Design and Control of a Kilo-Amp DC/AC Inverter for Integrated Starter-Generator (ISG) Applications

Jingbo Liu, Student Member, IEEE, Jiangang Hu and Longya Xu, Fellow, IEEE
Department of Electrical and Computer Engineering, The Ohio State University Columbus, OH 43210, U.S.A. liu.428@osu.edu, xu.12@osu.edu
Abstract- Design and control of a kilo-amp voltage source DC/AC inverter suitable for low voltage integrated starter-generator (ISG) operation is presented. Multi-parallel MOSFETs are used to achieve extremely high current capability. Issues related to power module integration, filtering components and thermal management are discussed. A prototype with current capability up to 1500 amps is designed and built to validate the kilo-amp inverter. A sensorless control scheme based on indirect flux orientation (IFO) in ISG application is studied. Computer simulation and experimental results are presented for verification. Keywords- integrated starter generator (ISG), voltage source inverter (VSI), low voltage, parallel MOSFETs, kilo-amp, sensorless indirect flux orientation control

base torque and current. Then, the AC machine switches to generator operation from 7,000 rpm with a constant power output. The generating mode could run up to a very high speed, 4 times of the base speed. Therefore, machine design would be very special because the operating torque-speed curve of the AC machine spans a very wide range due to the extreme values of starting torque (current) and generating speed (voltage). Presently, most proposed ISGs do not allow the conventional DC bus voltage at low level (12-30V). However, changing the operating voltage of existing systems requires a sea change of all electric standards for all subsystems and associated components [3]. Therefore, the real costs of using ISG with different voltages from those in an existing system are very high, often much beyond any economic gains the ISG can achieve from other aspects. On the other hand, sticking with the available low DC voltage of existing systems, people have to deal with many other issues. For instance, for a 10 kw ISG system with a low DC bus voltage of 12 volts, the starting current easily exceeds 1000 amps. Even in the continuous generating mode, the current will be as high as half kilo-amps. In this paper, we pursue a compact 10 kw DC/AC inverter design to satisfy both high performance and low voltage constraint for retrofitting existing systems. Using multi power MOSFETs in parallel as a single device, we discuss important issues related to power module integration, filtering components and thermal management of the package. A proofof-concept prototype is designed, built and tested with current up to 1500 amps. The results from the testing rig are used to verify the ISG feasibility, operating in kilo-amp and low voltage regime. II. PROPOSED ISG SYSTEM

I.

INTRODUCTION

The concept of using a single AC machine, as both a starter and generator, in an integrated starter generator (ISG) system becomes popular and appears particularly attractive in automotive and aircraft applications where space and weight reduction is of critical importance. With the introduction of 42V power net, the potential market for automotive ISGs has gained even more attention recently [1]-[5]. In general, the AC machine in an ISG system will operate as a motor to start the engine/turbine with a very high torque and then act as a generator at higher speeds supplying constant power to the DC battery bank. One of the striking benefits of using a DC/AC inverter, linking the battery pack to electric machine, as an ISG is the dramatically reduced DC current seen by the battery pack. As a result, the battery current stress is substantially relieved and battery life much extended. In addition, a DC/AC inverter powered ISG system can save the high costs for the expensive brushes and commutators. There are several challenging technical issues related to a VSI-based ISG system: a) the ISG system has to be highly reliable and at the lowest possible costs; b) design constraints are imposed in terms of thermal behavior because compactness of the power circuit is required due to the limited space; and c) the AC machine in the ISG system has to satisfy very special torque-speed characteristics for starting and generating respectively. For instance, for a future airplane ISG system, the AC machine will first run as a starter in the speed range of 05,000 rpm with a very large starting torque, 2.5 times of the

A. ISG System Configuration Fig. 1 shows the overall configuration of an ISG system, containing three major parts: a power converter, an AC machine and a DSP controller. The constraint of the system design is that the DC bus voltage is in the range of 12-30 volts, not allowed to change. The power circuit for the proposed ISG system is a threephase voltage source inverter (VSI) using power MOSFETs in parallel. Feedback signals such as currents and voltage are

IAS 2004

2754

0-7803-8486-5/04/$20.00 2004 IEEE

acquired and used by the DSP after the signal conditioning circuit. Based on the feedback information, advanced control algorithms embedded in DSP command the space vector PWM that in turn gates the power inverter for either starter or generator operation.

