ansoft application notes
TRANSCRIPT
© 2008 Ansoft, LLC All rights reserved. Ansoft, LLC Proprietary
Simulating EMC/EMI Effects for High Power Inverter Systems
Emmanuel Batista Alstom
PearlVincent Delafosse, Ryan Magargle Ansoft [email protected]@[email protected]
© 2008 Ansoft, LLC All rights reserved. Ansoft, LLC Proprietary
Acknowledgments
This work has been based on the work of Emmanuel Batista, J.M. Dienot, M. Mermet-Guyennet
Special Thanks: –
P. Solomalala (Pearl/Alstom)
–
O.Roll, X. Legoar, D. Prestaux, –
X. Wu, M. Rosu, S. Kher (Ansoft)
© 2008 Ansoft, LLC All rights reserved. Ansoft, LLC Proprietary
Pearl: Power Electronics Associated Research Laboratory
Models-Simulation-FabricationEMCSolve multi-domain/temps/structure
Passive ComponentsActive Components
Packaging
Research
and Validation of technologies Development
and validation of prototypes
Viability
and maintenance
Design of methods
for conception
© 2008 Ansoft, LLC All rights reserved. Ansoft, LLC Proprietary
Motivation
•
High power IGBT based inverter systems have specific EMC/EMI requirements
•
The prediction of EMC/EMI fields is very difficult . Physical prototyping can result in long design cycles
•
Simulation tools can help with the use of several techniques
•
The physical quantities in the inverter that need accurate simulation are:–
Quantity of current going through the conductors–
Frequency dependent parasitics (RLC) between conductors –
IGBT characterization curves–
Power dissipation–
Emitted fields
© 2008 Ansoft, LLC All rights reserved. Ansoft, LLC Proprietary
Overview
•
Introduction to the power study•
Static electromagnetic field study
•
Parasitics extraction•
IGBT characterization
•
System simulation•
Emitted fields
© 2008 Ansoft, LLC All rights reserved. Ansoft, LLC Proprietary
AM3~
Traction SupplyPantograph Traction Motor
Introduction
Inverter Inverter LegIGBT Module Top Row
•
These
power converters
are used
in high
speed trains (TGV)
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Introduction
6.5kV IGBT Module Characteristics
Baseplate
CollectorEmitter
IGBT Chips
Diode Chip
6.5kV6.5kV--600A 600A Module Module
24 IGBT and24 IGBT and
12 Diode Chips12 Diode Chips
Dielectric Gel
Packaging
Ceramic
Substrate
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Introduction
6.5kV IGBT Module Analysis
•
Include package in IGBT performance
•
Find DC current distribution
•
Find switching currents for power dissipation
•
Use power dissipation to determine environmental electromagnetic fields
© 2008 Ansoft, LLC All rights reserved. Ansoft, LLC Proprietary
Model design developed
at
Alstom/Pearl
IGBT Module Pack 3D accurate model
Parameters Extraction
Electromagnetic (EM) study
Design and Couplings Model
IGBT Model
•
Tridimensional IGBT pack model and EM study
• Parasitic model extraction
• IGBT circuit model
Far Field Study
• Far Field Study for Electric Field EM
Introduction
© 2008 Ansoft, LLC All rights reserved. Ansoft, LLC Proprietary
Different
Modeling
techniques will
be
seen
•
Tridimensional IGBT pack model and EM study
• Parasitic model extraction
• IGBT circuit model
• Far Field Study for Electric Field EM
Finite Element MethodFinite Element Method
Boundary Element Method
Boundary Element Method
Finite Element
Method
Finite Element
MethodSystem SimulationSystem Simulation
Introduction
© 2008 Ansoft, LLC All rights reserved. Ansoft, LLC Proprietary
Overview
•
Introduction to the power study•
Static electromagnetic field study
•
Parasitics extraction•
IGBT characterization
•
System simulation•
Emitted fields
© 2008 Ansoft, LLC All rights reserved. Ansoft, LLC Proprietary
ElectroMagnetic Study
•
Module layout
verification
•
The module contains
8 IGBTs
in parallel: does
each
IGBT receive
the same
amount
of current?–
If the current
flows
un-evenly, this
will
cause mechanical
stress and reliability
issues.–
Electromagnetic
simulation is
required. We
use Maxwell3D.
