6. HARDWARE PROTOTYPE AND EXPERIMENTAL RESULTS
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1 6. HARDWARE PROTOTYPE AND EXPERIMENTAL RESULTS Laboratory based hardware prototype is developed for the z-source inverter based conversion set up in line with control system designed, simulated and discussed in earlier chapters. The setup is used for the experimental verification of the results obtained through simulation. The experimental setup shown in Figure 6.1 is broadly divided into following sections: Diode Rectifier-IGBT inverter power module Z- network consisting of inductors and capacitors Controller section consisting of number of modules Three phase AC filter circuit Three phase Load Measuring digital meters, Digital Storage Oscilloscope (DSO) PICKit3 programming module (with MPLAB software) Variac Figure 6.1 Hardware Prototype of ZSI 150
2 For the experimental purpose a single phase variac is used for initializing variable power source that rectifies through a bridge uncontrolled rectifier to generate variable dc voltage. This dc source is connected to an IGBT based three phase bridge inverter through a z- network. Main development in this hardware prototype is its controller section which senses the voltage across a capacitor in z-network and through digital signal processing develops shoot-through pulses. The capacitor voltage range V is normalized to 0 to +5V. This includes realization of PID controller through PIC microcontroller. With this variable pulse width shoot-through pulse third harmonic injected (THI) maximum constant boost control (MCBC) technique is used for switching the IGBTs. AC filters are used to suppress the higher order harmonics in the three phase output. Digital meters are used to measure the input ac voltage, DC bus Voltage, DC bus current, load current etc. DSO is used to verify the waveforms in different sections. The programs code developed for different PIC microcontrollers under MPLAB software The algorithm of which is presented in Appendix-B.MPLAB Integrated Development Environment (IDE) is an integrated toolset for the development of embedded applications on Microchip's PIC microcontrollers. MPLAB IDE v8.87 is used to write the program for PIC16F886 (Peripheral interface controller) microcontroller. The program code was uploaded and burned via the PICKit 3 module provided with the PID modules described later. Detailed description of the hardware prototypes, their circuit diagram, components used including their photographic view are presented in this chapter. It also presents the waveforms at different test points and the results obtained through experiments for simple ZSI and Quasi-ZSI topologies Rectifier - Inverter power module It consists of the following sections as sketched in Figure 6.2 (a)diode Rectifier Four 16NSR120 diode are used with heat-sink as full wave single phase bridge rectifier circuit to rectify the variable ac input voltage. Two capacitors of value 470 microfarad, 450 maximum working voltages are connected at the output of the rectifier to get the smooth dc bus output. Figure 6.4 shows the view of the rectifier section which includes a time-delay circuit consisting of mainly a relay and microcontroller chip PIC16F. Time delay is introduced to provide the power circuit a soft start through green LED. The delay is 151
3 adjustable through the microcontroller program. The DC bus output is passed through a fast switching diode to the inverter via z-network (b) Three phase Inverter: Three phase six switches bridge inverter consists of six IGBTs of model FGA25N120ANTD as in Figure 6.5 to generate three phase output which is to be connected with three phase load. IGBTs are attached with suitable heat sink. (c) IGBT driver circuit: There are six driver circuits separately for six IBTS shown in the IGBT module in Figure 6.5. includes 6N138 is a low input current high gain Darlington optocoupler. A single driver circuit shown in Figure 6.6 includes an optocoupler and transistors. When an electrical signal is applied to the input of the optocoupler, its LED lights, its light sensor then activates and a corresponding electrical signal is generated at the output. Unlike a transformer, the opto isolator allows for dc coupling and generally provides significant protection from serious overvoltage condition in one circuit affecting the other. Pulses coming out from the signal conditioner circuit are fed to pin 2 of the optocoupler. Output from pin 8 is processed through various resistors, transistors and two back to back zener diodes to generate required pulse for the gate of IGBT. Table 6.1 Major components in Rectifier-Inverter Power Module Name Specification/Type Quantity Capacitor 470µF,450 V 2 Diodes for Rectifier,16NSR120 16A, 1200 V stud diode 4 Relay KT954 1 Microcontroller to introduce delay PIC16F-628A 1X 3 Optocoupler 6N138 1 X 6 Transistor for Driver circuit NPN, BC547 1 X 6 Transistor for Driver circuit PNP, BD140 1 X 6 Transistor for Driver circuit NPN, BD139 1 X 6 IGBT FGA25N120ANTD,25A,1200V 6 Driver power Supply IN 4007 / 470µF,35 V 4 X 6, 2 X 6 152
