POWER ELECTRONICS

Perfect power amplification to test your P-HIL harmony

To test power electronics based on Matlab or Simulink for electric drives, energy storage or utility interfaces the process has to be supported by Hardware-in-the-Loop (HIL) systems based on electronic emulators. For such applications EGSTON offers galvanically isolated high-speed interfaces allowing dynamic control with minimum latency.

HIL simulators are used in power system and power electronic applications to test protection equipment and electronic controllers. The device is connected to a simulator that runs the electric circuit using low levels of power, voltage and current. This concept is also used to test power components that require high power flows. It is called Power Hardware-In-the-Loop (P-HIL) and must be interfaced and connected using voltage and power amplifiers.

EGSTON – and you’ve got the power!

P-HIL simulation is a scenario where a simulation environment virtually exchanges power with real hardware like power converters, generators, FACTS and so on, in contrast to the usual hardware-in-the-loop simulation, which creates signal exchange only. EGSTON provides turn-key Power Electronic Test Benches based on P-HIL technology in a power range from 50 kVA up to 2 MVA.

Applications and emulation models run on real-time FPGA and standard HIL platforms that are an integrated part of the test benches. The high voltage bandwidth is 5 kHz at 440 VRMS and harmonics up to 20 kHz can be generated. This technology can be used as AC source/sink, DC source/sink, smart grid-, aerospace grid-, PV-module-, battery- or electrical machine emulator and even more.

Scientific & Research

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To test pow­er elec­tron­ic mod­els in a real live envi­ron­ment with real volt­ages and cur­rents a P-HIL Sys­tem is required. It sim­u­lates your mod­el in real time and gen­er­ates real volt­ages and cur­rents with a pow­er from kW up to MW and from DC up to 10kHz or more. EGSTON offers you the per­fect solu­tion for these test requirements.

COMPISO P-HIL System

A COMPISO sys­tem unit is a cus­tomer spe­cif­ic turn-key P-HIL solu­tion built out of stan­dard block sets. It is con­nect­ed to a 50 or 60 Hz low volt­age sup­ply grid. Bidi­rec­tion­al grid con­vert­ers are avail­able from 50 kVA up to 1 MVA. A grid trans­former pro­vides gal­van­ic iso­la­tion. Groups of 3 to 6 COMPISO dig­i­tal ampli­fiers are con­nect­ed to the DC-BUS. Volt­age and cur­rent is mea­sured at every ampli­fi­er out­put terminal.

All mea­sure­ments are avail­able in the HIL real-time proces­sor as inputs for the sim­u­la­tion mod­els. The ampli­fiers are rep­re­sent­ed as volt­age or cur­rent source in the HIL archi­tec­ture. The HIL dri­ves the ampli­fiers via high speed fibre optic link. The user can imple­ment its indi­vid­ual real-time mod­el in the HIL. To guar­an­tee a save oper­a­tion between the HIL and the ampli­fiers a high speed low laten­cy SFP Inter­face is provided.

The interface is supported by the HIL platforms:

• OPAL-RT
• Nation­al Instruments

Addi­tion­al­ly ana­logue inputs and out­puts are pro­vid­ed to con­nect HILs that do not sup­port the high speed SFP interface.

System configurations:

CSU100-4AMP
CSU100-8AMP
CSU100-6AMP

Appli­ca­tions:

• Renew­able ener­gy grid emulation
• House Emulation
• 12 pulse rectifier

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Renewable Energy

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In a renew­able ener­gy grid you can find many dif­fer­ent nodes like wind tur­bines, PV-farms, eCar load­ing sta­tions, stor­age devices, pri­vate and pub­lic house and busi­ness enter­pris­es. EGSTON pro­vides inte­grat­ed turn-key test solu­tions and emu­la­tion sys­tems to cov­er the whole range from sci­ence to R&D and certifications.

