EVALUATING VOLTAGE REGULATION COMPLIANCE OF MIL-PRF-GCSA(ARMY) FOR VEHICLE ON-BOARD GENERATORS AND ASSESSING OVERALL VEHICLE BUS COMPLIANCE Wesley G. Zanardelli, Ph.D. Advanced Propulsion Team Disclaimer: Reference herein to any specific commercial company, product, process, or service by trade name, trademark, manufacturer, or otherwise, does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or the Department of the Army (DoA). The opinions of the authors expressed herein do not necessarily state or reflect those of the United States Government or the DoA, and shall not be used for advertising or product endorsement purposes. US Army TARDEC CPT John Kelly ARSC, DET 8 US ARMY RDECOM-TARDEC : Distribution Statement A. Approved for public release.
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Presentation Overview Objectives Background Experimental Setup Characterization and Power Quality Test Procedures Experimental Results Modeling Simulation Results Modeling Parameter Variation Conclusions Future work
Objectives Component level compliance with MIL-PRF- GCSA(ARMY) Identification of parameters on power generation components Electrical machine characterization Modeling System level power quality compliance Optimization of high-voltage bus capacitance
Background
Background MIL-PRF-GCSA(ARMY) 3.1.3 Electrical Characteristics Steady-state Voltage 565V 635V (V ± 35V) Ripple Amplitude 9V Distortion Factor 0.015 Normal Transients: 475V 725V for 15ms Distortion Spectrum Distortion Factor V 2 h h 1 V DC
Background MIL-STD-704F vs. MIL-PRF- GCSA(ARMY) Normal Transients MIL-STD-704F (270VDC) MIL-PRF-GCSA(ARMY) (VDC) Specification MIL-STD-704F (270VDC) % of Nominal MIL-PRF-GCSA(ARMY) (VDC) % of Nominal Steady-State Voltage 250V - 280V (270V +10V / -20V) 11.1% 565V - 635V (V ± 35V) 11.7% Normal Transients 200V - 330V for 20ms (up) / 10ms (down), 40ms settling time 48.1% 475V - 725V for 15ms, 40ms settling time Ripple Amplitude 6V 2.2% 9V 1.5% 41.7%
Background MIL-STD-704F vs. MIL-PRF- GCSA(ARMY) Distortion Spectrum MIL-STD-704F (270VDC) Distortion Factor: 0.015 Frequency Amplitude, dbv Amplitude, V % of Nominal 10-10 0.316 0.12% 1000 10 3.16 1.2% 5000 10 3.16 1.2% 50,000-10 0.316 0.12% 500,000-50 0.00316 0.0012% MIL-PRF-GCSA(ARMY) (VDC) Distortion Factor: 0.015 Frequency Amplitude, dbμv Amplitude, V % of Nominal 10 115 0.562 0.09% 1000 135 5.62 0.9% 5000 135 5.62 0.9% 50,000 115 0.562 0.09% 500,000 75 0.00562 0.0009%
Background: Typical Vehicle Architecture Vehicle Loads Motor Drives & Voltage Converters Constant Power Capacitive (dc-link) Switching noise Resistive Loads Inductive Loads EMI filters Phase Margin Reduction
Background: Generator Control Theory Active Rectification Inverter required for Voltage Control Unity Power Factor is possible at terminals Generator Phasor Diagram Motor Phasor Diagram Vector Control
Experimental Setup
Electrical Diagram of Setup Generator, Inverter and Load Equivalent Circuit
Experimental Setup AC Dynamometer Constant Torque: 1244N m from 0-2,000rpm Constant Power: 260kW from 2,000-10,000rpm DC Power Supply 900V / 1000A / 250kW DC Load Bank 250kW in 5kW Steps Temperature and Flow Regulated PGW cooling loops
Characterization and Power Quality Test Procedures
