The subject matter disclosed herein relates to power conversion, and more specifically to controlling a power converter.
Various aspects of the present disclosure are now summarized to facilitate a basic understanding of the disclosure, wherein this summary is not an extensive overview of the disclosure, and is intended neither to identify certain elements of the disclosure, nor to delineate the scope thereof. Rather, the primary purpose of this summary is to present various concepts of the disclosure in a simplified form prior to the more detailed description that is presented hereinafter. The present disclosure provides power conversion systems, methods and computer readable mediums to operate an inverter to drive a motor load through an output filter, in which a control output value is computed according to a current reference value and a current feedback value using a proportional-integral (PI) current regulator, the control output value is filtered using a lag compensator filter to compute an inverter output command value, and the inverter is controlled according to the inverter output command value.
Referring now to the figures, several embodiments or implementations are hereinafter described in conjunction with the drawings, wherein like reference numerals are used to refer to like elements throughout, and wherein the various features are not necessarily drawn to scale.
The disclosed techniques and apparatus facilitate current control using a current proportional-integral (PI) regulator with a lag compensator to filter the control output from the PI regulator and/or to filter a current feedback signal consumed by the PI regulator to operate an inverter of a motor drives with an output sine wave filter, a transformer, long cable, and motor. PI regulator together with one or multiple lag compensators further call PI controller. One or multiple first order lag compensator(s) can be designed based upon characteristics of the sine wave filter. In certain implementations, the filtering is implemented by one or more processors of a drive controller, and the lag compensation is tuned according to various parameters of the system, such as a current control loop resonance frequency of a current control loop, an inverter operating fundamental frequency, a peak resonance frequency of the output filter, a PI regulator corner frequency of the PI current regulator, a desired amplitude margin below unity at the resonance frequency of the current control loop, a desired current control loop crossover frequency of the current control loop, and a plant corner frequency. Certain embodiments can be successfully employed to facilitate accurate stable control of voltages and currents provided to the load in the presence of the output filter between the power conversion system and the load where the power delivered to the load is different from that delivered to the input of the filter. The output inverter stage of the motor drive in certain examples can be controlled according to feedback signals measured at the inverter output terminals, but these feedback values generally do not represent the currents or voltages ultimately provided to the load. Feedback sensors can be provided at the load itself for direct measurement of the load parameters, but this increases system cost, and may not be possible in all applications. The disclosed examples can be used, for example, in sensorless position control applications, such as deep well pump motor control where direct sensing of the motor load position and/or speed is difficult or impractical. In certain applications, a step-up transformer is used to boost the motor drive output voltage, allowing use of a low-voltage drive to power a medium voltage induction motor, and/or to reduce I2R losses and facilitate use of a smaller diameter cable wire for long cable runs between the motor drive and the driven motor. Certain applications also employ output filters between the motor drive inverter output and the transformer primary in order to suppress reflected wave voltage spikes associated with pulse width modulated (PWM) variable frequency drives. Use of sensorless voltage-frequency control techniques may lead to problems, particularly where a transformer and/or sine wave filter is connected between the motor drive and the motor load. Sensorless field-oriented-control (FOC) or other open loop speed control techniques have thus far been largely unsuitable for low-speed motor drive operation where output filters and transformers are used, such as in electric submersible pumps (ESPs), and these difficulties are particularly problematic in driving permanent magnet synchronous motors (PMSMs). Moreover, motors in sensorless speed control applications also suffer from oscillation in rotor velocity about the setpoint speed following load transitions or speed setpoint adjustments, particularly at low speeds. In certain situations, moreover, the driven motor may be unable to start successfully from a stopped condition due to unstable motor speed oscillations. Furthermore, operation at high speeds is sometimes prevented or inhibited by the resonant frequency of the connected output filter. In this regard, conventional motor drives and control techniques often suffer from instability problems at high motor speeds.