Multi-Use Test Benches for R&D

EGSTON offers you var­i­ous test bench­es for R&D labs, indus­try and research that pro­vide the whole bun­dle of stan­dard test devices like AC and DC sources, elec­tron­ic loads, AC and DC grid emu­la­tors, PV pan­el emu­la­tors, bat­tery emu­la­tors and even more.

What makes them unique is that they are mul­ti-use test bench­es. That means one and the same test bench can act as an AC-grid emu­la­tor, an elec­tron­ic load or as a PV pan­el emu­la­tor at dif­fer­ent times. And it is always the same hard­ware, just the con­fig­u­ra­tion and appli­ca­tion has been adapted.

Everything you need for your tests just when you need it

We also design inte­grat­ed solu­tions that you can use e.g. for a PV invert­er test bench that acts as a grid emu­la­tor and a PV-pan­el emu­la­tor at the same time and where every part can act inde­pen­dent form the oth­er or inte­grat­ed to per­form com­bined test scenarios.

This mul­ti-use test bench approach reduces the num­ber of test devices that you need in your lab dras­ti­cal­ly. At the same time widens the flex­i­bil­i­ty to have exact­ly the test bench type you need by just select­ing the appli­ca­tion you want.

Up-to-date Certification

We have appli­ca­tions to run whole cer­ti­fi­ca­tion tests ful­ly auto­mat­ed. You just con­nect the device under test — and all tests with this spe­cif­ic set­up will be processed step by step auto­mat­i­cal­ly. And when new stan­dards are pub­lished you do not need to have a com­plete new test appli­ca­tion — you sim­ply param­e­trize and store the new test procedure.

The freedom to create your own tests and emulation

P-HIL is an extreme­ly pow­er­ful tool to design and per­form any test or emu­la­tion you want based on math­e­mat­i­cal mod­els like Mat­lab, Simulink or oth­er tech­nolo­gies. You just cre­ate your indi­vid­ual mod­el of a test set­up or a real world device and then upload it into the HIL real-time proces­sor and exe­cute it. Out of your mod­el the con­nect­ed pow­er ampli­fiers cre­ate volt­ages and cur­rents with­in a pow­er range of 50 kVA up to MVA.

Realistic test scenarios made easy

In this way you get a real life rep­re­sen­ta­tion of your indi­vid­ual sim­u­la­tion with­out being restrict­ed to lim­it­ed appli­ca­tions like stan­dard elec­tron­ic load emu­la­tors or AC Source gen­er­a­tors. And you are able to devel­op and emu­late your indi­vid­ual sce­nario like an emu­la­tion of house with dif­fer­ent pow­er con­sumers and ener­gy sources like a small PV sys­tem includ­ing the change of ener­gy con­sump­tion and gen­er­a­tion over a whole day, a month or dur­ing sum­mer and wintertime.

System configurations:

CSU100-4AMP
CSU100-8AMP
CSU100-6AMP

Applications:

• Arbi­trary Wave Form Generator
• Grid Emulation
• Low Volt­age Ride Through
• High Volt­age Ride Through
• Elec­tron­ic Load
• House Emulation

Rail

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All over the world there occur more and more unex­pect­ed res­o­nances in rail­way pow­er grids. They are caused by the steadi­ly grow­ing num­ber of dig­i­tal pow­er elec­tron­ic com­po­nents and reg­u­la­tors in the sup­ply infra­struc­ture. Their num­bers and ampli­tudes are also sig­nif­i­cant­ly high­er than the ampli­tudes of the har­mon­ic res­o­nances that were present in tra­di­tion­al infrastructures.

Grid resonances — a serious threat to your railway infrastructure

If these har­mon­ic res­o­nances are undamped, their ampli­tude can be as high as the sig­nal ampli­tude of the base fre­quen­cy of the sup­ply grid. Res­o­nances caused by har­mon­ics could not only dam­age the sup­ply infra­struc­ture itself but also the equip­ment con­nect­ed to it. The band­width of these res­o­nances ranges from a few Hz up to a cou­ple of kHz.