T1

T3

T5

After many comparison studies on several types of power MOSFETs, IFRP2907 with TO247 package is chosen for its best ratio of performance to cost. Specifically, IRFP2907 has the ratings of 75V, 209A (peak), 175 C junction-temperature and ultra low on-state resistance of only 4.5 m . The improved repetitive avalanche rating and the fast switching speed of IRFP2907 enable the designed kilo-amp inverter highly efficient and reliable. Six IRFP2907 are paralleled as a switch in the proposed ISG system, achieving a compact package as shown in Fig. 2. The intrinsic anti-paralleled body diode within power MOSFET shows the similar current and voltage ratings as those of the MOSFET according to the device datasheet. Therefore, in the circuit, the body diodes are utilized as the freewheeling diodes. For the generating mode operation, the inverter acts as a synchronous rectifier and the MOSFET channel are effectively utilized for reversed current conduction. No additional anti-paralleled diodes are needed and, thus, much space and cost is saved.

T4

T6

T2

ib
ia

Figure 1. ISG system diagram

The specifications for the intended ISG system are listed in Table 1.
TABLE I. ISG SYSTEM SPECIFICATIONS 12-30 50 10 1500 400 Forced air 10x10x6.0 > 90% Figure 2. Dimensions of six IRFP2907

DC voltage (V) Peak torque at starting (Nm) Continuous power for generating (KW) Maximum current in starting (peak, A) Continuous current in generating (peak, A) Cooling Dimensions (inch) Efficiency

2) Passive components Passive components, especially the DC bus capacitors, are of critical importance for ISG inverter design. It is almost impossible if only conventional electrolytic capacitors are used for filtering in the extremely high current applications. This is because of the limited ripple current capability and undesirable equivalent series inductance of the electrolytic capacitors. In the design, DC bus capacitors for high current applications need to meet the following: Low equivalent series resistance (ESR) Low equivalent series inductance (ESL) High ripple current capability High thermal stability and reliability Compact size (volume)

B. Power Components 1) MOSFETs with ultra low on-state resistance For the proposed ISG system, the current carrying capability of each switch reaches 1500A to guarantee sufficient starting torque. In addition, the power circuit should be compact, imposing limits to the physical dimension of the power device. After surveying various technologies, it is found that no single power device simultaneously meets the requirements of high current, compact package and low onstate resistance. Power MOSFETs are popular candidates in lower voltage range such as battery powered systems because of their merits of fast switching, positive temperature coefficients, low on-state resistance, etc. The state-of-the-art power MOSFETs have increased cell density, allowing for higher current per device area [6]. It is evident that paralleled power MOSFETs makes them a good choice for low voltage high current applications. Using power MOSFETs in parallel, not only the current carrying capability of the switch is greatly improved, the total ON resistance of an equivalent switch is also significantly reduced.

Switch Mode Power Supply (SMPS) multilayer ceramic (MLC) capacitors with extremely low ESL and ESR are chosen to offer the required performance for high frequency switching. The extremely low ESL of SMPS MLC capacitor allows very high di/dt with little noise voltage generated, very valuable characteristics of the input filter. In addition, due to their low ESR at higher frequencies, SMPS MLC capacitors have very high ripple current capabilities. Because MLC capacitors are only available in small capacitance, low ESR and high ripple current electrolytic capacitors are also needed in parallel across DC bus to provide additional low frequency capacitance. Table 2 shows the important parameters of the selected capacitors used for the proposed converter.

IAS 2004

2755

0-7803-8486-5/04/$20.00 2004 IEEE

TABLE II.