As seen in
The motor drive 40 receives single or multiphase AC input power from a power source 10 and converts this to a DC bus voltage using a rectifier 42 which provides a DC output voltage to a DC link circuit 44 having a capacitor C. The rectifier 42 can be a passive rectifier including one or more diode rectifier components, or may be an active front end (AFE) system with one or more rectifier switching devices (e.g., IGBTs, etc.) and an associated rectifier controller (not shown) for converting input AC electrical power to provide the DC bus voltage in the link circuit 44. Other configurations are possible in which the drive 40 receives input DC power from an external source (not shown) to provide an input to the inverter 46, in which case the rectifier 42 may be omitted. The DC link circuit 44 may include a single capacitor C or multiple capacitors connected in any suitable series, parallel and/or series/parallel configuration to provide a DC link capacitance across inverter input terminals 46A. The illustrated motor drive 40 is a voltage source converter configuration including one or more capacitive storage elements in the DC link circuit 44. The various concepts of the present disclosure may be implemented in association with current source converter architectures in which a DC link circuit 44 includes one or more inductive storage elements, such as one or more series-connected inductors situated between the source of DC power (e.g., rectifier 42 or external DC source) and the input 46A of the inverter 46. In other possible implementations, the motor drive 40 includes a direct DC input to receive input power from an external source (not shown), and in certain embodiments the rectifier 42 and DC link circuit 44 may both be omitted.
The DC input 46A of the inverter 46 includes first and second (e.g., plus and minus) terminals connected to the DC link circuit 44, as well as a plurality of switching devices S1-S6 coupled between the DC input 46A and the motor drive AC output 46B. In operation, the inverter switching devices S1-S6 are actuated by inverter switching control signals 101 provided by the controller 100 to convert DC electrical power received at the DC input 46A to provide AC electrical output power as inverter output voltages, Vu, Vv, and Vw and inverter output currents iu, iv, and iw at the AC output 46B. The filter circuit 30 receives the AC output from the inverter 46 of the motor drive 40. Although illustrated as driving a permanent magnet synchronous motor 20, the motor drive 40 can be employed in connection with other types of AC motor loads 20 and/or other forms of power converters to drive non-motor loads 20 using an output inverter 46. One or more feedback signals or values may be provided from the motor 20 itself, including a motor (e.g., rotor) position or angle signal θr and a motor speed or velocity signal ωr, although not a strict requirement of all embodiments of the present disclosure. The concepts of the present disclosure advantageously facilitate the sensorless speed estimation by the inverter controller 100, and thus direct feedback from the driven motor load 20 is not required in all implementations. The motor drive 40 in certain embodiments implements a motor speed and/or position and/or torque control scheme in which the inverter controller 100 selectively provides the switching control signals 101 in a closed and/or open-loop fashion according to one or more setpoint values such as a motor speed setpoint. The setpoint in one example is a signal or value generated by the controller 100, or a fixed setpoint value, or such setpoint value can be received from an external system (not shown). In practice, the motor drive 40 may also receive a torque setpoint and/or a position (e.g., angle) setpoint, and such desired signals or values (setpoint(s)) may be received from a user interface and/or from an external device such as a distributed control system, etc. (not shown). As used herein, a signal can be an analog signal, such as a current or a voltage signal, or a signal can include digital values generated or consumed by the processor 102.
The inverter 46 of the motor drive 40 is connected to the load 20 through the intervening filter circuit 30. In the example of
The output of the filter circuit 30 provides motor phase currents iout to control the motor load 20. The filter capacitor currents iC flow in the filter capacitors C1 and non-zero voltages vL (i.e., filter voltages) may develop across one or more of the filter inductors Lr, whereby simple closed-loop control based on measured inverter output current signals or values iu, iv, iw may result in less than optimal operation of the driven load 20. At the same time, however, directly measuring the motor currents iout and/or motor voltages would require additional hardware and cabling, which may not be economically feasible or technically possible in certain applications. Nevertheless, for those cases where motor currents and/or motor voltages, such as Vu, Vv, Vw, Vf_out_v, and Vf_out_w in
The controller 100 and the components thereof may be any suitable hardware, processor-executed software, processor-executed firmware, logic, or combinations thereof that are adapted, programmed, or otherwise configured to implement the functions illustrated and described herein. The controller 100 in certain embodiments may be implemented, in whole or in part, as software components executed using one or more processing elements, such as one or more processors 102. The controller 100 may be implemented as a set of sub-components or objects including computer executable instructions stored in the electronic memory 104 for operation using computer readable data executing on one or more hardware platforms such as one or more computers including one or more processors, data stores, memory, etc. The components of the controller 100 may be executed o the n the same computer processor or in distributed fashion in two or more processing components that are operatively coupled with one another to provide the functionality and operation described herein.
