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Fault-Tolerant PMSG Direct-Drive Wind Turbines,

using Vector Control Techniques with Reduced


DC-Link Ratings
Imed Jlassi, Fernando Bento and Antonio J. Marques Cardoso
CISE – Electromechatronic Systems Research Centre (Portugal)
Universidade da Beira Interior, Covilhã (Portugal)
jlassi-imed@hotmail.fr; fjfbento@ieee.org; ajmcardoso@ieee.org

Abstract—This paper presents a fault-tolerant permanent


magnet synchronous generator (PMSG) drive for wind turbine I. INTRODUCTION
systems, with the ability to handle power semiconductor open- Direct-drive wind turbines based on permanent magnet
circuit (O-C) faults in the full-scale back-to-back converter. The synchronous generators (PMSGs) with full-scale back-to-back
fault-tolerant topology consists of a five-leg converter, with a topologies became very popular for the newly developed and
shared leg connected to a generator phase and to its
installed wind energy conversion systems. The high
corresponding grid phase. The main contribution of this paper
consists on the development of an alternative vector-control-
efficiency, high power-to-weight ratio, and increased
based pulse-width-modulation (PWM) control scheme for both reliability arising from the absence of gearboxes, are the main
machine-side converter (MSC) and grid-side converter (GSC), advantages of this emerging and promising technology.
allowing to reduce the dc-bus voltage ratings. Moreover, a Though wind turbine technologies have changed dramatically
reliable fault diagnosis algorithm is also integrated, providing the during the last years, their reliability and availability levels are
information required to instantaneously trigger fault-tolerant still lower than expected [1]. Industry statistical results
remedial strategies, without any additional sensors. Simulation presented in [2] show that power converters are among the
and experimental results are presented to validate the wind turbine components with higher failure rates, whereas
effectiveness of the proposed fault-tolerant PMSG drive. power semiconductors are among the main responsible for
critical failures [2], [3]. In order to increase the reliability and
Keywords; Fault-tolerant back-to-back converter, power availability levels of wind turbines, it is important to develop
switch open-circuit (O-C) faults, pulse-width-modulation (PWM), fault-tolerant converters with capability to maintain their
permanent magnet machines, wind turbine systems. operation after an unforeseen power switch open-circuit (O-C)
fault occurrence, with acceptable performance until repair
actions are taken. The five-leg converter (FLC) without
NOMENCLATURE redundant power switches has been addressed in several
SLC Six-leg converter studies, by connecting the midpoint of the dc-bus to the
FLC-SL Five-leg converter with shared leg converter phases [4], [5], or to the machine/grid transformer
MSC Machine-side converter neutral point [6], resorting to three TRIACs. In comparison
GSC Grid-side converter with the conventional six-leg converter (SLC), the maximum
isd , isq PMSG dq-axes current components output voltage of the FLC is halved, or the phase currents
increase by a factor of 3 . Converter topologies based on the
Rs PMSG stator resistance dc-bus midpoint connection impose high current stresses on
Ls PMSG stator inductance the capacitors, limiting even more their reliability, since
capacitors are relevant contributors to power converter
ωr PMSG rotor speed failures, as well. In [7], a four-leg converter topology was
usd , usq PMSG dq-axes voltage components proposed, maintaining its operation when faults occur in two
PM different converter legs. Apart from the dc-bus midpoint
PMSG magnets flux linkage
connection issues, this topology requires six TRIACs and
p Number of pole pairs additional sensors, thus increasing the system complexity and
igd , igq Grid dq-axes current components cost. In order to overcome the issues related to the dc-bus
Rf Grid filter resistance midpoint connection, alternative five-leg converter with a
shared leg (FLC-SL) topologies have been proposed, by
Lf Grid filter inductance connecting the machine phases to their associated grid/other
ωg Grid electrical frequency machine phases, resorting to three TRIACs [8]-[13]. For these
topologies, the converter maximum output voltage is reduced,
ucd , ucq Converter dq-axes voltage components (grid side) and the shared leg currents are twice as high when compared
u gd , u gq Grid dq-axes voltage components to the standard SLC. In [14], the converter voltage capability