SELECTED CAPACITOR PARAMETERS SMPS MLC Capacitor 30 0.86 2.98 100 -55 to +125 1.5x0.87x0.65 Electrolytic Capacitor 2200 N/A 16 63 -40 to +125 1x1.5 (DxL)

III.

SENSORLESS FIELD ORIENTATION CONTROL OF INDUCTION MACHINE

Capacitance (uF) ESL@ 100 kHz (nH) ESR@100 kHz ( m ) Rated voltage (V) Temperature range (C) Size (inch)

In the proposed ISG system, a squirrel-cage IM is chosen for its rugged structure, mature manufacturing technology, and low cost. In particular, induction machines can be completely demagnetized, a feature especially useful to avoid over voltage at high speed when system is in fault. In the presented ISG system, indirect field orientation (IFO) control is applied to ensure that the torque and flux is controlled independently and thus, high performance obtained. Furthermore, to enhance reliability and accommodate highspeed operation, the field orientation control algorithm is implemented without a speed sensor. The sensorless control is realized with the rotor speed estimated in desirable accuracy by a software approach programmed into the high speed DSP. A. Induction machine dynamic model To apply the field orientation control scheme, the following dynamic model of the squirrel-cage IM in the synchronous rotating reference frame is used [11]:

3) Thermal design & Package Integration Thermal design is optimized to guarantee safe operation of the ISG. When power devices are used in applications with high power losses, it should be ensured that the losses do not lead to thermal overload of any switching power devices. As clarified in many literatures, the junction temperature depends on both the power generated inside the power devices and the thermal resistances associated with the dissipation path. The thermal design consideration has focused on reducing the overall system thermal resistance by enhancing tight thermal contact between the device case and heat sink. Forced air cooling with sufficient air flow rate is also emphasized to dramatically reduce the heat sink temperature. In the prototype design, a forced air cooled heat sink with the dimensions of 8.4x7.9x3.0 inches is used. A cooling fan is installed to provide forced-air cooling with an air flow rate of 300 m3/h. A 3-D drawing characterizing the electrical packaging and thermal management of the designed inverter is shown in Fig 3. The 36 power MOSFET devices are divided into three phases, 12 in each. The source terminals of all lower switches of Phase A are soldered together to the negative bus through one laminated copper sheet while the drain terminals of all upper switches to the positive DC bus through another laminated copper sheet. One copper bar, connecting together the drain of the lower switches to the source of the upper switches, is used as the AC output of Phase A. Similar soldering is done for Phases B and C. All of the capacitors are placed physically very close to power switches in order to minimize the inductance to the input of power switches.

and

de ds e e qs dt de e e vqs = Rsiqs + qs + e e ds dt de e 0 = Rr idr + dr (e r )e qr dt de e 0 = Rr iqr + qr + (e r )e dr dt

e e vds = Rsids +
e e e e e = ( Lm + Lls )ids + Lmidr = Lsids + Lmidr ds

(1) (2) (3) (4)

(5) (6) (7) (8)

= ( Lm + Lls )i + L i = L i + L i
e qs e qs e m qr e s qs e dr e qr e dr e qr e m ds e m qs e r dr e r qr

e m qr e m ds e m qs

= ( Lm + Llr )i + L i = L i + L i = ( Lm + Llr )i + L i = L i + L i
where

e and r are synchronous and rotor rotating frequency;

e e ids and iqs are d- and q-axis stator currents;

e and e are d- and q-axis stator flux linkages; ds qs

Rs and Rr are stator and rotor resistances;

Lm , Ls and Lr are magnetizing, stator and rotor inductance.