Grid Harmonics Tolerance Test (GHTT) for e-locomotives

To avoid the mal­func­tion of an e-loco­mo­tive its tol­er­ance against har­mon­ics that may occur in the rail sup­ply grid should be test­ed. EGSTON pro­vides a spe­cif­ic test sys­tem for this task that ensures a sig­nif­i­cant­ly high­er reli­a­bil­i­ty dur­ing operation.

IMS method to investigate and avoid harmonic grid resonances

Newest pub­li­ca­tions explain the caus­es of har­mon­ic res­o­nances and pro­vide ana­lyt­i­cal meth­ods how to mea­sure, analyse and avoid them. The Imped­ance Mea­sure­ment Sys­tem (IMS) cre­ates imped­ance plots from e-loco­mo­tives and rail sup­ply grids. With the help of IMS har­mon­ics that are caused by their inter­ac­tion can by pre­dict­ed before they even occur.  This increas­es the avail­abil­i­ty of your rolling stock in your dai­ly oper­a­tion significantly.

System configuration:

• CSU — Har­mon­ic Injection

Applications:

IMS Rail
• GHTTS Rail

Downloads:

2016_0919_01 Rail01_E-Loc GridHarmToleranceTest.pdf
2016_0919_07 Rail02_E-Loc Imped­ance Mea­sure­ment System.pdf

System Configurations

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CSU Architecture

COMPISO Sys­tem Unit (CSU) a uni­ver­sal con­fig­urable P-HIL test bench sys­tem con­sists the fol­low­ing archi­tec­ture elements:
The 3 phase sup­ply­ing grid is con­nect­ed by 50kVA – 1MVA iso­lat­ing grid trans­former to pro­vide poten­tial free pow­er to CSU.
With this trans­former the sys­tem can be adapt­ed to any 3 phase pow­er grid volt­age from 400V to 690V and 50/60 Hz.
Togeth­er with the bidi­rec­tion­al Grid Invert­er it forms the so called ͞Grid Sec­tion͟. The Grid Invert­er con­verts the vary­ing AC Volt­age in to a con­trolled DC Volt­age (DC-Link) 750VDC@full load. It can source or sink ener­gy from or to the grid depend­ing on how the CSU works over­all. The grid sec­tion defines and lim­its the max­i­mum pow­er which can be sourced or sank from/to the grid.
This is per­fect­ly bal­anced con­nect­ed the COMPISO dig­i­tal ampli­fiers (CDAs) block. In var­i­ous con­fig­u­ra­tions CDAs turn the cal­cu­lat­ed HIL or appli­ca­tion mod­els into the expect­ed wave­forms and pow­er. Free selec­table con­fig­u­ra­tions of sin­gle CDAs allow to cre­ate DC, AC 1phase, AC 3phase with and with­out Neu­tral and any com­bi­na­tions of it.

Pre­cise mea­sure­ments of volt­age and cur­rent on each CDA out­put enables real time closed loop con­trol. COMPISO SCADA PC is an inte­grat­ed part of the COMPISO Sys­tem Unit.

The COMPISO SCADA (Super­vi­so­ry Con­trol and Data Acqui­si­tion) Sys­tem ful­fils the fol­low­ing roles:

  • Sys­tem Configuration
  • Sys­tem Parameterization
  • Sys­tem Online Operation
  • Sys­tem Mon­i­tor­ing and will be han­dled by a graph­ic user inter­face (GUI).

A COMPISO sys­tem unit is fail­safe designed cov­ered by the fol­low­ing safe­ty items inside each CDA and CSU cabinet:

  • Over­cur­rent protection
  • Over­volt­age pro­tec­tion (VDC_LINK, VOUT)
  • Dew point detec­tion on the water cool­ing rail
  • Tem­per­a­ture Alarm­ing (air, pow­er semi­con­duc­tors, cool­ing rail) Emer­gency OFFDoor Open shut down
  • Fast Dis­charge of DC-Link Capacitors
  • Shut OFF Input & Out­put Switches
  • Exter­nal Safe­ty Con­nec­tions (con­nect­ed to inter­nal Safe­ty PLC)
  • Tem­per­a­ture in Cabinet
  • Water Pres­sure

Option­al­ly a CSU can be equipped by SIL (Safe­ty Integri­ty Lev­el 2 or 3) com­po­nents, Real­time HIL proces­sors and cus­tom designed out­put matrix­es to cre­ate tai­lor made solutions.

