TRENDS IN POWER

ELECTRONICS AND DRIVES

Dr.V.Kamaraj
Professor
Electrical and Electronics Engineering
SSN College of Engineering

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 Introduction

“Nearly 65% of the total electric energy

produced in the USA is consumed by electric
motors.”

- R. Krishnan, “Electric Motor Drives Modeling,

Analysis, and Control” Prentice Hall,Inc.,2001

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 Some Applications of Electric
Drives
‹ Hard Disk Drive, Treadmill, Air conditioner
‹ Pumps, fans, compressors
‹ Spindles and servos
‹ Appliances and power tools
‹ Cement kilns
‹ Paper and pulp mills; textile mills
‹ Automotive applications
‹ Conveyors, elevators, escalators, lifts

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 Drive System
Four distinct elements of a drive system are :
1. The load
2. The motor
3. The Power Electronic Converter
4. The Control Electronics
Drive system development challenges:
1. Power Density
2. Performance
3. Energy Efficiency
4. Cost
5. Time to Market

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 DRIVE SYSTEM TECHNOLOGIES

I CONTROL ELECTRONICS

II SEMICONDUCTOR DEVICES
TECHNOLOGY

III MATERIAL TECHNOLOGY

IV CAD TECHNOLOGY

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 I CONTROL ELECTRONICS
Functions to be implemented by Control Electronics

‹ Monitoring and Diagnostics

‹ Communication Interfaces

‹ Real time PWM Control

‹ Sensing

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Need for a Controller

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System with Controller

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 Analog Controllers
Advantages:
1.Low cost if the controller is simple
2.Easy Interpretation
Disadvantages
1.Reconfigurability of the control is not possible
without changing the hardware
2.Number of passive components used are more
3.More sensitive to variation in temperature
4.Reliability is low

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 Digital controllers using DSP and
Microcontrollers
Advantages:
1.Reconfigurability of the control without changing the
hardware
2.Less passive components are used
3.Less sensitive to temperature variations
Disadvantages:
1.The hardware resources are fixed and it cannot be changed
once the particular DSP/Microcontroller is selected
2.Design depends more on the hardware architecture of the
processor

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 FPGA Based Digital Controllers
Advantages:
1.Reconfiguarabilty of the hardware
2.The user is independent of the architecture of the
device

These two advantages makes Digital Controllers with

FPGA a better choice

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Configuration of Cyclone FPGA

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 CONTROLLERS USING POWER
INTEGRATED CIRCUITS
‹ PWM CURRENT REGULATING FECILITY

‹ DECODING COMMUTATION LOGIC

‹ HALL SENSOR

‹ PROTECTIVE FEATURES

‹ LM621,MC33034

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 II SEMICONDUCTOR DEVICES
TECHNOLOGY
SEMICODUCTOR DEVICES ENHANCES
• PERFORMANCE
• RELIABILITY
• COST EFFECTIVENESS
OF
DRIVE SYSTEM

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 SEMICONDUCTOR DEVICE
TECHNOLOGY CHALLENGES
TERMINAL MATERIAL PARAMETERS
CHARACTERISTICS AND
AMBIENT CONDITIONS

DC I-V GEOMETRY
AC STEADY STATE i,v ENERGYGAP
TRANSIENT i,v DOPING
MOBILITY
LIFETIME
DIELECTRIC
CONSTANT
TEMPARATURE
ILLUMINATION

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 ATLAS

ATLAS enables device technology

engineers to simulate the electrical, optical,
and thermal behavior of semiconductor
devices. ATLAS provides a physics-based,
easy to use, modular, and extensible
platform to analyze DC, AC, and time
domain responses for all semiconductor
based technologies in 2 and 3 dimensions.

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TECHNOLOGY

ENERGY/MATERIAL/INFORMATION

PROCESSING PRECISE
CONDITIONS CONTROL

• HIGH
PERFORMANCE
PRODUCT • HIGH
RELIABILITY
• LOW COST

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 POWER SEMICCONDUCTOR
DEVICES
‹ PWMSWITCHING FREQUENCIES ABOVE THE
AUDIBLE FREQUENCIES

‹ CONVERTER EFFICIENCY AND RELIABILITY

‹ IGBT

‹ DEMISE OF GTO’S AND SCR’S

‹ SILICON CARBIDE TECHNOLOGIES

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 III NEW MAGNETIC MATERIALS
SMC (Somaloy500) Material Properties
Physical
Mechanical
Density 7.37 g/cm3
Compressive
340 Mpa
Strength Specific heat 450 J/kg*K

Fatigue Strength 23 Mpa Thermal expansion 11E-6 m/m*K

Resistivity 70 uΩ*m
Young’s modulus 117 Gpa

Poisson’s Ratio 0.18 Magnetic

Impact Energy 1J B@4000A/m 1.26 T

Damping Factor B@10000A/m 1.51 T

1.1E-3
(1/Q) Hc 270 A/m

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Soft Magnetic Composite (SMC)

‹ Soft Magnetic Composites

(SMC) are composed of
surface-insulated iron powder
particles.

