POWER CONVERTERS “Digital Twin” approach for three-phase power converters

Related Vendors

CeramTec GmbH

Diotec Semiconductor AG

ROHM Semiconductor GmbH

DT (Digital Twin) “perfectly mimics” a physical object. When it comes to power electronics, such a technology could enhance the design, save production time, and cut down on costs for manufacturing units and engineers. The article discusses a recent experiment that implements the digital twin approach to monitor and improve the functionality of three-phase power converters.

Digital Twin or simply DT is a virtual version of a real-time or intended object, place, system, process, or person. The digital twin follows the exact data required to function like the physical entity. The entity for which the DT has to be created is usually present in the physical world. However, the entire product lifecycle of conceptual projects and hypothetical models can also be replicated through the digital twin approach.

In the electrical and electronics industries, relevant data is extracted from advanced sets of sensors, IoT hardware, electronic devices, simulation software, and historical records of similar models. Modern CAD and data modeling software are used to interpret such data and create accurate digital twins. This process enables product engineering teams to monitor the conditions of the electronics circuit or device that exists in the physical world or is planned to be manufactured shortly.

DT approach to designing better three-phase power converters

A recent study experimentally verified algorithms to implement a digital twin approach to monitor the operational conditions of a three-phase power electronics converter. Strikingly, the experiment showed that the DT acted like a “watchdog” to monitor real-time signals associated with the power converter.

SUSTAINABILITY

Greening the Internet of Things

Condition monitoring

The main idea behind condition monitoring is to “keep an eye” on the operation of the power electronic converter over time. Due to long-term operation, the power converter may change its electrical properties which affects its performance. Another possibility of electrical breakdown is also there.

Component deterioration is an indicator of performance degradation over time. Continuously monitoring the operating conditions of the power converter enables the replacement of faulty components and ensures seamless operation. Various methodologies have been verified to test the real-time functionality of components such as power semiconductors and capacitors.

Digital twin

The study created a DT for a 3L-NPC (Three Leg Neutral Point Clamped) power converter. The 3L-NPC power converter is a type of three-phase multilevel converter that uses clamping diodes to stabilize the neutral point voltage. These power converters are used in photovoltaic and https://www.power-and-beyond.com/what-is-wind-energy-definition-types-and-more-a-e95f3c16c898e889f0757f62ee91038d/ systems.

The 3L-NPC power converter produces voltages of various levels for efficient operation and low harmonic distortion. In addition, this power converter has a high number of power semiconductors. IGBTs are the switching devices in this power converter. PWM generates switching signals for these IGBTs.

The above-mentioned power converter is implemented as a dual hybrid converter through a VSC (Voltage Source Converter) topology. The first power converter functions like a UPS (Uninterrupted Power supply) with the load connected to the grid and the second one operates to be a compensator.

The DT approach is applied for the first converter. It takes feedback from the power converter to update its state and parameters. Such a DT approach is called a closed-loop digital twin. The digital twin responds just like the power converter.

Filter degradation

In every power converter, the filtering stage is crucial to reduce harmonic content in the output waveforms. Usually, an LC filter is used to suppress high-frequency harmonic components in voltages and currents. LC filter is a combination of the inductor (L) and a capacitor (C).

Over time, filters wear and tear out due to various electrical and mechanical stresses. Another limitation is the shift in resonant frequency with time. This study focuses on monitoring the “health” of LC filters in 3L-NPC power converters.

GREEN HYDROGEN

Efficient Electrolysis through Comprehensive Power Conversion Solutions

The two main algorithms used are PSO (Particle Swarm Optimization) and GO (Genetic Algorithm). Both these algorithms validate the optimization of condition monitoring of LC filter circuits triggered by a programmed event. In simple words, both these algorithms measure the degradation estimation of LC filter circuits.

Results

Despite facing total harmonic distortion challenges, the overlapping signals between digital and physical twins validated the results. A high signal fidelity was seen on the embedded computing platform. The information from the digital twin is eventually fed to the real-time physical power converter to improve the performance.

Benefits of using the DT approach in power electronics

The DT approach offers a powerful toolbox for power electronics engineers, enabling:

• Digital twins perform real-time monitoring, predictive maintenance, optimization, and fault analysis in power electronic systems.

• Cost-effective approach to test a first-time or new converter topology.

• Optimization of the converter performance in advance.

• Replacement of faulty components.

• Cuts downtime.

• Saves time for product and systems engineering teams.

• Reduces manufacturing costs.

Further applications

About 29% of manufacturing companies have implemented the digital twin approach globally. Rapid growth is expected in the DT approach up to 2027. The projected CAGR is about 29%.

• Digital twins monitor operating conditions and perform fault analysis in renewable sectors like solar technologies and wind turbine farms.

• Digital twins are used for predictive grid maintenance.

• Digital twins are applicable in motor industrial applications.

References

www.sciencedirect.com
aws.amazon.com
iot-analytics.com

Power Electronics in the Energy Transition

The parameters for energy transition and climate protection solutions span education, research, industry, and society. In the new episode of "Sound On. Power On.", Frank Osterwald of the Society for Energy and Climate Protection Schleswig‐Holstein talks about the holistic guidance his organization can provide.

Listen now!

(ID:50072083)