phase currents reconstruction using a single current sensor of three-phase ac motors fed by...

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Phase Currents Reconstruction using a Single Current Sensor of Three-Phase AC Motors fed by SVM-Controlled Direct Matrix Converters.

Brahim Metidji, Student Member, IEEE, Nabil Taib, Lotfi Baghli, Senior Member, IEEE, Toufik Rekioua, Sedik Bacha, Member, IEEE

Abstract This paper presents a novel method for phase AC motor currents reconstructing with a single current sensor in three-phase Direct Matrix Converter (DMC) drive system using SVM control technique. The main goal is to reduce the cost and to improve the reliability of drive systems that involve closed loop control strategy. For this purpose a new structure and algorithm were developed which divide the zero vector application time in two intervals and measures the phases currents using a new placement of the single Hall current sensor in Direct Matrix Converter. These proposals constitute a good solution in the low power range direct matrix converter, (below 15 kW), where reducing size and cost is the key objective.

The simulation of the three-phase to three-phase Direct Matrix Converter feeding an induction motor was done to demonstrate the advantages of the proposed system. Experiments were carried out thanks to a DS1104 control broad to check the validity of the proposed method.

Index Terms AC motor, Current sampling, Direct Matrix Converter, Phase currents reconstruction, Single current sensor, Space vector modulation.

I. INTRODUCTION

he AC-AC matrix converter was investigated firstly in 1976 [1] and has recently been the subject of lots of

research works because of its numerous advantages [2],[3]. This makes the matrix converter a competitive solution regarding the traditional voltage source inverter in AC motor drive using various high performance control techniques as vector control [4], direct torque control [5]. However, the matrix converter presents some disadvantages: the limited voltage transfer ratio to 0.866 in linear modulation region; the complex protection of the converter; the high sensitivity to the grid voltage distortions; and the high number of power switches thus increasing the connection

and control complexity, and the overall cost. In the low-power range (less than 15 kW with 1550A devices), where low volume and low cost are the main objectives [6], any solution oriented to cost reduction is welcome. Several researches proposed some solution for cost and size reduction. The three-phase to three-phase entire power stage DMC has been proposed in single power modules [7]. Bidirectional switches driver power supply cost reduction are also considered [6][8].

Since its first application in matrix converter control [3], the space vector modulation (SVM) is more and more used in three phase direct matrix converter control [9][10][11]. In recent years, many works focused to improve and generalize the space vector modulation application on direct matrix converters [9], [12]-[14].

The majority of AC motor closed loop control techniques require phase currents knowledge, consequently the current sampling plays an important role in three-phase AC motor _ Induction Motor (IM), Permanent Magnet Synchronous Motor, Brushless Direct Current motor (BLDC)_ drive systems for controllers, observers and protection functions. Traditionally, phase currents are detected with two or three current sensors installed in motor phases. Several disadvantages are caused by adopting this solution from the standpoint of drive cost and size, especially for low power drives, where the cost is an important criterion. More recently, by using traditional voltage source inverter, single current sensor operation has been proposed to reconstruct phase currents with the DC link current sensor [15]. In this way various approaches have been proposed in the literature. Some methods introduce an adjustment to the PWM signal to ensure that, in each period, the two phase currents can be sampled [16]-[20]. Other strategies introduce modifications to the modulation algorithm in order to guarantee the reliability of the measurements from the DC Link current sensors in all the operating conditions [21],[22]. Other interesting approaches are based on the prediction-correction technique to estimate the motor phase currents, thus introducing an additional computational burden to the drive system [23]-[26].

The motivations for this research effort have included cost savings associated with reducing the current sensor number. The majority of these works are based on DC link current measure using a traditional voltage source inverter to feed AC machines [27]-[31], Permanent Magnet Synchronous Motor (PMSM) [34]-[36], Brushless DC Motor (BLDC) [37],[38] and Switched Reluctance Motor (SRM) [39]. In [27] the authors do not use DC link current but they presents two new sensor placement and a specially developed algorithm for three

T

Manuscript received November 26, 2011; revised February 26, 2012, April 26, 2012 and August 19, 2012; accepted for publication November 22, 2012. Copyright (c) 2012 IEEE. Personal use of this material is permitted. However, permission to use this material for any other purposes must be obtained from the IEEE by sending a request to [email protected]. B. Metidji, N. Taib, and T. Rekioua are with L.T.I.I. Laboratory, University of Bejaia, Bejaia 06000, Algeria (e-mail: [email protected]; [email protected]; [email protected]). L. Baghli is with the Universite de Tlemcen, Tlemcen 13000, Algeria, and also with the Universit de Lorraine, Vandoeuvrels-Nancy F-54500, France (e-mail: [email protected]). S. Bacha is with the Laboratory of Electrical Engineering of Grenoble, St. Martin dHeres 38402, France, and also with the University Joseph Fourier of Grenoble, Grenoble 38041, France (e-mail: [email protected]).

