Real Time Digital Hardware Simulation of
Real Time Digital Hardware Simulation of
Abstract—This paper presents a digital hardware realization of while providing immunity to damage to the actual equipment
a real-time simulator for a complete induction machine drive using due to any malfunction of the controller. However, currently
a field-programmable gate array (FPGA) as the computational available real-time simulators still suffer from modeling inac-
engine. The simulator was developed using Very High Speed Inte-
grated Circuit Hardware Description Language (VHDL), making curacies and limited computational bandwidth. The modeling
it flexible and portable. A novel device-characteristic based model of the power converter is a particular challenge due to the
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suitable for FPGA implementation has been proposed for the demands its high frequency operation places on the accuracy
2-level 6-pulse IGBT-based voltage-source converter (VSC). The and precision of accounting the gating signals coming from the
VSC model is computed at a fixed time-step of 12.5 ns allowing digital controller. This has prompted several correction algo-
a highly detailed and precise accounting of gating signals. The
simulator also models a squirrel cage induction machine, a direct rithms [4]–[7], both offline and real-time, to be proposed using
field-oriented control system, a space-vector pulse-width modula- techniques such as interpolation/extrapolation and variable
tion scheme (SVPWM) and a measurement system. A multirate simulation step-size.
simulation of the system shows the slow (machine) as well as the Power-electronic devices are often modeled in time-domain
fast (VSC and control) dynamic components. Real time simulation
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simulation programs mainly using one of the following three
results under steady-state and transient conditions demonstrate
modeling accuracy and efficiency. behavioral [8] models: 1) ideal model, 2) switching function
model, and 3) averaged model. The ideal model represents
Index Terms—Field-programmable gate arrays, induction
each switch as a two-valued resistor for its on and off states. A
motor drives, pulse-width-modulated power converters, real-time
change of switch status, therefore, results in a change of circuit
systems.
O topology which, in turn, requires the modification of the system
matrix—a computationally intensive procedure especially at
I. INTRODUCTION high switching frequencies. For real-time simulation, the pre-
ferred approach is to precompute and store all possible matrix
permutations for a converter with switches, trading
EAL-TIME digital simulators can play a vital role in
R higher memory requirements for computational gains. The
D
the design and development of large industrial ac drives
[1]–[3]. The two main components of a modern variable-speed switching function model circumvents this precomputation and
ac drive are the power stage and the controller stage. The power storage requirement by representing the switches as controlled
stage includes an insulated-gate bipolar transistor (IGBT)-based voltage and current sources. This model is suitable for high-fre-
quency operation, and the switching functions can be usually
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1236 IEEE TRANSACTIONS ON POWER DELIVERY, VOL. 22, NO. 2, APRIL 2007
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stand-alone processors or as companion processors for DSPs.
This paper reports the first application of FPGAs for modeling
a complete ac drive system. The rest of the paper is organized as
follows: Sections II–VI present the modeling details followed
by the FPGA realization of the VSC, the induction machine,
the control system, the gating signal generator, and the mea-
surement system, respectively. Section VII shows how all of
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the individual models are brought together to achieve real-time
simulation of the complete drive system on a Altera Stratix
EP1S80 FPGA. Real-time simulation results are presented in
Section VIII, followed by conclusions in Section IX.
only the most important features of the IGBT must be taken into used by the manufacturer to determine the IGBT timing char-
account. acteristics. The values of the circuit elements are also standard
For drive applications, the IGBTs are used only in switched values defined by the manufacturer.