Referring also to
The controller 100 is configured to implement the method 300, wherein the processor 102 of
At 306, the processor 102 computes a current reference value Id,q.ref according to the torque reference value Torque.ref. At 306, the controller 100 uses one or more lookup tables 202 or solves one or more parametric equations (not shown) to compute one or more motor current reference values. In the example of
At 308, the control processor 102 computes a control output value COd,q according to a current reference value Id,q.ref and a current feedback value Id,qfbk using a proportional-integral PI current regulator 106 implemented by the controller 100. At 309 the processor 102 filters the control output value COd,q to compute an inverter output command value Vd,q.com using the lag compensator filter 108 implemented by the controller 100. In certain examples, the PI regulator(s) 106 and the lag compensator filter(s) are implemented as programmable instructions stored in the memory 104 to be executed by the processor 102.
At 310 in
As shown in
In other possible implementations, the controller 100 operates to control the inverter 46 according to the inverter output current reference value(s) Id,q.inverter.ref. In this case, the controller 100 computes the inverter output current value(s) Id,q.in according to the inverter output current reference value Id,q.inverter.ref and the inverter output current value Id,q.in, and provides the inverter switching control signals 101 to control the inverter 46 (e.g., at 310 in
The lag compensator filter 108 in certain examples includes one or more lag compensators designed according to a current control loop resonance frequency ωd,q.res of a current control loop, an inverter operating fundamental frequency ωfund, a peak resonance frequency ωpk of the output filter 30, a PI regulator corner frequency ωld of the PI current regulator 106, a desired amplitude margin 1010, 1110 below unity at the resonance frequency ωd,q.res of the current control loop, a desired current control loop crossover frequency ωco of the current control loop, and a plant corner frequency ωΣ. Moreover, the drive 40 and the controller 100 are programmable to adapt to different filter and/or driven motor combinations.
Referring now to
The following presents an analysis of a current control loop implemented in the controller 100 for operation of the inverter 46 in combination with an output sinewave filter 30. The output filter 30, as previously mentioned, does not include any damping resistors, and thus has a low damping factor and relatively low resonance frequency ωpk (e.g., the resonance frequency ωpk is not far from required current loop frequency crossover).
where “ωΣ” is a plant corner frequency given according to the following formulas, where Tpk is the time constant of the output filter 30, C is the filter capacitance, Lr is the inductance of the filter inductors, and Rr is the resistance of the filter inductors:
From equations 3 and 4, the following equations can be derived for the time constant Tpk and a damping factor ξ:
where “ξ” and “ωpk” are filter damping factor and filter resonance frequency, respectively. A typical range of the damping factor “ξ” for a standard sinewave filter is 0.01-0.0005, and a typical range of a resonance frequency “ωpk” for a standard filter is 800-1,100 Hz. The amplitude of the resonance peak “Apk” at the point of the resonance frequency “ωpk” can be calculated as follows:
According to the damping factor range, the amplitude of the resonance peak “Apk” is given in one example by the following:
Or in a decibel units:
20·log(Apk)=20·log(50-500)=(34−60) db (10)
ωd,q.res=ωpk−ωfund (11)
As seen in
Stabilizing the current control loop using an ordinary PI regulator is difficult with appropriate current loop frequency crossover at the crossover frequency ωco of the current control loop, due to very large resonance peak of the output filter 30. In one possible embodiment, the controller 100 uses PI regulators 106 in combination with one, two or more lag compensator units, either following the PI regulators 106 in a current control or 101, or using an alternate filter position in the current feedback loop 108k as shown in
The graph 700 in
In one example, the lag compensator filter 108 includes a first lag compensator filter having a first lag filter corner frequency ωlag 1 between the current loop crossover frequency ωco and the current control loop resonance frequency ωd,q.res. In other examples, as discussed further with reference to
where the integral and proportional constants are given by the following per equations 13 and 14:
For the triangle “FGM” in
Or:
For the triangle “DGM”, the following holds:
Or:
From equations 20a and 22, the following can be derived:
where “ωco.1” is a current loop frequency crossover for the single lag unit approach.