TARDEC s Standardized Tests and Evaluations Traction Motor Servo Motor Generator Alternator DC/DC Converter Machine Characterization Winding Resistance Characterization Inductance Characterization Back EMF Measurement and Characterization Rotor Inertia Spinning Losses (Iron Loss, Friction, Windage) Spin Down Test Drive Performance Validation/Determination Maximum Electrical Speed Maximum Starting (Stall) Torque Torque Ripple Speed / Torque (Current) Envelope Continuous Efficiency Speed vs. Power Envelope (Continuous) Drive System Controllability Speed Regulation / Response Torque (Current) Response Voltage Regulation / Response System Robustness Fault Tolerance Reliability Evaluation Conducted EMI Evaluation Drive System Integration Practicability Safety Evaluation / Testing SWaP-C Evaluation Power Quality Compliance (MIL-PRF- GCSA(ARMY) / MIL-STD 704/1275) Current Harmonics Drive System Technology Readiness Level (TRL)
Power Quality Testing Scenarios 4.2.1 Voltage Regulation to Step Load. All power sources shall be bench tested with a simulated load profile (equivalent to the worst case operation of the system) to verify that electrical characteristics meet normal transient performance. 19 88kW resistive load bank step, 1800rpm 88 19kW resistive load bank step, 1800rpm 0 50kW resistive load bank step + 19kW constant power (2700μF),1800rpm 3.1.1.11 Distortion Spectrum. The distortion spectrum is defined as the maximum allowable limit of distortion expressed in decibels above 1 microvolt as a function of frequency. 3.1.1.12 Distortion Factor. The distortion factor is defined as the ratio of distortion to the steady state voltage. 19kW resistive load bank, 1800rpm 88kW resistive load bank, 1800rpm 50kW resistive load bank + 19kW constant power (2700μF), 1800rpm
Experimental Results
Vbus Experimental Results Voltage Transient Response Vbus 4.2.1 Voltage Regulation to Step Load 700 725V 700 725V 650 635V 650 X: 3.646 Y: 653.4 635V 550 X: 3.646 Y: 554.2 565V 550 565V 500 475V 500 475V 3.63 3.64 3.65 3.66 3.67 3.68 3.69 3.7 3.71 3.72 sec 3.63 3.64 3.65 3.66 3.67 3.68 3.69 3.7 3.71 3.72 sec 19 87kW resistive load bank step, 1800rpm 87 19kW resistive load bank step, 1800rpm
Experimental Results - Steady State db V db V db V Bus Voltage, 18.7kW Load Bank, 1800rpm Distortion Spectrum, 18.7kW Load Bank, 1800rpm Bus Voltage, 18.7kW Load Bank, 1800rpm 140 605 Bus Voltage, 18.7kW Load Bank, 1800rpm 620 605 Bus Voltage, 18.7kW Load Bank, 1800rpm 605 604 604 120 604 603 603 603 602 100 580 602 602 601 601 80 601 0 0.5 1 1.5 2 2.5 03 0.01 3.5 0.02 4 4.5 0.03 0.04 10 1 0.05 100.06 2 0.07 10 3 0.08 0.09 10 4 10 5 10 6 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 Bus Voltage, 87.8kW Load Bank, 0 1800rpm 0.01 0.02 0.03 0.04 0.05 Distortion 0.06 0.07 Spectrum, 0.08 87.8kW 0.09 Bus Voltage, 87.8kW Load Bank, 1800rpm Load Bank, 1800rpm 605 Bus Voltage, 87.8kW Load Bank, 1800rpm 140 605 Bus Voltage, 87.8kW Load Bank, 1800rpm 620 605 604 604 604 120 603 603 603 602 100 602 580 602 601 601 601 80 0 0.5 1 1.5 2 02.5 0.01 3 0.02 3.5 0.03 0.04 10 1 0.05 0.06 10 2 0.07 10 3 0.08 0.09 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 10 4 10 5 10 6 0 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 Bus Voltage, 18.7kW Power Supply, 50.1kW Load Bank, 1800rpm Bus Voltage, 18.7kW Power Distortion Supply, 50.1kW Spectrum, Load Bank, 18.7kW 1800rpm Power Supply, 50.1kW Load Bank, 1800rpm 605 Bus Voltage, 18.7kW Power Supply, 50.1kW Load Bank, 1800rpm 605 Bus Voltage, 18.7kW Power Supply, 50.1kW Load Bank, 1800rpm 140 605 604 620 604 604 603 120 603 603 602 602 100 602 601 580 601 601 80 0 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0 0.5 1 1.5 2 2.5 30.01 3.5 0.02 40.03 0.04 10 1 Time 0.05(s) 0.06 10 2 0.07 10 3 0.08 0.09 0 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 10 4 10 5 10 6 Time (s) Time Time (s) Frequency (Hz) Distortion Factor 0.0012 0.0015 0.0010
