Tutorials

November 26th, 2023

November 28th, 2023

Tutorial 10 *

xEV Powertrain Control Software Development & Testing with HIL

Typhoon HIL

* Complimentary tutorial

Tutorials Abstracts

Tutorial 1: High-power, MW-rated medium-voltage DC-DC converters have not yet reached their full commercial industrial maturity, as applications are not sufficiently well defined and/or supported by a strong business case. Nevertheless, a large body of academic and industrial research has been done in medium voltage direct current (MVDC) power distribution networks, where high-power DC-DC converters are an important technology. The tutorial will explore this field, with a narrow focus on bulk power conversion challenges (in contrast to modular solid-state transformer concepts made of many blocks rated for a fraction of the total converter power), topologies, high-voltage power semiconductors, magnetic components, and relevant control and protection methods. Large number of original results will be presented from the authors’ ongoing research activities in the EU-sponsored ERC Consolidator Grant project “EMPOWER”.

Tutorial 2: Starting with a brief overview of legal regulations, like CE mark and Declaration of Conformity, a selection of emission and immunity standards are presented. This includes the description of test set-ups, for example for measuring conducted emissions using conventional or STFFT based test receivers and their detector circuits, as well as test parameters, like frequency ranges, based on European and International standards. Then four coupling mechanisms (impedance, capacitive, magnetic and radiated) are discussed, based on components and PCB structures. Subsequently basic countermeasures are proposed and evaluated according meaningful applicability to switched-mode power supplies. The section signals and characteristics explains common-mode and differential-mode interferences as well as the Fourier Transform in detail with a number of waveforms, like rectangular, triangular and trapezoidal waveforms, which are typically for switched-mode power supplies. In particular switching transients are discussed against the background of wide band gap devices like GaN transistors. One large section discusses the origin of electromagnetic interferences referring to the previous sections. This section addresses some widely used circuits, their operating modes, like continuous conduction mode, discontinuous conduction mode and boundary conduction mode, and also parasitics of passive components, using high frequency equivalent circuits of capacitors, inductors and transformers, and active components, like junction capacitances and terminal inductances. A large number of examples is presented in form of results of measurements, simulations or calculations. The second half of the presentation deals with EMC design of switched-mode power supplies, also evaluating efficiency and control issues. This section is subdivided into a number of subsections. Firstly the power factor correction is briefly presented. A large subsection addresses EMC filters, which is subdivided into pre filters and post filters. The filter structure is discussed according common-mode and differential-mode attenuation and source and load impedance. Problem solving approaches of the gap between measurements according standards and filter effectiveness are presented. Additionally an outlook to active EMI filters is given. Also design aspects of magnetic components are discussed. Followed by suitable components, which presents for example the impact of start of winding of a magnetic component, suitable circuits with soft-switching principles are compared to hard-switching circuits. After that shielding basics are presented, in particular the impact of holes for cooling purposes on electromagnetic shielding effectiveness. Finally PCB layout structures are evaluated and recommendations are presented. These investigations also address grounding, one of the most discussed topics in PCB design among engineers, as well as component placing and component selection, e. g., based on integrated circuit pin out and return current paths.Most aspects are explained by measured, simulated or calculated examples. Many examples are discussed against the background of electromagnetic compatibility as well as their impact on efficiency, lifetime and costs of the power supply. The tutorial contains on the one hand practical examples and uses on the other hand the basic physics of Maxwell for a principle understanding. Many principles can be transferred to other electronic circuits.

Tutorial 3: The transition towards eco-friendly electric transportation presents a complex journey that requires advancements in both battery energy storage and fast charging technologies. Making significant progress in these areas is vital for overcoming key obstacles to the widespread adoption of sustainable e-mobility. The performance of electric vehicles heavily depends on battery technology, which determines factors such as range, cost, and overall efficiency. Additionally, the development of fast charging technology and infrastructure is crucial for enabling long-distance travel and addressing concerns about limited range and charging times. Battery technology has already undergone notable advancements, enhancing the viability of electric vehicles as a transportation option. Lithium-ion batteries (LIB) have become more compact, lightweight, and powerful, resulting in longer driving ranges and improved acceleration. However, the internal characteristics of LIB are nonlinear and highly sensitive to various operating and environmental conditions. Thus, it is crucial to implement an intelligent safety framework and smart battery management systems (BMS) to ensure the longevity, reliability, and safety of batteries. Ineffective BMS, particularly inadequate thermal management control, has been identified as a primary cause of fire incidents in electric vehicles (EVs). Exploring alternative battery chemistries like solid-state batteries, sodium-ion batteries, and hybrid energy storage systems could further enhance performance and safety. Consequently, this tutorial will delve into recent advancements in battery technology, BMS, and battery thermal management, covering current issues, challenges, and future research directions. It will also explore the integration of artificial intelligence, machine learning, digital twin technology, the Internet of Things (IoT), cloud computing, and wireless BMS in battery systems. Another crucial aspect of achieving sustainable e-mobility is the development of fast-charging technology. Without industry-ready solutions like DC-fast charging and wireless fast charging, coupled with insufficient charging infrastructure, electric vehicles may still face significant limitations, even with improved battery capacity and advanced technologies. Simply adding more batteries to increase range would result in heavier and costlier vehicles, as well as higher total ownership costs. To attract more users and ensure the future success of electric vehicles, it is essential to provide EV drivers with convenient access to fast charging stations that offer comparable refueling times to traditional gasoline vehicles. Failure to meet this requirement would raise doubts about the viability of EVs. Therefore, this tutorial will provide a comprehensive discussion on recent developments, issues, and challenges in EV charging, including DC fast charging and wireless charging. Additionally, potential solutions to enhance charging infrastructure development will be explored.