mode, i.e., Region I in Fig. 1. Furthermore, the largest possible Figs. 3 and 4 show a typical timing chart of an IGBT during
value for gate-to-emitter voltage is used to minimize con- turn-on and turn-off, respectively. These figures are also used
duction loss in this region. In this case, the forward characteristic to show the switching time definitions. As can be observed in
of the IGBT can be represented by a linear substitute character- Fig. 3, when the IGBT is turned-on, there is a initial time delay
istic (dotted line in Fig. 1), which is given as follows: between the on-signal at the gate and the growing value
of (and decreasing of ). After this time delay grows
(1) exponentially until it reaches its steady value after an overshoot,
defining the rise time depicted in Fig. 3. Fig. 4 shows the
In (1), is the device on-state resistance and is time delay between the turn-off gate signal and the instant at
the collector-emitter threshold voltage. These data can be easily which starts to decrease, defining . After this delay,
found in the IGBT manufacturer’s datasheet. the current decreases until it reaches 10% of its initial value,
Another important characteristic of an IGBT for the VSC is defining the fall time . These figures also define the current
the timing chart for switching operation of the device. This chart time , which is the elapsed time between the sensed gate signal
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PARMA AND DINAVAHI: REAL-TIME DIGITAL HARDWARE SIMULATION OF POWER ELECTRONICS AND DRIVES 1237
TABLE I
IMPLEMENTED DATA FOR CM100DU-24F IGBT UNIT FROM POWEREX
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Fig. 7. One leg of the three-phase VSC.
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by their off-state resistances and the steady-state output voltage
becomes .
For example, consider that at time , the gate signals
of and are changed to 1 and 0, respectively. If is
O positive, for it would flow through the diode
the steady-state output voltage would be
and
, the
voltage drop across the diode. After , will
start to conduct and will flow through the IGBT. The output
voltage will then rise linearly until it reaches its steady-state of
Fig. 5. Idealized timing characteristic of an IGBT during turn-on. . On the other hand, if is negative
and assuming that for the gate signals of and
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were equal to 0 (dead-time), the current would flow through
the diode , and at it will continue flowing through
the same diode, resulting in the steady-state output voltage of
. The third and last possibility is when
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is equal to zero. In this case, the steady-state value for the output
voltage will be similar to the situation when the current was pos-
itive. The remaining switching combinations listed above can be
analyzed in a similar fashion.
B. FPGA Implementation
Fig. 6. Idealized timing characteristic of an IGBT during turn-off.
The functional block diagram of the hardware realization of
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1238 IEEE TRANSACTIONS ON POWER DELIVERY, VOL. 22, NO. 2, APRIL 2007
TABLE II
NUMBER FORMAT FOR THE VSC MODEL VARIABLES
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numbers except the gate signals which are single bits. Table II
summarizes the number format for the input and output vari-
ables. In this table, 19.5 means that 19 b are used to represent
the integer part of the number and 5 b are used to represent the
fractional part. The internal variables of the model usually have
more fractional bits than the input/output variables in order to
preserve the resolution of the simulation calculations. The de-
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veloped model considers that in one simulation time-step there
is no change in the current signal. This is a valid assumption
Fig. 8. Functional block diagram of the hardware realization for one VSC leg. since the time-step chosen for the VSC model was 12.5 ns.
O III. INDUCTION MACHINE MODEL
subset and the rotor speed for the second subset. The model can
be completely described by (2)–(6)
Fig. 9. System components for real-time simulation.
dc link.
As mentioned earlier, the model implements the voltage
drop across the IGBT. Due to the small value of (typically
around 1 according to the datasheet), it is possible to
consider a constant voltage drop independent of the current .
In this case, (1) is replaced by when the
current is flowing through the IGBT. The voltage drop (2)
across the anti-parallel diode is also considered a constant value
when the current is flowing through it. All of the necessary data
retrieved from the component’s data sheet are shown in Table I.