© 2008 Ansoft, LLC All rights reserved. Ansoft, LLC Proprietary
ElectroMagnetic Study
•
The layout
in imported
from
the CAD tool•
The DC solver
is
used•
The input current
(600 A) is
defined•
The sink
(return current
path) is
defined
•
Outputs: conduction path
and current
distribution
600 A Sink
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ElectroMagnetic Study
The structure is
meshed
using
automatic
and adaptive meshing
Current
DistributionIGBTs
on, Diodes off
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ElectroMagnetic Study
•
The end IGBTs
see
less
current
than
the center ones.•
This can
cause reliability
issues as the center IGBTs
will
be
overloaded•
An optimization
of the copper
tracks
can
be
made in order
to equalize
the currents.
Igbt1a and Igbt4a have the highest
quantity
of current
© 2008 Ansoft, LLC All rights reserved. Ansoft, LLC Proprietary
Overview
•
Introduction to the power study•
Near field electromagnetic study
•
Parasitics extraction•
IGBT characterization
•
System simulation•
Emitted fields
© 2008 Ansoft, LLC All rights reserved. Ansoft, LLC Proprietary
Parasitics Extraction
•
Once the layout
is
optimized, the next
step
is
to extract
the resistance, inductance and capacitance (RLC) parameters
of the package.•
For this
we
use the boundary
element
method
in Q3D•
Example
for two
conductors
© 2008 Ansoft, LLC All rights reserved. Ansoft, LLC Proprietary
Parasitics Extraction
•
Frequency Dependent Effects•
Integrated power-electronic modules exhibit frequency-dependent behavior due to eddy current and skin effects.
•
In these cases, it may not be sufficient to rely on resistance and inductance extracted at a single operating frequency
•
For example, coax
conductors:
Low Frequency High Frequency
Samegeometry
Different frequency
=
Different Parasitics
© 2008 Ansoft, LLC All rights reserved. Ansoft, LLC Proprietary
•
Extracting parameters is straightforward as the nets are automatically assigned.
Parasitics Extraction
Gate
net
Emitter
net
Collector
net
© 2008 Ansoft, LLC All rights reserved. Ansoft, LLC Proprietary
•
How do we set up the frequency sweep?–
Through Nyquist
sampling, we know that to capture a time step of Ts, we need to obtain frequency domain information up to:
–
For a time domain waveform with a risetime
of 80 ns, in order to capture the ringing in the time domain, we would want to capture at least 4 samples during this risetime. This implies a sampling time of 20 ns
•
We
need
to solve
up to 50 MHz (= 1/20ns)
stF
×=
21
max
Parasitics Extraction
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Parasitics Extraction
•
The simulation outputs consist of the RLC matrices for different
frequencies
© 2008 Ansoft, LLC All rights reserved. Ansoft, LLC Proprietary
Parasitics Extraction
•
How do we
use the parasitics in the circuit simulator?•
Basic methodology:•
Compute N-port S parameters (frequency sweep)•
Convert this into information that circuit simulator understands•
Circuit simulator performs inverse FFT to find impulse response
•
Convolution is used to produce time-domain results
∫ ∞−−=⊗=→=
tdxtstxtstyjXjSjY τττωωω )()()()()()()()(
)())(()()1(
tkxtknstnyn
Nnk
ΔΔ−≅Δ ∑−−=
Vol
tage
876.5m
1.1
900.0m
950.0m
1.0
1.1
1.1
17.55u 20.00u18.00u 18.50u 19.00u 19.50uTime (Seconds)
Voltage versus Time Using Different 2D Extractor Mode
VM11.V [V] VM_Linear_1Hz_Model.V [V] VM_Linear_1MHz_Model.V [V] VM_Frequency_Model.V [V]
Damping
Phase
Copper shield
Silicon
Polyethylene
Silicon
Copper
Copper shield
Silicon
Polyethylene
Silicon
Copper
© 2008 Ansoft, LLC All rights reserved. Ansoft, LLC Proprietary
Overview
•
Introduction to the power study•
Near field electromagnetic study
•
Parasitics extraction•
IGBT characterization
•
System simulation•
Emitted fields
© 2008 Ansoft, LLC All rights reserved. Ansoft, LLC Proprietary
SIMPLORER 8
•
Simplorer 8 is
a circuit simulation tool
for solving
multi-domain
lumped
circuit problems.
•
Link projects
together
to achieve
dynamic
linking
of multiple simulations on a single sheet.