Tutorial 4: In the last decades, fast modern microcontrollers have been continuously growing, allowing the development and implementation of new and more intelligent control strategies as an alternative to conventional techniques for power converters. Model Predictive Control is one of these powerful and attractive alternatives that has received special attention in the last time. The use of predictive control offers several interesting advantages: it is an intuitive control approach, it does not need linear controllers and modulators, and it is possible to easily include nonlinearities and restrictions in the control law. It can be expected that the advantages of predictive control will lead to industrial applications in the future after some further progress. In this tutorial new advances and trends of model predictive control for power electronics and electrical drives will be presented.

Tutorial 5: The world must solve important challenges to control and transform energy in an efficient way. Examples of this are in transportation, renewable energies and industrial processing applications. These problems can be solved using power converters based on modern power semiconductor devices. The ideal converter in many of these applications may have the following characteristics: i) Sinusoidal input and output currents. ii) Operation with unity power factor. iii) Regeneration capability. iv) Compact design with a good power to weight ratio. All these characteristics can be fulfilled by Matrix Converters and this is the reason for the tremendous interest in this topology. In the last decade many advances in the development of this topology have been presented, including industrial applications up to megawatt levels. The use of Matrix Converters in real applications and the challenges that these applications present is very topical and important. This tutorial will present to the power electronics community a review and the state-of-the-art of the most recent advances with topics such as:
1) Matrix Converter basic principle of operation, commutation concepts, modulation and dimensioning. 2) Matrix Converter derived topologies (multi-level, HF link, indirect, sparse, very sparse, ultra sparse, etc.). 3) Practical examples of Matrix Converter demonstrators for aerospace, transportation, renewable energy and industrial applications as well as converters using new semiconductor device technology. 4) New control/modulation methods for Matrix Converter applications, including SVM, DTC, Predictive Control. 5) Existing and future applications of Matrix Converters in Industrial applications and associated hardware device and options for circuit constructions (given by a suitable industrialist – tba). 6) Matrix Converter power quality, reliability and converter stability issues.

Tutorial 6: Digital control systems are present in several industrial processes and, in the most systems, used in our daily lives, such as: power supplies, refrigerators, automobiles, aircrafts, computers, among others. In theory and application of control systems, adaptive controllers have evolved significantly in recent decades, mainly due to substantial evolution of digital electronic systems, which allowed its implementation in microcontrollers or microprocessor. Numerous publications address adaptive controllers under different aspects. However, most of these publications do not present the theory of these systems, in a didactic way. In addition, few publications analyze the design details and digital implementation of these controllers, in discrete time. In this way, it is intended in this tutorial, present adaptive control theory more directly and didactic, in addition to present the characteristic details of programming the adaptive algorithms for parameters estimation and system control, with the motivation, mainly, to apply these techniques in power electronics converters. To achieve these objectives, several problems are presented and solved through softwares Matlab and PSIM. The tutorial “Adaptive control applied to power electronics” aims to help undergraduate students, professors, researchers and technology professionals to develop practical skills in the design and implementation of adaptive techniques in digital control systems applied to power static converters. Parameters estimation and adaptive gains techniques are presented, using both the state-space approach, such as the input-output approach. Some problems are presented using Matlab and PSIM so that, through of these programs, the professional will be able to better understand the implementation of the adaptive algorithms. In addition to the algorithms, an APP, developed in Matlab, is available for the designer to develop projects and quick tests of adaptive controllers. The tutorial has been developed such as to be useful to both beginners to the most advanced in adaptive control. The theory presented in this tutorial can be used in the control of: machines electrical equipment, DC-DC and DC-AC static converters, robotic systems, power generation systems, among others. The tutorial is organized as follows. Section I: Math review of adaptive control. Section II: Parameters estimation techinques. Section III: Model Reference Adaptive Control (MRAC). Section IV: Introduction to stability analysis for adaptive control. Section V: Technical details about design and implementation of adaptive control in discrete time. Section VI: Applications of adaptive control in power electronics. Section VII: APP for the design and simulation of MRAC controllers.