Torque (N m) Ke (V_line-line (pk) / rpm) Machine Characterization Ke vs. Temperature Voltage Constant K e = 0.253 V ll(pk) / rpm Negligible variation across speed (150rpm - 2700rpm) and temperature (30C, 46.7C, 63.3C, 80C) 0.29 0.28 0.27 0.26 0.25 0.24 0.23 0.22 0.21 Phase resistance R s = 10.7 mω 0.2 30 40 50 60 70 80 Inlet Coolant Temp. (deg. C) 80 No Load Torque vs. Speed 70 Friction (combined Coulomb (static) and viscous (dynamic)) 60 50 40 30 20 0 500 1000 1500 2000 2500 3000 Speed (rpm)
volt Electrical and Mechanical Response Estimation amp volts rpm 19 87kW resistive load bank step, 1800rpm 148A 150 610 1900 595 44rpm 1800 580 100 580 570ms 1700 560 60ms 50 565 1 32A Vdc Idc 540 1.87 1.88 1.89 1.9 1.91 1.92 1.93 1.94 1.95 sec 0 550 4.6 4.8 5 5.2 5.4 5.6 5.8 sec Vdc Speed 1500 Voltage Transient: DV 48V and 60 msec Speed Transient: D 44rpm and 570 msec
Modeling
Modeling Effort Objectives: 1) Evaluate the required amount of bus capacitance need for bus stability 2) Assess the total vehicle electrical system s compliance to MIL-PRF- GCSA(ARMY) Procedure: 1) From test data develop a model of the generator/controller system 2) Compare simulation results with experimental results to validate the model 3) Adjust generator/controller model s dc-link and apply load transients 4) Incorporate the generator/controller model into a vehicle electrical system model
Modeling: Experimental Setup Models: Generator Controller Voltage Current Power Stage Inverter Dc-link Generator dq frame of reference Speed input Loads Switchable Resistance Constant Power Dynamometer Speed Command Torque response
Simulation Results and Modeling Parameter Variation
Vbus Vbus Modeling: Experimental Validation Comparison between Experimental and Simulation Results: Voltage Transient 70kW Resistive Step Load 70kW Resistive Step Load +Constant Power Load (Lab Power Supply) 595 590 585 595 590 585 580 575 570 580 575 570 565 560 70kW Step: Resistive Load Bank 70kW Step: Resistive Load Bank(Simulation) 565 560 70kW Step: Pow er Supply + Resistive Load Bank 70kW Step: Pow er Supply + Resistive Load Bank(Simulation) 3.84 3.85 3.86 3.87 3.88 3.89 3.9 sec 3.84 3.85 3.86 3.87 3.88 3.89 3.9 sec
Vbus Modeling: Evaluation of Generator/Controller Capacitance Vbus Comparison between 100% and 50% dc-link capacitance: Voltage Transient 70kW Resistive Step Load 70kW Resistive Step Load +Constant Power Load (Lab Power Supply) 590 590 580 580 570 570 560 560 550 70kW Step: Resistive Load Bank (Simulation) 550 70kW Step: Pow er Supply + Resistive Load Bank(Simulation) 540 70kW Step: 50% Reduced Capacitance, Resistive Load Bank(Simulation) 540 70kW Step: 50% Reduced Capacitance, Pow er Supply + Resistive Load Bank(Simulation) 3.84 3.845 3.85 3.855 3.86 3.865 3.87 3.875 3.88 sec 3.84 3.845 3.85 3.855 3.86 3.865 3.87 3.875 3.88 sec
Modeling: Simulating a Vehicle Load Cycle V,Amps rpm Simulation of a Vehicle s Electrical System Generator Startup Transition between Passive and Active Rectification Voltage and Speed Transients Generator Controller Current Limits 800 2000 1700 rpm V 1500 70kW Step Load 400 1000 rpm 1000 Speed Vdc Idc 200 Passive Rectification Active Rectification 148 A 500 0 0 1 2 3 4 5 6 7 8 9 10 0 sec
Conclusions and Future Work
Conclusions Compliance verification with MIL-PRF-GCSA(ARMY) Established the laboratory capability to validate the results M&S tools for power generation system analysis and optimization Characterization of a black-box power generation system, and model development Evaluation of system response with varying DC-link capacitance values and EMI filter parameters, controller gains, and driveline inertia
Future Work Combine component models with those of an engine and high-voltage bus architecture to assess power quality at the vehicle level FY13 power generation system SIL and vehicle integration Optimization of the bus capacitance for power generation systems Vehicle high-voltage bus capacitance allocation