EVALUATING VOLTAGE REGULATION COMPLIANCE OF MIL-PRF-GCS600A(ARMY)

FOR VEHICLE ON-BOARD GENERATORS AND ASSESSING OVERALL VEHICLE

BUS COMPLIANCE Wesley G. Zanardelli, Ph.D. Advanced Propulsion Team

US Army TARDEC

CPT John Kelly ARSC, DET 8

US ARMY RDECOM-TARDEC

16 August 2012 UNCLASSIFIED: Distribution Statement A. Approved for public release.

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1. REPORT DATE 16 AUG 2012

2. REPORT TYPE Briefing

3. DATES COVERED 16-07-2012 to 15-08-2012

4. TITLE AND SUBTITLE EVALUATING VOLTAGE REGULATION COMPLIANCE OFMIL-PRF-GCS600A(ARMY) FOR VEHICLE ON-BOARDGENERATORS AND ASSESSING OVERALL VEHICLE BUS COMPLIANCE

5a. CONTRACT NUMBER

5b. GRANT NUMBER

5c. PROGRAM ELEMENT NUMBER

6. AUTHOR(S) Wesley Zanardelli; John Kelly

5d. PROJECT NUMBER

5e. TASK NUMBER

5f. WORK UNIT NUMBER

7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES) U.S. Army TARDEC,6501 East Eleven Mile Rd,Warren,Mi,48397-5000

8. PERFORMING ORGANIZATIONREPORT NUMBER #23263

9. SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES) U.S. Army TARDEC, 6501 East Eleven Mile Rd, Warren, Mi, 48397-5000

10. SPONSOR/MONITOR’S ACRONYM(S) TARDEC

11. SPONSOR/MONITOR’S REPORT NUMBER(S) #23263

12. DISTRIBUTION/AVAILABILITY STATEMENT Approved for public release; distribution unlimited

13. SUPPLEMENTARY NOTES FOR GVSETS 2012

14. ABSTRACT Briefing Charts

15. SUBJECT TERMS

16. SECURITY CLASSIFICATION OF: 17. LIMITATION OF ABSTRACT

Public Release

18. NUMBEROF PAGES

30

19a. NAME OFRESPONSIBLE PERSON

a. REPORT unclassified

b. ABSTRACT unclassified

c. THIS PAGE unclassified

Standard Form 298 (Rev. 8-98) Prescribed by ANSI Std Z39-18

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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

16 August 2012

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Objectives

• Component level compliance with MIL-PRF-

GCS600A(ARMY)

• Identification of parameters on power generation

components

• Electrical machine characterization

• Modeling

• System level power quality compliance

• Optimization of high-voltage bus capacitance

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Background

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Background

MIL-PRF-GCS600A(ARMY)

• 3.1.3 Electrical Characteristics

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Steady-state Voltage 565V – 635V (600V ± 35V)

Ripple Amplitude 9V

Distortion Factor 0.015

• Normal Transients: 475V – 725V for 15ms • Distortion Spectrum

DCV

hh

V

1

2

Factor Distortion

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• MIL-STD-704F (270VDC) • MIL-PRF-GCS600A(ARMY) (600VDC)

Background

MIL-STD-704F vs. MIL-PRF-

GCS600A(ARMY)

16 August 2012

• Normal Transients

Specification MIL-STD-704F (270VDC) % of Nominal MIL-PRF-GCS600A(ARMY) (600VDC)

% of Nominal

Steady-State Voltage 250V - 280V (270V +10V / -20V) 11.1% 565V - 635V (600V ± 35V) 11.7%

Normal Transients 200V - 330V for 20ms (up) / 10ms (down), 40ms settling time

48.1% 475V - 725V for 15ms, 40ms settling time

41.7%

Ripple Amplitude 6V 2.2% 9V 1.5%

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UNCLASSIFIED Background

MIL-STD-704F vs. MIL-PRF-

GCS600A(ARMY)