For the triangle “DKN”, using equation 16, the following holds:
where “ωfund” is the fundamental frequency (maximum fundamental frequency determined by a specific application. The lag compensator filter 108 in one example includes a first lag compensator filter having a first lag filter corner frequency (ωlag 1) between the current loop frequency crossover (ωco) and the current control loop resonance frequency (ωd,q.res):
ωlag.1=α·ωco.1 (25)
A minimum value for the coefficient “α” can be selected based on an appropriate additional phase shift that “lag unit” brings into an overall phase shift at the current loop frequency crossover point. In certain examples, the first lag compensator (and any included second lag compensator) is designed to provide a non-zero phase margin (1010, 1110 in
Or, from (26):
αmin=2.144 (26a)
In a future calculation we will use round “amin“” as follows:
αmin=2 (27),
Then:
Digital implementation brings a limit for maximum value of this coefficient. Practically, good performance for a first order filter can be achieved if the maximum corner frequency (ωlag.max) is no larger than 10% from firmware scan frequency (ωscan) (where 10% is practical arbitrary number). Usually the firmware scan frequency (ωscan) can be determined as follows:
ωscan=2·(2·π·fcarrier) (28)
And therefore:
Therefore for “αmax” the following can be written:
Finally:
αmin<α<αmax (30
Or:
From (24) and (25) we can derive:
In addition, (see
where the stability margin limit can be determine as follows (3.5 db is a practical arbitrary number):
3.5 db≤20 log(margin). Or: 1.5≤margin and marginmin=1.5 (34)
Appropriate values can be calculated for current loop frequency crossover using equations 32 and 33:
Or, with the help of equations 27 and 34:
According to equation 36, a current loop frequency crossover can be selected as follows:
Where “ωΣ” is the plant corner frequency (see equation 2).
According to (27, and 29) the following can be written:
And real margin can be calculated from (25, 32 and 33) as follows:
Now we need to determine appropriate “Ki,Kp” values.
From triangle “ZYF” the following can be written:
Or:
From triangle “ZYE” the following can be written:
Or:
From (41) and (43):
ωE2=ωco.1·ωld (44)
From triangle “XPE” the following can be written:
Or with the help of (44):
Now, from triangle “XPB” the following can be written:
Or:
From (46) and (48):
Let's take into account equation (2), then:
Let's determine the limitation for “ωld” as follows:
ωΣ≤ωld.real≤ωco.1.real (51)
Let's represent “ωld” using the following equality:
ωld=b·ωΣ (52)
Or
According to (51) limitation for “b” can be written as follows:
Finally “Ki” and “Kp” can be determined according to equations (18, 50) and (19, 50) as follows:
K
i
=R
Σ·ωint=Lsysωco.1.realωld=Lsys·ωco.1.real·breal·ωΣ (54)
Or:
K
i
=K
pωld=Kp·breal·ωΣ (56)
Equations (39, 51-56) determines all PI controller parameters.
To determine PI controller's parameters more precisely let's analyze phase margin at the current loop frequency crossover point.
According to
Finally:
Where “τ” is inverter time delay and can be represented as follows:
Appropriate phase margin at the point of current loop frequency crossover can be determine based on the follows equation:
Δφ0(ωco.1.real)=1800φtotal-phase-shift-open-current-loop≥300 (60)
Where “300” is a practical arbitrary phase margin.
