Power Quality Improvement in DTC Based Induction Motor Drive Using Minnesota Rectifier

Bhim Singh and G. Bhuvaneswari

Dept. of Electrical Engineering Indian Institute of Technology Delhi New Delhi-110016, India bhimsingh1956@gmail.com, bhuvan@ee.iitd.ernet.in
AbstractThis paper presents power quality improvement at the utility interface for a Direct Torque Controlled (DTC) induction motor drive by making use of a Minnesota rectifier. The proposed Minnesota rectifier for a 2.2 kW drive is designed, modeled and simulated in MATLAB/Simulink platform. The design of the proposed Minnesota rectifier is developed along with the necessary modifications required for making it suitable for retrofit applications, where presently a 6-pulse diode bridge rectifier is used. The performance parameters of the DTC drive fed by a 6-pulse uncontrolled converter is compared with the one fed by Minnesota rectifier for variable load conditions. The results show that the THD and power factor at the ac mains are improved perceivably even with the magnetic rating being as low as 40.94% of the drive rating. Keywords-Minnesota Rectifier; Zig Zag auto-transformer; Power Quality Improvement; Direct Torque Control; Induction Motor; Power Factor Correction.

Sandeep Madishetti
Dept. of Electrical Engineering Indian Institute of Technology Delhi New Delhi-110016, India sandeep.madishetti@gmail.com is relatively simple in implementation and less sensitive to the parameter variations yet performs as well as FOC technique [1]. It is based on the decoupled and independent control of stator flux and torque providing a quick and robust response. However, the conventional DTC strategy using switching table of a six pulse voltage source inverter (VSI) presents notable torque, flux, current and speed ripple. In DTC, stator voltage vectors are selected according to the differences between the reference and actual torque and stator flux linkage. The DTC based induction motor drive (IMD) [2] uses a single-phase or three-phase uncontrolled ac-dc converter (for rectification of ac mains voltage), an energy storage element (capacitor filter for smoothening the dc link voltage), and a three-phase voltage source inverter (VSI) for feeding a threephase squirrel cage induction motor. Fig. 1 shows the basic block diagram of conventional DTC based IMD with uncontrolled three-phase diode bridge rectifier. Such type of utility interface suffers from problems related to power quality such as poor power factor, injection of current harmonics into the ac mains, variation in dc link voltage with fluctuations in the voltage of input ac supply, equipment overheating due to harmonic current absorption, voltage distortion at the point of common coupling (PCC) due to the voltage drop caused by harmonics currents flowing through system impedance and decreased rectifier efficiency. These power quality problems can cause malfunction of sensitive electronic equipments, interference in telephone and communication lines due to high frequency switching, failure of switching capacitors and other power equipment and loss of data. Different international organizations have given guidelines to impose strict limits on the levels of harmonic current emissions through various standards such as IEEE-519, IEC 61000-3-2, IEEE-1531 etc. Different active and passive filtering techniques [3] are used to mitigate distortions in the input line current. The approach of active power factor correction can achieve unity power factor and very low total harmonic distortion (THD) of ac mains current along with a good regulation of the dc link voltage. But the disadvantages are high cost (cost is nearly doubled), increased complexity in control (particularly if optimum performance is desired under preexisting supply voltage distortions), and higher dc-link voltage due to boost operation. The main objective of this paper is to design an improved power quality AC-DC converter at the front end of a DTC

I.

INTRODUCTION

Induction motors, the most widely used motors in industry, have been traditionally operated in open-loop control applications, for reasons of cost, size, reliability, ruggedness, simplicity, efficiency, less maintenance, ease of manufacture and their capability to operate in dirty or explosive conditions. However, because the induction motor requires more complex control methods, the dc motor has dominated in high performance adjustable speed drive applications. With developments in micro-processors/digital signal processor (DSP), power electronics and control theory, the induction motor can now be used in high performance variable-speed and cost-sensitive applications, such as heating, ventilation, and air conditioning (HVAC) systems, waste water treatment plants, blowers, fans, textile mills, rolling mills etc. due to their advantages like energy conservation and reduction in inrush current drawn, etc. The use of variable frequency induction motor drives (VFIMDs) has further increased due to their capability to achieve good dynamic performance using vector control (or field oriented control-FOC) and direct torque and flux control (DTC). With these control techniques, induction motor drives can achieve similar or even better performance than dc motor drives. It is well known that the FOC needs complicated co-ordinate transformations to decouple the interaction between the flux and torque components of stator currents. The implementation of FOC is difficult and very sensitive to parameter variations. Direct torque control (DTC)
978-1-4577-1510-5/11/$26.00 2011 IEEE

drive. For achieving AC-DC conversion, a Minnesota rectifier is designed and simulated in Simulink to achieve low current THD and unity power factor at the utility interface.