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phase SVM-PWM inverter application. They use a "single-survived-sensor" with all-scenario current sensor fault tolerance hardware/software configuration. In these methods, a Hall effect current sensor is used to measure the sum of two powers switch currents (phase-leg-based measurement and cross-leg-based measurement).

All the above-mentioned works reconstructs the phase currents of the AC motor fed by a Voltage Source Inverter (VSI). On the contrary, all closed loop control for AC motor fed by Direct Matrix Converter (DMC) [4] [5] need two current sensors at least. Isolated current sensors, like Hall-effect sensors and current transducers, are typically used. Additional hardware such as ADC and filtering are needed to implement a digital current control. Thus, it will result in an increase of the complexity, cost and size of the system and it will weaken the system reliability.

In this paper, a novel solution for phase currents reconstruction, based on single Hall effect current sensor, is presented. It is able to reconstruct the phase currents of AC motor fed by Direct Matrix Converter (DMC). Thus, the number of current sensors is reduced and consequently, the cost. The weight and the volume of the total system are also reduced. The method proposed in this paper reconstructs the motor phase currents, during each modulation cycle, by sampling a combination of power switch currents, during a zero vector period. The proposed method is simple and effective. The performance of the proposed current sensing solution has been verified experimentally by means of a three phase induction motor test drive based on a SVM-controlled direct matrix converter.

II. SINGLE CURRENT SENSOR METHOD OF THREE PHASES DIRECT MATRIX CONVERTER.

In recent power electronic applications, different and numerous types of current sensors such as magnetic coupling, Hall effect and many others have been introduced. The Hall effect current sensor will be applied in this proposed technique.

A. Single hall effect current sensor location in direct matrix converter

The proposed method uses the proper zero vectors selection of SVM algorithm with specific current sensor emplacement for AC motor phase current reconstruction using a single current sensor.

For the implementation of this method, a simple hardware modification in the power converter connection is needed for the current sensor location. A block diagram of the solution is shown on Fig. 1.

The current measured by the sensor with this location is:

1

Fig. 1. Proposed method for the current sensor location in DMC

B. Proposed phase currents reconstruction strategy

During the remaining part of the switching period Ts, zero vectors are applied and the output line voltages are equal to zero. The three zero vectors combinations, which are [AAA], [BBB] and [CCC], are allowed by connecting all three output terminals to the same input terminal. During the zero vectors intervals, all input currents equal to zero and the output load currents are freewheeling through the matrix converter switches.

In the classical direct matrix converter scheme, a zero vectors are chosen to minimize the total number of matrix converter switching transitions. Without this condition we can use any zero vector [AAA],[BBB] or [CCC] during the zero vector intervals.

Fig. 2. Asymmetrical switching patterns and current sampling periods

The proposed method is based on a two-interval division of the zero vector interval and the application of [AAA] zero vector in the first interval and [BBB] in second one. Fig. 2 and Fig. 3 show that we can replace a [CCC] zero vector by the two zero vectors [AAA] and [BBB].



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Fig. 3. Symmetrical switching patterns and current sampling periods

With this modification of asymmetrical or double-sided symmetrical switching patterns and by using the proposed current sensor location, we can measure the current of phase a during the first zero vector interval and the current of phase b in the last zero vector interval. Fig. 4 shows the current flow in current sensor when [AAA] zero vector is applied and Fig. 5 shows the current flow in current sensor with [BBB] zero vectors applied.

Fig. 4. Current flow when a [AAA] zero vector is applied

Fig. 5 Current flow when a [BBB] zero vector is applied

In the motor, the phase currents are supposed constant during the sampling control period (zero-order hold), when we measure and , can be calculated by the relation:

0 (2)

C. Minimum zero vector time requirement

For an efficient phase current reconstruction in practical systems, the zero vector application time should be continued at least for a required minimum time (T0min), and both current sampling instants must be firmly synchronized with SVM pulses. Optimal sampling instants should be calculated relatively to the zero vector transition moments.