© 2008 Ansoft, LLC All rights reserved. Ansoft, LLC Proprietary
SIMPLORER 8
•
Modeling
•
New Parametrization
tool for IGBT
•
Enhanced SMPS Library -
Over 450 New VHDL-AMS DC/DC Converter Models in SMPS
Digital Co-simulation
•
Spice – Pspice integration
•
Enhancements
to individual
models
…
© 2008 Ansoft, LLC All rights reserved. Ansoft, LLC Proprietary
System Integration
•
How do we
import the results
from
Q3D?: Q3D dynamic link
•
2 Types of links: Single Frequency
or Frequency
dependent•
No need
to manually
import output file•
Simplorer incorporates
directly
the Q3D project
•
If some
results
are not available, Simplorer dynamically
launches
Q3D•
Parameters
and variables can
be
passed
between
S8 and Q3D
© 2008 Ansoft, LLC All rights reserved. Ansoft, LLC Proprietary
System Simulation
IGBT
Wattmeter
VcVg
Power Module from
Q3Dfor board
parasitics
© 2008 Ansoft, LLC All rights reserved. Ansoft, LLC Proprietary
IGBT Characterization
•
Accurate
models
of the semiconductors
are needed
to achieve
a good circuit simulation
•
Simplorer 8 offers
a parameterization
tool
for IGBTs•
The user needs
to import the data from
the datasheet
2 types of models
are available
in Simplorer 8: Basic Dynamic
and Average
Dynamic
© 2008 Ansoft, LLC All rights reserved. Ansoft, LLC Proprietary
IGBT Characterization
Objective Average Basic Dynamic
Advanced Dynamic
DC characteristics
-
Transfer characteristic
Ic(Vge) accurate-
Output characteristic
Ic(Vce) accurate in the regions of voltage and current saturation-
Intrinsic temperature dependencyElectrical Dynamics
- Considered
Thermal Dynamics
Partial Fractional orContinued Fractional
Capacitance Models
- Default C(V)
Full access to the C(V) characteristics
© 2008 Ansoft, LLC All rights reserved. Ansoft, LLC Proprietary
IGBT Characterization
Sub circuit of the basic dynamic IGBT model
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SheetScan
IGBT Characterization
© 2008 Ansoft, LLC All rights reserved. Ansoft, LLC Proprietary
•
Once all the curves
and data are entered, start
extraction•
The tool
fits
the data to the internal
Simplorer model using
Genetic
Algorithm
IGBT Characterization
Characterization toolComponent dialog
© 2008 Ansoft, LLC All rights reserved. Ansoft, LLC Proprietary
IGBT Characterization
Test Circuit
499.90 499.95 500.00 500.05 500.10 500.15 500.20 500.25 500.30Time [us]
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U1.
VC
E
-15.00
-10.00
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0.00
5.00
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VM
2.V
[V]
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0.00
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R2.
I [A
]
Ansoft Corporation Simplorer1switch_on
Curve InfoU1.VCE
TRVM2.V
TRR2.I
TR
999.00 999.50 1000.00 1000.50 1001.00 1001.50 1002.00 1002.50 1003.00Time [us]
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U1.
VC
E
-15.00
-10.00
-5.00
0.00
5.00
10.00
15.00
VM
2.V
[V]
-10.00
0.00
10.00
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50.00
R2.
I [A
]
Ansoft Corporation Simplorer1switch_offCurve Info
U1.VCETR
VM2.VTR
R2.ITR
Switch on
Switch off
Vce
Vce
Ic
Ic
rise time= 40 μsfall
time = 50
μs
© 2008 Ansoft, LLC All rights reserved. Ansoft, LLC Proprietary
System Simulation
2500 Voltage Source
Line Resistance and Line Inductance
Vg: Gate
Voltage (+/-15V)
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System Simulation
•
Issue: •
Accurate
simulation of the switching
of the IGBTS requires
very
small
time steps
(hmin
= 10ps)•
System simulation requires
long time step
(t = 5ms)•
Simplorer allows
the user to dynamically
change hmin
and hmax
using
State Graphs. •
When
the switching
has occured, the time step
can
be
increased.
Switching Steady state Switching
© 2008 Ansoft, LLC All rights reserved. Ansoft, LLC Proprietary
System Simulation
Vce, Vge, Ic
over time (Igbt3b)
Reduce Time Step HMin
IcVce
-Vge
VgeVce
Ic
Ic
VgeVce
Ic
VgeVce
Vge
Vce
Icg
c
e
© 2008 Ansoft, LLC All rights reserved. Ansoft, LLC Proprietary
Vce
Vg
Vge
Ic
Power
The power pulse duration is much smaller than the rise/fall time
of Ic
and Vce
System Simulation
© 2008 Ansoft, LLC All rights reserved. Ansoft, LLC Proprietary
System Simulation
Instantaneous power level through Igbt3a
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System Simulation
Power levels of the full set of IGBT’s
on switch on
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System Simulation
•
Igbt1a and Igbt4a receive the highest power levels.