Figure 2. System configuration of DTC based IMD with a Minnesota rectifier.

Figure 1. Block diagram of DTC based IMD with a 6-pulse diode bridge rectifier.

II.

SYSTEM CONFIGURATION

In order to improve the power quality at the front of DTC based IMD, a Minnesota rectifier is used. Fig. 2 shows the system configuration of DTC based IMD with three-phase Minnesota rectifier. A. Minnesota Rectifier By injecting third harmonic current into the ac line, the input power quality of a six-pulse converter can be improved [4]. Minnesota rectifier consists of a six-pulse diode bridge rectifier and two boost converters that modulate the dc link current at third harmonic frequency which is injected in to ac line through a zigzag auto-transformer [5]. Fig. 3 shows power circuit of the proposed Minnesota rectifier. The two third harmonic modulated currents are added (2i3h) at point n and circulated to input line through a zigzag auto-transformer. The zigzag auto-transformer acts as high magnetizing impedance for the fundamental current and low leakage impedance for third harmonic current. The total third harmonic current (2i3h) equally splits into three phases having a magnitude of iinj= (2/3)i3h. The injected current iinj is subtracted from input current iash to the diode bridge rectifier and results in the ac line current ias to have a sinusoidal wave shape with reduced harmonics. Fig. 4 shows the block diagram of a controller for Minnesota rectifier. The actual dc link voltage Vdc is compared with reference Vdc* to generate Id* through a limiter using proportional plus integral (PI) controller.
* I* d(n) = I d(n-1) + K pm (Vdc_e(n) - Vdc_e(n-1) ) + K im Vdc_e(n)

Figure 3. Power circuit of the proposed Minnesota rectifier.

Figure 4. Minnesota rectifier controller block diagram.

The phase of reference third harmonic current i3h* is calculated with respect to the input source voltage vas u = vas/Vm = sin(t) i3h = KI3p sin(3t+)
*

(3) (4)

where, Vm is line peak source voltage, K and are the optimal magnitude and phase of injected third harmonic current i3h*. The boost inductor reference currents iL1* and iL2* are generated as given below iL1* = i3h* IC* + Id* iL2* = i3h +
*

(1)

where, Id(n)*, Id(n-1)* are the output of the PI controller and Vdc_e(n), Vdc_e(n-1) are the errors of dc link voltage at the nth and (n-1)th instants. The difference in two capacitors voltage is compensated in generation of reference currents iL1* and iL2* to make equal voltage across dc bus capacitors.

(5) (6) (iL1*, iL2*)

IC*

+ Id

I* C = K p (VC1 - VC2 )

(2)

and sensed The boost inductor reference currents currents (iL1, iL2) are compared in the hysteresis band current controller to generate PWM pulses to the IGBTs S1 and S2.

B. DTC Based IM Drive DTC scheme consists of three main blocks: Flux and torque hysteresis controller, voltage switching table and actual flux, torque and speed estimators [6]. In this control, the torque and stator flux of the drive are directly controlled by inverter voltage space vector selection through a lookup table as shown in Table-I. The switching vectors to the inverter are selected in such a way as to minimize flux and torque errors. A speed regulator with limiter is used to generate reference torque Te*.
* * Te(n) = Te(n-1) + K p (e( n ) - e(n-1) ) + K ie(n)

TABLE I. INVERTER VOLTAGE SWITCHING H HTe 1 1 0 -1 1 -1 0 -1 S(1) S(2) S(3) S(4) S(5) S(6)

V2(110) V3(010) V4(011) V5(001) V6(101) V1(100) V7 V6 V3 V8 V5 V8 V1 V4 V7 V6 V7 V2 V5 V8 V1 V8 V3 V6 V7 V2 V7 V4 V1 V8 V3 V8 V5 V2 V7 V4