Therefore, to get a reliable current value, the signal sampling must be done after an added pre-calculation delay time [30]:

(3)

The sample delays include the total switching device delay time (Ton), the measured current signal rise time (Tr), and the signal settling time (Ts).

A safe converter commutation has been achieved by using multi-steps Bi-directional Switch commutations strategies as four-step or two-steps commutation strategy, based on voltage or current sensing [14][40][41]. The Ton parameter includes the IGBT driver signal processing time, the worst case switching device ON-time delay which incorporates one-step commutation delay (for two-steps commutation strategy). The zero vector application minimum time is

2 (4)

TADC stands for the ADC sampling and conversion time. Fig.6 shows the optimal sampling times and the minimum required zero vector time.



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Fig.6 Current measurement minimum time requirement

As presented in (4)-(8) the zero vector time depends of several parameters: Input phase displacement ,output phase displacement ,input phase shift angle !,transformation ratio q, and sampling period Ts. Fig.7 gives d0 variations (d0 =T0 / Ts) in function of and variations for maximum voltage ratio (q=0.866) and unity input power factor (! 0). For a set of parameters (!,q, and Ts), it can be minimal for " " #$.

Fig. 7 Variation of zero vector time in function of %& and %' variations

III. TECHNICAL IMPROVEMENT The proposed current reconstruction technique is based on a

measurement of the current when the SVM applies zero-voltage vector. Thus, the proposed method is very sensitive to the availability of this zero vector. The technical solutions to get a safe reconstruction are studied and carried out in the following subsections.

A. Sampling period choice

From a practical point of view, a suitable choice of the sampling period allows to avoid a null zero vector [42]. The digital control system must be synchronized with the input

converter line voltage and the sampling frequency should be an integer multiple of the input line voltage frequency (5):

( 62* 1( 5

Fig.8 shows the variation of the zero vector delay in function of the sampling frequency for a maximum voltage ratio and a unity input power factor, with a minimum zero vector delay equal to 2s. As shown, the maximum frequency is lower than 3 kHz .The switching frequency can be the same or a multiple of the sampling frequency.

Fig. 8 Variation of the zero vector delay in function of sampling frequency for

maximum voltage ratio

B. Voltage ratio limitation For a linear controller based closed loop current control

technique as Field Oriented Control (FOC) or SVM Direct Torque Control (DTC-SVM) where a high sampling frequency is not mandatory, we can chose a low current sampling frequency (2.1 kHz for example). On the other hand, we can choose a high switching frequency (10.5 kHz for example) to reduce the input filter size. Whereas, in nonlinear controllers based techniques, as DTC or Sliding Mode Control, a high control frequency is needed. In order to guarantee a zero vector delay larger than the minimum required, we must reduce the voltage ratio. Fig.9 presents the variation of the maximum voltage ratio in function of the sampling frequency, for a unity input power factor, with a minimum zero vector delay equal to 2us. For a sampling frequency lower than 25 kHz, the voltage ratio is always greater than 0.8227 (95% of full scale) which is satisfactory.



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Fig. 9 Variation of the maximum voltage ratio in function of sampling

frequency

C. Multi-periods sampling sequencer In order to reduce the input filter size, the switching

frequency should be high. Then, to reconstruct the currents safely, the measurement time should be sufficient, thus it imposes a minimum zero vector application time. For a high switching frequency, we propose to sample only once within a switching period, in order to reduce the minimum zero-vector application time. Fig.10 shows the proposed sampling sequence. One can see that we only use one zero vector per switching period (AAA or BBB).

Fig10 Two-periods sampling sequencer example

By using the symmetrical SVM switching patterns the implementation of this algorithm and the sampling time synchronization is easy. It relies on a synchronization of the DSP or microcontroller ADC and the SVM signal generator timers.

D. Comparison of commutation loss In SVM, the switching patterns are arranged to minimize

the number of commutations. For example when both the output voltage and the input current references lie in sector I, the correlations between active output voltage vectors and switching states, are ,-- . ,,- . ,,/ . ,// . ///

Zero vector [CCC] is chosen to minimize the total number of switching transitions of the matrix converter [42]. To achieve the symmetric switching patterns in the modulation period a double-sided symmetrical patterns is used. ,-- . ,,- . ,,/ . ,// . /// . ,// . ,,/ . ,,-

. ,--

In this example, the commutation number of each period is 4 commutations with an asymmetrical switching pattern and 8 commutations with a symmetrical switching pattern.

