Fuji IGBT Simulator for Automotive Ver. 6.1 or later Operation manual

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Harold McDaniel
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2 End-User Software License Agreement (Caution) Before downloading and using the software, please read the following End-user Software Agreement. By downloading the software, you agree to be bound by the terms of the following agreement. If you don t agree the agreement, remove the software and erase all copies of the software and the related documents. End-User Software License Agreement This is a software license agreement (the Agreement ) between you ( Customer ) and Fuji Electric Co. Ltd. ( Fuji ) with regard to the use of Fuji IGBT Simulator ( Software ).. [Right of Use] This software is available to use without paying additional fees to Fuji. No right or license, either express or implied, under any patent, copyright, trade secret or other intellectual property right owned by Fuji Electric Co., Ltd. is (or shall be deemed) granted. 2. [Copyright] Fuji retains the copyright, title and ownership of the software, the manual and related documents. 3. [Prohibitions] You may not reverse engineer, decompile, or disassemble this software. 4. [Limited Warranty] Fuji makes no representation or warranty, whether express or implied, relating to the infringement or alleged infringement of other's intellectual property rights which may arise from the use of the applications described herein. Fuji pays close attention to the quality of the contents on this simulator. However, such continents are provided as is without guarantees of any kinds. 5. [Program update] The program specification of this software is subject to change without any notice. MT5F36567 Fuji Electric Co., Ltd. All rights reserved 2

3 Contents. Setup p.4 2. Menu p.5 3. Module Selection p.6 4. Thermal Conditions p.7 5. Single Mode Calculation p.8 6. Parameter Sweep Calculation p.3 7. Cycle Mode Calculation p.6 8. Circuit Topology, PWM Method p.25 MT5F36567 Fuji Electric Co., Ltd. All rights reserved 3

4 Software Setup This software operates on Microsoft Windows7, Windows8 and Windows0 systems. Microsoft.NET Framework 3.5 or later is required. Fuji IGBT Simulator doesn t need to be installed. Unzip the downloaded file and copy to a custom folder. Please just double-click on the file IGBTSim.exe to start the simulator. Windows is a registered trademark of the Microsoft Corporation in the U.S. and other countries. MT5F36567 Fuji Electric Co., Ltd. All rights reserved 4

Menu 2 The language selection Click the language or 言語

actual manual and the actual version of this Software.

5 Menu 2 The language selection Click the language or 言語 Button to select the language. - English - Japanese - Chinese 2 Help In the "Help Menu you will find links to the Fuji Electric Website to download the actual manual and the actual version of this Software. Your actual version is displayed in the top bar. MT5F36567 Fuji Electric Co., Ltd. All rights reserved 5

6 Selection of Module Click the module selection tab Select Module Series, Circuit, Voltage rating [V ces ] and Current rating [I c ] by clicking on the certain buttons to open the drop down menu 3 3 See the fitting modules by opening the Module dropdown menu and make your choice. Select the flow rate of cooling water (FR=4,6,8,0L/min). 4 Click the Next button if selected the right module Click on the Download Data Sheet button to see the actual data sheets. Clicking the Technical Information button will lead you to the Fuji Web Site which contains technical documents By clicking the Web Site button you can see the Fuji Semiconductor Website. MT5F36567 Fuji Electric Co., Ltd. All rights reserved 6

7 Set Thermal Conditions Input the fixed coolant temperature T W The following calculation is based on a constant coolant temperature T W Junction temperature Thermal resistance Coolant temperature MT5F36567 Fuji Electric Co., Ltd. All rights reserved 7

9 Input Circuit Conditions (Single Mode) Click the "Single Mode" tab Select the circuit topology Refer to 27 page for more details. Select the PWM modulation method. Refer to pages for more details. Input operating conditions. MT5F36567 Fuji Electric Co., Ltd. All rights reserved 9

11 Simulation Results (Single Mode) 2 Total loss per arm. = T + D + T2 + D2 + D5 ( arm total loss) 3 2 Total loss of inverter system (In the case of a 3 phase inverter circuit) Total Loss = ( arm total loss) x 6 (In the case of chopper circuit) Total Loss= (T + D) 4 T vj(peak) T vj(ave) 3 Chip junction Temperature. Please see the details in the picture above. ΔT vj T vj(min) T j-w(ave) 4 Coolant temperature T W MT5F36567 Fuji Electric Co., Ltd. All rights reserved

12 Simulation Results (Single Mode) Loss waveforms ( cycle). 2 Temperature waveforms ( cycle). 3 Save the window as image file filename: *.bmp 4 5 Export the results to csv. file Fileextension: *.csv Close this Window by clicking on the Back Button. The Single Mode window will be shown afterwards MT5F36567 Fuji Electric Co., Ltd. All rights reserved 2

