candidates. One approach is to use a single
designed to provide a sensing level current that accurately current sensor to measure the dc link current and estimate
mirrors its total forward current. Recognizing that the output (reconstruct) the phase currents using the active voltage vector
current in each phase flows through the low-side switch for only timing [2-4]. Unfortunately, this method encounters
a portion of the fundamental cycle, a technique has been
developed to reconstruct the full phase current waveforms for R- limitations when the duration of the active states becomes very
L loads using only the incomplete phase current measurements. short (i.e., low output voltage conditions).
The performance characteristics of the proposed current
reconstruction technique are experimentally verified, including
demonstration of a closed-loop three-phase current regulator Vdc
using the reconstructed current feedback from the integrated Ia Ib Ic +
pilot current sensors.
-ve -ve -
D D -ve D
Keywords: Current sensors, pilot current sensing, pulse width
Kelvin Kelvin Kelvin
modulated inverters, power MOSFETs, insulated gate bipolar G G G
transistors S Current S Current S Current
I. INTRODUCTION
Three-phase voltage-source PWM inverters with closed-
loop current regulators are widely used in many applications.
Galvanically-isolated current sensors such as Hall-effect signal conditioning and current reconstruction in DSP
detectors placed in flux concentrating toroidal cores are
typically introduced into at least two of the inverter output
Fig.1: Three-phase voltage-source inverter with integrated current sensors in
lines in order to provide the needed current feedback signals. the three low-side switches.
Such field-based current sensors perform well but are typically
Increased pressure to reduce cost by integrating more
quite expensive and too bulky to be easily integrated inside
functionality into power modules is creating renewed interest
power modules. Recent work using miniature giant
in integrated pilot current sensors [5,6] as a promising means
magnetoresistive field detectors as galvanically-isolated
to integrate accurate, current feedback information. Integrated
current sensors has shown that such methods perform well and
pilot current sensors are already widely used in commercially-
are suitable for cost effective integration inside modules [1].
produced power modules for purposes of overcurrent
However, such field detector methods are dependent on the
protection, and work is under way to improve the linearity and
spatial distribution of magnetic fields inside of modules,
dynamic performance characteristics of these devices for use
which makes them challenging to integrate. Non-
in current regulation circuits.
galvanically-isolated approaches such as current shunt
resistors with level-shifting integrated circuits can be cost This paper presents a new technique for reconstructing the
effective alternatives for some power module applications, but phase currents in a three-phase inverter using current
the associated power dissipation becomes more troublesome measurements from integrated pilot current sensors placed in
This work was supported primarily by the ERC Program of the National
Science Foundation under Award Number EEC-9731677.
current through
0
3.5
Mirror Current (mA)
3 250 c
2.5
2
750 c
1.5
1 i
polarity currents
ic ia b
No. of negative
0.5
2
0
0 2 4 6 8 10 1
Imaginary
Axis
a b c phase 'b' axis
*
iαβ
rotation
iα β
*
θe
θe
Fig. 4: Zero-voltage (000) inverter PWM state.
reference
Vb*
-0 . 5
Vc* phase 'c' axis
-1 000 100 110 111 111 11 0 100 000 Fig. 6: Instantaneous complex current vectors showing current command
*
-1 . 5
T s /2 T s /2 vector iαβ and the actual phase current vector iαβ
sampling sampling
instant instant
-2
nearly equal in length, the sampled currents using this
approach will closely correspond to the desired instantaneous
0 .0 5 5 0 .0 6 0 .0 6 5 0 .0 7 0 .0 7 5 0 .0 8 0 .0 8 5
the zero-voltage space vector (000) is applied, assuming space IV. PHASE CURRENT RECONSTRUCTION ALGORITHM
vector pulse width modulation (SVPWM). This zero (000)
vector corresponds to the inverter condition when all three of Using conventional terminology, the two-phase complex
the lower switches are gated on, as shown in Fig. 4. current vector in the stationary reference frame is defined as
The current sampling instant is selected to occur at the
approximate midpoint of each PWM timing interval when the iαβ =
2
3
[
ia + e − j 2π / 3ib + e j 2π / 3ic ] (1)
zero (000) voltage vector is applied. This sampling approach
is illustrated in Fig. 5 using an equivalent sine-triangle where ia , ib and ic are the instantaneous phase currents in the
comparison method where an appropriate zero-sequence stationary frame. It is assumed that the machine is wye-
component is added to the sinusoidal three-phase current connected with a floating neutral so that there is no zero-
references. The PWM frequency is high compared to the sequence component (i.e., ia + ib + ic = 0 at all times).
fundamental frequency so that the three voltage reference
Figure 6 provides a view of the complex current command
waveforms look like nearly horizontal lines in this figure. As
indicated in Fig. 5, current sampling is timed to occur at the
*
vector iαβ and the actual phase current vector iαβ in the space
peaks of the triangle carrier waveform.
ia ,ib ,(i2c ) 1 ib
Fig. 7: Complex current vector plane illustrating arc sectors in which the
phase a current ia is measurable.
