Fiber-Adapted Integrated SST Controller HIL Testing Solution Fiber-Adapted Integrated SST Controller HIL Testing Solution
Fiber-Adapted Integrated SST Controller

The fiber-adapted integrated SST controller hardware-in-the-loop testing solution builds a high-fidelity hardware-in-the-loop test platform for complete SST controller hardware (master, phase and sub-controllers). Its key innovation is the “fiber-adapted” communication architecture, which replaces most of the complex physical I/O wiring with fiber-optic communication, significantly improving integration convenience and test iteration efficiency while ensuring system-level test integrity.

System Schemes

The platform adopts a distributed multi-simulator collaborative architecture: one master simulator simulates the front-end cascaded H-bridge circuit in real time with a 1 μs time step, while three slave simulators accurately simulate the back-end high-frequency DC-DC converters of each phase with an extremely small 100 ns time step. Real-time data interaction between the four simulators through fiber, together with clock synchronization lines ensuring strict synchronization, forms a high-precision, unified virtual controlled plant.

At the communication and interface level, the master simulator connects to a fiber aggregation box through three high-speed fiber links; the aggregation box converts the signals into multiple low-speed fiber links that connect point-to-point with the front-end sub-controllers, transmitting key signals such as sub-module voltages and PWM control; back-end communication interacts directly with the corresponding sub-controllers through the physical I/O of the slave simulators. This design successfully builds a high-precision, highly reliable test environment that fully supports development needs from controller functional verification to system dynamic performance testing.

System Schemes
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Technical Features
Cost-Effective System-Level Testing with Easy Wiring
Cost-Effective System-Level Testing with Easy Wiring

Prioritizing wiring convenience and cost-effectiveness, it meets the testing needs of laboratory rapid iteration and multiple rounds of regression.

Multi-Simulator Co-Simulation
Multi-Simulator Co-Simulation

To address the limited resources of a single simulator, multiple simulators run in parallel; after decoupling at the system DC side, electrical quantities are transmitted with low latency and strong noise immunity through fiber, and clock synchronization is guaranteed by clock synchronization lines, achieving accurate whole-system simulation of the solid state transformer.

High Scalability and Modularity
High Scalability and Modularity

High-speed fiber-optic data interaction and a strict clock synchronization architecture provide the underlying support for energy router simulation with high-voltage multi-stage cascaded H-bridges and large-scale DABs, ensuring system scalability.

Testing Item
  • 01No-Load Soft-Start Test
  • 02CHB Reactive Power Switching + DAB Full-Load Active Power Test
  • 03Load Step Test
No-Load Soft-Start Test
No-Load Soft-Start Test

The figure shows the measured soft-start process of multiple DABs. According to the primary/secondary separately-enabled startup sequence, the DAB secondary-side voltage rises from 0 V to the rated DC voltage, and the process is consistent with the offline results, verifying the soft-start capability of the system.

CHB Reactive Power Switching + DAB Full-Load Active Power Test
CHB Reactive Power Switching + DAB Full-Load Active Power Test

Under the 100% active load condition, switch the reactive power command; the reactive power should follow the command change with a response time within 60 ms and steady-state control accuracy within 2%.

Load Step Test
Load Step Test

Test the 50%-100%-50% output voltage dynamic response; the load-side voltage dynamic response and recovery time should meet the requirements and relevant standards — for example, the recovery time after a DC load voltage change should not exceed 100 ms, and the overshoot should not exceed the voltage setpoint standard.

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