According to (58, 60) the following can be written:
Practically, term
is very small (less than 1 degree) and can be omitted.
Finally, phase margin can be rewritten as follows:
Or, after some manipulation:
Or:
Where:
Manipulate with “ωld”, “ωlag”, sometimes “ωco.1.real” and take into account (37, 38, and 51) finally we can establish all necessary PI controller's parameters with appropriate phase margin.
Where “Ki” and “Kp” can be determined by according to equations (18-19).
For triangle “SRT” the following can be written:
Or:
For triangle “DTR” the following can be written:
Or:
From (68) and (70) we can derive:
For triangle “FGM” the following can be written:
approach.
Or:
MG=ω
lag.1/ωco.2 (74)
For triangle “DGM” the following can be written:
Or:
From (74) and (76) we can derive:
Or:
ωD=√{square root over (ωco.2·ωlag.1)} (78)
From (72) and (78) we can derive:
ωS3=ωlag.2·ωD2=ωco.2·ωlag.1·ωlag.2 (79)
For triangle “SNK” the following can be written:
Or:
From (79) and (81) we can derive:
A stability margin limit can be determine as follows (3.5 db is a practical arbitrary number):
3.5 db≤20 log(margin) (84)
Or:
1.5≤margin (85)
From (85):
marginmin=1.5 (86)
Therefore from equation (83):
Finally, we can calculate a limit value for current loop frequency crossover using equations (82, 86, and 87):
According to equations (25, 27)
ωlag.1.min=2·ωco2 (89)
According to equation (27a) maximum phase shift at a current loop frequency crossover for “ωlag.1.min” equals:
Δφ0(ωlag.1.min(@ω
“ωlag.2” can be represented as follows:
ωlag.2=d·ωco.2 (90)
Practically (just for example) this additional phase shift should not be more than 15 degrees (arbitrary number). Therefore “dmin” can be calculated as follows:
Or, from (26):
dmin=3.73 (90b)
In a future calculation we will use round “dmin” as follows:
dmin=3.5 (90c),
Then:
Therefore combined additional phase shift from 2 lag units equals (see equations 89a and 90d):
Δφ2.lag.units0=Δφ0(ωlag.1.min(@ω
ωlag.2.min=3.5·ωco.2 (91)
Now we can recalculate current loop frequency crossover limit (88) with the help of equations (86, 89, and 91) as follows:
According to (92) with some additional margin we can choose any current loop frequency crossover as follows:
Minimum corner frequency of a lag1 unit can be calculated as follows:
ωlag.1.min=2·ωco.2.real (94)
Minimum corner frequency of a lag2 unit can be calculated as follows:
ωlag.2.min=3.5·ωco.2.real (95)
According to (94, 95) and practical digital implementation (29) of lag units the following can be written:
And real margin can be calculated as follows:
Now we need to determine appropriate “Ki, Kp” values.
From triangle “ZYF” the following can be written:
Or:
From triangle “ZYE” the following can be written:
Or:
From (100) and (102):
ωE2=ωco.2·ωld (103)
From triangle “XPE” the following can be written:
Or with the help of (103):
Now, from triangle “XPB” the following can be written:
Or:
From (105) and (107):
Let's take into account equation (2), then:
Let's determine the limitation for “ωld” as follows:
ωΣ≤ωld≤ωco.2.real (110)
Finally “Ki” and “Kp” can be determined according to equations (18, 109) and (19, 110) as follows:
K
i
=R
Σ·ωint=Lsys·ωco.2.real·ωld=Kpωld (112)
Equations (96-97, 111-112) determines all controller's parameters.
It is possible to determine controller's parameters more precisely if we will analyze phase margin at the current loop frequency crossover point. According to
Finally:
Where “τ” is inverter time delay and can be represent as follows:
Appropriate phase margin at the point of current loop frequency crossover can be determine based on follows equation:
Δφ0(ωco.2.real)=1800−φtotal-phase-shift-open-current-loop-2lag≥300 (116)
According to (105, 107) the following can be written:
Practically, term
is very small (less than 1 degree) and can be omitted.