Figure 3. 3-D model of the proposed design

Notice that the IM equations (1)-(8) can be used to represent the electric machine operated as both a starter and a generator [8]-[10]. In the starter operation, the output torque and speed are controlled variables and an additional motion

IAS 2004

2756

0-7803-8486-5/04/$20.00 2004 IEEE

equation is needed. In the generator operation, the machine speed is given by the prime mover (engines) and the torque (current) control is used to govern output power. In the generating mode, the field orientation control technique is utilized for controlling energy flow rate so that at the different speeds and load conditions the rated DC voltage is maintained. With the field orientation algorithm, the output DC voltage could be controlled properly.
Rload
* iq

idc

iload

ibat

icap

S1

S2

S3

Cdc

ia Vdc

ib
ic

* iq

iq
V
e q

s q

Rbat

Vdc
* Vdc

r
i
* q

Vde

Vds

Vds

e
* id

Vdc

Figure 5. Battery source VSI with dc capacitor

ia

* id

id

ib
e

Vqs, d
* iq ,d

iqs,d

slip
r

iq ,d

In the figure, the AC side currents through the inverter are modeled by the switching functions S1, S2 and S3 multiplied by the AC currents, respectively. When the switch is ON, the corresponding switching function equals to 1 and when OFF zero. The DC current flowing to VSI ( idc in Fig. 5) is expressed as
i dc = S1 i a + S 2 i b + S 3 i c

Figure 4. ISG system controller block diagram

Fig. 4 shows the block diagram of the indirect field orientation (IFO) controlled induction machine for the proposed ISG system. The mode selector will determine the ISG system operation mode according to machine speed. In starting mode, the q-axis current command iq* is directly determined according to the specified starting toque requirement, assuming IM at the rated magnetic flux level with an appropriate id*. Later when the IM entering generator mode, iq*is determined by the needed power pumped to the DC battery bank. The battery voltage drops if flow-in power is less than the flow-out power. Therefore, a DC bus voltage regulator can be used to determine iq*. It is noticeable that in ISG applications, the induction generator is classified as a stand-alone system. The selfexcited induction generator relies on the DC-link capacitors to provide excitation energy through the power converter. Controlling id*, we can change the magnetizing current and flux level of the induction machine. Below the base speed, id* is a constant. At a speed above the base speed, the magnetic flux of the generator has to be weakened inversely proportional to the speed. The control algorithm embedded in the DSP controller is able to regulate the machine field level so that fluxweakening and constant power operation is achieved. As indicated in the control block diagram, id* is determined according to the machine speed. For sensorless control operation, algorithms of sliding mode flux and speed estimations are used. For details of flux and speed estimation, [11] is referred. B. Modeling of battery voltage To explain the voltage control of the battery bank in the DC bus in generator operation, Fig.5 shows the DC bus circuit schematics, describing the interactions among the batteries, the VSI inverter, the DC capacitor and DC side loads.

On the other hand, according to KCL,

i dc = (icap + ibat + iload )

where

idc is the current flowing into VSI;

icap is the current flowing into the dc capacitor;

ibat is the current flowing into the battery; iload is the current flowing through the dc load;
Further, we can consider the battery follows a linear model that includes an internal resistance Rbat and an internal voltage E. The dc-link voltage dynamics then is expressed as
idc = C dc dVdc Vdc Vdc E + + dt Rload Rbat

(9)

For ISG system DC voltage control in the generating mode, Eq. (9) is incorporated into the system. It should be noted that the switch for the load Rload is not turned on in the starter operation. On the other hand, in the generator operation the switch is turned on to represent certain loads connected to the dc battery. C. Computer simulation of the ISG system 1) Starter Operation In order to verify the proposed control strategies discussed in the above sections, computer simulations are conducted. Indirect field orientation control is simulated for the proposed induction machine ISG system for both starting and generating operation modes. The per-unit machine parameters used in computer simulation are shown in Table 3, where the base voltage is 9.55V and base current 1046A.

IAS 2004

2757

0-7803-8486-5/04/$20.00 2004 IEEE

TABLE III.

INDUCTION MACHINE PARAMETERS USED FOR COMPUTER

SIMULATIONS

Value (p.u.) Magnetizing reactance (Xm) Stator leakage reactance (Xls) Rotor leakage reactance (Xlr) Stator resistance (Rs) Rotor resistance (Rr) 9.49 0.24 0.24 0.19 0.10

Fig. 6 shows the simulation results of the starting process with the designed ISG system. As indicated, in the brief starting process, both the induction machine and inverter experience nearly 1500 amps for about 5 seconds. Then the starting currents taper down to several hundred amps for another 15 seconds. In the starting process, the peak torque reaches 50 Nm.

