Design and Develop an IGBT Inverter for AC Motor Drive Applications

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Design and Develop an IGBT Inverter for AC Motor
Drive Applications

• Done By
• Ali Jumah 199900147
• Mohammad Salem 199905041
• Ahmad Al-Wahedi 200000137
• Advisor
• Dr. Md Enamul Haque
• Eng. Ahamd Abdrabou

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Outline

• Project title and objectives.
• Introduction.
• The Power Supply.
• Implementation of Power Supply.
• PCB.
• The Firing Circuit.
• Implementation of Firing Circuit.
• dSPACE.
• Opto-isolator.

• Implementation of Opto-isolator.
• The IGBT module.
• Implementation of IGBT inverter.
• The System Case.
• The Simulation.
• System Mechanism
• Analyzing the results.
• Conclusion.

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Project Title and Objectives

• Design and Development an IGBT Inverter for
  AC-Motor Drive Applications.
• Objectives
• Design and develop an IGBT inverter.
• Improving the motor performance.
• Simulating the circuit using any simulation
  software.
• Prototyping and testing the circuit.
• Participating in team work activities.
• Implementing the theoretical background in real
  applications.
• Interacting with industry.

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What is IGBT ?

• The IGBT inverter (Insulated Gate Bipolar
  Transistor) main component is the transistor.
• It is a very fast switching inverter that is
  widely used in many applications such as
• Refrigerators.
• Electric vehicles.
• Lifts.
• Oil and petroleum industries.
• UPS (Uninterruptible Power Supply).

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IGBT Advantages

• Low acoustic noise due to high switching
  frequency.
• Low torque ripple.
• Low losses associated with switching device.
• Low cost driver circuits.
• Variable speed operation over a wide speed range
  results in significant energy savings.
• High efficiency.
• Smaller size.
• Lower overall cost.

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Introduction

• The Schematic Diagram of an AC Motor Drive

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Main Power Supply

• It is a power supply that was used to feed the
  IGBT module with 342Vdc.
• Supplied by 2 phases line to line AC power
  supply.
• Rectified by a Full-Wave Rectifier.
• Filtered by 4 capacitors.

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Main Power Supply
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Secondary Power Supply

• It is a power supply that was used to feed the
  Firing Circuit and the Opto-isolator circuit with
  15Vdc.
• Supplied by 1 phase AC power supply (220Vac).
• Transformed by step down transformer.
• Rectified by a Full-Wave Rectifier.
• Filtered by 2 capacitors.

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Secondary Power Supply
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PCB

• PCB( Printed Circuit board).
• Printed circuit boards, or PCBs, are used to
  mechanically support and electrically connect
  electronic components.
• Circuit boards were created in the mid-1930s .

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PCB

• It consist of
• Base board.
• An insulator (usually fiberglass).
• Threads of conductive material serving as wires
  on the base of the board .

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PCB Manufacturing

• Use a program to built the circuit.
• Select each components place.
• Print the circuit layout.

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PCB Manufacturing

• Paste the layout to a copper board.
• Put it in closed box with a light source inside
  for several minutes.
• Replace the layout.

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PCB Manufacturing

• Put the board in solvent (Ferric Chloride) to
  remove all copper except the circuit.
• Drill the board.
• Soldering the component to the board.

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Firing Circuit

• The firing circuit is a circuit that used to keep
  the IGBT inverter safe from any fault. It also
  used to control the input signal of the IGBT
  inverter so that only 2 gates at the same time
  are working

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Firing Circuit
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dSPACE

• Controlling system
• Controller board.
• Software.
• Connections.
• Advantages
• Available.
• Easy to handle based on software.

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dSPACE
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dSPACE
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Opto-isolator

• Helps cut down on ground loops.
• Block voltage spikes.
• 6 opto-isolator chips were used to build the
  opto-isolator circuit.

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Opto-isolator
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The IGBT Module

• It consists of 6 IGBT inverters.
• Each arm has two inverters.
• Each arm has only one inverter working at a time.
• Its output is an AC three phase output.

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The IGBT Module
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The System Case

• Selecting a flexible and quite hard material
  (Plastic)
• Cutting the plastic as the shape we want, in out
  case in Cube.
• Paste the edges together by using Cl-Acid and
  angles.
• Make a door in the front side or on the top of
  the case.
• Put the whole system inside the case.

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The System Case
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The Simulation

• The Schematic diagram of the simulation

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The Simulation Results
Rotor and Stator currents
Simulation Results Input AC voltage, DC voltage,
PWM signals and the Resultant Sine wave
Speed of the motor
Torque of the motor
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The Spectrum analysis of the signals using
PowerGUI tool
The spectrum of the input voltage supply of phase
a and b with THD of 0.0
The spectrum of the ripple of the DC power supply
comes out form the rectifier
The spectrum of the resultant sine wave based on
the PWM signals with some distortion
The spectrum of the three level of PWM signals
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System mechanism

• An AC input supply of two phases is rectifier
  through the power rectifier to get a DC voltage
  goes to the inverter.
• Before the DC output of the rectifier goes to the
  inverter, it should first be filtered to pure DC
  voltage through 4 parallel capacitors of 330µF
  with rated voltage of 400VDC.
• This DC voltage feeds the IGBT Module.

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System mechanism

• Then 6 PWM pulses will be generated form the
  MATLAB through the DSpace device.
• These 6 PWM pulses will go to the opto-couplers
  then to the firing circuit which controls the
  switching of the IGBT module based on the PWM
  signal to get the desired sine waves of phase a,
  b, and c at the output of the inverter module
  which enters to the motor

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System mechanism

• The secondary power supply with output voltages
  of 5Vdc, 15Vdc, and -15Vdc was build to feed the
  auxiliary circuits of the system such as the
  firing circuit and the opto-couplers.
• The amplitude of the produced sine waves of
  phases a, b, and c will depends on the modulation
  index of the PWM signals. And their frequencies
  will be equals to the frequency of the reference
  signal used for modulation.

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Testing Results
The Main Power Supply

• Theoretical result is
• Experimental result
• By using a differential probe of scaling to 1/200
• And oscilloscope scaling to 100

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Testing Results
The Secondary Power Supply
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Testing Result
PWM signals out of the Opto-couplers Circuit
Comparison between Theoretical and Experimental
Results
Experimental Results
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Testing Result
The output signal of phase b from the firing
circuit to the IGBT module (PWM-3)
The negative output signal of phase b from the
firing circuit to the IGBT module (PWM-4)
Out of three firing circuits, only channel of
phase (b) gives an acceptable output signals.
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During Testing

• Two of the firing circuits were burned.
• By rebuilding the burned circuits and checking
  the whole connections again it was found that one
  channel of the IGBT Module was short circuited
  which caused the burn of the two firing circuit.
• The IGBT Module was changed, but still there were
  no acceptable output signals.

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Conclusion

• Many problems were faced during implementation
  and testing the system. However, these problems
  build our personalities and developed our skills
  to better level of experience.
• Some of these problems are
• Out of stock components.
• Slow computers with weak CPU processor.
• Need to be careful for dealing with high power.
• Stuck at the final stage of the project with
  unknown and unsolved obstacle.

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Conclusion

• The project developed our skills in three major
  subjects.
• In Power Electronics field
• by designing an IGBT Inverter for AC Motor drive
  application
• In Control field
• Using PWM form controlling the frequency of the
  Motor
• in Power Machinery field
• By learning the mechanism of work of the
  different machinery such as generators, DC and AC
  induction motors

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Thank you for your listening

• We are happy to answer your questions