4 Figure 6.2 Rectifier-Inverter power module and IGBT driver circuit schematic Figure 6.3 Hardware circuit of Rectifier - Inverter power module 153
5 Figure 6.4 Hardware circuit for Single phase Bridge rectifier 154
6 Figure 6.5 IGBT Module with driver circuit Figure 6.6 IGBT Driver circuit 155
7 6.2. Triangle Wave generator The function generator IC chip XR2206 has been used to generate high quality, high frequency triangular wave. The output waveforms can be both amplitude and frequency modulated by an external voltage. Frequency of operation can be selected externally over a range of 0.01Hz to more than 1MHz. As shown in Figure 6.7 of the schematic, the fixed capacitor of value 0.01 microfarad connected between the pin no 5 and 6 and 24.7 k variable resistance across pin no 7 produces the desired frequency triangular wave at output pin 2. A variable resistance is connected between pins 15 and 16 to adjust the symmetry of the output waveform. Figure 6.6 represents the block diagram of the function generator IC and Figure 6.9 show the view of the hardware circuit of the generator. The signal is then amplified with the help of TL082 operational amplifier and offset is adjusted by 5K pot connected with non-inverting terminal. Finally it produces a 6 KHz and 5 volt peak triangular wave as captured in DSO and shown as Figure 6.10 Figure 6.7 Schematic of Triangle wave generator 156
8 Figure 6.8 Block diagram of IC XR2206 Figure 6.9 Hardware circuit of triangle wave generator 157
9 Figure 6.10 High frequency triangular wave of 5volt peak. Table 6.2 Major components for triangle wave generator Name Specification Quantity Function generator, XR2206 Max operating frequency = 1 MHz Adjustable Duty Cycle, 1% to 99% 1 Operational amplifier, TL082 Wide Gain Bandwidth: 4 MHz High Slew Rate: 13 V/μs 1 Internally Trimmed Offset Voltage: 15 mv Trim Pot 20K, 10K, 5K 2,1,1 158
10 6.3. Voltage Sense IC Chip ACPL-782T is used as voltage sensor to sense the voltage across capacitor of the z- network. Capacitor voltage is passed through a voltage divider circuit of 1M x 4 and 50 ohm resistances and voltage across 50 ohm is connected to the 8-pin ACPL-782T IC chip. ACPL-782T is an isolation amplifier applied mainly for voltage and current sensing. The output from pin 6 and 7 of this chip is processed through LM358 op-amp to convert this in a suitable level. It is then connected to the PID controller PCB to generate the shoot through pulses to compensate the input voltage fluctuation. The schematic of the circuit is shown in Figure 6.11 which also includes a 5V dc power supply for providing power to the ICs. Figure 6.12 is the view of the PCB developed for the purpose. Figure 6.11 Voltage Sense circuit diagram 159
11 Table 6.3 Major components in voltage sense PCB Name Specification Quantity Diode IN voltage regulator, 7805 Three terminal positive 5 V 1 Voltage Sensor chip, ACPL- 8 pin isolation 1 782T amplifier DIP 2% Gain Tolerance 100 khz Bandwidth Operational Amplifiers, LM358 Dual Differential Input Large DC Voltage Gain: 100Db Wide Power Supply Range 1 160
12 Figure 6.12 Hardware circuit for Voltage Sense 6.4. Third Harmonic Injected (THI) Sine-wave modulating signal generation PIC16F886 microcontroller is used to generate three phase 50 Hz sinusoidal waveform which is then added with the third harmonic 16% of amplitude of same sinusoidal waveform to get the third harmonic injected sine waveform. This total operation is made through microcontroller program details of which is presented as APPENDIX-C. is Presented in the circuit sketch in Figure 6.13, terminals A1-A8, B1-B8 and C1-C8 generate the 8-bit three phase outputs each 120 degree out of phase representing the THI sinusoidal digital signals. These signals become the eight bit inputs to the three digital to analog converters DAC0800. The separate analog outputs of DACs are processed through corresponding op-amp (LM358) to generate variable maximum ±5 volt peak to peak THISIN three phase modulating signals. The amplitude of these signals can be varied through program to adjust modulation index. The 161