COMPISO Digital Amplifier CDA

The COMPISO Dig­i­tal Ampli­fi­er (CDA) is the heart of every COMPISO solu­tion. Designed as a 4Q-Pow­er Ampli­fi­er, CDA works as a 6 legs inter­leav­ing buck-boost con­vert­er with cou­pled induc­tors. Every leg switch­es at rate of approx. 21 kHz, so the effec­tive switch­ing fre­quen­cy results into 125 kHz. The pow­er ampli­fi­er is well opti­mized for high dynam­ics, wide band­width and low latency.

It is fail safe and sends warn­ings when para­me­ters exceed warn­ing lev­els. Fur­ther­more, it switch­es auto­mat­i­cal­ly off when dan­ger­ous con­di­tion lev­els are exceed­ed. To build it as com­pact as pos­si­ble the CDA is water cooled. A CDA pro­vides a full span out­put volt­age up to 5 kHz. More­over, with reduced ampli­tude, up to 15 kHz is avail­able at the out­put, too.

COMPISIO Dig­i­tal Ampli­fi­er is dri­ven by dig­i­tal set points for volt­age and cur­rent with a set point fre­quen­cy of 250 kHz. The dig­i­tal input sig­nals will be turned by CDA into prop­er ana­logue out­put sig­nals with an excel­lent THD. The low trans­port delay between dig­i­tal set point sig­nal and PWM gen­er­a­tion of 4μsec only per­mits high speed closed loop controls.

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CSU100-4AMP

A 100 kVA COMPISO Sys­tem Unit (CSU) con­sist­ing a group of 4 COMPISO Dig­i­tal Ampli­fi­er (CDA) can be con­nect­ed and con­trolled in var­i­ous 4 Ampli­fi­er sys­tem con­fig­u­ra­tions. This high flex­i­bil­i­ty makes it future-proof even if some of these con­fig­u­ra­tions are cur­rent­ly not need­ed. For each con­fig­u­ra­tion datasets to the CDAs will be pro­vid­ed by COMISO SCADA.
Pos­si­ble con­fig­u­ra­tions are:

  • Free Amp Mode: each of the 4 ampli­fiers is used independently
  • AC sym­met­ri­cal 1~ Mode: 2 ampli­fi­er groups of 2 par­al­leled ampli­fiers each are used to gen­er­ate 1~ AC between its outputs
  • AC 3~ + N Mode: 3 ampli­fiers gen­er­ate a 3 phase sys­tem the 4th ampli­fi­er is used for a neu­tral line
  • DC unipo­lar Mode: 1 up to 4 ampli­fiers are par­al­leled to gen­er­ate a DC vs. DC Minus (-)
  • DC bipo­lar Mode: 2 ampli­fiers groups of 2 par­al­leled ampli­fiers each gen­er­ate a +/- DC between their outputs

All these con­fig­u­ra­tions are either work as a source with a load con­nect­ed to the out­puts or as a sink to load an exter­nal source for ful­ly flex­i­ble bidi­rec­tion­al sink-source combinations.

CSU100-8AMP

A 100 kVA COMPISO Sys­tem Unit (CSU) con­sist­ing 2 groups of 4 COMPISO Dig­i­tal Ampli­fi­er (CDA) each can be con­nect­ed and con­trolled in var­i­ous 4 Ampli­fi­er sys­tem con­fig­u­ra­tions. This high flex­i­bil­i­ty makes it future-proof even if some of these con­fig­u­ra­tions are cur­rent­ly not need­ed. For each con­fig­u­ra­tion datasets to the CDAs will be pro­vid­ed by COMISO SCADA.