Figure 7. Simulation results for stand-alone generator operation

3) Operating with trapezoidal speed profile To demonstrate the closed-loop speed control capability of the ISG system, speed tracking on a trapezoidal reference profile is also simulated. Actually, in operating the ISG system with trapezoidal speed tracking control, the induction machine is operated as a motor and generator, alternatively.

G en e ratin g

M o to rin g

Figure 6.

Computer simulation result for starting current

2) Stand-alone Generator Operation Field orientation controlled induction generator driven by a prime mover with regulated dc output is studied by computer simulations. In simulation, the ISG system is assumed variable speed operation from 7,000 to 12,000 rpm given by the prime mover (engine). At the same time, the DC voltage after VSI control is required 30V, subject to certain loads connected to the DC bus. Fig.7 shows the simulation results for IFO controlled induction generator in the stand-alone condition, driven by a prime mover with the regulated DC voltage. The waveform on the top is the electromagnetic torque and the middle the regulated DC voltage. The third waveform is the phase voltage and the AC phase current (1/10 scaled). Note that since a motor convention is assumed for the system, the torque becomes negative and AC phase voltage and current are out of phase for nearly 180 degrees once the system is in generator operation.

G en e ratin g R e g io n

M o to rin g R eg io n

Figure 8. Simulation results when IM operating with trapezoidal trajectory

IAS 2004

2758

0-7803-8486-5/04/$20.00 2004 IEEE

Fig. 8 shows the simulated results when the ISG system is operated in speed tracking control. The IM is first accelerated to 2,500 rpm and kept at 2,500 rpm for 1 second. Then the IM is decelerated to 500rpm within 3 seconds. After staying at 500 rpm for 1 second, the machine is accelerated to 2,500 rpm again within 3 seconds. The waveform on the top is the actual rotor speed and the second the electromagnetic torque. The third is the DC bus voltage and the fourth the corresponding phase currents. The bottom two waveforms show details of the phase voltage and current (1/20 scaled) for two moments, one in generating and another motoring operation. IV. PROTOTYPE AND EXPERIMENTAL RESULTS

current is very well controlled in terms of magnitude and frequency. Compared to the results shown in Fig.6 investigated by computer simulation, the starting currents produced by the prototype are satisfactory.

P h ase C u rre n t (4 0 0 A /d iv )

To prove the hardware design and the control strategies investigated by computer simulation, a prototype system is designed, built and tested in the laboratory environment. Fig. 9 shows the inverter prototype built according to the design specifications. The software development platform is TMS320F2812, a newly released DSP with highly integrated peripherals.
T im e (2 s/d iv )

Figure 10. Experimental result of starting current (400A/div, 2s/div)

Figure 9. Prototype of the 10 kw Inverter

A. Testing results of inverter current capability A three-phase R-L load bank is used to test the current capabilities of the inverter with thermal conditions monitored. 1) Starting current testing The experiments are conducted in two parts to test the inverter current capabilities. In the first part, the current is controlled corresponding to the starting process. The testing results are shown in Fig. 10. In this part, the current is raised extremely high, about 1,500 amps, for several seconds and then lowered gradually to 400 amps. If the same current was sent to the induction machine, the corresponding speed range in starting is from zero to 5,000 rpm. That translates into a frequency range of 0-167 Hz. The entire starting process lasts about 20 seconds while the 1,500 amp current lasts only about 5 seconds. In Fig. 11 the starting current waveform is amplified to show the details. As the testing results indicate, the inverter hardware and controller software have functioned well and the

P h a se C u rre n t (4 0 0 A /d iv )

T im e (0 .2 s/d iv )
Figure 11. Detail of the starting current shown in Fig.10 (400A/div, 0.2s/div)

Corresponding to the AC current shown in Fig. 10, the actual DC bus current is recorded to investigate the real power flowing through the battery pack. Fig. 12 shows the DC current seen by the battery pack (- ibat in Fig. 5) during starting with AC current peaked to 1,500 amps. The experimental result reveals that the DC side current is substantially smaller than that AC side current, actually below 400 amps. Further, most of the high frequency AC ripple components are effectively absorbed by the designed DC bus capacitors. It is clearly verified that the designed ISG is very beneficial for the battery life.