13 Parameter Sweep Calculation The sweep function allows to perform a calculation by using one parameter as a variable. It is possible to calculate the losses and the temperature rise in dependence of the selected parameter. MT5F36567 Fuji Electric Co., Ltd. All rights reserved 3

14 Sweep Calculation Click the "Single Mode" tab. 4 2 Activate the Sweep function by marking the checkbox Select the parameter you want to sweep by the radio buttons right next to the parameters. 4 Click the Calculate Button to start the computation. MT5F36567 Fuji Electric Co., Ltd. All rights reserved 4

15 Sweep Calculation Results Calculated losses [W] (vertical axis) Selected sweep parameter(horizontal axis) Calculated temperature rise [ C] (vertical axis) Selected sweep parameter (horizontal axis) MT5F36567 Fuji Electric Co., Ltd. All rights reserved 5

17 Cycle Mode Calculation Click the "Cycle Mode" tab You can change the coolant temperature here. Enter gate resistance values for your calculation. 6 4 Select the boundary conditions. Refer to 9 page for more details. 5 You need to change the sampling number according to the number of cycle data 6 Enter the operation pattern. Refer to 20-2 pages for more details. 7 Click the Calculate Button to start the computation. MT5F36567 Fuji Electric Co., Ltd. All rights reserved 7

18 Save / Load Cycle Mode Data 7 8 Click the Save" button to export the operation pattern to a xmlfile Save file name : ****. xml Click the Load button to import an operation pattern from a xml-file Load file name : ****. xml 7 8 MT5F36567 Fuji Electric Co., Ltd. All rights reserved 8

19 Cycle Mode Boundary Conditions Cyclic: Calculation is performed under the condition that the operation pattern will run continuously. The operation pattern Output 0 t t x 2 Time Shot: The operation pattern will only run for one cycle. Initial condition is needed. Output The operation pattern The initial condition - 0 t Time Enter your initial conditions in line. MT5F36567 Fuji Electric Co., Ltd. All rights reserved 9

Input of Cycle Operation Pattern 2 3 4 Time For more information see p.2 3 Duty In the case of DC lock or chopper, enter the duty values in this column. Otherwise, the entry field value is ignored.

20 Input of Cycle Operation Pattern Time For more information see p.2 3 Duty In the case of DC lock or chopper, enter the duty values in this column. Otherwise, the entry field value is ignored. 2 Output Current In the case of DC lock mode or chopper enter the I o,peak [A]. Otherwise enter the I o [A rms]. 4 Application Circuit Click on the arrow on the right to open a dropdown menu. Choose the application circuit and PWM modulation mode from the list. MT5F36567 Fuji Electric Co., Ltd. All rights reserved 20

Input of Cycle Operation Pattern A If you change a parameter value between two time steps (t), the parameter change will be linear Example A: # #2 (linear change of

A Linear change B Step change 2 3 4 5 6 A B B If you change a parameter value by using the same time (t), the parameter will have a step change Example B: #3 #4

21 Input of Cycle Operation Pattern A If you change a parameter value between two time steps (t), the parameter change will be linear Example A: # #2 (linear change of the output current I o ) (t=0sec, I o =0A t=sec, I o =00A) I o will change linearly from 0A to 00A within sec. A Linear change B Step change A B B If you change a parameter value by using the same time (t), the parameter will have a step change Example B: #3 #4 (stepwise change of I o, PF) t=2sec, I o =50A, PF=0.9 t=2sec, I o =50A, PF=-0.9, at the time of 2sec I o and PF will do a step change from I o =00A to 50A and PF = 0.9 to -0.9 MT5F36567 Fuji Electric Co., Ltd. All rights reserved 2

Input of Cycle Operation Pattern How to use copy/paste for cells Select

choose Paste How to copy/paste a whole line Select the cell which is

the cell which is left to the line you want to paste the values,

22 Input of Cycle Operation Pattern How to use copy/paste for cells Select the cell you want to copy (or more cells), right-click and choose Copy from the dropdown menu. Select the cell to paste the values (or more cells), right-click and choose Paste from the dropdown menu. How to copy/paste a whole line Select the cell which is left to the line you want to copy, right-click and choose Copy from the dropdown menu. Select the cell which is left to the line you want to paste the values, right-click and choose Paste from the dropdown. MT5F36567 Fuji Electric Co., Ltd. All rights reserved 22

23 Simulation Results (Cycle Mode) Total loss per arm. = T + D + T2 + D2 + D5 Total losses of inverter system (In the case of a 3 phase inverter circuit) Total Loss = ( arm total loss) x 6 (In the case of chopper circuit) Total Loss = ( T + D) 4 3 Chip junction Temperature Please see the details in the left picture 4 Coolant temperature. MT5F36567 Fuji Electric Co., Ltd. All rights reserved 23

Simulation Results (Cycle Mode) Loss Waveforms: T, D 2 3 Temperature Waveforms: T j(t), T j(d), T W Temperature Waveforms: T W 4 5 6 7 Clicking the "Print" button allows you to print the display.