After the model of one leg of the converter was built, it was (3)
duplicated to build the other two legs to implement the three-
phase VSC shown in Fig. 9. The overall VSC model requires
as inputs, the three phase currents, the dc voltage and the three (4)
gate signals. The outputs of the model are the three voltages ,
and with respect to the negative dc bus and the current (5)
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PARMA AND DINAVAHI: REAL-TIME DIGITAL HARDWARE SIMULATION OF POWER ELECTRONICS AND DRIVES 1239
TABLE III
INDUCTION MACHINE PARAMETERS
TABLE IV
NUMBER FORMAT FOR THE INDUCTION MACHINE MODEL VARIABLES
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Fig. 10. Functional block of the implemented induction machine model. adders and multipliers, and registers were used to add the nec-
essary time-delays. The block in Fig. 10 responsible for deter-
where mining the flux magnitude, given by (8), was implemented using
O a binary square root function. The flux position determination,
given by (9) and (10), was implemented with two dividers and
two multiplexers to implement the two position options in these
(6) equations
(8)
is the mutual inductance; and are the stator and
rotor self inductances; and are the stator and rotor re- when
(9)
when
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sistances; is the electrical rotor speed; is the number of
poles and is the total rotor inertia. is the load torque; , when (10)
, and are the stator and rotor flux components; , when
, and are the stator and rotor current components; The model also converts and to the rotor flux ref-
and are the stator voltage components in the stationary
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to the multiplication of state variables. Owing to the mechan- shows the number format for the input and output variables.
ical time constant being larger than the electrical time constants,
the system can be analyzed as two decoupled systems. There- IV. CONTROL SYSTEM
fore, during discretization the rotor speed can be assumed to be
constant during one time-step of the electrical system solution, A. Direct Field-Oriented Control
which is followed by the mechanical system solution. This ap- Since its introduction by Blaschke [16], it is well known that
proach avoids the nonlinearity due to variable multiplication. field-oriented control allows high performance speed and torque
Trapezoidal rule with a time-step s was used to response of induction machines. When the control is oriented by
discretize the model based on the following transformation: the rotor flux, the induction machine behaves like a dc machine
with separate excitation. Considering a machine representa-
(7) tion, where the axis is aligned with the rotor flux space vector
rotating at rad/s and the axis is 90 apart, the following
equations [17] can be obtained:
The functional block diagram of the discretized machine
model is shown in Fig. 10. The discretized versions of (2)–(6)
were implemented using basic arithmetic functions such as (11)
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1240 IEEE TRANSACTIONS ON POWER DELIVERY, VOL. 22, NO. 2, APRIL 2007
Fig. 11. Direct field-oriented controller based on rotor flux. Fig. 12. Implementation of a PI controller.
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TABLE V
(12) NUMBER FORMAT FOR THE CONTROLLER VARIABLES
(13)
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is the rotor time constant defined as .
When the induction machine is fed by a voltage source con-
verter instead of a current source converter, the following equa-
tions can also be obtained:
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(14) the controller. The adder that is used as an integrator has an en-
able input, which is disabled every time the controller’s output
reaches its limit (saturation), avoiding a continuing integration
(15)
of the error when the controller is saturated. Due to the inherent
parallelism of the FPGA, all the controllers execute their func-
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(16) tions at the same time, which would allow a much higher oper-
ational frequency than the chosen 4 kHz.
(17) The gains of the PI controllers were chosen using the pole-
placement method followed by fine tuning in offline simula-
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Equations (14)–(17) reveal that there is an axis coupling rep- tion. The model was implemented in MATLAB/SIMULINK
resented by the terms and , which is contrary to the with a posteriori conversion to the VHDL code. It is impor-
principle of vector (decoupled) control of the induction motor. tant to notice that the control system was directly implemented
However, it is addressed by the high gain current controller. in the hardware, without the use of any co-processor such as
Fig. 11 shows the controller block diagram. The controller re- the embedded softcore NIOS processor, available for the Stratix
quires the measurement of rotor speed , stator currents ( FPGA.