978-1-5090-6684-1/18/$31.00 ©2018 IEEE 1214


is increased by connecting the shared converter leg to the
transformer neutral point, which requires a power transformer
at the grid connection point. Regarding the converter post-
fault control strategies, vector control combined with pulse-
width-modulation (PWM) techniques were proposed in [8]-
[10], aiming torque ripple minimization, current distortion
reduction and dc-bus voltage imbalance compensation. In
alternative, direct control techniques have been applied in [5],
attaining advantages such as fast dynamic response, simplicity
and low sensitivity to parameter variations. For both control
strategies, the dc-bus reference voltage must be increased
twice as high under post-fault operation. Recently, model
predictive control techniques were proposed in [7], [11]-[13],
allowing to decrease the dc-link ratings. The main advantages
of predictive control techniques are the fast control dynamics
Fig.1. Fault-tolerant converter topology: (a) under healthy operating
and the ability to include multiple constraints into a designed conditions, (b) after O-C fault occurrences in leg “B” (I2 or I5).
cost function, whereas the heavy online calculation effort
requested by prediction calculation present the main drawback
of these control techniques. In particular, for wind turbine
control systems integrating fault-tolerant control algorithms,
the calculation effort rises exponentially.
The topology proposed in this paper is a FLC-SL
connecting the PMSG phases to their associated grid phases,
avoiding the issues inherent to the dc-link midpoint
connection. In opposition to [7], where the fault-tolerant
topology employs six TRIACs, the proposed fault-tolerant
topology only requires three TRIACs. Moreover, and
comparing to the fault-tolerant control strategies proposed in
[5], [7]-[10], which requires an increment of 100% of the dc-
link voltage, the proposed control strategies employ a new
vector control scheme that allows a significant reduction of the
dc-link ratings. Taking into account the need for a reliable
diagnostic method for O-C faults, without extra hardware, the
adaptive threshold-based method proposed in [15] is adopted Fig. 2. Reconfigurable PWM control of the back-to-back topology.
in this paper. The performance of the proposed fault-tolerant
PMSG drive is evaluated and confirmed by means of
simulation and experimental results. The included TRIAC is intended to reconfigure the circuit
of the back-to-back topology, assuring the current flowing in
II. FAULT-TOLERANT CONVERTER TOPOLOGY both directions, between the machine and grid phases. Finally,
Typically, PMSG direct-drive wind turbines require two after the hardware reconfiguration, software modifications are
power converters connected in a back-to-back topology. Each required to adapt the post-fault control strategy to the new
converter is based on a typical voltage source inverter, with converter topology. Accordingly, vector control based
six IGBTs and corresponding antiparallel diodes. The sinusoidal pulse-width-modulation (S-PWM) techniques are
proposed fault-tolerant converter topology is based on the proposed for both converters (MSC and GSC), simplifying the
back-to-back converter with three additional TRIACs that control system implementation.
connect the generator phases to their corresponding grid
phases. Under normal operating conditions, all TRIACs III. PWM CONTROL OF THE CONVERTER
remain open, as shown in Fig. 1 (a). Under O-C fault A. PWM Control of the SLC
condition, this topology allows the continuous drive operation, Through the mathematical model of a surface-mounted
with one shared leg connected to the grid and machine phases PMSG in the dq synchronous reference frame, and considering
resorting to the TRIAC. Let us consider an O-C fault scenario that the dq-axes rotate at the synchronous speed and the d-axis
in IGBT I2 or I5 (refer to Fig.1 (b)) of the grid-side converter is aligned with the rotor flux space vector, then the stator
(GSC) as an example: after the fault detection, the faulty leg voltage and the electromagnetic torque equations are given by
will be disconnected by removing the gate command signals (1) and (2), respectively.
assigned to the two leg switches; then, the grid-phase “B” will
be connected to the PMSG-phase “b”, by triggering on the 
 disd
TRIAC TRb, that changes the back-to-back topology from a 
usd  Rs isd  Ld   s Ld isq

 dt
SLC to a FLC-SL. Likewise, in the scenario of an O-C fault in  (1)
IGBT R2 or R5 of the machine-side converter (MSC), phases 
 disq

usq  Rs isq  Ld   s Ld isd  PM
“b” and “B” are connected by triggering on the TRIAC TRb. 
 dt