Tutorial 7: Model Predictive Control (MPC) emerged few decades ago as an attractive control strategy for power electronics systems. Main advantages of MPC are the simple concept, the capability to include easily different control objectives and the high dynamic performance. On the contrary, like any new strategy, it also has disadvantages such as dependence on the mathematical model, dependence on the parameters and a variable frequency spectrum. However, thanks to the work carried out by the scientific community, each of these disadvantages has been resolved. The progress of MPC over the past few years has seen a transition from a novel strategy to a commercial product by the ABB company. This tutorial aims to introduce the audience to MPC and show them its evolution and applications. It is for this reason that this tutorial is organized into three main sections: i) provide the basic concepts of MPC operation; ii) show the main MPC applications in drives, photovoltaic and grid connection; iii) Finally, the objective is to show the audience the most relevant trends of MPC. In this way, it is expected that the audience will be able to obtain in this tutorial an overview of MPC, observe the main developments according to the various applications of power electronics and will obtain an overview of the progress of MPC and how they have been resolved to improve the strategy.

Tutorial 8: Power electronics and power conversion in general is today part of every segment of our life. Any piece of electric equipment we have today is somehow based on power electronics and converters; home appliance, industrial equipment, renewable energy, automotive, avionic, etc., etc. Conversion efficiency, specific power, power density and converter cost are today the most critical requirements for new converters. One way to increase the efficiency and reduce cost/size/weight is to deploy multi-level and/or multi-cell converters and partial power processing power converters. A novel solution to ultra-high efficiency and specific power dc/dc converters has been proposed and theoretically investigated in this tutorial. The solution is based on the fact that in most of application we do not need to process entire dc bus voltage and output current. We can process a fraction of the dc bus voltage and/or the load current. In other words, we do not need to process the converter total rated power; we would process just a fraction of the rated power. This is so-called concept of Partial Power Rated Converters (PPRC). Typical target applications are PV boost converters, energy storage (batteries and ultra-capacitors) interface converters, isolated ac/dc power supplies, electric drives, etc. Advantages of the PPRC concept, such as significant reduction of the input/output filter size & weight, voltage rating of power devices and conduction/switching losses are theoretically investigated and discussed in the tutorial. Various applications such as energy storage interface converters, isolated ac-dc converters and double feed electric machines are also discussed. Several case studies and design examples are given in concluding part of the tutorial. One particular design example presented in the tutorial is 25 kW battery interface dc/dc converter. An extraordinary efficiency of 99.5%, specific power of 30 kW/kg and power density of 50 kW/dm3 have been achieved. This tutorial is aimed at power electronics engineers, professionals and graduate students who want to improve their knowledge and understanding of advanced concepts of power conversion, such as Partial Power Rated Converters and applications.

Tutorial 9: In last years, resonant power converters have become more popular and widely applied in several applications where a high performance is required. In order to clarify how these converters are developed, this tutorial addresses the fundamentals related to the analysis, design, dynamic modelling, and control systems of resonant power converters, focusing in classical approaches and usual topologies (series, parallel, and series-parallel). The tutorial first describes the foundation of resonant power converter analysis, from where the converter static gain is obtained, as well as the main insights of its behavior. The main modulation techniques for resonant power converter will be discussed also. Following, the design of resonant power converters will be debated. Afterwards, the tutorial then moves to the control of resonant power converter, where initially the main procedures and methods to predict the resonant power converter dynamic behavior are presented. Finally, with the resonant power converters dynamic behavior known, the control system design will be under analysis. The final part of the tutorial addresses some examples of power resonant converter employed in high performance LED drivers, and Battery chargers.

Tutorial 10: Experience a streamlined xEV powertrain controller development environment comprising AURIX TM  based controllers with ultra-high fidelity Hardware-in-the-Loop (HIL) real-time simulation. In this session, we will introduce system modeling basics for HIL simulations, present the AurixTM integration of real-time instrumentation and parameter visualization, and demonstrate a simulation of a PM motor drive unit with Infineon microcontroller and Typhoon HIL simulator