(7)

where, e is the speed error between the reference speed (r*) and the sensed speed (r). The command stator flux and s* torque Te* magnitudes are compared with the respective estimated values (s, Te), and the errors are processed through hysteresis-band controllers as shown in Fig. 2. The flux hysteresis controller is as follows: H = 1 if |s*| |s| > +HBs H = 1 if |s*| |s| < HBs The torque hysteresis controller is given by HTe = 1 if |Te*| |Te| > +HBTe HTe = 1 if |Te*| |Te| < HBTe |Te|) < +HBTe HTe = 0 if HBTe < (|Te*| (10) (11) (12) (8) (9)

Similarly, three-phase currents iabc also transformed into two-phase idss and iqss using above equation as, iqss = (1/3)(2iaibic) idss = (1/3)(ibic) where, ia and ib are the sensed stator currents. ic = (ia+ib). III. MATLAB SIMULATION (22) (23)

DTC based IMD fed with a simple diode bridge rectifier and Minnesota rectifier are simulated in MATLAB/ Simulink platform. The simulink model for DTC based IMD with Minnesota rectifier is shown in Fig. 5. The model of the proposed three phase Minnesota rectifier is shown in Fig. 6. The rating of the induction motor considered in this simulation is 2.2 kW (3 hp), 230 V and 50 Hz. IV. RESULTS AND DISCUSSIONS Performance of the DTC based IMD is studied for both the configurations namely, a six-pulse diode bridge rectifier and Minnesota rectifier at the front end. Fig. 7 shows the dynamic performance of the drive fed from a six-pulse diode bridge rectifier for different load conditions. Waveforms consist of source phase voltage (vas), source line current (ias), rotor speed (Nr), stator currents (iabc), electromagnetic torque (Te) and Vdc for light-load (20% of TFL=2.8N-m) and rated load (TFL=14Nm). The ac mains current waveform and its harmonic spectra at full load and light load are shown in Figs. 8 and 9 which shows that THD at full load and light load are respectively 66.65% and 100.13%. The power factor also deteriorates from 0.8 at FL to 0.69 at light load. From these results it can be concluded that it is necessary to use improved power quality converters at front end of the DTC based IMD. As the next step, a Minnesota rectifier is employed in place of the uncontrolled 6-pulse converter. The waveforms of a DTC based IMD for different load conditions fed from a Minnesota rectifier at the front end are shown in Fig. 10. The ac mains current and its harmonic spectra for full load and 20% load are shown in Figs. 11 and 12. It can be noted that the THD of ac mains current at full load is 4.88% and the power factor obtained is 0.997. At light load, THD of ac mains current is 9.28% and power factor is 0.986 which shows a significant improvement as compared to the case fed from a simple diode bridge rectifier. Table-II shows the comparison of different power quality indices at two different load conditions for DTC based IMD with a simple diode bridge rectifier and a Minnesota rectifier. The comparison of THD and PF with variable load for DTC based

where, HBs and HBTe are the flux and torque predefined hysteresis bands. The actual stator flux s and electro-magnetic torque Te are estimated by using vdss, vqss and idss, iqss as, ds = (vdss idssRs)dt + ds0 qs = (vqss iqssRs)dt + qs0
s = ds 2 + qs 2

(13) (14) (15) (16)

Te = (3/2)(P/2)( ds iqss qs idss)

where, Rs is the stator resistance, ds0 and qs0 initial stator dq fluxes. Considering d-axis is aligned with the a-axis, the threephase voltages vabc are transformed into stationary dq reference frame (vdss and vqss) by using Clarke transformation as, vqss = (1/3)(2vavbvc) vdss = (1/3)(vbvc) (17) (18)

The stator phase voltages vabc are determined by the switching states (Sa, Sb and Sc) and sensed dc link voltage Vdc using the following equations: va = (Vdc/3)( Sa+2SbSc) vb = (Vdc/3)(Sa+2SbSc) vc = (Vdc/3)(SaSb+2Sc) (19) (20) (21)

Discre te , Ts = 2e -005 s. powe rgui

H_psi_s
wr psi_s* E_psi_s H_psi_s H_psi_s 6 Pulses

Sabc

Sabc

vdss

vdss [vas]

FIELD WEAKENING [psi_s]

FLUX HYSTERESIS CONTROLLER

H_Te

H_Te

Vdc

Vdc

vqss

vqss

[ias] Nr [iabc]

vdss,vqss psi_ds
psi_ds Sa,Sb,Sc E_Te H_Te idss

Signal 1

wr* Te* wr

wr* wr

Sabc [iab]
iab

idss [Te]

psi_qs SPEED CONTROLLER [Te] [ias] TORQUE HYSTERESIS CONTROLLER

psi_qs

iqss

iqss

Vdc

VOLTAGE SWITCHING TABLE

iabc to idss,iqss vdss

vdss psi_ds

psi_ds

[vas]

