High voltage converter (HVC) are widely used in metallurgy, chemical industry, mining, shipping and many other industrial fields, and have gained wide recognition from users in reducing the energy consumption of electric motors, improving the control level of the drive system, frequency conversion soft starting, and improving the power factor and efficiency of equipment. HVC exists higher voltage level, complex topology, testing difficulties and other issues, in order to ensure that the high-voltage inverter efficient, safe and reliable operation, in the industrial reality of the "R & D - production - test" product iteration links, R & D test engineers have to repeatedly modify the controller parameters, circuit parameters in order to carry out a series of HVC testing in different operating conditions, based on the semi-physical simulation to support any topology model building and highly accurate features,the use of hardware-in-the-loop solutions for the development and testing of HVC has become a mainstream trend nowadays.
By using the semi-physical simulation platform provided by ModelingTech, which features high accuracy, ease of use, and comprehensive data post-processing capabilities, we are able to conduct experiments that traditional testing methods cannot complete or have low efficiency, such as High/low voltage ride through testing, grid-connected testing, and software functionality verification. Compared to traditional testing methods, the introduction of Hardware-in-the-Loop (HIL) platform of ModelingTech has increased our testing efficiency by approximately 10 times. For experiments that require repeated testing to obtain data, the semi-physical simulation platform provides rapid and abundant test data support.In the future, we hope to introduce automated testing capabilities of ModelingTech to further improve testing efficiency. Additionally, it is worth mentioning the excellent technical support service provided by ModelingTech. Their after-sales response is particularly timely, and they assist us in resolving various issues encountered during the application of the HIL platform in the field of power electronics.
Based on the MT 8020's superb CPU performance and ultra-high FPGA computational accuracy, the grid, phase-shifted transformer and uncontrolled rectifier parts can be run on the CPU of the 8020 real-time simulator, and the cascaded H-bridge and motor parts can be run on the FPGA.The The MT 1070 rapid prototyping controller is used on the control side to run the control algorithm of the HV inverter system and send out PWM signals to control the cascade H-bridge; signals are exchanged between the MT 8020 and the MT 1070 through real physical IOs to realise a true HIL (Hardware-in-the-Loop) simulation test system.
1us step simulation meets the requirements of high-precision simulation, can be freely configured with different structures of HVC systems, and accurately simulate the operating characteristics of HVC.
Provide professional automation test Python API, convenient for industrial users to develop automation test project; support “HIL Scope” high-speed recording function, can achieve 500k sampling rate for multi-channel waveform observation.
Support up to 8 sfp fibre-optic signal modules, can easily achieve physical IO expansion or multi-device parallel simulation, to meet the requirements of HVC large system testing.
Supports high-speed and wide voltage range digital inputs, adapted to industrial inverter control interface; supports Modbus TCP, Modbus RTU, CAN and other industrial communications.
For software performance testing, full-load and no-load tests and parameter identification tests under VF control and open-loop vector control are required to ensure correct controller performance.
Inverter must meet the IEEE519-1992 and China's power grid on the strict requirements of harmonics, higher than the national standard GB/T14549-93 standard on harmonic distortion requirements, to ensure that the inverter grid-side current is nearly a perfect sinusoidal wave, will not cause harmonic pollution of the power grid.
HVC should be equipped with flying start function, when the motor is still rotating to maintain normal start, that is, to ensure that the motor in the speed range of any speed, no need to stop to start the high-voltage frequency conversion speed control system directly without impact.
HVC should have very strong adaptability to the grid voltage fluctuation, and it can output at full load within the range of -20%~+15% grid voltage fluctuation. The converter should have high-voltage instantaneous power loss and restart function, after the converter instantaneous power loss, within 5 week waves, the converter operation is not affected in any way. If more than 5 weeks, the converter automatically derate operation, when the input voltage returns to normal, automatically re-raise the output frequency to the given value, this process is controlled by the time of addition and subtraction should not have the initialisation time.
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