The proposed method, which is based on a two-interval division of the zero vector interval and the application of [AAA] and [BBB] each period whatever other vector applied vectors, generates an additional switching. The double-sided symmetrical patterns become: ,-- . ,,- . ,,/ . ,// . ,,, . --- . ,// . ,,/

. ,,- . ,-- Which add 8 additional commutations (16 in total) for the

original SVM pattern, i.e. a ratio of 100%. This ratio is the maximum one and depends on the input and the output sectors. It can be reduced to less than 50% by using the multi-period sampling sequencer proposed above.

IV. SIMULATION RESULTS

To check the correctness and feasibility of the single current sensor phase currents reconstruction strategy using the proposed method, a complete simulation system was built in Matlab/Simulink environment. In this simulation, we use an induction motor fed by a Direct Matrix Converter using a constant V/f algorithm with SVM control strategy. We apply a 5 Nm constant load torque.

The ratings of the IM are: 50 Hz, 415 V, 1.1 kW, star connected, 1420 rpm, with the following parameters: Rs=6.06, Rr=4.14, Lls=29.9mH, Llr=29.9mH, Lm=489.3mH, J=0.012kg.m2, 4 poles.

The simulation results are presented on Fig.11-13. The output line to line voltage (Vab) and phase currents (Ia) are shown on Fig.11.a. Fig.11.b shows the waveforms of the input voltage and filtered input current of matrix converter in phase A.

Fig. 11. (a): Output line to line voltage Vab and output phase current Ia waveforms; (b): input voltage and filtered input current waveforms.



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Fig. 12. Measured phase currents waveforms (a), reconstructed phase currents

waveforms (b) and single current output waveform(c)

At t=1s, we change the output frequency from 10 Hz to 30 Hz. Thus, the output voltage and the motor speed change with respect to the imposed V/f ratio. Fig.12 shows the three phase measured current waveforms (a), the reconstructed phase currents waveforms (b) and the single current sensor current waveform (c). It is clear that the proposed method allows a good phase current reconstruction.

Fig. 13. Measured phase currents waveforms, a) Actual current b)

Reconstructed current c) Current error d) Actual and reconstructed current comparison.

Measured and reconstructed motor a phase current presented on Fig.13a and Fig.13b respectively. Fig.13c shows the reconstruction method error. Fig.13d is a zoomed window of measured and reconstructed phase current.

V. EXPERIMENTAL TESTS

To demonstrate the feasibility of the single-sensor current control of an AC machine fed by a Direct Matrix Converter, an

experimental system with the diagram shown on Fig.14 was built. A photo of the experimental setup is shown in picture Fig. 15. In this way, a 10kW matrix converter has been designed.

The experimental system of the Direct Matrix Converter consists of 18 IGBTs, input filter, voltage clamp circuit, currents and voltage detection circuits, and a DSPACE DS1104 control board for generating control signals to drive the IGBTs. A safe converter commutation was achieved by using four-steps Bi-directional Switch commutations strategies which are implemented in CPLD (EPM240T100).

The induction motor has the same characteristics as the one used for the simulation (50 Hz, 415 V, 1.1 kW and 1420 rpm). A load torque is produced by a 1.1kW DC generator coupled to the rotor shaft and loaded by a 33 variable resistance. The generated energy can dissipate into a resistive dump. Position feedback is obtained thanks to an incremental encoder.

The measured current is sensed using a HAL 50-S LEM Hall effect transducer (50A). Two turns are applied to the primary of each phase to reduce the current range to 25A and increase the sensitivity. Additional current sensors are placed on the two motor phases for comparison purposes. All current samples are digitized using 12 bits analog to digital converters.

Fig. 14. Experimental system scheme



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Fig. 15. Direct Matrix Converter experimental system picture

To assess the single sensor current controller, its output is compared with that of a system which uses direct line current sensing. The experiment results are shown on Fig.16-23. The switching frequency is fixed to 10 kHz, the output frequency is 25Hz.The input voltages are balanced sinusoidal voltages.