Pos­si­ble con­fig­u­ra­tions are:

  • Free Amp Mode: each of the 4 ampli­fiers is used independently
  • AC sym­met­ri­cal 1~ Mode: 2 ampli­fi­er groups of 2 par­al­leled ampli­fiers each are used to gen­er­ate 1~ AC between its outputs
  • 2 x AC sym­met­ri­cal 1~ Mode: Two CDAs each are used to gen­er­ate 2 inde­pen­dent bipo­lar sin­gle phase sym­met­ri­cal AC out­put sig­nals. Load is con­nect­ed between CDA 1 and 2 and between CDA 3 and 4 outputs.
  • AC 3~ + N Mode: 3 ampli­fiers gen­er­ate a 3 phase sys­tem the 4th ampli­fi­er is used for a neu­tral line
  • DC bipo­lar Mode: 2 ampli­fiers groups of 2 par­al­leled ampli­fiers each gen­er­ate a +/- DC between their outputs
  • DC unipo­lar Mode: Up to four CDAs par­al­leled are used to gen­er­ate a unipo­lar DC out­put sig­nal. Load is con­nect­ed between CDA out­puts and DC minus.

All these con­fig­u­ra­tions are either work as a source with a load con­nect­ed to the out­puts or as a sink to load an exter­nal source for ful­ly flex­i­ble bidi­rec­tion­al sink-source combinations.

CSU 200

A 200 kVA COMPISO Sys­tem Unit (CSU) is the basic 6 Ampli­fi­er Test bench sys­tem for mul­ti-pur­pose use. CSU 200 con­sists a group of 6 COMPISO Dig­i­tal Ampli­fi­er (CDA). These can be con­nect­ed and con­trolled in var­i­ous sys­tem con­fig­u­ra­tions. This high flex­i­bil­i­ty makes it future-proof even if some of these con­fig­u­ra­tions are cur­rent­ly not need­ed. For each con­fig­u­ra­tion datasets to the CDAs will be pro­vid­ed by COMISO SCADA.

A selec­tion of pos­si­ble con­fig­u­ra­tions are:

  • Free Amp Mode: each of the 6 ampli­fiers is used inde­pen­dent­ly -AC sym­met­ri­cal 1~ Mode: 2 ampli­fi­er groups of 3 par­al­leled ampli­fiers each are used to gen­er­ate 1~ AC between its outputs
  • AC 3~ + N Mode: 3 ampli­fiers gen­er­ate a 3 phase sys­tem the oth­er 3 ampli­fi­er are par­al­leled and used for a high pow­er neu­tral line
  • DC unipo­lar Mode: 1 up to 6 ampli­fiers are par­al­leled to gen­er­ate a high pow­er DC vs. DC Minus (-)
  • DC bipo­lar Mode: 2 ampli­fiers groups of 3 par­al­leled ampli­fiers each gen­er­ate a +/- DC between their outputs
  • Option­al 3~ Trafo N: Three times two CDA out­puts dri­ve the pri­ma­ry trans­former wind­ings of 3 sin­gle phase trans­form­ers with up to 500VAC. Sec­ondary trans­former wind­ings can be con­nect­ed to 3 phase + neu­tral sys­tem. Sec­ondary trans­former volt­age can be cus­tomized designed.

All these and many more con­fig­u­ra­tions are either work as a source with a load con­nect­ed to the out­puts or as a sink to load an exter­nal source for ful­ly flex­i­ble bidi­rec­tion­al sink-source combinations.

Mul­ti­ple CSU 200 can be grouped and par­al­leled to cre­ate out­put pow­er up to 1MVA.

 

Applications

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  • Arbi­trary Wave Form Generator
  • Grid Emu­la­tion
  • Low Volt­age Ride Through
  • High Volt­age Ride Through
  • Elec­tron­ic Load
  • House Emu­la­tion
  • IMS Rail
  • GHTTS Rail
  • IMS Wind
  • GHTTS Wind

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