A
A B C

vas ias A1 B1 C1 B C VdcA Vdc+

IGBT Inverter
g + A

TL step [iab]

From idss
idss psi_qs

psi_qs

B C

A B C

iab
Tm

C
-

A1
B C

A m

vqss wr -KNr iqss

vqss

psi_s

[psi_s]

MEASUREMENT

B1 C1

B C iqss Te

MINNESOTA RECTIFIER

[Te]

+ -

MEASUREMENTS
v

Vdc

INDUCTION MOTOR 3 HP / 230 V

FLUX & TORQUE ESTIMATOR

Figure 5. MATLAB Simulink model of DTC based IMD with Minnesota rectifier.

IMD with the Minnesota rectifier and the diode bridge rectifier are shown in Fig. 13. Table III gives the comparison of different power quality indices of DTC based IMD with a Minnesota rectifier at different load conditions. It can be concluded that by using Minnesota rectifier at front end instead of a diode bridge rectifier, the THD of ac mains current is considerably reduced. This has been achieved within the specifications of IEEE standard 519 [7]. The waveforms of injected 3rd harmonic current (i3inj), source current (iash) before injection point and source current (ias) after injection point are shown in Fig. 14. Fig. 15 shows the waveforms of currents (iL1&iL2) flowing through the inductors (Ld1&Ld2) and voltage (VC1&VC2) across capacitors (C1&C2). Considering 85% of induction motor efficiency, 95% of inverter efficiency and 95% of a Minnesota rectifier, the rating of a Minnesota rectifier is designed as 2.87 kVA. In the proposed converter it needs a zigzag auto-transformer of rating 1.175 kVA which is 40.94% of Minnesota rectifier rating.
iL2
i + k k m m m k i1 a

D
m k
+ i -

Idc

L
S1 D g

D1
a a

D3
a

D5

S1
m S

Vc1 C1
+ v Vc1

Figure 7. Dynamics of a DTC based IMD with a simple diode bridge rectifier.
Vdc

1 A 2 B 3

iash
+ i -

4 n S2 5 D g

Vdc+

+ v -

Vdc-

S2
m

Vc2 C2
+ v Vc2

D4
a a

D2
a

D6

i2 i - +
A1 B1 C1 N1

D'
m k a ias [i3inj]

2/3*i2

i + -

(2/3)*i3

[i3inj]

i + -

iL1 2*i3
[i3]

L4

iash 400 ZIG-ZAG AUTO-TRANSFORMER Fre q vas u(1) * 1 Fcn Divide V(pu) wt Sin_Cos Vc1 Vc2 i1 i2 Vdc_ref Vdc
Vdc*

vas

Source

i1
Vdc wt Vc1 Vc2 i1 i2 S2 S1

S1 i2 [i3] i1&i2, i3

Discrete 1-phase PLL

Vc1 S2 Vc2 Vdc Vc1 & Vc2

CONTROLLER

Figure 6. MATLAB Simulink model of proposed 3-phase Minnesota rectifier.

Figure 8. AC mains current waveform and harmonic spectrum for DTC based IMD with a simple diode bridge rectifier at rated load.

FFT window: 3 of 100 cycles of selected signal 4 2 0 -2 -4 1.48 1.49 1.5 1.51 Time (s) 1.52 1.53

Mag (% of Fundamental)

10

Fundamental (50Hz) = 3.189 , THD= 10.83%

Figure 9. AC mains current and harmonic spectrum for DTC based IMD with a simple diode bridge rectifier at light load (20%).

10 15 20 Harmonic order Figure 12. AC mains current and harmonic spectrum for DTC based IMD with Minnesota rectifier at light load (20%).

Figure 10. Dynamics of a DTC based IMD with Minnesota rectifier.

FFT window: 3 of 100 cycles of selected signal 10 0 -10 1.58 1.59 1.6 1.61 Time (s) 1.62 1.63

Mag (% of Fundamental)

10

Fundamental (50Hz) = 10.5 , THD= 4.87%

10 15 20 Harmonic order Figure 11. AC mains current and harmonic spectrum for DTC based IMD with Minnesota rectifier at rated load.

Figure 13. Variation of THD and PF with the load on DTC based IMD with a simple diode bridge rectifier and a Minnesota rectifier.