Fig. 16. Input voltage (50V/div) and input current (1A/div)

The experiment results achieve unity displacement factor at the input side of the converter (Fig.16). The output lines voltages, the line to line voltage, and output current are shown on Fig.17.

Fig. 17. Output lines Voltages (100V/div), line to line voltage (250V/div) and output current (2A/div)

The comparison between the actual and reconstructed currents is shown on Fig.18. Their waveforms are nearly sinusoidal with low distortion.

Fig.18 Actual and reconstructed currents and their error (2A/div)

Fig.19 Measured current from the single current sensor and two phases line currents (1A/div)



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Fig.20 Zoom for measured current from the single current sensor and two phases line currents (1A/div)

The measured current from single current sensor is shown on Fig.19. its envelope change between the two phase current (a,b). Fig.20 show a zoom for single current output signal and the phase a and b current waveforms.

To test the proposed method under transient conditions, we make a step change of the output to the input voltage transfer ratio (from 0.2 to 0.5) and the output frequency from 10Hz to 25Hz. The waveform of the actual and the reconstructed current are shown on Fig.21. Fig 22 shows the input voltage and current in transient condition.

Fig.21 Actual and reconstructed currents and their error in transient conditions (1A/div)

Fig.22 Input line voltage (50V/div) and current (1A/div) in transient conditions

Fig.23 Spectrum of the reconstructed current

Fig.23 shows the reconstructed output current spectrum, the THDs of the reconstructed current are 11.5%.

VI. CONCLUSION

A novel scheme based on a single current sensing for a phase current reconstruction has been presented. This method can be applied to any closed-loop current control in AC motors drives fed by Direct Matrix Converter (DMC). The location of the Hall current sensor in the DMC, the new SVM switching pattern and the minimum mandatory zero vector time are discussed. Solutions are proposed and discussed. The proposed algorithm can easily be used for reconstructing the phase currents of any three phase AC motor (IM, PMSM, BLDC) fed by DMC and controlled by SVM technique.

Simulation and experimental results are presented and establish the feasibility of the proposed method.

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Brahim METIDJI (M12) was born in Bouira in 1977, Algeria. He received the M.S degree in electrical engineering in 2004 from the A/Mira University of Bejaia, Algeria. Now he is PhD student in electrical engineering at the A/Mira University. His research interests are in

variable-speed ac motor drives and power converter in particular the matrix converter.

Nabil TAIB, was born in Bejaia, Algeria, in 1977. He received the M.S. degree and doctor degree on Electrical Control systems in 2004 and 2012 respectively from the University of Bejaia (Algeria). From 2009, he is a lecturer in the Electrical engineering Department at the University

A. Mira of Bejaia, Algeria. He is an Editor Board Member in the International Journal of Computer Science and Emerging Technologies (IJCSET). He is interested now, by the applications of the matrix converters on the renewable energy systems.

Lotfi BAGHLI (M12-SM12) (1971) received his Electrical engineering diploma degree with honours in 1994 from the Ecole Nationale Polytechnique of Algiers, Algeria. He received his DEA and becomes a Doctor in Electrical Engineering of the Universit Henri Poincar, Nancy, France, respectively in

1995 and 1999. He is a lecturer at Nancy Universit and a member of Groupe de Recherche en Electrotechnique et Electronique de Nancy. He is currently a visiting lecturer at Tlemcen University. His works concern digital control using DSP, PSO and genetic algorithms applied to the control and identification of electrical machines.

Toufik REKIOUA received his Engineer from the National Polytechnic Institute of Algiers and earned the Doctoral degree from I.N.P.L of Nancy (France) in 1991. Since 1992 he is Professor at the Electrical Engineering Department-University of Bejaia (Algeria), he is presently the Director of

the LTII laboratory. His research activities have been devoted to several topics: control of electrical drives, modeling, wind turbine and control in A.C machines.

Seddik BACHA(M08) received his Engineer and Master from National Polytechnic Institute of Algiers respectively in 1982 and 1990. He joined the Laboratory of Electrical Engineering of Grenoble (G2Elab) and received his PhD and HDR respectively in 1993 and 1998. He is

presently manager of Power System Group of G2Elab and Professor at the University Joseph Fourier of Grenoble. His main fields of interest are Renewable integration and power quality.

phase currents reconstruction using a single current sensor of three-phase ac motors fed by...

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