16 August 2012

• MIL-STD-704F (270VDC)

• Distortion Factor: 0.015

• MIL-PRF-GCS600A(ARMY) (600VDC)

• Distortion Factor: 0.015

• Distortion Spectrum

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%

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%

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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

16 August 2012

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Background:

Generator Control Theory

• Active Rectification – Inverter required for Voltage Control

– Unity Power Factor is possible

at terminals

• Vector Control

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Generator Phasor Diagram Motor Phasor Diagram

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Experimental Setup

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Electrical Diagram of Setup

• Generator, Inverter and Load Equivalent Circuit

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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

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Characterization and Power Quality

Test Procedures

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TARDEC’s Standardized Tests

and Evaluations

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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-

GCS600A(ARMY) / MIL-STD 704/1275)

• Current Harmonics

Drive System Technology Readiness Level

(TRL)

Traction Motor Servo Motor Generator Alternator DC/DC Converter

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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

16 August 2012

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Experimental Results

16 August 2012

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Experimental Results – Voltage

Transient Response

16 August 2012

3.63 3.64 3.65 3.66 3.67 3.68 3.69 3.7 3.71 3.72

500

550

600

650

700

sec

Vbus

X: 3.646

Y: 554.2

565V

635V

725V

475V

3.63 3.64 3.65 3.66 3.67 3.68 3.69 3.7 3.71 3.72

500

550

600

650

700

sec

Vbus

X: 3.646

Y: 653.4

635V

565V

475V

725V

4.2.1 Voltage Regulation to Step Load

19 → 87kW resistive load bank step, 1800rpm 87 → 19kW resistive load bank step, 1800rpm

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Experimental Results - Steady

State

16 August 2012

Distortion Factor

0.0012

0.0015

0.0010

0 0.5 1 1.5 2 2.5 3 3.5 4 4.5

580

600

620

Bus Voltage, 18.7kW Load Bank, 1800rpm

0 0.5 1 1.5 2 2.5 3 3.5

580

600

620

Bus Voltage, 87.8kW Load Bank, 1800rpm

0 0.5 1 1.5 2 2.5 3 3.5 4

580

600

620

Bus Voltage, 18.7kW Power Supply, 50.1kW Load Bank, 1800rpm

Time (s)

101

102

103

104

105

106

80

100

120

140

dB

V

Distortion Spectrum, 18.7kW Load Bank, 1800rpm

101

102

103

104

105

106

80

100

120

140

dB

V

Distortion Spectrum, 87.8kW Load Bank, 1800rpm

101

102

103

104

105

106

80

100

120

140

dB

V

Distortion Spectrum, 18.7kW Power Supply, 50.1kW Load Bank, 1800rpm

Frequency (Hz)

0 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09600

601

602

603

604

605Bus Voltage, 18.7kW Load Bank, 1800rpm

0 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09600

601

602

603

604

605Bus Voltage, 87.8kW Load Bank, 1800rpm

0 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09600

601

602

603

604

605Bus Voltage, 18.7kW Power Supply, 50.1kW Load Bank, 1800rpm

Time (s)

0 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09600

601

602

603

604

605Bus Voltage, 18.7kW Load Bank, 1800rpm

0 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09600

601

602

603

604

605Bus Voltage, 87.8kW Load Bank, 1800rpm

0 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09600

601

602

603

604

605Bus Voltage, 18.7kW Power Supply, 50.1kW Load Bank, 1800rpm

Time (s)

0 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09600

601

602

603

604

605Bus Voltage, 18.7kW Load Bank, 1800rpm

0 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09600

601

602

603

604

605Bus Voltage, 87.8kW Load Bank, 1800rpm

0 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09600

601

602

603

604

605Bus Voltage, 18.7kW Power Supply, 50.1kW Load Bank, 1800rpm

Time (s)

