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Efficient Motor Control and Power Conversion System

This critical design review on February 24, 2009, by Nicholas Barr, Daniel Fargano, Kyle Simmons, and Marshall Worth focuses on the purpose and specifications of a motor power system and controller for IEEE Future Energy Challenge ‘09. The system requires a cold torque of 30 N-m, 3000 RPM in 3-5 seconds, and 1 KW power with a NEMA Frame 56 motor. The control system employs innovative algorithms like Vector, Clark, and Park transforms, as well as PWM using CrossWorks code. The power system features a cascaded B/B inverter with high-frequency operation and low power losses, utilizing advanced components like MOSFETs and IGBTs for efficient performance. The driver configuration includes a bi-directional buck-boost DC-DC circuit, complemented by simulated 3-phase waveforms and sensors. This project also outlines division of labor, project milestones, and opportunities for further discussion.

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Efficient Motor Control and Power Conversion System

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Presentation Transcript

  1. Team MotorBoard Efficient Motor Control and Power Conversion System Critical Design Review 24 February 2009 Nicholas Barr, Daniel Fargano, Kyle Simmons, Marshall Worth

  2. Overview

  3. Purpose and Specifications • Provide a general purpose motor power system and controller • More specifically will be used in the IEEE Future Energy Challenge ‘09 • 30 N-m Cold Torque • 3000 Rpm 3-5 seconds • 1 KW Power • NEMA Frame 56

  4. Motor Requirements

  5. Torque Characteristics

  6. System Description

  7. System Diagram

  8. Control System

  9. Control Algorithm

  10. Vector Controller

  11. Clark Transform

  12. Park Transform

  13. PWM

  14. CrossWorks Code written for Development board using CrossWorks

  15. Power System

  16. Power System - Overview

  17. Power System – Cascaded B/B

  18. Power System - 3φ Inverter

  19. Power System – Switches • Power MOSFET • high-frequency operation • low-voltage drop (low power losses) • saturation temperature sensitivity • IGBT • low drive current • fast switching time • higher voltage drop (higher conduction losses) • IGBT w/Diode Co-pack • Voltage - Collector Emitter Breakdown (Max): 600V • Current - Collector (Ic) (Max): 85A

  20. Power System – Driver • Configuration: High and Low Side, Independent • Bootstrap circuit designed to prevent gate voltage from dropping below minimum gate threshold voltage

  21. Power System – Driver

  22. DC-DC Bi-Directional Buck-Boost

  23. Simulated 3 Phase Waveforms

  24. Simulated 3 Phase Waveforms

  25. Sensors

  26. Parts List – Mass Production

  27. Division Of Labor

  28. Project Milestones

  29. Questions?

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