Need for SpeedReal-Time Simulation for Power Electronics Applications
Erich Scheiben, Head of Control Testing, Traction Converters, MATLAB EXPO 2016 Switzerland, Bern, 23 June 2016
© ABB June 15, 2016 | Slide 1
Key Takeaways
Challenges in control software testing
Benefits regarding time and quality using real-time simulation
reduced commissioning time with lower risks
The future calls for smart simulation solutions
that reduce the modelling effort
ABB Business Unit Power Conversion
© ABB Group
Power and productivity for a better world
ABB is a leader in power and automation technology
In over 100 countries
$35 billion revenue (2015)
Formed in 1988 from merger of Swiss (BBC, 1891)
and Swedish (ASEA, 1883) engineering companies
We help our customers
to use electrical power efficiently
to increase industrial productivity
to lower environmental impact in a sustainable way
What do we do?Power Protection Solar Inverters
E-bus Propulsion Fast EV Chargers
ABBTraction
© ABB Group
All operated by a single controller
Offers complete traction solutions, incl. transformer, traction
converter and motor/generator
A traction converter is a product that contains all
power conversion functions
Controlling the motor speed
Feeding braking energy back into the power network
Providing wagon auxiliary power for lighting, heating &
charging your phone
Battery charging
Traction/wheel-slip control
Product Group Traction Traction Converter
Power Electronics
Controller (PEC)
Regional Trains
High-speed Trains
Our products For all kind of rail applications
Power Electronics Control Software Testing
Why is it important to test and validate Power Electronics Control software?
Good reasons for high quality software
Power Electronics Control Software TestingOne good reason for software testing …
Power Electronics Control Software TestingChallenges related to Power Electronics Control software development
Reduced project delivery time and shorter commissioning schedules
Increased complexity of software due to
More requirements (reducing energy consumption, improve performance, lower
wear, adapt to line harmonic requirements, …)
Improved protection functions
Higher number of signals more software
Higher computing power more functionality in one single control computer
Higher requirements related to availability and reliability of the system
Higher quality expectations
Power Electronics Control Software Testing… and how to meet these challenges
State-of-the-art tool chain for software development
Standardization and modularization of software
Offline simulation of the application software
Hardware-in-the-loop testing with real-time simulator
Automated testing with real-time simulator
History of real-time simulation at ABB
Traction Converters at ABB Transportation Systems (later ADtranz)
Power Control & Renewables
Transportation (Traction Converters)
Medium Voltage Drives
R&D Power Platform
R&D Power Electronics
at Corporate Research
Different applications in power electronics, power transmission,
and other areas. Still used today in special applications.
Power Systems HVDC and FACTS
2012
2011
2010
2008
2003
1996
1993
before
1993
analog RTS
digital RTS
Power Electronics Control Software TestingHistory at ABB Traction
© ABB Group June 15, 2016 | Slide 10
2009 2010 2011 2012 2013 2014 2015 20160
10
20
40
60
80
100
120
140Model Generalization
Configurations (e.g. converter projects, combined test, etc.)
Models
Power Electronics Control Software Testing
Power Electronics Control Software TestingSoftware testing process overview
Manually operated
Real Time Simulator
Automated Testing on
Real Time SimulatorPower Lab Testing Commissioning Field Operation
Model-Based Design,
Offline Testing
Power Electronics Control Software TestingModel-Based Design
Link requirements &
documentation
Automatically generate
embedded software code
Integrate simulation &
testing with design
Observe & tune
running application
• Model-Based Design with MATLAB and Simulink provides
a common design environment:
• Facilitates communication
• Facilitates verification
• Enables early detection of bugs and design errors
• Has less interfaces and therefore less failure sources
• Plant modeling using Simscape PowerSystems
(offline only)
Manually operated
Real Time Simulator
Automated Testing on
Real Time SimulatorPower Lab Testing Commissioning Field Operation
Model-Based Design,
Offline Testing
Power Electronics Control Software TestingModel-Based Design vs. Classic Workflow
Manually operated
Real Time Simulator
Automated Testing on
Real Time SimulatorPower Lab Testing Commissioning Field Operation
Model-Based Design,
Offline Testing
Classic software development workflow
System
engineer 1 4 8
Software
engineer 2 3 5 9
Test
engineer 6 10
Commissioning
engineer 7 11
Power Electronics Control Software TestingModel-Based Design vs. Classic Workflow
MBD software development workflow
Classic software development workflow
System
engineer 1 4 8
Software
engineer 2 3 5 9
Test
engineer 6 10
Commissioning
engineer 7 11
Manually operated
Real Time Simulator
Automated Testing on
Real Time SimulatorPower Lab Testing Commissioning Field Operation
Model-Based Design,
Offline Testing
Power Electronics Control Software TestingReal-Time Simulator – HIL
Hardware-In-the-Loop Simulation
Device Under Test
Physical Model
Simulator Control
• AC 800PEC controller
• Power supplies
• Interface boards
• Control software
• Automatic code generation
• Real-Time Simulation
• High-performance computer
• Fast IO boards
• MATLAB/Simulink application
• Virtual vehicle
control
Manually operated
Real Time Simulator
Automated Testing on
Real Time SimulatorPower Lab Testing Commissioning Field Operation
Model-Based Design,
Offline Testing
Power Electronics Control Software TestingReal-Time Simulator – Device Under Test
Manually operated
Real Time Simulator
Automated Testing on
Real Time SimulatorPower Lab Testing Commissioning Field Operation
Model-Based Design,
Offline Testing
Power Electronics Control Software TestingReal-Time Simulator – Physical model
Mechanical domain
Electrical domain
Line ConverterLine, Power Supply Trafo DC Link, Filter Motor Converter
Gear, Axle,
Wheel
Train,
Track
Wheel-Rail
Contact
Train
Dynamics
Machine
Manually operated
Real Time Simulator
Automated Testing on
Real Time SimulatorPower Lab Testing Commissioning Field Operation
Model-Based Design,
Offline Testing
Power Electronics Control Software TestingReal-Time Simulator - Workplace
Device Under Test
Physical Model
Simulator Control
Manually operated
Real Time Simulator
Automated Testing on
Real Time SimulatorPower Lab Testing Commissioning Field Operation
Model-Based Design,
Offline Testing
Power Electronics Control Software TestingReal-Time Simulator – Test scenarios
Verify protection functions (line overvoltage, motor temperatures, braking resistor, etc.)
