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    OPAL RT Advanced Power Emulators - Enabling Real Time pHIL

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    aboofazil
    1) Opal-RT's solution overcomes three challenges for power hardware-in-the-loop (pHIL) testing through its high-speed real-time simulation, high-speed deterministic communications, and high-fidelity power emulation. 2) The solution enables full power vehicle testing in the lab without needing an actual vehicle or components through a DC emulator that can generate power signals and emulate batteries, and a motor emulator that can simulate electric motors. 3) pHIL testing allows innovative designs to be tested more extensively earlier in development, improving products while reducing costs and time to market.

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    OPAL RT Advanced Power Emulators - Enabling Real Time pHIL

    Uploaded by

    aboofazil
    35 views23 pages
    1) Opal-RT's solution overcomes three challenges for power hardware-in-the-loop (pHIL) testing through its high-speed real-time simulation, high-speed deterministic communications, and high-fidelity power emulation. 2) The solution enables full power vehicle testing in the lab without needing an actual vehicle or components through a DC emulator that can generate power signals and emulate batteries, and a motor emulator that can simulate electric motors. 3) pHIL testing allows innovative designs to be tested more extensively earlier in development, improving products while reducing costs and time to market.

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    Advanced Power Emulators – Enabling Real‐Time pHIL

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    OPAL RT Advanced Power Emulators – Enabling Real‐Time pHIL

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    1) Opal-RT's solution overcomes three challenges for power hardware-in-the-loop (pHIL) testing through its high-speed real-time simulation, high-speed deterministic communications, and high-fidelity power emulation. 2) The solution enables full power vehicle testing in the lab without needing an actual vehicle or components through a DC emulator that can generate power signals and emulate batteries, and a motor emulator that can simulate electric motors. 3) pHIL testing allows innovative designs to be tested more extensively earlier in development, improving products while reducing costs and time to market.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    35 views23 pages

    OPAL RT Advanced Power Emulators - Enabling Real Time pHIL

    Uploaded by

    aboofazil
    1) Opal-RT's solution overcomes three challenges for power hardware-in-the-loop (pHIL) testing through its high-speed real-time simulation, high-speed deterministic communications, and high-fidelity power emulation. 2) The solution enables full power vehicle testing in the lab without needing an actual vehicle or components through a DC emulator that can generate power signals and emulate batteries, and a motor emulator that can simulate electric motors. 3) pHIL testing allows innovative designs to be tested more extensively earlier in development, improving products while reducing costs and time to market.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
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    of 23

    Opal‐RT Spotlight

    September 27, 2019

    June 2018
    Advanced Power Emulators – Enabling Real‐Time pHIL

    Three Significant Challenges Overcome


    1. Opal‐RT’s High‐Speed Simulation
     FPGA‐based hardware provides real‐time simulation capability in closed‐
    loop environment
     Advanced Motor and Battery Models
    2. DV’s High Speed Deterministic Communications
     SFP fiber interface with 1uS Latency
     2.5Gbps 8b10b protocol
    3. DV’s High Fidelity Power Emulation
     20kHz Wide Bandwidth

    Design to Simulation to Emulation in a couple of button clicks

    2
    Opal‐RT Spotlight
    pHIL Changing the Product Development Landscape

     Enables simulation & testing of innovative design strategies


     Significantly expands quantity of test cases
     Identify issues earlier in development cycle
    • Full unit testing (control & power)
    • System integration – instabilities and resonances
     Brings real‐time simulation into the design validation phase
    • Creates common test platform across product phases
     Enables full power testing without being in vehicle and without
    real vehicle components

    Decreased
    Product Improved Decreased
    Development Products Time to Market
    Cost

    3
    Opal‐RT Spotlight
    p‐HIL Changing the Product Development Landscape

    Advanced Power Emulators Enabling p‐HIL


    • High Speed Deterministic
    Communications
    • High Fidelity Power Emulation

    Move full‐scale test


    from vehicle to lab

    Full power vehicle


    test without chassis
    dyne or battery

    4
    Opal‐RT Spotlight
    There are two components of Advanced Power Emulation

    Direct Current Emulator (DCE)


    Battery Pack Emulator
    DC Bus Emulator
    High Frequency Load

    eMotor Emulator (EME)


    3 or 6 Phase Motors
    Electronic Dynamometer Test Stand

    DC Emulator Motor Emulator

    5
    Opal‐RT Spotlight
    DC Emulator – Grid Tied 2 Quadrant Source/Load

    Model # 105050
    Rating 0 to 500V / +/‐500A / 100kW

    Series / Parallel to 1000V / 1.8MW

    Performance Wide Bandwidth (to 20kHz)

