30kVA三相逆变器模块设计及电感线圈损耗的分析和计算
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摘要
随着新能源的开发和分布式发电系统的推广以及不间断电源(UPS)的应用，作为它们核心元件的逆变器受到特别关注。这些不仅要求逆变器的功率等级越来越高，而且功率密度的要求也越来越高，如何进行高功率密度下逆变电源的模块化设计成为新的研究热点。LC滤波器不仅能消除开关频率及邻近频带的谐波，还能改善逆变器的动态性能。其中，电感器性能的好坏不仅影响到系统的效率还影响到整个逆变器系统的稳定性。所以有必要对电感损耗，在高频下主要是线圈损耗和它的线圈交流电阻进行研究分析。
本文首先综述了现代逆变器控制技术策略的现状和大功率开关器件的发展，并且简单分析了电感寄生电阻对逆变器性能的影响。在第二章中，介绍了30kVA实验样机的硬件设计，讨论了设计过程中的器件选择，散热设计，驱动保护电路设计，层叠式直流母线的设计方法和优点，采样电路设计和基于DSP和CPLD的数字控制平台等内容。
在第三章中，首先完成了系统的LC滤波器设计和双环控制参数设计，最后对所设计的系统进行了仿真和实验两方面的验证。
在第四章中，针对电感器，建立了更加精确的电感线圈的物理模型，分析了LCR表测得电感的模型图。然后针对不同的电感采用不用的方法，包括一维的计算方法和两维的仿真分析方法对电感的交流电阻和线圈损耗做出了具体计算分析，最后分别用单股铜线，Litz线和多股线并绕绕制了不同的电感进行了实验验证。
With the development of the new energy, distributed power systems, and the wide use of UPS, research on the inverter is being given more and more attentions. The power rating and the power density are geting higher and higher. How to design a high power density inverter module becomes a R&D hotspot. LC filter is an important component of the inverter to reduce the output harmonics. And the inductor is the indispensable for the LC filter. The equivalent resistance of the inductor affects the performance of the inverter. So the winding loss and the AC resistance of the inductors should also be considered.
This dissertation firstly introduces the modern control strategy for inverters, and how the equivalent resistance of the inductor affects on the performance of inverters is pesented. In the second chapter, the hardware design of the inverter module, including designs of its main circuit, the drive circuit, the sampling circuit, and the control circuit etc. is presented in detail.
In the third chapter, the designs of the LC filter and the double loop control circuit are presented. And both the simulation results based on SABER platform and the experiment results on an experimental prototype are presented, which verify the theoretical analysis.
In the forth chapter, a model of inductors is built up to reflect its more accurate characters. For different inductors, it gives different methods to analyze and calculate the winding losses and the AC resistances of the inductors. Finally different inductors wound by single-strand copper wires, Litz wires, and the parallel multi-strand wires have been made to prove the presented method.
本文首先综述了现代逆变器控制技术策略的现状和大功率开关器件的发展，并且简单分析了电感寄生电阻对逆变器性能的影响。在第二章中，介绍了30kVA实验样机的硬件设计，讨论了设计过程中的器件选择，散热设计，驱动保护电路设计，层叠式直流母线的设计方法和优点，采样电路设计和基于DSP和CPLD的数字控制平台等内容。
在第三章中，首先完成了系统的LC滤波器设计和双环控制参数设计，最后对所设计的系统进行了仿真和实验两方面的验证。
在第四章中，针对电感器，建立了更加精确的电感线圈的物理模型，分析了LCR表测得电感的模型图。然后针对不同的电感采用不用的方法，包括一维的计算方法和两维的仿真分析方法对电感的交流电阻和线圈损耗做出了具体计算分析，最后分别用单股铜线，Litz线和多股线并绕绕制了不同的电感进行了实验验证。
With the development of the new energy, distributed power systems, and the wide use of UPS, research on the inverter is being given more and more attentions. The power rating and the power density are geting higher and higher. How to design a high power density inverter module becomes a R&D hotspot. LC filter is an important component of the inverter to reduce the output harmonics. And the inductor is the indispensable for the LC filter. The equivalent resistance of the inductor affects the performance of the inverter. So the winding loss and the AC resistance of the inductors should also be considered.
This dissertation firstly introduces the modern control strategy for inverters, and how the equivalent resistance of the inductor affects on the performance of inverters is pesented. In the second chapter, the hardware design of the inverter module, including designs of its main circuit, the drive circuit, the sampling circuit, and the control circuit etc. is presented in detail.