•
This is consistent with the DC Conduction Maxwell3D solution
Igbt1a
Igbt4a
© 2008 Ansoft, LLC All rights reserved. Ansoft, LLC Proprietary
System Simulation
The fundamental frequencies of the power range between 16 and 54 MHz
t @ Pmax(μs)
t @ P <300W
(μs)
Freq(MHz)
Igbt1a 500.2262 500.2867 16.5Igbt1b 500.2193 500.2429 23.8Igbt2a 500.2241 500.2743 49.5Igbt2b 500.2182 500.2369 53.5Igbt3a 500.2294 500.2675 21Igbt3b 500.2178 500.2363 54Igbt4a 500.2256 500.2869 16.5Igbt4b 500.2191 500.2402 47.5
© 2008 Ansoft, LLC All rights reserved. Ansoft, LLC Proprietary
System Simulation
FTT of the power through Igbt1a
Most of the power level is below 110 MHz
© 2008 Ansoft, LLC All rights reserved. Ansoft, LLC Proprietary
Emitted Fields
•
There is
very
high
power going
through
the IGBTs
(almost
60 000 W in this
study) during
a very
short period
of time (60 ns). This switching
can
cause EMI issues in the inverter, but also
in the surrounding
equipment
•
To be
answered
using
the finite
element
method
in HFSS:
•
Will the module radiate? •
Are the field
levels
surrounding
the module within
mandated
levels?
© 2008 Ansoft, LLC All rights reserved. Ansoft, LLC Proprietary
Emitted Fields
•
The power pulse in the IGBTs
have most
of the energy
in the 16-
110 MHz range.•
The largest
metallic
piece
is
150 mm in the module•
There is
a chance of having
radiation if λ
< 4 * L = 600 mm. This is
for a frequency
of 500 MHz.
•
By itself, the module will
not radiate.
•
However, the power module in the train is
surrounded
by other
metallic
objects
than
can
be
fairly
large. These
objects
can
cause the radiation of electric
fields
during
switching.
Maxwell’s Equations
div D = ρ
curl E = -∂B/∂t
div B = 0
curl H = J + ∂D/∂t
© 2008 Ansoft, LLC All rights reserved. Ansoft, LLC Proprietary
Emitted Fields
•
Regulators
impose maximum levels
of electric
fields
close to electric
equipment.•
In the 10-110 MHz range:
Emax=61V/m
Exposure
limits
defined
by European
Community
© 2008 Ansoft, LLC All rights reserved. Ansoft, LLC Proprietary
Emitted Fields
•
Each
IGBT pad is
excited
using
lumped
ports•
The port lies between
the collector
and emitter
pads
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Emitted Fields
•
The structure is
discretized
with
adaptive meshing. The meshing
frequency
is
100 MHz•
The frequency
sweep
ranges from
15MHz to 120 MHz
© 2008 Ansoft, LLC All rights reserved. Ansoft, LLC Proprietary
Emitted Fields
For each
frequency, the power amplitude is
entered
Spectrum (MHz)
Power (W)
E field at 1m for 1000w (V/m)
E field at 1m (V/m)
16.52892562 21439.97604 2.6312 56.4128649733.05785124 8635.09049 2.7994 24.1730723249.58677686 5579.619715 2.8731 16.030805466.11570248 4131.16773 3.063 12.65376676
82.6446281 3276.823585 3.4045 11.1559458999.17355372 2712.888158 3.8924 10.55964586115.7024793 2308.359536 4.4861 10.35553171
132.231405 2022.75744 4.905 9.921625241
Spectrum from
Simplorer
Outputs from
SimplorerInputs for HFSS
Outputs From
HFSS(normalized
results)Fields Levels
© 2008 Ansoft, LLC All rights reserved. Ansoft, LLC Proprietary
Emitted Fields
•
The E field
is
very
localized
close to the module even
at
100 MHz•
However, the very
high
power can
lead
to large values of E field
even
far from
the module•
This design is
fine at
110MHz.
mag
E @ 100 MHz, Power = 10 000W
Spectrum (MHz)Power
(W)Spectrum (MHz)Power
(W)E field at 1m
(V/ m)E field at 1m
(V/ m)115.7024793 2308.359536115.7024793 2308.359536 10.3555317110.35553171
© 2008 Ansoft, LLC All rights reserved. Ansoft, LLC Proprietary
Conclusion
•
We have seen that the combination of several simulation techniques can give a good approach to EMC/EMI issues, both in conduction and emission modes
•
Accurate prediction requires the use of Finite Element Methods, Boundary Element Methods, System Simulation along with Accurate Component
Characteristics
•
Package traces need optimization to balance current distribution
•
The simulated module does not radiate for the given harmonics, and is within regulated near field field limits.