‹ SMC can be compressed to

form uniform isotropic
components with complex
shapes in a single step.
Electrically Insulated Fe-powder Particles
‹ SMC makes it possible to
define a magnetic field in three
dimensions, thereby permitting
the designer to build an electric
motor beyond the restrictions
set by the traditional
lamination technology.

Typical SMC micro-structure

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SMC Parts Manufacturing

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 Soft Magnetic Composite (SMC) Magnetic Property

Technology improvement narrows the gap between steel and SMC.

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 Advantages
‹ Reduced eddy current loss
‹ Increased efficiency
‹ Reduction in materials
‹ Potential for reduced air gap length as a result of the tight tolerances
maintained in manufacturing SMC material
‹ Potential elimination of the ground wall insulation since the SMC stator
itself acts as an insulator
‹ Reduced conducted EMI when machine is used with inverter supplies since
the stator SMC body acts as an insulator and does not conduct current to
ground,
‹ Reduced bearing currents in the presence of PWM waveforms again
because of the use of SMC which acts as insulation against this type of
current flow,
‹ Modular construction allows the possibility of easy removal of an
individual modular unit for quick repair or replacement,
‹ Stator is easily recyclable since the stator can again be compressed back
into powered form with pressure and the copper windings readily removed.

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 Disadvantages

‹ Relatively high hysterisis loss (low frequency

loss),
‹ Slight penalty a result of smaller saturation
flux density,
‹ Relatively brittle material,
‹ Lower relative permeability (700 vs roughly
3000)

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 IV CAD TECHNOLOGY
‹ Computer Aided Design is the technology concerned
with the use of computer systems in the
» CREATION
» MODIFICATION
» ANALYSIS
» OPTIMIZATION
‹ OBJECTIVES
» Improve the performance

» Improve the power density

» Improve the reliability

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 CAD ADVANTAGES
1. CAD methods doesn't require assumed flux paths or
Empirical factor

2. Complex geometries can be designed

3. Design improvement is possible in the design stage itself.

4. Weight of the material can be greatly minimized.

5. Design validation without resorting to expensive field

tests.

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CAD PACKAGES
 ORGANIZTION OF A CAD
PACKAGE
Three identifiable Modules
1. Preprocessor
2 Solver
3. Post Processor

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 PRE-PROCESSING

‹ Modeling
‹ Mesh Generation
‹ Material Properties Specification
‹ Boundary Condition Application
‹ Excitation
‹ Model Validation

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 POST PROCESSING

‹ Fluxplots
‹ Numerical values
‹ Animation

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MagNet
MagNet gives complete and accurate
electromagnetic field simulations.
Engineers can design, analyze and
optimize motors transformers
actuators or any electric or
electromechanical components
regardless of how complex.

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 MAXWELL
‹ Ansoft offers the Maxwell SV to help engineering
students visualize electromagnetic fields and
broaden their understanding of electromagnetic
physics. The Maxwell SV is a subset of Ansoft's
commercially distributed Maxwell 2D. Students can
perform AC/DC electromagnetic and electrostatic-
field simulation without limitation

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 ANSYS
‹ ANSYS Emag software addresses the analysis needs
of the low-frequency electromagnetics industry,
including electric motors, relays, solenoids, toroids,
induction heating, accelerators,medical instruments
and magnet design.

