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Andreas Ecklebe, ABB Corporate Research, CEI 25.3.2011

Magnetic Component Modeling – an Example of ABBs Power Electronics Research

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Overview

ABB Group

ABB Corporate Research

Research in Power Electronics

Example: Magnetic Component Modeling

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A global leader in power and automation technologiesLeading market positions in main businesses

124,000 employees in about 100 countries

$35 billion in revenue (2008)

Formed in 1988 merger of Swiss and Swedish engineering companies

Predecessors founded in 1883 and 1891

Publicly owned company with head office in Switzerland

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How ABB is organizedFive global divisions

Power Products

Power Systems

Discrete Automation and Motion

Process Automation

$10 billion32,500

employees

$6.8 billion17,500

employees

$5.6 billion25,500

employees

$7.4 billion26,500

employees2010 revenues (non-consolidated) and Dec.31, 2010, employee numbers (except Discrete Automation and Motion division, which includes employees from January acqusition of Baldor)

Low Voltage Products

$4.5 billion20,000

employees

Electricals, automation, controls and instrumentation for power generation and industrial processes

Power transmission

Distribution solutions

Low-voltage products

Motors and drives

Intelligent building systems

Robots and robot systems

ABB’s portfolio covers:

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Corporate Research Center in Baden-Dättwil

Founded in 1967

About 200 Employees by end of 2009

> 80 interns/diploma students/PhD`s in 2009

> 30 Nationalities

Research Areas:

Industrial Automation

Power Devices and Systems

Power Electronics

Material Science

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Power Electronics Research Research Fields

Power Semiconductors

Semiconductors Packaging

Power Electronics Integration

Power Electronic Circuits and Topologies

Power Electronics Control

Reliability

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Power ElectronicsTrends, Drivers, Requirements & Challenges

CharacteristicsProductsHigh volumesHigh power densities(typ. ~ 4 kW/liter)Low cost platform integration

Low PowerLow Voltage

High PowerHigh Voltage

CharacteristicsSystemsLow volumesLow power densities(typ. ~ 0.5 kW/liter)High engineering effort

Higher power,higher voltages,transformer less,Modularity,Higher efficiency

Lower cost,higher densities,high IP classes,Higher efficiency

• Semiconductors (10 kV IGCT, BIGT, high Tj, SiC, GaN, superjunction,…)

• Control algorithms (OPP, MP3C,...)• High performance cooling• Advanced numerical design and optimization

Drivers• Thermal management, mechanical integration• Magnetic components• EM(C) modeling• Design methodologies, Multi-domain modeling• Material science and manufacturability• Reliability

Challenges for Integration

EMC modelingLV drives example

LV drive Simulations

Measurements

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Important parasitics:

1. Impedance of PCB traces

2. High frequency behavior of chokes

3. Switching behavior of semiconductors

4. Capacitances to Gnd of Semi-conductors, PCBs, Cables and the Motor etc.

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Magnetic ComponentsEMC Modeling

OCCM

DM

State-of-the-art in choke modeling:1. Physical choke modeling:

Models based on Maxwell equations, e.g. Maxwell 3D (very difficult to model and to extract an equivalent circuit)

Models based on semi analytic equations, e.g. PExpert (not enough precise for EMC modeling)

2. Behavioral choke modeling:

One model reproduces only one effect (CM or DM)

Only one resonance peak can be modeled

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Magnetic ComponentsEMC Modeling

ABB novel behavioral choke modeling technique:1. One model reproduces all effects (CM, DM and OC)

2. All measured resonance can be modeled

3. Single- and three-phase chokes model is available

4. Automated procedure for the model extraction

[1] I. Stevanovic and S. Skibin, “Behavioral circuit modeling of single- and three-phase chokes for EMI simulations,” ECCE ASIA June 2010[2] I. Stevanovic and S. Skibin, “Behavioral circuit modeling of single- and three-phase chokes with multi-resonances,” ECCE Asia June 2011[3] S. Skibin and I. Stevanovic, “Behavioral circuit modeling of chokes with multi-resonances using genetic algorithm,” IEEE EMC, Aug. 2011

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Magnetic ComponentsLoss Modeling – why?

0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.50

2

4

6

8

10

12

dB[T]

Loss

es[W

]

MetglasAntaiYeke

Same core (AMCC-80), different manufacturers

f=5kHz and HDC=0A/m

Same core (N87), same dB, f - different premagnetization

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Magnetic ComponentsImproved loss modeling

Steinmetz equation

Loss Measurement

Improved Steinmetz equation

J. Mühlethaler, J. Biela, J. W. Kolar, and A. Ecklebe, „Core losses under DC bias condition based on Steinmetz parameters“, ECCE Asia, June 2010.

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Magnetic ComponentsResults

Results

Formula( ) ∑∫

=

− +∆=n

lll

T

i PQtBtBk

TP

1rr

0v d

dd1 αβ

α Relaxation effect considered.

J. Mühlethaler, J. Biela, J. W. Kolar, and A. Ecklebe, „Improved Core Loss Calculation for Magnetic Components Employed in Power Electronic Systems, APEC, 2011

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Conclusion

Still room for research and improvements in PE beside new applications driving research as well

Focus on component details: semiconductors, magnetics, caps and also related topics as drivers, controller, auxiliaries

For device and system level:

Thermal Management

Packaging (etc. high temp.) and manufacturability

Multi domain modeling

Component and system optimization including „side“ topics as reliability, acoustics…

Research results must be applicable to industry environments

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