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3 where the threshold ξ is set to 0.4, based on extensive tests.
Te  pPM isq (2)
2 Considering the FLC with the shared leg “b” connected to
the machine and grid phases (Fig. 1 (b)), if Δisd and Δisq are
On the other side, considering that the dq-axes rotating at less than Δigd and ξ, respectively, the priority is assigned to the
the grid voltage frequency and the q-axis is aligned with the control of the GSC. Regarding the MSC, further
grid voltage space vector, then the GSC voltages are given by improvements can also be introduced by applying the zero-
 sequence signal only when Sb and SB are different. For
 digd

ucd  R f igd  L f   g L f igq instance, if Sabc and SABC are {101} and {001}, respectively,

 dt the formulated switching state S’abcAC is {10101}, where S’b
 (3)

 digq corresponds to the switching state common to both converter

ucq  R f igq  L f   g L f igd  u gq sides. Let us consider now that SABC is {011}. The zero voltage

 dt
vector for the MSC will be realized using {111} instead of
Vector control strategies are implemented based on the {000}, meaning that S’abcAC is {11101}. The same rationale
machine and grid models. The rotor field oriented control can be applied for the equivalent FLC-SL hardware
strategy is combined with the S-PWM technique and applied connections for the other fault cases.
to the MSC. A voltage oriented control based on S-PWM
C. Converter Design Considerations and Post-Fault
technique is implemented on the GSC. The block diagram of
Operating Limits
the fault-tolerant S-PWM control strategies is shown in Fig. 2.
As it is observed, the machine and grid currents are indirectly The converter operation at rated power during the post-fault
controlled resorting to voltages uabc and u ABC , respectively. The period requires the oversizing of voltage and current ratings of
* the power converters. On the other hand, the operation under
reference voltages uabc and u *ABC are usually generated through
derated mode allows the drive to operate in a limited range
proportional-integral (PI) controllers, properly tuned in order without oversizing the ratings of the converters components.
to achieve high performance of the PMSG drive. The In comparison with the standard SLC, the FLC-SL topology
switching states Sabc and SABC are then determined by has a smaller output voltage capability. The linear modulation
comparing the reference voltages with a high-frequency
range can be defined as follows
triangular carrier. The relationship between the converter
output voltages and the switching states is given by udc
u s  uc  (6)
3
ua , A   2 1 1 S a , A 
  u  
u   dc  1 2 1 S  (4) where us and uc are the amplitudes of the fundamental
 , 
    , 

b B b B
u  3    phase-to-neutral voltages of the MSC and GSC, respectively,
 
1 1 2  Sc ,C 
c ,C and udc is the dc bus voltage.
Taking into account that the required MSC output voltage
B. PWM Control of the FLC-SL depends on the machine speed, and considering that the grid
Under converter post-fault operation, software voltage is constant, the increase of the dc-link voltage and/or
modifications are required in order to adapt the post-fault the decrease of the machine speed are the two available
control strategy to the new converter topology. Therefore, all options, in order to maintain the converter operation within the
switching states are formulated based on Δisd, Δisq and Δigd, linear modulation region (6).
which stand for the absolute values of the reference current Considering three different operating conditions (case (a):
errors isd *  isd , isq*  isq and igd *  igd , respectively. us=uc, case (b): us=0.5uc, case (c): uc=0.5us), the FLC-SL
voltage capability is reduced by approximately 29%, 39%,
The value of Δisd is compared to Δigd, aiming to assign the 39%, respectively, with respect to the voltage capability of the
control priority to one of the converters: an appropriate standard SLC, which is 58 % of the dc link voltage. Therefore,
voltage vector is chosen for the converter with priority, while in the cases (b) and (c) the dc-link voltage must be increased
the other converter is subjected to a zero vector, using the
by 50%, while in case (a) it must be increased by 100%.
switching states {000} or {111}.
In case (a), the required dc link voltage can be reduced by
It is important to emphasize that, according to (1) and (2),
the zero voltage vectors applied to the MSC may lead to limiting the generator speed. Therefore, the maximum speed is
undesirable electromagnetic torque oscillations, because the limited by the maximum amplitude of the MSC converter
permanent magnets are always rotating, and the rotor flux output voltage, given by
keeps moving towards the fixed stator flux. Accordingly, the 1
interaction between the stator voltage and the rotor magnets us , max  udc , max  uc , max (7)
must be taken into account. In order to reduce the zero voltage 3
sequences in the MSC, the absolute value of the reference where udc,max is the maximum dc bus voltage and uc,max is the
current error Δisq is also compared to a fixed threshold ξ. The maximum amplitude of the GSC converter output voltage.
priority is assigned as follows: Considering that the maximum dc bus voltage is one and a

GSC control , if isd < igd and isq < 
half times the rated value (udc,max=1.5 udc,n), the maximum
priority  
 (5) speed should be limited to 50% of the rated speed. Therefore,

MSC control , otherwise
 the fault-tolerant converter requires power semiconductors and