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CAD OF SWITCHED
RELUCTANCE MACHINE

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Torque Ripple

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Proposed Method to Reduce
Torque Ripple

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 Acoustic Noise
Source of the Problem

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 Effect of Skewing on Acoustic Noise

Geometry Displacement in μm Stress Kg/m2

Standard 0.589 Max:31.477

Structure Min :0.233

Skewed rotor 0.624 Max:59.845

structure Min :0.134

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 A Method to Reduce Acoustic
Noise
‹ POWDER MIX

‹ COMPACTION

‹ CURING OR HEAT
TREATMENT

‹ NET SHAPE

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 Future Scenario
‹ Technology advancement, cost and size reduction are
promoting extensive application of drive system in
residential, Industrial and Transportation Systems
‹ Boost in global industrial automation
‹ Higher cost of energy and environmental regulation will
promote energy saving by Power Electronics
‹ Wide growth of environmentally clean wind and PV Energy
‹ Wide growth of Electric and Hybrid Vehicles as fuel cost
increases
‹ Power Electronics will be a key technology like computers

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 REFERENCES
‹ M. Balaji, S. Ramkumar and V. Kamaraj
"Performance evaluation of switched reluctance machine using finite element analysis"
Proceedings of the 2nd National Conference on Cutting Edge Technologies In Power Conversion And
Industrial Drives, Sathyamangalam, India, 24 - 25 March, 2006, Paper No. PE72.
‹ R.T. Naayagi and V. Kamaraj
"Shape optimization of switched reluctance machine for aerospace applications"
Proceedings of IECON '05, the 31st Annual Conference of the IEEE Industrial Electronics Society,
Raleigh, NC, USA, 6 - 10 November, 2005, pp 1748 - 1751.
‹ R.T. Naayagi and V. Kamaraj
"Optimum pole arcs for switched reluctance machine with reduced ripple"
Proceedings of PEDS '05, the 6th IEEE International Conference on Power Electronics and Drive
Systems, Kuala Lumpur, Malaysia, 28 November - 1 December, 2005, Vol. 1, pp 761 - 764.
‹ R.T. Naayagi and V. Kamaraj
"Minimization of torque ripple in switched reluctance machine for direct drive applications"
Proceedings of IEEE Symposium on Emerging Technologies, Islamabad, Pakistan, 17 - 18 September,
2005, pp 388 - 392.
‹ R.T. Naayagi and V. Kamaraj
"Modeling and design of shape optimized SRM with reduced ripple"
Proceedings of the IEEE Symposium on Emerging Technologies, Islamabad, Pakistan, 17 - 18
September, 2005, pp 399 - 404.
‹ R.T. Naayagi and V. Kamaraj
"Optimal design of switched reluctance machine"
Proceedings of ROVISP '05, International Conference on Robotics, Vision, Information and Signal
Processing, Penang, Malaysia, 20 - 22 July, 2005, Paper No. B3-5.

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 References
‹ R.T. Naayagi and V. Kamaraj
‹ "Optimal design of switched reluctance machine using genetic algorithm"
Proceedings of EDPE 2005, International Conference on Electrical Drives and Power Electronics, Dubrovnik, Croatia, 26
- 28 September, 2005, Paper No. E05-11.
‹ R.T. Naayagi and V. Kamaraj
"Optimal design of switched reluctance machine using genetic algorithm"
Proceedings of AEE '05, the WEAS 4th International Conference on Applications of Electrical Engineering, Prague, Czech
Republic, , 2005.
‹ R.T. Naayagi and V. Kamaraj
"Torque ripple minimization of switched reluctance machine (3 phase) using genetic algorithm"
Proceedings of SOSM 2005, the 15th International Conference on Soft Computing, Optimization, Simulation and
Manufacturing Systems, Cancun, Mexico, , 2005.
‹ R.T. Naayagi and V. Kamaraj
"A comparative study of shape optimization of SRM using genetic algorithm and simulated annealing"
Proceedings of INDICON 2005, IEEE India Annual Conference, Chennai, India, 11 - 13 December, 2005, pp 596 - 599.
‹ M. Balaji, C.A. Vaithilingam and V. Kamaraj
"Torque ripple minimization in switched reluctance motor drives"
Proceedings of PEMD '04, the 2nd International Conference on Power Electronics, Machines and Drives, Edinburgh, UK,
31 March - 2 April, 2004, Vol. 1, pp 104 - 107.
‹ K. Sivaprasad, P. Naveenkumar, M. Balaji and V. Kamaraj
"Performance prediction of switched reluctance machine using multilevel simulation"
Proceedings of EPE-PEMC 2004, the 11th International Power Electronics and Motion Control Conference, Riga, Latvia,
2 - 4 September, 2004, CDROM Paper No. A52627.
‹ V. Kamaraj and C.A. Vaithilingam
"Modeling and simulation of switched reluctance machine (SRM) using MagNet6.0"
Proceedings of PEDS '03, the 5th IEEE International Conference on Power Electronics and Drive Systems, Singapore, 17
- 20 November, 2003, Vol. 1, pp 480 - 484.

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