In the third chapter, the designs of the LC filter and the double loop control circuit are presented. And both the simulation results based on SABER platform and the experiment results on an experimental prototype are presented, which verify the theoretical analysis.
In the forth chapter, a model of inductors is built up to reflect its more accurate characters. For different inductors, it gives different methods to analyze and calculate the winding losses and the AC resistances of the inductors. Finally different inductors wound by single-strand copper wires, Litz wires, and the parallel multi-strand wires have been made to prove the presented method.
引文
[1．1] 吴红缨，UPS高频化技术及其系统的研究，浙江大学博士学位论文，1998年
[1．2] Mohammad N. Marwali, Jin-Woo Jung, Ali Keyhani, "Control of Distributed Generation Systems-Part Ⅱ: Load Sharing Control", IEEE Trans. On Power Electronics, vol. 19, No. 6, Nov. 2004
[1．3] Karthick Thyagarajan, Asad Davari, Ali Feliachi, "Load Sharing Control in Distributed Generation System", SSST'05, page: 424-428, Mar. 2005.
[1．4] 郑琼林，郝荣泰，机车用50KVA IGBT逆变器的电磁兼容设计，中国电机工程学报，Vol．20 No．5 May 200
[1．5] 李永东，倚鹏，大功率高性能逆变器技术发展综述，电气传动，2000，(6)：3-8．
[1．6] 杜磊，50KVA三极管箝位三电平逆变器模块研究，浙江大学硕士论文，2006．5
[1．7] 黄挚雄，李志勇，危韧勇，智能功率模块IGBT-IPM及其应用，电气传动自动化，2002 Vol．24 No．2
[1．8] 徐维广，邹江峰，智能功率模块IGBT-IPM在逆变器中的应用，电气应用，2005 Vol．24 No．4
[1．9] 李树良，张杰，尹放，新一代智能功率模块(IPM)基本原理及其控制IC原理分析，微处理机，2001 No．02
[1．10] 徐德鸿主编，电力电子系统建模及控制，浙江大学出版社，2006．1
[1．11] 林渭勋主编，现代电力电子电路，浙江大学出版社，2002．7
[1．12] 佘艳，孙云莲，陈忠仁，基于DSP变频调速系统的对称电压空间矢量控制，低压电器，2004 No．11
[1．13] 石红芹，曾辉，吕方亮，改进的SPWM等面积算法在UPFC中的应用研究，微计算机信息，2006 Vol．22 No．22
[1．14] 孟凡军，李正熙，基于DSP的一种不对称规则SPWM采样算法，电机技术，2006 No．2
[1．15] Moriyama A, Ando I., Takahashi I., "Sinusoidal voltage control of a single phase uninterruptible power supply by a high gain PI circuit", Industrial Volume 1,31 Aug.-4 Sept. 1998 Page(s):574-579 vol. 1
[1．16] Ying-Yu Tzou, Shih-Liang Jung, Hsin-Chung Yeh, "Adaptive repetitive control ofPWM inverters for very low THD AC-voltage regulation with unknown loads",Power Electronics, IEEE Transactions on Volume 14, Issue 5, Sept. 1999 Page(s):973 - 981
[1．17] Jae-Ho Choi, Byoung-Jin Kim, "Improved digital control scheme of three phase LIPS inverter using double control strategy", Applied Power Electronics Conference and Exposition, 1997. APEC '97 Conference Proceedings 1997., Twelfth Annual Volume 2,23-27 Feb. 1997 Page(s):820 - 824 vol.2
[1．18] Abdel-Rahim N.M., Quaicoe J.E., "Analysis and design of a multiple feedback loop control strategy for single-phase voltage-source UPS inverters", Power Electronics, IEEE Transactions on Volume 11, Issue 4, July 1996 Page(s):532-541
[1. 19] Zhang kai, Kang Yong, Xiong Jian, Zhang Hui, Chert Jian, "Study on an inverter with pole assignment and repetitive control for UPS applications", Power Electronics and Motion Control Conference, 2000. Proceedings. PIEMC 2000. The Third International, Volume:2,15-18 Aug,2000.
[1．20] 樊楼英，数字PID调节器的计算机实现，电脑知识与技术(技术论坛)，2005 No．6
[1．21] 杨成林，三相逆变器DSP控制技术的研究，浙江大学硕士学位论文，2004年
[1．22] 邹伯敏主编，自动控制理论，机械工业出版社，2003年
[1．23] Y. Chung , J. Galayda, "Effect of Eddy Current in the Laminations on the Magnet Field", Advanced Photon Source Argonne National Laboratory, LS Note No. 200, April, 1992.