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a capacitor bank with one and a half times the voltage rating. AC Load Encoder Torque Sensor PMSM
Machine
In comparison to the topologies proposed in [5], [7]-[10],
which require an increase of 100% of the dc-link voltage,
independently of the system operating point, the proposed
topology has an improved voltage capability.
The current rating of the switches in both MSC and GSC
are the same as in the SLC, except for the shared leg. The
current rating for the common leg is equal to the sum of the Grid-Side PMSM-Side
Converter Converter
machine phase current and the grid phase current. Considering
that the generator and grid rated RMS currents are equal, and
in order to avoid the oversizing of the converter current
ratings, the load torque should be limited to 50 % of the rated
torque. If the rated torque is intended to be reached, the shared Voltage & Current Protection
leg has to be designed to withstand a rated current two times Filter Sensors Boards Relay
as high. The proposed topology has an improved current Fig. 3. General view of the power stages.
capability in comparison to the FLC-SL topologies based on
the machine/transformer neutral point connection [14], where
the current in the shared leg has to be designed to withstand a
10
rated current four times as high. iA iB iC

Grid Currents (A)


It must be noticed that the capacitor current of the FLC-SL 5
is only related with the high frequency switching current, as in 0
the SLC, whereas the capacitor current has a component at the
fundamental frequency in the case of converter topologies -5 Fault Detection+Isolation
Fault in I2 +Hardware and Software Reconfiguration
based on the dc-bus midpoint connection [8]. -10
0.6 0.7 0.8 0.9 1 1.1
IV. OPEN-CIRCUIT FAULT DIAGNOSIS Time (s)
5 ia ib ic
PMSG Currents (A)

An effective and reliable fault diagnostics method was


proposed in [15] for diagnosing multiple O-C faults in PMSG
drives, without resorting to any additional sensors. The 0
method is adopted in this paper with the aim to quickly
diagnose an unforeseen O-C fault, providing the required -5
information to instantaneously trigger fault-tolerant remedial 0.6 0.7 0.8 0.9 1 1.1
strategies. In [15], the fault is detected based on the Time (s)
comparison of the current form factors Fk (k=a,b,c,A,B,C) 250
DC Bus Voltage (V)

with the adaptive thresholds Sk, calculated from the measured


and estimated currents, respectively. Then, the average values
200
of the measured currents ikAv are used in order to identify the
faulty switch in the back-to-back converter. Due to the use of
adaptive thresholds, the method presents an intrinsic immunity 150
against false diagnostics. Simultaneously, the technique allows 0.6 0.7 0.8 0.9 1 1.1
a fast diagnostic of multiple IGBTs O-C faults in both MSC Time (s)
and GSC.
-2
Torque (N.m)

V. SIMULATION AND EXPERIMENTAL RESULTS -4


The modeling and simulation of a 2.2 kW PMSG drive -6
(parameters shown in Table I), controlled by vector-based S-
-8
PWM techniques shown in Fig. 2, was carried out in a
Matlab/Simulink environment. 0.6 0.7 0.8 0.9 1 1.1
The experimental setup comprises a PMSG (with the same Time (s)
parameters used for the simulation study) coupled to a four- 510
Mechanical Speed (rpm)

quadrant test bench, two Powerex POW-R-PAK voltage 505


source converters connected in a back-to-back topology, a
filter of 20 mH, and a dSPACE DS1103 digital controller (see 500
Fig. 3). Vector control based S-PWM techniques with the 495
proposed fault-tolerant control strategies are implemented into
the dSPACE digital controller board, using a PWM frequency 490
0.6 0.7 0.8 0.9 1 1.1
of 6 kHz, and a sampling time of 50 µs. IGBTs O-C faults are Time (s)
applied by forcing to zero their corresponding gate command Fig. 4. Simulation results regarding the fault-tolerant drive response to an O-C
signals. fault in the converter.

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TABLE I: PMSG PARAMETERS.
Power P 2.2 kW 5 iA iB iC

Grid Currents (A)


Speed N 1750 rpm
Voltage V 316 V 0
Current I 5.3 A
Torque TL 12 N.m Fault Fault Detection+Isolation
Frequency f 145.8 Hz -5 in I2
+Hardware and Software Reconfiguration
Armature Resistance Rs 1.72 Ω 0.3 0.4 0.5 0.6 0.7 0.8 0.9
d/q-axis inductance Lsd/q 20.5 mH Time (s)
5