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Machine Characterization

• Voltage Constant Ke = 0.253 Vll(pk) / rpm

– Negligible variation across speed (150rpm -

2700rpm) and temperature (30C, 46.7C,

63.3C, 80C)

• Phase resistance Rs = 10.7 mΩ

• Friction (combined Coulomb (static) and

viscous (dynamic))

16 August 2012

30 40 50 60 70 800.2

0.21

0.22

0.23

0.24

0.25

0.26

0.27

0.28

0.29

Ke vs. Temperature

Ke (

V_lin

e-l

ine (

pk)

/

rpm

)

Inlet Coolant Temp. (deg. C)

0 500 1000 1500 2000 2500 300020

30

40

50

60

70

80No Load Torque vs. Speed

Torq

ue (

N m

)

Speed (rpm)

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Electrical and Mechanical

Response Estimation

16 August 2012

1.87 1.88 1.89 1.9 1.91 1.92 1.93 1.94 1.95540

560

580

600

sec

volt

1.87 1.88 1.89 1.9 1.91 1.92 1.93 1.94 1.950

50

100

150

am

p

60ms

148A

32A

4.6 4.8 5 5.2 5.4 5.6 5.8550

565

580

595

610

volts

4.6 4.8 5 5.2 5.4 5.6 5.81500

1600

1700

1800

1900

sec

rpm

Vdc

Speed

570ms

44rpm

19 → 87kW resistive load bank step, 1800rpm

Vdc

Idc

Voltage Transient: DV 48V and 60 msec

Speed Transient: D 44rpm and 570 msec

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Modeling

16 August 2012

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Modeling Effort

16 August 2012

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-

GCS600A(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

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Modeling: Experimental Setup

16 August 2012

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

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Simulation Results and Modeling

Parameter Variation

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Modeling: Experimental Validation

16 August 2012

Comparison between Experimental and Simulation Results: Voltage Transient

3.84 3.85 3.86 3.87 3.88 3.89 3.9

560

565

570

575

580

585

590

595

600

sec

Vbus

70kW Step: Resistive Load Bank

70kW Step: Resistive Load Bank(Simulation)

70kW Resistive Step Load

70kW Resistive Step Load +Constant

Power Load (Lab Power Supply)

3.84 3.85 3.86 3.87 3.88 3.89 3.9

560

565

570

575

580

585

590

595

600

sec

Vbus

70kW Step: Pow er Supply + Resistive Load Bank

70kW Step: Pow er Supply + Resistive Load Bank(Simulation)

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Modeling: Evaluation of

Generator/Controller Capacitance

16 August 2012

3.84 3.845 3.85 3.855 3.86 3.865 3.87 3.875 3.88

540

550

560

570

580

590

600

sec

Vbus

70kW Step: Pow er Supply + Resistive Load Bank(Simulation)

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

540

550

560

570

580

590

600

sec

Vbus

70kW Step: Resistive Load Bank (Simulation)

70kW Step: 50% Reduced Capacitance, Resistive Load Bank(Simulation)

Comparison between 100% and 50% dc-link capacitance: Voltage Transient

70kW Resistive Step Load

70kW Resistive Step Load +Constant

Power Load (Lab Power Supply)

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Modeling: Simulating a Vehicle

Load Cycle

16 August 2012

0 1 2 3 4 5 6 7 8 9 100

200

400

600

800

sec

V,A

mp

s

0 1 2 3 4 5 6 7 8 9 100

500

1000

1500

2000

rpm

Speed

Vdc

Idc

70kW Step Load

148 A

1700 rpm

600 V

1000 rpm

Passive Rectification Active Rectification

Simulation of a Vehicle’s Electrical System – Generator Startup

– Transition between Passive and Active Rectification

– Voltage and Speed Transients

– Generator Controller Current Limits

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Conclusions and Future Work

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Conclusions

• Compliance verification with MIL-PRF-GCS600A(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

16 August 2012

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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

16 August 2012