[1．24] Nienchtze Teng, "Fe-Si-Al Powder E-cores Compete with Gapped Ferrites", Magnetics Div. Spang, Butler, Pa.
[1．25] 赵修科主编，开关电源中磁性元器件，2004．8
[1. 26] Pekik Argo Dahono, Yogi Rizkian Bahar, Yukihiko Sato, and Teruo Kataoka, "Damping of Transient Oscillations on the Output LC Filter of PWM Inverters by Using a Virtual Resistor", Power Electronics and Drive Systems, 2001. Proceedings., 2001 4th IEEE International Conference on Volume 1, 22-25 Oct. 2001 Page(s):403-407 vol.1
[2．1] 杜磊，50KVA三极管箝位三电平逆变器模块研究，浙江大学硕士论文，2006．5
[2．2] 三菱公司，三菱电机三代IGBT和智能功率模块应用手册．日本，三菱电机公司，1996
[2．3] 三菱公司，PM150CLA120应用技术手册
[2．4] Lai, J.-S., Leslie, L., Ferrell, J., Nergaard, T, "Characterization of HV-IGBT for high-power inverter applications", Industry Volume 1,2-6 Oct. 2005 Page(s):377-382 Vol. 1
[2．5] Lounis, Z., Rasoanarivo, I., Davat, B., "Minimization of wiring inductance in high power IGBT inverter", Power Delivery, IEEE Transactions on Volume 15, Issue 2, April 2000 Page(s):551-555
[2．6] 谢昱北 蓝曼 刘昌丽等编著，模具设计典型范例教程，电子工业出版社，2006，9
[2．7] 顾海洋，IPM应用手册，三菱电机集团上海摄阳国际贸易有限公司
[2．8] 张卫宁，TMS320C2000系DSPs原理及应用，国防工业出版社，2002．4
[3．1] 徐德鸿主编，电力电子系统建模及控制，浙江大学出版社，2006．1
[3．2] 杨水涛，张帆，刘金云，钱照明，一种新型半桥逆变器电容均压控制策略，电工技术学报，2006 Vol．21 No．7
[3．3] 陈敏，非线性负载下的逆变器特性研究，浙江大学博士学位论文，2007年
[3．4] 邹伯敏主编，自动控制理论，机械工业出版社，2003年
[3．5] 李培芳主编 离散信号与系统分析 浙江大学出版社，2002年
[4．1] 徐德鸿主编，电力电子建模及控制，浙江大学出版社 2006．1
[4．2] C. R. Sullivan, "Computationally efficient winding loss calculation with multiple windings, arbitrary waveforms, and two-or three-dimensional field geometry". IEEE Trans. on PE, 2001, 16(1): 142～150.
[4．3] Xi Nan and Charles R. Sullivan, "An Improved Calculation of Proximity-Effect Loss in High-Frequency Windings of Round Conductors". IEEE PESC'03. 2003, 34(2): 853～860.
[4．4] J. A. Ferreira, "Analytical computation of ac resistance of round and rectangular litz wire windings", IEEE Proceedings-B Electric Power Applications, 1992,139(1): 21-25.
[4.5] J. A. Ferreira, "Improved analytical modeling of conductive losses in magnetic components". IEEE Trans. on PE, 1994, 9(1): 127～131.
[4.6] M. Bartoli. N. Noferi, et al. "Modeling winding losses in high-frequency power inductors [J]. World Scientijic Journal of Circuits Systems, and Computers" , Special Issue on Power Electronics, 1995, 5(4): 603-607.
[4.7] M. Bartoli, N. Noferi, et al. Modeling Litz-wire winding losses in high-frequency power inductors [A].IEEE PESC'96[C]. 1996, 27(2): 1690～1696.
[4.8] Y. Chung, J. Galayda, "Effect of Eddy Current in the Laminations on the Magnet Field", Advanced Photon Source Argonne National Laboratory, LS Note No. 200, April, 1992.
[4.9] Nienchtze Teng, "Fe-Si-Al Powder E-cores Compete with Gapped Ferrites ", Magnetics Div. Spang, Butler, Pa.
[4.10] P. Wallmeier. "Improved Analytical Modeling of Conductive Losses in Gapped High-Frequency Inductors " . IEEE Trans. on PE, 2001, 37(4): 1045～1054
[4.12] Anderson F. Hoke, Charles, R. Sullivan. "An Improved Two-Dimensional Numerical Modeling Method for E-Core Transformers" . IEEE APEC '2002.2002, 17(1): 151～157.