PMSG Currents (A)


ia ib ic

Simulation and experimental tests were carried out at a grid 0


phase-to-phase RMS voltage of 55 V. A reference dc-link
voltage of 150 V is imposed under normal operating
conditions, allowing the machine to operate at 500 rpm. The -5
amplitude of the fundamental voltages us and uc are equal to 0.3 0.4 0.5 0.6 0.7 0.8 0.9
83 V and 50 V, respectively. Under post-fault operation, the Time (s)
dc-link voltage value is increased to 230 V in order to 250

DC Bus Voltage (V)


maintain the converter operation within the linear modulation
region, according to (6). 200
Fig. 4 and Fig. 5 present the simulation and experimental
results, respectively, regarding the fault-tolerant drive 150
response to an O-C fault in IGBT I2 of the GSC. The power
0.3 0.4 0.5 0.6 0.7 0.8 0.9
switch fault detection is performed within the first half-cycle
Time (s)
of the grid current fundamental period. A delay time of one 5
period is imposed to guarantee the proper post-fault operation
Torque (Nm)

of the GSC. 0
In Fig. 4, the fault is introduced at t = 0.7 s under a load
-5
torque equivalent to 42 % of the machine rated load torque,
triggering the remedial procedures after the fault detection. -10
Leg “B” command signals are forced to zero, and TRIAC 0.3 0.4 0.5 0.6 0.7 0.8 0.9
TRb is then turned on, while the switching state is Time (s)
reformulated and the reference dc-bus voltage is increased to 600
Mechanical Speed (rpm)

230 V. A transient state is imposed to the GSC currents during 550


the dc-bus voltage ramp. The steady-state operation is reached
when the dc-bus voltage takes the new reference value. The 500
increment of the dc-bus voltage allows the mechanical speed 450
to be kept always close to its reference value, as well as a
400
balanced PMSG three-phase currents system, whereas the 0.3 0.4 0.5 0.6 0.7 0.8 0.9
electromagnetic torque ripple increases a little bit comparing Time (s)
to the healthy situation. Therefore, a stable drive operation is Fig. 5. Experimental results regarding the fault-tolerant drive response to an
O-C fault in the converter.
ensured.
Experimental results, presented in Fig. 5, are similar to the
ones obtained from simulation, shown in Fig. 4. A load torque
equivalent to 25% of the machine rated load torque is VI. CONCLUSION
considered. The evaluation parameters of the GSC are shown In this paper, a FLC-SL was adopted for post-fault
in Table II. As it can be seen, the reduction of the grid RMS operation of a back-to-back converter. Comparing to the
currents value, witnessed during the post-fault operation, are already proposed FLC-SL based on PWM control techniques,
attributed to the increment of the dc-bus voltage. Nevertheless, which requires the increase of the dc-bus voltage twice as
a practically unity power factor is always achieved. high, the topology proposed in this paper employs new SPWM

TABLE II: EXPERIMENTAL EVALUATION PARAMETERS OF THE GSC.


Grid RMS Currents Grid Power
Vdc
iA iB iC factor
Normal Operation Control 1.38 A 1.38 A 1.37 A 0.995 150 V
Fault-Tolerant Control 0.95 A 0.95 A 0.94 A 0.990 230 V

1218
control techniques, requiring a lower increment of the dc-bus [14] N. M. A. Freire and A. J. M. Cardoso, “Fault-tolerant PMSG drive with
reduced dc-link ratings for wind turbine applications,” IEEE J. Emerg.
voltage to maintain the drive operation with satisfactory Sel. Topics Power Electron., vol. 2, no. 1, pp. 26-34, Mar. 2014.
performance. Simulations and experimental results were [15] I. Jlassi, J.O. Estima, S. Khojet El Khil, N. Mrabet Bellaaj and A. J. M.
presented, demonstrating the feasibility of the proposed fault- Cardoso, “Multiple open-circuit faults diagnosis in back-to-back
tolerant PMSG drive. converters of pmsg drives for wind turbine systems,” IEEE Trans.
Power Electron., vol. 30,no. 5, pp. 2689-2702, May 2015.

ACKNOWLEDGMENT
This work was supported in part by Santander Totta under
fellowship BIPD/ICI-FE-Santander Universidades-UBI/2016.
This work was also supported by the European Regional
Development Fund (ERDF) through the Operational
Programme for Competitiveness and Internationalization
(COMPETE 2020), under Project POCI-01-0145-FEDER-
029494; and by National Funds through the FCT - Portuguese
Foundation for Science and Technology, under Projects
PTDC/EEI-EEE/29494/2017, UID/EEA/004131/2013, and
SFRH/BD/131002/2017.

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