Finally, phase margin can be write as follows:
After some manipulation we can derive:
Where:
Manipulate with “ωld”, “ωlag1”, “ωlag2”, sometimes “ωco.2.real” and take into account (93, 96, 97, and 110) finally we can establish all necessary PI controller's parameters. Disclosed examples include power conversion systems 40, methods 300 and computer readable mediums 104 to operate an inverter 46 to drive a motor load 20 through an output filter 30, in which a control output value COd,q is computed according to a current reference value Id,q.ref and a current feedback value Id,qfbk using a proportional-integral PI current regulator 106, the control output value COd,q is filtered using a lag compensator filter 108 to compute an inverter output command value Vd,q.com, and the inverter 46 is controlled according to the inverter output command value Vd,q.com. The examples of
In the preceding specification, various embodiments have been described with reference to the accompanying drawings. It will be evident that various modifications and changes may be made thereto, and additional embodiments may be implemented, without departing from the broader scope of the invention as set forth in the claims that follow. The specification and drawings are accordingly to be regarded in an illustrative rather than restrictive sense.
The following U.S. patents, patent applications and published patent applications are hereby incorporated by reference in their entireties: U.S. Pat. No. 9,124,209 issued Sep. 1, 2015 to Liu et al., entitled METHOD AND APPARATUS FOR CONTROLLING POWER CONVERTER WITH INVERTER OUTPUT FILTER; U.S. Patent Application Publication No. 2015/0123579 A1 to Liu et al., entitled METHOD AND APPARATUS FOR CONTROLLING POWER CONVERTER WITH INVERTER OUTPUT FILTER, and filed as U.S. patent application Ser. No. 14/555,769 on Nov. 28, 2014; U.S. Pat. No. 9,054,621 issued Jun. 9, 2015 to Liu et al., entitled POSITION SENSORLESS OPEN LOOP CONTROL FOR MOTOR DRIVES WITH OUTPUT FILTER AND TRANSFORMER; U.S. Patent Application Publication No. 2015/0194901 Al to Liu et al., entitled POSITION SENSORLESS OPEN LOOP CONTROL FOR MOTOR DRIVES WITH OUTPUT FILTER AND TRANSFORMER, and filed as U.S. patent application Ser. No. 14/666,894 on Mar. 24, 2015; U.S. Pat. No. 9,054,611 issued Jun. 9, 2015 to Liu et al., entitled METHOD AND APPARATUS FOR STABILITY CONTROL OF OPEN LOOP MOTOR DRIVE OPERATION; U.S. Patent Application Publication No. 2015/0002067 A1 to Nondahl et al., entitled METHOD AND APPARATUS FOR STABILITY CONTROL OF OPEN LOOP MOTOR DRIVE OPERATION, and filed as U.S. patent application Ser. No. 14/193,329 on Feb. 28, 2014; U.S. patent application Ser. No. 14/565,781 filed Dec. 10, 2014 to Nondahl et al., entitled TRANSITION SCHEME FOR POSITION SENSORLESS CONTROL OF AC MOTOR DRIVES; U.S. patent application Ser. No. 15/014,360 filed Feb. 3, 2015 to Royak et al., entitled CONTROL OF MOTOR DRIVES WITH OUTPUT SINEWAVE FILTER CAPACITOR CURRENT COMPENSATION USING SINEWAVE FILTER TRANSFER FUNCTION; U.S. patent application Ser. No. 15/053,135 filed Feb. 25, 2016 to Nondahl et al., entitled SENSORLESS MOTOR DRIVE VECTOR CONTROL WITH FEEDBACK COMPENSATION FOR FILTER CAPACITOR CURRENT; and U.S. patent application Ser. No. 15/053,273 filed Feb. 25, 2016 to Nondahl et al., entitled SENSORLESS MOTOR DRIVE VECTOR CONTROL.