13 hardware view of this section is presented in Figure The DSO captured view of these three phase signals is shown in Figure PIC16F886 is a 28 pin CMOS Microcontrollers with nanowatt technology having 24 numbers I/O pins, 8192 flash word memory, 368 bytes SRAM and 256 bytes EEPROM memory with maximum operating speed of 20 MHz. The block diagram of the microcontroller is copied in Figure Program is developed for the microcontroller through the MPLAB IDE software and burning of program is done through PICkit3 programmer shown in Figure 6.17.The DAC0800 is a commonly used 8-bit high-speed current-output digital-to-analog converters (DAC) featuring typical settling times of 100 ns. Figure 6.13 Circuit Diagram of THI Sine wave Generation Schematic 162
14 Figure 6.14 Hardware circuit for THI Sinewave Generation PCB Figure 6.15 THI Sine wave waveform 163
15 Figure 6.16 Block Diagram of PIC16F
16 Figure 6.17 PIC kit-3 programmable module 6.5. PID Controller section The signal which is coming from the voltage sense PCB is connected as input for this section which through a voltage follower and zener is connected to the microcontroller PIC16F886. It is supported by a 20 MHz crystal oscillator connected between pin 9 and 10. A program is developed with extensive logics for the PID operation of the whole system. There is a provision of burning the program in this PCB through a 6-pin connector. PID set points like KP, KI and KD are set through 4 push-switches K1, K2, K3 and K4. The four numbers seven segment displays are used to display the set values (SV) and also present value (PV) by adjusting the push-switches a number of times. Five LEDs connected alongside indicate the mode of display i.e. whether it is PV, SV, KP, KI or KD. The four switches are used for selecting the parameter, setting the parameters i.e. increase and decrease the values and entering the final value respectively. The 8 bit output from microcontroller section is then connected to the DAC0800 for digital to analog conversion of the control output signal. Finally through LM358 opamps this is processed and limited 165
17 within a range of 0 to 5 V control signal which is fed to the signal conditioner circuit. The schematic diagram of this section is shown in Figure 6.18 and photographic view in Figure Figure 6.18 PID Controller section Figure 6.19 Hardware circuit for PID Controller section 166
18 Table 6.4 Major components in PID Controller Section Name Specification Quantity DAC Bit Digital-to-Analog Converters 1 LED Seven segment Display board 4 7 Segment Display 4x1 LM324 Low power quad op amp 1 Microcontrollers PIC16F886 LM358 Details given in THI sinewave generator section Low power dual operational amplifier Details given earlier 1 2 LED Board 5 red LEDs for SP, PV, KP, KI and KD 1 X 5 Push switch board Push to connect ground switches 1X4 Crystal Oscillator for PIC 20 MHz 1 Connector for Programmer 6- pin Signal Conditioner Three phase third harmonic injected (THI) sinusoidal modulating signals are compared separately by LM358 opamp comparators with a high frequency triangular carrier signal coming from triangular signal generator card. Across the non-inverting and inverting input terminals modulating and carrier signals are fed respectively to obtain high frequency PWM switching pulses. Across the output terminals 5.1V zener diode is connected to ensure the 5 volt peak switching pulses. This comparison and generation of pulse for a single phase are captured in a DSO and presented as Figure These pulses are then fed to Schmitt Trigger inverter IC7414. The 7414 IC is composed of six independent Schmitt-Triggered single-input inverter gates. Schmitt Trigger logic gates have a greater immunity to noise in the input lines. With noise suppression, the logic gates (in this case inverters) are more likely to remain in their current state unless a true change to the input was intended. Glitches and high speed random noise in the line is less likely to toggle the status of the 167