and ), the modulus of the rotor flux and rotor flux posi- As mentioned in the previous subsection, the controller re-
tion . and are the references for the rotor flux and quires the information about the rotor flux, which is usually ob-
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electrical speed, respectively. The information about the rotor tained from an observer. As this was a simulated system, the
flux (magnitude and angle) is usually obtained with the aid of a rotor flux information was readily available in the induction ma-
flux observer [18], [19]. chine model and the observer was not modeled. Table V shows
the number format for the input and output variables of the im-
B. FPGA Implementation plemented controller.
The hardware realization is a straightforward implementation
of the block diagram shown in Fig. 11. All PI controllers have V. GATING SIGNAL GENERATION
saturated outputs and are implemented in the same fashion, as
shown in Fig. 12. A. Space Vector Pulse-Width Modulation
The control frequency was chosen to be 4 kHz in order to The aim of symmetrical space vector pulse-width modulation
maintain compatibility to average commercial controllers, al- (SVPWM) is to generate a controllable three-phase voltage for
though a higher control frequency is also possible. Each PI con- the ac machine by using only two adjacent available voltage
troller uses one two-input subtractor, two adders with two inputs space vectors. This is achieved in a way that the mean value
and three multipliers with one input (the other input is a constant of the voltage output within the PWM period is equal to the
value). The comparator and multiplex blocks are used to saturate reference value used to generate the PWM pattern, in order to
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PARMA AND DINAVAHI: REAL-TIME DIGITAL HARDWARE SIMULATION OF POWER ELECTRONICS AND DRIVES 1241
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Fig. 13. Synthesized voltage space vectors.
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the PWM period; is the time during which the upper switch
of the leg is ON.
The SVPWM algorithm can be described as follows.
O 1) At the beginning of the PWM period, the voltages to be
generated are sampled.
2) The voltages are sorted according to .
3) , and are evaluated from (18).
4) The turn-off time of each switch is calculated in order to
produce a symmetrical SVPWM.
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5) The gate signals of Fig. 14(a) are applied to each upper
Fig. 14. (a) Generic gating signal pattern generated by the SVPWM. (b) Phase switch of the VSC ( , , or ). The gate signals for the
voltage generated by the VSC, with respect to the load neutral point. lower switches are the complements of those for the upper
switches. Dead-time insertion is part of the VSC model
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signals , , and are applied to switches , , and , according to . Then the model implements (18)
respectively, then the voltage space vectors used to synthesize to obtain the , , and values, which are within the PWM
the voltage output are those denoted in Fig. 14(a), and the phase period, by symmetrical comparators. The output of the symmet-
voltage , , and will be equal to , , and , respec- rical comparators are the gate signals , , and , which are
tively. Fig. 14(b) clearly shows that only two adjacent active properly related to the outputs , , and by the unsorted
voltage space vectors are used in one PWM period and that the logic block.
application time of the active vectors depends only of the switch The model also generates a synchronization signal (one single
time difference. If , , and represent the mean value of clock pulse on each new PWM period) not shown in Fig. 15
the output voltages to be generated with , the which will be used by the measurement block explained in the
following equation can be obtained from Fig. 14: next section. Table VI summarizes the number format for the
input and output variables of the implemented SVPWM.
(18)
VI. MEASUREMENT SYSTEM
where , 2, 3 represents the legs , , after the required The voltage input to the machine as a consequence of the
ordering ; is the dc link voltage; is PWM VSC control is a waveform with high frequency com-
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1242 IEEE TRANSACTIONS ON POWER DELIVERY, VOL. 22, NO. 2, APRIL 2007
TABLE VI
NUMBER FORMAT FOR THE SVPWM VARIABLES
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components of the input voltage. This voltage measurement is
usually done by filtering the input voltage by analog or digital
means with the drawback of adding a phase delay proportional Fig. 16. Stratix FPGA development board used to build the real-time simulator.
to the fundamental frequency of the voltage. When the control
system is a variable frequency control, such as vector control,
this phase delay may be difficult to predict and to compensate.