TABLE II. COMPARISON OF DIFFERENT POWER QUALITY INDICES OF A DTC BASED IMD WITH DIFFERENT CONVERTERS Topology Simple diode bridge rectifier Minnesota rectifier THD (%) vas FL 4.51 2.57 ias THD (%)
Full Load Light Load (20%)

Ias_rms (A)
Full Load Light Load (20%) Full Load

DF
Light Load (20%) Full Load

DPF
Light Load (20%) Full Load

PF
Light Load (20%)

Vdc (V)
Full Load Light Load (20%)

66.65 4.88

100.13 9.28

8.57 7.43

2.73 2.29

0.83 0.99

0.71 0.98

0.970 0.999

0.985 0.997

0.8 0.997

0.69 0.986

305 400

314 400

TABLE III. Comparison of Different Power Quality Indices of a DTC Based IMD with Minnesota Rectifier Load (%) 20 40 60 80 100 THD (%) ias vas 9.28 6.03 5.61 4.98 4.88 3.28 2.74 2.63 2.62 2.57 CF of ias 1.57205 1.56069 1.4862 1.45937 1.48048 DF 0.98952 0.99364 0.99534 0.99718 0.99771 DPF 0.99744 0.99889 0.99933 0.99951 0.99966 PF 0.98699 0.99254 0.99467 0.99669 0.99737 Vdc(V) 400 400 400 400 400

with the proposed Minnesota rectifier, the power quality indices at the utility interface have significantly improved as compared to the case of uncontrolled rectifier, even under varying loads on DTC based IMD. The THD, power factor and other power quality indices are well within IEEE 519 standard limits even with the magnetic rating of the zigzag transformer being only 40.94% of drive rating. It is able to provide close to unity power factor for various loading conditions. The proposed ac-dc converter is having advantage of a regulated dc link voltage. In all, the Minnesota rectifier is found to offer a practical solution to the power quality related problems for a variable speed induction motor drive. APPENDIX Motor Specifications: Three-phase, 3 hp (2.2 kW) Squirrel Cage Induction Motor, 4-Pole, 1430 rpm, 230 V, 50 Hz, Yconnected, rated current = 8.3 A, 0.82 PF, Rs = 0.603 , Rr = 0.7 , Xls = 1.007 , Xlr = 0.9212 , Xm = 23.56 , J = 0.011 kg-m2. Minnesota Rectifier: Ld1 = Ld2 = 1.85 mH, Cd1 = Cd2 = 2000 F, Vdc*=400 V. Input:230 V L-L, 50 Hz, source inductance Ls = 0.5% . REFERENCES
[1] Bhim Singh, Pradeep Jain, A. P. Mittal and J. R. P. Gupta, Direct torque control: a practical approach to electric vehicle, in Proc. of IEEE Power India Conference, June 2006. B. Singh, G. Bhuvaneswari and V. Garg, A Twelve-Phase AC-DC Converter for Power Quality Improvement in Direct Torque Controlled Induction Motor Drives, in Proc.of IEEE Industrial Electronics and Applications, May 2006. B. Singh, B. N. Singh, A. Chandra, K. Al-Haddad, A. Pandey and D. P. Kothari, A review of three-phase improved power quality AC-DC converters, IEEE Trans. Industrial Electronics, vol.51, no.3, June 2004. Predrag Pejovi, Three-Phase Diode Rectifiers with Low HarmonicsCurrent Injection Methods, Springer Science, 2007. Rajendra Naik, Mukul Rastogi and Ned Mohan, Third-Harmonic Modulated Power Electronics Interface with Three-Phase Utility to Provide a Regulated DC Output and to Minimize Line-Current Harmonics, IEEE Trans. Industry Applications, vol.31, no.3, May/June 1995. Bimal K. Bose, Modern Power Electronics and AC Drives, Pearson Pretice Hall, Fourth Edition, 2007. IEEE Guide for harmonic control and reactive compensation of Static Power Converters, IEEE Standard 519-1992.

Figure 14. Injected 3rd harmonic current (i3inj), source currents (ias & iash) before & after injection point.

[2]

[3]

Figure 15. Current flowing through the inductors and voltage across capacitors.

[4] [5]

V.

CONCLUSION
[6] [7]

A Minnesota rectifier based three phase improved power quality converter has been designed and modeled for the front end of a 2.2 kW DTC based IMD. The entire drive scheme has been simulated along with the conventional diode bridge rectifier and the proposed Minnesota rectifier. It is found that