    High power swept frequency testing for


    resonance identification
    Inject controlled noise and ripple onto DC Bus

    Accurate reproduction of captured/simulated


    waveforms
    High‐speed fiber (1uS latency) for interface with Real‐
    Time Simulator
    Operating Modes Voltage – Low Impedance / Fast dV/dt
    DC Emulator Current – CC / CP / CR

    6
    Opal‐RT Spotlight
    DC Emulator – Grid Tied 2 Quadrant Source/Load

    Large Signal Current Response

    +500A to ‐500A
    in 50uS

    600A P‐P @ 20kHz no


    DC component

    7
    Opal‐RT Spotlight
    DC Emulator – Grid Tied 2 Quadrant Source/Load

    Large Signal Voltage Response

    Fast Voltage Mode


    10V/uS

    Low Z Mode
    220V/mS

    8
    Opal‐RT Spotlight
    DCE as a Battery and/or DC Bus Emulator

     Wideband Controlled Impedance ‐ Real, Reactive & Nonlinear for Accurate Battery Emulation
    • Battery packs can be modelled and emulated at the highest fidelity
     Creates DC Bus for safe lab level testing – no battery pack or vehicle required
     System Transients and other HV Bus emissions can now be studied

    9
    Opal‐RT Spotlight
    DCE as a Swept Voltage Source

    The DCE replaces the Battery and adds swept


    frequency AC on top of the DC voltage

    100V P‐P AC on top of 250V DC

    10
    Opal‐RT Spotlight
    DCE as Current Source ‐ Fast Charge Algorithm

    120A step in 10uS


    Accurate reproduction of desired 25uS pulse

    11
    Opal‐RT Spotlight
    DCE as a Load Emulator

    High Frequency Load


     Generates controlled noise and ripple up to 20kHz to emulate AC components including the inverter
    switching frequencies
     Constant Power, Constant Current, Constant Resistance, Constant Voltage
     Power slew rate of ‐100% to +100% Rated Power in <100uS

    12
    Opal‐RT Spotlight
    DCE as a Swept Frequency Load to Identify Resonances

    The DCE adds a swept frequency


    component in addition to the normal loads

    100A P‐P, 20Hz to 20kHz, no current reversal

    13
    Opal‐RT Spotlight
    DCE to Create DC Bus Transients – Aircraft Contactor Closing

    Constant
    resistance load
    – no overshoot
    with 0‐270V
    transient

    ZOOM

    Constant
    current load
    – limited
    overshoot

    14
    Opal‐RT Spotlight
    Case Study: Real‐Time Simulation of Inverter/Motor

    AFRL Test Setup

    • 80kW EDA Unit

    • DCE in Current Mode


    to emulate
    Inverter/Motor DUT

    • Closed loop command


    by OPAL‐RT using
    switched‐level model

    15
    Opal‐RT Spotlight
    Case Study: Real‐Time Simulation of Inverter/Motor

    16
    Opal‐RT Spotlight
    Case Study: Real‐Time Simulation of Inverter/Motor

    17
    Opal‐RT Spotlight
    Case Study: Real‐Time Simulation of Inverter/Motor

    18
    Opal‐RT Spotlight
    Using DCE in Combination – Full System Simulation/Emulation

    Back to back DCEs for research level DC source


    and load emulation

    19
    Opal‐RT Spotlight
    Electric Motor Emulator

    An electronic dynamometer test stand used for traction inverter testing

     Test control without real motor


     Verify motor design ‐ FEA to test
     Accurate drive cycle emulation
     No moving parts creates safe
    environment

    20
    Opal‐RT Spotlight
    Electric Motor Emulator

    Rating Up to 960VDC

    300ADC Cont/430ADC Max

    350Arms Cont/550Arms Max

    Parallel up to 4

    Performance 3 or 6 Phase; Synchronous PM or


    Induction
    Independent or dual channel operation

    Integrated with HV & LV Battery Emulators

    Position and Temperature Emulation

    Supports multiple voltage levels


    Internal 3D Models Flux = f(T)
    External Models – cogging & harmonics

    21
    Opal‐RT Spotlight
    Electric Motor Emulator – Drive Cycle and DAC Outputs

    YL: DUT PWM


    Voltage

    DAC Outputs

    GR: Ph A Current

    MG: DC Current

    BL: BEMF Volt

    22
    Opal‐RT Spotlight
    p‐HIL Changing the Product Development Landscape

    Move full‐scale test


    from vehicle to lab

    Full power vehicle


    test without chassis
    dyne or battery

    23
    Opal‐RT Spotlight

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