cos( θ e* ) iabc _ m
ia _ r = ic _ m for 30 0 ≤ θ e* ≤ 90 0 (9)
cos( θ e* + 120 0 ) Reconstruction iabc _ r
Algorithm
3-2
For the other two arc sectors, the reconstruction algorithm i dq
ph
Decoupling stationary
uses the available direct and indirect measurements of the terms
synchronous
phase a current provided by the pilot current sensors,
according to the expressions provided earlier in (2) and (3)
ia _ r = ia _ m = ia _ FET for 900 ≤ θ e ≤ 270 0 (10) ω e* 1
s
θ e*
ia _ r = ia _ m = −( ib _ FET + ic _ FET ) for − 300 ≤ θ e ≤ +300 (11) Fig. 9: Block diagram of synchronous-frame current regulator using
reconstructed pilot current feedback
Reconstruction of the other two phase currents follows *
exactly the same procedure. Expressions in the form of (8) or For these tests, the q-axis reference current iq was held at
*
(9) are used to estimate the two unmeasured currents in each zero so that id alone determines the amplitude of the phase
of arc sectors where only one of the phase currents is currents. A passive, three-phase wye-connected R-L load (R =
measurable, while expressions in the form of (10) and (11) 20 Ω, L = 4.2 mH per phase) with a floating neutral was
provide measurements of the phase currents in the other two connected at the output terminals of the inverter. The inverter
arc sectors. Using this approach, the reconstruction algorithm dc link input voltage was set at 130 Vdc.
is capable of delivering continuous feedback signals for each A complete set of phase current measurements is generated
of the three phase currents over the entire 3600 interval. independently in the test circuit for comparison with the
V. EXPERIMENTAL TEST EQUIPMENT reconstructed current. For this purpose, three small shunt
resistances are inserted in series with the three low-side
Fig. 9 shows a block diagram of the current-regulated
inverter switches and the resulting shunt voltages are
control scheme implemented in the experimental test
measured. Since each shunt resistor captures the current
equipment using a three-phase R-L load. The control scheme
flowing through both the low-side MOSFET switch and its
uses the well-known synchronous-frame complex vector
anti-parallel diode, both polarities of phase current are
current regulator configuration, including provisions to
measured. As a result, a complete set of phase current
decouple the synchronous frequency-dependent cross-
measurements can be assembled by sampling the voltage drop
coupling and the resistive voltage terms [9].
across the three shunt resistances during each zero (000)
The three-phase PWM inverter uses three integrated pilot voltage vector. This measured shunt current vector is called
current sensors in the lower phase-leg switches as shown iabc_ sh in the Fig. 9 block diagram.
earlier in Fig. 1. The same 400V, 10A power MOSFETs
discussed in Section II (Model IRFC740) are used for the A selector switch that appears in Fig. 9 makes it possible to
lower inverter switches. The PWM frequency is 16 kHz and choose either the reconstructed pilot currents iabc_ r or the
the regulator gain parameters are set to achieve a current measured shunt currents iabc_ sh for the regulator feedback
regulator bandwidth of approximately 2 kHz. current and for the decoupling signals.
2 2
Ia* Ia *
Phase ‘a’ current [A]
2 2
Ia* Ia*
Phase ‘a’ current [A]
0 0
Ia sh
Ia -sh -
-2 -2
0.666 0.668 0.67 0.672 0.674 0.676 0.662 0.664 0.666 0.668 0.67 0.672 0.674
2 2
Ia* Ia*
0 0
Ia r
Ia-r -
-2 -2
0.666 0.668 0.67 0.672 0.674 0.676 0.662 0.664 0.666 0.668 0.67 0.672 0.674
2 2
Id *
Id*
1 1
d-axis current [A]
Id - s h
Id -sh
0 0
0.662 0.664 0 .6 6 6 0.668 0 .6 7 0 .6 7 2 0.674 0.662 0.664 0.666 0.668 0.67 0.672 0.674
2 2
Id* Id*
1 1
Id - r Id-r
0 0
0.662 0.664 0 .6 6 6 0.668 0 .6 7 0 .6 7 2 0.674 0.662 0.664 0.666 0.668 0.67 0.672 0.674
Time[sec] Time[sec]
Fig. 10: Comparison of measured shunt and reconstructed pilot sensor Fig. 11: Comparison of measured shunt and reconstructed pilot sensor
currents in steady state (top) and with 1 A step commands in stationary currents in steady state (top) and with 1 A step commands in stationary
frame (center) and synchronous frame (bottom). Conditions: 500 Hz frame (center) and synchronous frame (bottom). Conditions: Same
fundamental frequency, current regulator BW: 2kHz, fsam:16kHz with test conditions as in Fig. 10, except with reconstructed pilot sensor
measured shunt current as feedback. current as feedback.
The topmost set of trace comparisons in both figures show dynamic test results, the shunt and pilot sensor currents are
the test results for phase a current during steady-state compared individually with the commanded reference current
1
Id*
d-axis current [A]
2
Id* 2
Id*
1
d-axis current [A]
1
d-axis current [A]
Id-sh Id-sh
0
0.66 0.665 0.67 0.675
0
2 0.66 0.665 0.67 0.675
Id* 2
Id*
1
Id-r 1
0 Id-r
0.66 0.665 0.67 0.675
0
0.66 0.665 0.67 0.675
Time[sec]
∧ ∧ Time[sec]
R = 1.2R , L = L ∧ ∧
L = 1.2 L , R = R
Fig. 12: Effects of error in estimated load resistance on measured shunt
and reconstructed pilot current waveforms for 1 A step change in Fig. 13: Effects of error in estimated load inductance on measured shunt
reference current. Same test conditions as in Fig.10, with reconstructed and reconstructed pilot current waveforms for 1 A step change in
pilot current as feedback. reference current. Same test conditions as in Fig.10, with reconstructed
pilot current as feedback.
estimated resistance and inductance values are used in the
current regulator to decouple the voltage drops associated with errors. In addition, it can be observed that these waveforms
the load resistance and the frequency-dependent cross- exhibit low sensitivity to the load parameter estimation errors.
coupling terms as indicated in Fig. 9. In the presence of This is achievable because the current regulator has
inaccurate load parameter estimates, the current regulator does sufficiently high bandwidth to compensate for the parameter
its best to correct for the resulting error voltages caused by the estimation inaccuracy.
parameter inaccuracy.