In order to avoid this varying time delay, a digital integration
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of the PWM voltage in one PWM period was implemented. The
measurement system implements (19) and (20) given as follows:
(19)
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(20)
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PARMA AND DINAVAHI: REAL-TIME DIGITAL HARDWARE SIMULATION OF POWER ELECTRONICS AND DRIVES 1243
TABLE VII accuracy and the available FPGA resources. The bit-length of
FPGA RESOURCES UTILIZED BY SYSTEM COMPONENTS input/output variables, such as voltages measured in a prac-
tical application, was limited to 24 b, in order to simulate a
24-b ADC. The fractional part of such variables was represented
using 5 b, which results in a reasonable resolution (0.03125)
commonly found in real world applications where ADCs are
introduced. The bit-length of the internal variables of the sim-
ulator was limited to a maximum value of 32 b with a longer
fractional part in order to reduce the discretization error of the
input variables, and to minimize the round-off error of output
variables.
For example, for the implementation of the field-oriented
controller (Section IV-B), it was necessary to implement a
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function for axis conversion. This function was im-
plemented using a look-up-table, whose output has a 2.11
representation (two b for the integer part and 11 b for the
fractional part), while the reference voltage was coded using
a 19.5 representation, with only 5 b for the fractional part.
With a 2.11 representation, the possible numerical range is
1.99951171875 to 2.00000000000, which easily accommo-
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dates the range of the function with
an accurate resolution (0.00048828125), while minimizing the
round-off error of the output variable (reference voltage). The
rest of the control variables, such as currents and speed signals
O listed in Table V, use a 32-bit resolution (19.13) to achieve
required accuracy.
Fig. 18. Real-time simulator timing resolution.
VIII. RESULTS AND DISCUSSION
This section presents the real-time experimental results ob-
Once the VHDL code for the simulator was compiled, the
tained from the simulator. The results are shown with the aid of
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bitstream was downloaded to the development board through
a four-channel oscilloscope connected to the DACs. The results
the JTAG interface. Table VII summarizes the FPGA resources
show a detail of the IGBT switching characteristic, the VSC
used by individual components of the simulator. In this table,
steady-state waveforms, and the induction machine transients.
the connection system refers to the final file necessary to con-
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frequencies. The most important component, the VSC, requires reaches at . The voltage
the highest frequency ns to model its dynamics, remains until , when lin-
while it is directly connected to the induction machine model early increases until it reaches at
s and the measurement system ns , . In this case, the IGBT does not even turn
which runs at a slower frequencies. on, since its on-time is the minimum value allowed, equal to
All the required frequencies were derived from the common , which is less than the dead-time added by the cir-
clock frequency of 80 MHz. The subfrequencies were obtained cuit that drives the gate signal.
directly inside the FPGA using a PLL or after a further fre- Fig. 20 is similar to Fig. 19 but when the current is zero
quency division to achieve the desired frequency. and is turned-on after the dead-time. In this case, as can be
observed, at , linearly decreases until it
A. Impact of Bit Length on Simulation Accuracy reaches at and remains
at this value during the entire dead-time, when both switches
An important issue about the FPGA-based real-time simu- are off . When is turned-on,
lation is the bit-length of the implemented variables, and the after the dead-time, linearly falls again, accordingly to the
number of fractional bits reserved for each variable. This issue rise-time of switch , until it reaches at
was resolved as a compromise between the required numerical .
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1244 IEEE TRANSACTIONS ON POWER DELIVERY, VOL. 22, NO. 2, APRIL 2007
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Fig. 19. Output voltage (V ) of one leg of the three-phase VSC with respect Fig. 21. Steady state of the 60-Hz voltage v applied to the machine. (v ,
v ): 555 V/div.
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to the negative dc bus (Fig. 7) as a function of the gate signal (A1) when I
is positive.
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v ): 480 V/div.