24 Simulation Results (Cycle Mode) Loss Waveforms: T, D 2 3 Temperature Waveforms: T j(t), T j(d), T W Temperature Waveforms: T W Clicking the "Print" button allows you to print the display. Clicking the Save Image button allows you to save the screen (image) in a bmp-file. Filename : ****. bmp Clicking the Data Export button allows you to save the numeric data in a csv-file. Filename: ****. csv Close this Window by clicking on the Back Button. The Cycle Mode window will be shown afterwards MT5F36567 Fuji Electric Co., Ltd. All rights reserved 24

26 Circuits & Modulation Methods List of the available circuit configurations and the available PWM control systems in the simulator software. Circuit 3-Phase 2-Level Inverter PWM Modulation Method Sinusoidal Modulation Space Vector Modulation 3 rd Harmonic Injection DPWM two-phase modulation ( A) DPWMMIN two-phase modulation ( B) DC lock DC Chopper Boost Chopper Buck Chopper MT5F36567 Fuji Electric Co., Ltd. All rights reserved 26

27 Circuit Topology 3-Phase 2-Level Inverter Buck Chopper DC Chopper Boost Chopper If all devices are mounted on a single heat sink If all devices are mounted on a single heat sink If all devices are mounted on a single heat sink MT5F36567 Fuji Electric Co., Ltd. All rights reserved 27

28 PWM Method (SPWM, SVPWM) V CC Sinusoidal PWM V CC Space Vector PWM V ref V ref The reference voltage is a sinusoidal waveform. The amplitude of the reference voltage V ref is defined by the following equation using modulation ratio m. V ref = m * V CC The maximum value of m is. The amplitude of the reference voltage V ref is defined by the following equation using modulation ratio m. V ref = 3/2 * m * V CC m is defined to be the same output voltage to the sinusoidal PWM. The maximum m is 2/ 3 ( =.547). MT5F36567 Fuji Electric Co., Ltd. All rights reserved 28

29 PWM Method (3 rd harmonic injection) V CC 3 rd Harmonic Injection V ref The amplitude of the reference voltage V ref is defined by the following equation using modulation ratio m. V ref = 3/2 * m * V CC m is defined to be the same output voltage to the sinusoidal PWM. The maximum value of m is 2/ 3 =.547 MT5F36567 Fuji Electric Co., Ltd. All rights reserved 29

The maximum value of m is 2/ 3 =.547 The amplitude of the reference voltage V ref is defined by the The maximum value of m is 2/ 3 =.

30 2-Phase Modulation 2-Phase (A) DPWM 2-Phase (B) - DPWMMIN V CC V CC V ref V ref The amplitude of the reference voltage V ref is defined by the following equation using modulation ratio m. V ref = 3/2 * m * V CC m is defined to be the same output voltage to the sinusoidal PWM. The maximum value of m is 2/ 3 =.547 The amplitude of the reference voltage V ref is defined by the following equation using modulation ratio m. V ref = 3/2 * m * V CC m is defined to be the same output voltage to the sinusoidal PWM. The maximum value of m is 2/ 3 =.547 MT5F36567 Fuji Electric Co., Ltd. All rights reserved 30

31 Motor Lock Calculate the loss of IGBT/FWD for the case that the motorshaft of a servo drive is locked. As shown in the diagram below, one IGBT of the upper (or lower) arm is switched on as well as the two lower (upper) IGBT s of the other phases. I o I o /2 I o /2 The current route of IGBT - on The current route of IGBT off MT5F36567 Fuji Electric Co., Ltd. All rights reserved 3

32 Further Information If you have any questions about this software, please contact your local Fuji Office or the Fuji Electric Co., Ltd. For details about our products please also check below link. MT5F36567 Fuji Electric Co., Ltd. All rights reserved 32

Melcosim IGBT Loss Simulator

Application NOTES: First Release May 17, 2005 Melcosim IGBT Loss Simulator Software Disclaimer Powerex assumes no responsibility for the use of this software and makes no guarantees, expressed or implied,