Test normal operation
Simulate special operating conditions, examples:
Rolling backwards with 20 km/h and applying full tractive effort
Line voltage variations (overvoltage, undervoltage)
Weak line supply (rotating converters)
Torsional oscillations
Test things that would break hardware (destructive test)
Manually operated
Real Time Simulator
Automated Testing on
Real Time SimulatorPower Lab Testing Commissioning Field Operation
Model-Based Design,
Offline Testing
Power Electronics Control Software TestingReal-Time Simulator – Limitations
Real-Time Capability of the Models
Calculation Performance restricted by limited execution time
e.g. Input Admittance Simulation limited to some 100 Hz
Modeling Depth
Power electronics with ideal switching behavior
Physical limits in model (e.g. frequency range)
Model Complexity
Current system supports one converter per vehicle
Manually operated
Real Time Simulator
Automated Testing on
Real Time SimulatorPower Lab Testing Commissioning Field Operation
Model-Based Design,
Offline Testing
Power Electronics Control Software TestingReal-Time Simulator – Example: Effort transmission between wheel & rail
Manually operated
Real Time Simulator
Automated Testing on
Real Time SimulatorPower Lab Testing Commissioning Field Operation
Model-Based Design,
Offline Testing
Power Electronics Control Software TestingReal-Time Simulator – Example: Effort transmission between wheel & rail
Unstable
Maximum
Stable
DrivingBraking
Manually operated
Real Time Simulator
Automated Testing on
Real Time SimulatorPower Lab Testing Commissioning Field Operation
Model-Based Design,
Offline Testing
Power Electronics Control Software TestingAutomated testing on Real-Time Simulator
Fully automated test execution, evaluation and report
generation
Source Control integration
Test Management environment
Main benefits:
Increasing test depth & coverage
Reproduction of Tests
“Conservation” of expert knowledge
Usage of Simulator outside working hours
Experts can focus on advanced test aspects
Manually operated
Real Time Simulator
Automated Testing on
Real Time SimulatorPower Lab Testing Commissioning Field Operation
Model-Based Design,
Offline Testing
Power Electronics Control Software TestingClassic process
Software
Quality
Time
Design & Implementation
Power Lab Testing
Commissioning
Field Operation
Start Commissioning
Power Electronics Control Software TestingBenefits regarding time & quality
Software
Quality
Model-Based Design & Offline Simulation
Faster design loops
Advanced offline testing capabilities
Real-Time Simulator Testing
Started before original HW is available
Quality increases significantly faster than in the commissioning phase,
thanks to:
Availability of test environment at any time
Safe and easy access to control boards
Easy cooperation and consultation with in-house specialists
Improved test efficiency by automated testing
Power Lab Testing
Focus on lab-specific topics (EMV, thermal behavior and HW setup)
System aspects (interfaces, protection, state machine) are already verified
Commissioning
Duration usually reduced from months to days, with lower risks
Simulator can be controlled remotely for further investigations
Field Operation
Software quality reaches a higher level because:
Simulator allows deep insight into system quantities
Simulator allows tests that are costly or prohibitive in the real world
Automated tests enlarge test coverage and depth
Time
Start Commissioning
Power Electronics Control Software Testing
Stable, validated software which has successfully passed stress test
Trouble shooting in lab instead of vehicle
Verified extreme operating conditions
Verified protection functions
Considerably reduced commissioning time
usually from months to days
with lower risks
Conclusion
© ABB Group June 15, 2016 | Slide 26
Challenges in real-time simulation
The future calls for smart simulation solutions
that reduce the modelling effort
for large switched nonlinear systems
while satisfying the required speed and accuracy
RTS in the future
© ABB Group June 15, 2016 | Slide 28