Fig. 20. Output voltage (V ) of one leg of the three-phase VSC with respect
to the negative dc bus (Fig. 7) as a function of the gate signal (A1) when I
is zero.
component at , the FFT calculated by the oscillo-
scope shows a fictitious dc component which was
added by the DAC since its output is a monopolar value between
B. Steady-State Results
0 V and 5 V. Other significant components are the sidebands
Figs. 21 and 22 show the VSC output after the induction ma- centered at kHz and kHz, since the PWM fre-
chine reaches its steady-state with . Fig. 21 quency is equal to 8 kHz. This FFT analysis is coherent with the
shows the VSC output voltage , a detailed portion of it, analytical results presented in [20].
its mean value within a PWM period determined by the Fig. 22 is equivalent to the previous figure, but shows
measurement system and its fast Fourier transform (FFT). The instead of . Considering a balanced load, the voltage
voltage is equal to the phase voltage , of the balanced is proportional to the phase-to-phase voltage ; it is
three-phase system that supplies the machine. In this figure possible to observe the one level voltage present in the phase-to-
is possible to observe the typical 2 level voltages present in phase voltage. The FFT results agree very well with analytical
the converter phase voltage. Besides the fundamental frequency analysis.
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PARMA AND DINAVAHI: REAL-TIME DIGITAL HARDWARE SIMULATION OF POWER ELECTRONICS AND DRIVES 1245
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Fig. 23. Machine speed (! ), electromagnetic torque (T ) and VSCs I cur- Fig. 25. Machine speed (! ) and currents (i and i ) for: machine startup at
rent for: machine startup at t , speed set-point variation at t , application and t , speed set-point variation at t , application and removal of load at t and t ,
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removal of load at t and t , respectively, and speed reversal at t . (! , ! ): respectively, and speed reversal at t . (! , ! ): 377 (rad/s)/div., (i , i ): 150
377 (rad/s)/div., T : 400 N.m./div., I : 150 A/div. A/div.
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Fig. 26. Offline simulation: machine speed (! ) and currents (i and i ) for:
machine startup at t , speed set-point variation at t , application and removal
Fig. 24. Offline simulation: machine speed (! ), electromagnetic torque (T ) of load at t and t , respectively, and speed reversal at t .
and VSCs I current for: machine startup at t , speed set-point variation at t ,
application and removal of load at t and t , respectively, and speed reversal at
t. observed from the machine torque and speed, the controller has
a fast performance during the transients, and no perturbation
C. Transient Results can be seen in the speed during the application or removal of
the load. As the machine was modeled ignoring the mechanical
Fig. 23 shows the machine speed , the speed reference losses, and the machine resistances are quite small, the value of
, the electromagnetic torque , and the mean value of is almost zero once the machine reaches steady-state. A sig-
within one PWM period when the machine is subjected to the nificant value of different from zero can be observed during
following transients: (1) machine startup with a speed set-point the machine transients and when the load is applied to the shaft.
of 150 rad/s at , (2) speed set-point variation to 377 rad/s at During the transients, the converter must supply or absorb the
, (3) application of 100 N.m. load at and removal of the power consumed or generated by the machine as a function of
load at , and (4) speed reversal to 377 rad/s at . As can be the controller action. It is possible to observe that this current
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1246 IEEE TRANSACTIONS ON POWER DELIVERY, VOL. 22, NO. 2, APRIL 2007
can be positive or negative, depending on the transient, which [5] V.-Q. Do, D. McCallum, P. Giroux, and B. D. Kelper, “A backward-
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IX. CONCLUSION
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tation can be interfaced with a larger and more complex power Gustavo G. Parma (S’98-M’06) received the B.Eng.
system model running on a large-scale real-time simulator. The and Ph.D. degrees in electrical engineering from Uni-
applications of such implementation include the modeling of versidade Federal de Minas Gerais, Belo Horizonte,
Brazil, in 1996 and 2000, respectively.
multilevel multipulse converters not only for drives but also for Currently, he is a Professor at the University of
power system applications such as FACTS and HVDC systems. Minas Gerais, Belo Horizonte, Brazil. He was a
R
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