[4.14] Michael W. Horgan, "Inductor Core Technology Shrinking Power Supplies". 2002.Magnetics Division of Spang & Co., Butler. Pa.
[4.15] 亨利，海特维西．电感计算，李远译[M]．北京：国防工业出版社，1954．
[1．2] Mohammad N. Marwali, Jin-Woo Jung, Ali Keyhani, "Control of Distributed Generation Systems-Part Ⅱ: Load Sharing Control", IEEE Trans. On Power Electronics, vol. 19, No. 6, Nov. 2004
[1．3] Karthick Thyagarajan, Asad Davari, Ali Feliachi, "Load Sharing Control in Distributed Generation System", SSST'05, page: 424-428, Mar. 2005.
[1．4] 郑琼林，郝荣泰，机车用50KVA IGBT逆变器的电磁兼容设计，中国电机工程学报，Vol．20 No．5 May 200
[1．5] 李永东，倚鹏，大功率高性能逆变器技术发展综述，电气传动，2000，(6)：3-8．
[1．6] 杜磊，50KVA三极管箝位三电平逆变器模块研究，浙江大学硕士论文，2006．5
[1．7] 黄挚雄，李志勇，危韧勇，智能功率模块IGBT-IPM及其应用，电气传动自动化，2002 Vol．24 No．2
[1．8] 徐维广，邹江峰，智能功率模块IGBT-IPM在逆变器中的应用，电气应用，2005 Vol．24 No．4
[1．9] 李树良，张杰，尹放，新一代智能功率模块(IPM)基本原理及其控制IC原理分析，微处理机，2001 No．02
[1．10] 徐德鸿主编，电力电子系统建模及控制，浙江大学出版社，2006．1
[1．11] 林渭勋主编，现代电力电子电路，浙江大学出版社，2002．7
[1．12] 佘艳，孙云莲，陈忠仁，基于DSP变频调速系统的对称电压空间矢量控制，低压电器，2004 No．11
[1．13] 石红芹，曾辉，吕方亮，改进的SPWM等面积算法在UPFC中的应用研究，微计算机信息，2006 Vol．22 No．22
[1．14] 孟凡军，李正熙，基于DSP的一种不对称规则SPWM采样算法，电机技术，2006 No．2
[1．15] Moriyama A, Ando I., Takahashi I., "Sinusoidal voltage control of a single phase uninterruptible power supply by a high gain PI circuit", Industrial Volume 1,31 Aug.-4 Sept. 1998 Page(s):574-579 vol. 1
[1．16] Ying-Yu Tzou, Shih-Liang Jung, Hsin-Chung Yeh, "Adaptive repetitive control ofPWM inverters for very low THD AC-voltage regulation with unknown loads",Power Electronics, IEEE Transactions on Volume 14, Issue 5, Sept. 1999 Page(s):973 - 981
[1．17] Jae-Ho Choi, Byoung-Jin Kim, "Improved digital control scheme of three phase LIPS inverter using double control strategy", Applied Power Electronics Conference and Exposition, 1997. APEC '97 Conference Proceedings 1997., Twelfth Annual Volume 2,23-27 Feb. 1997 Page(s):820 - 824 vol.2
[1．18] Abdel-Rahim N.M., Quaicoe J.E., "Analysis and design of a multiple feedback loop control strategy for single-phase voltage-source UPS inverters", Power Electronics, IEEE Transactions on Volume 11, Issue 4, July 1996 Page(s):532-541
[1. 19] Zhang kai, Kang Yong, Xiong Jian, Zhang Hui, Chert Jian, "Study on an inverter with pole assignment and repetitive control for UPS applications", Power Electronics and Motion Control Conference, 2000. Proceedings. PIEMC 2000. The Third International, Volume:2,15-18 Aug,2000.
[1．20] 樊楼英，数字PID调节器的计算机实现，电脑知识与技术(技术论坛)，2005 No．6
[1．21] 杨成林，三相逆变器DSP控制技术的研究，浙江大学硕士学位论文，2004年
[1．22] 邹伯敏主编，自动控制理论，机械工业出版社，2003年
[1．23] Y. Chung , J. Galayda, "Effect of Eddy Current in the Laminations on the Magnet Field", Advanced Photon Source Argonne National Laboratory, LS Note No. 200, April, 1992.
[1．24] Nienchtze Teng, "Fe-Si-Al Powder E-cores Compete with Gapped Ferrites", Magnetics Div. Spang, Butler, Pa.