19 output. Pin 14 of IC7414 is connected to +5volt supply and pin no 7 is grounded. Across pin no 1,5,11 the PWM pulses are applied as shown in the circuit schematic Figure Pin 2 is the complemented output of pin 1. Pin 2 and 3 are shorted and hence the output at pin 4 is similar to the input at pin1 (because of double inversion). So pulses at pin 2 and pin 4 are complement to each other. Similarly pulses at pin 10 and 12 as well as pin 6 and 8 are complement to each other. The six PWM pulses are fed to two OR gate IC7432 at pin 1, 4,9,12 and 1, 4 respectively. As shown in the sketch in Figure 6.20, there are three microcontrollers PIC16F628A connected in between and the three inverted PWM signals from IC7414 are passed through them. There are two three pins jumpers connected at the output of each set of pulses. This circuitry is made to introduce the options of dead time during switching. Though dead time is not necessary in case of shoot-through switching, a provision is kept to include it, in case of operating the circuit as conventional PWM inverter. A programmable dead time is inserted to the three PIC16F628A separately. Dead time can be bypassed in case of shootthrough operation with the help of jumper arrangements as shown in the sketch. Again, in the lower half of the sketch in Figure 6.20, control voltage from the PID controller PCB is compared with the same carrier triangular signal to generate the shoot through pulses. Negative shoot through pulses for the lower half switches is generated by comparing with the negative PID control voltage. Two sets of shoot-through pulses are then passed through scmitt-trigger buffers (IC7414) without any inversion and are then ORed with the PWM switching pulses by OR gate IC7432. Six output signals after OR-ing are fed to 20 pin IC74244 octal 3-state buffer/line driver to generate desired switching pulses which are fed to individual IGBT driver circuit. The photoview of the signal conditioner Board is shown in Figure
20 Figure 6.20 Signal Conditioner 169
21 Table 6.5 Major components in Signal Conditioner PCB Name Specification/Schematic diagram 8-Bit CMOS, 18 pin Microchip Microcontroller Flash word memory 2048, SRAM 224 EEPROM 128 I/O 16, 20 MHz operating max speed. Quantity Microcontrollers PIC16F628A 3 Operational Amplifiers LM358 Details given earlier 4 Schmitt Trigger Inverter, Six inverting buffers with Schmitt-triggerLowpower dissipation. OR Gate IC chip 7432 Quad 2-Input OR Gate 2 Octal non-inverting buffer/line driver with 3-state outputs. Buffer/Line Driver IC chip,
22 Figure 6.21 Signal Conditioner Figure 6.22 THI SINPWM and Triangular wave comparator to produce single IGBT pulse Figure 6.22 presents the DSO captured view of the THI Sine wave, triangular signal and resulting PWM pulses together through three channels. 171
23 Figure 6.23 The Controller section Figure 6.23 shows the overall view of the controller section developed for the system and Figure 6.24 represents the PWM pulse, shoot through pulse and the resulting pulses going to the driver circuit of the single IGBT. 172
24 Figure 6.24 pulse across single IGBT(Top- PWM pulses, Middle-shoot through pulses, Bottom-pulse for each IGBT) The impedance network and ac filter parameters for the experiment are chosen as L 1 = L 2 = 1mH C 1 = C 2 = 500μF L f = 10mH C f = 10μF Table 6.6 and 6.7 present the experimental results of the simple ZSI system selecting two different values of shoot through duty ratios D. With increase of D the output voltage as well as capacitor voltage is increasing. Table 6.8 presents a closed loop experimental results where the input single phase ac voltage is varied in steps from the variac and corresponding output voltage is recorded. Output remains almost steady with little variation and this satisfies the perfect working of the prototype under closed loop condition. Experiments are carried out both for simple ZSI and Quasi ZSI. Figure 6.25 and Figure 6.26 are the DSO captured waveforms separately taken without ac filter and with ac filter respectively. 173
25 Table 6.6 Experimental results of ZSI(M=0.8,Shoot through duty ratio D=0.32) V dc (Volt) V c1 (Volt) V_ac(Volt) Table 6.7 Experimental results of ZSI (M=0.7,D=0.37) V dc (Volt) V c1 (Volt) V_ac(Volt) Table 6.8 Performance of the regulator ZSI QZSI Single phase Three phase output line ac DC Bus voltage(v) voltage(vrms) input(vrms)
26 Figure 6.25 Output line voltage without filter Figure 6.26 Output line voltage with filter 175
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