[1．25] 赵修科主编，开关电源中磁性元器件，2004．8
[1. 26] Pekik Argo Dahono, Yogi Rizkian Bahar, Yukihiko Sato, and Teruo Kataoka, "Damping of Transient Oscillations on the Output LC Filter of PWM Inverters by Using a Virtual Resistor", Power Electronics and Drive Systems, 2001. Proceedings., 2001 4th IEEE International Conference on Volume 1, 22-25 Oct. 2001 Page(s):403-407 vol.1
[2．1] 杜磊，50KVA三极管箝位三电平逆变器模块研究，浙江大学硕士论文，2006．5
[2．2] 三菱公司，三菱电机三代IGBT和智能功率模块应用手册．日本，三菱电机公司，1996
[2．3] 三菱公司，PM150CLA120应用技术手册
[2．4] Lai, J.-S., Leslie, L., Ferrell, J., Nergaard, T, "Characterization of HV-IGBT for high-power inverter applications", Industry Volume 1,2-6 Oct. 2005 Page(s):377-382 Vol. 1
[2．5] Lounis, Z., Rasoanarivo, I., Davat, B., "Minimization of wiring inductance in high power IGBT inverter", Power Delivery, IEEE Transactions on Volume 15, Issue 2, April 2000 Page(s):551-555
[2．6] 谢昱北 蓝曼 刘昌丽等编著，模具设计典型范例教程，电子工业出版社，2006，9
[2．7] 顾海洋，IPM应用手册，三菱电机集团上海摄阳国际贸易有限公司
[2．8] 张卫宁，TMS320C2000系DSPs原理及应用，国防工业出版社，2002．4
[3．1] 徐德鸿主编，电力电子系统建模及控制，浙江大学出版社，2006．1
[3．2] 杨水涛，张帆，刘金云，钱照明，一种新型半桥逆变器电容均压控制策略，电工技术学报，2006 Vol．21 No．7
[3．3] 陈敏，非线性负载下的逆变器特性研究，浙江大学博士学位论文，2007年
[3．4] 邹伯敏主编，自动控制理论，机械工业出版社，2003年
[3．5] 李培芳主编 离散信号与系统分析 浙江大学出版社，2002年
[4．1] 徐德鸿主编，电力电子建模及控制，浙江大学出版社 2006．1
[4．2] C. R. Sullivan, "Computationally efficient winding loss calculation with multiple windings, arbitrary waveforms, and two-or three-dimensional field geometry". IEEE Trans. on PE, 2001, 16(1): 142～150.
[4．3] Xi Nan and Charles R. Sullivan, "An Improved Calculation of Proximity-Effect Loss in High-Frequency Windings of Round Conductors". IEEE PESC'03. 2003, 34(2): 853～860.
[4．4] J. A. Ferreira, "Analytical computation of ac resistance of round and rectangular litz wire windings", IEEE Proceedings-B Electric Power Applications, 1992,139(1): 21-25.
[4.5] J. A. Ferreira, "Improved analytical modeling of conductive losses in magnetic components". IEEE Trans. on PE, 1994, 9(1): 127～131.
[4.6] M. Bartoli. N. Noferi, et al. "Modeling winding losses in high-frequency power inductors [J]. World Scientijic Journal of Circuits Systems, and Computers" , Special Issue on Power Electronics, 1995, 5(4): 603-607.
[4.7] M. Bartoli, N. Noferi, et al. Modeling Litz-wire winding losses in high-frequency power inductors [A].IEEE PESC'96[C]. 1996, 27(2): 1690～1696.
[4.8] Y. Chung, J. Galayda, "Effect of Eddy Current in the Laminations on the Magnet Field", Advanced Photon Source Argonne National Laboratory, LS Note No. 200, April, 1992.
[4.9] Nienchtze Teng, "Fe-Si-Al Powder E-cores Compete with Gapped Ferrites ", Magnetics Div. Spang, Butler, Pa.
[4.10] P. Wallmeier. "Improved Analytical Modeling of Conductive Losses in Gapped High-Frequency Inductors " . IEEE Trans. on PE, 2001, 37(4): 1045～1054
[4.12] Anderson F. Hoke, Charles, R. Sullivan. "An Improved Two-Dimensional Numerical Modeling Method for E-Core Transformers" . IEEE APEC '2002.2002, 17(1): 151～157.
[4.14] Michael W. Horgan, "Inductor Core Technology Shrinking Power Supplies". 2002.Magnetics Division of Spang & Co., Butler. Pa.
[4.15] 亨利，海特维西．电感计算，李远译[M]．北京：国防工业出版社，1954．
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