IAS 2004

2759

0-7803-8486-5/04/$20.00 2004 IEEE

D C b u s C u rre n t (8 0 A /d iv )

temperature at 26.0C . The thermal testing results verify that the thermal management design of the inverter is successful. The temperature rise of the heat sink is only 6 degrees, giving sufficient safety margin even if the ISG is momentarily overloaded.

32.5 32.0 31.5 31.0 30.5

Temperature ( c)

30.0 29.5 29.0 28.5 28.0 27.5 27.0 26.5 26.0

T im e (2 s/d iv )

Figure 12. Experimental result of DC bus current in starting (80A/div, 2s/div)

25.5 0 1 2 3 4 5 6 7 8 9 10

2) Continuous operation mode In the second part of testing, the inverter operates in the continuous mode, quite different from the brief starting process. The second part of the experiments is to verify the continuous current capability and thermal stability of the inverter package. In the proposed ISG system, the induction machine is to operate as a generator in the frequency range of 250-400Hz. Fig. 13 shows the experimental results for the continuous operation mode at 400Hz. To reach the stabilized thermal condition, the inverter has been in continuous operation for more than 10 minutes.

Time (minute)

Figure 14. Heat sink temperature vs. time in continuous operation

ia

ib

B. Experimental testing results with induction machine The prototype ISG is also tested with an induction machine. Due to the lab limitation, we cannot test the ISG inverter with the most suitable induction machine but a substitution of similar conditions at higher power and voltage rating a 45-kw 6-pole induction machine. The DC bus voltage is also modified to 36V. The parameters for the induction machine under test are shown in appendix.
P h ase C u rre n t (5 0 A /d iv )

D C B u s C u rre n t (5 0 A /d iv )

Figure 13. Current waveforms (phase A and B) in continuous operation (300A/div, 1ms/div)

T im e (1 s/d iv )

Thermal behavior of the inverter is monitored by a thermal coupler placed on one side of the heat sink, near the power MOSFETs. Temperatures changing with respect to time are recorded and the results are shown in Fig. 14. The exponential fitting-curve obtained from the temperature vs. time shows the heat sink temperature reaches its steady state at 31.8C after 10 minutes in the ambient

Figure 15. Experimental results for sensorless IFO control (50A/div, 1s/div)

In testing, the induction machine is operated as a motor and a generator alternatively with trapezoidal speed profile. In the experiment, the IFO sensorless control is applied and the experimental results are shown in Fig.15. The top trace shows the phase current (50A/div) and the bottom the dc bus current

IAS 2004

2760

0-7803-8486-5/04/$20.00 2004 IEEE

(- ibat in Fig. 5, 50A/div). The next two traces as shown in Fig. 16 are the amplified waveforms shown in Fig. 15. It is clearly shown by these traces that when the AC current reverses its sequence at the very low frequency, it is the time the rotor reverses its rotation direction. At the same moment the induction machine switches it operation mode from generation to motoring. The power flow to the battery also reverses its direction as indicated by the DC link current. It is also noticeable that during high speed cruise, the DC battery current is negligibly small although the AC current through the induction machine still quite large.

From the testing results, it seems that more compact package in design is possible without sacrificing thermal robustness. Novel package technology such as direct copper bonded DCB will be one possibility to both allowing electrical isolation and improving the thermal properties of the overall system. Investigation on these new ideas is planned in our future work and results will be published once available. APPENDIX The parameters of the 45kw 6-pole three-phase induction machine used for the experiment are: Stator resistance Rs=0.027 ; Rotor resistance Rr =0.048 ; Stator leakage inductance Lls =46.4 H ; Rotor leakage inductance Llr =46.4 H ; Magnetizing inductance Lm=1.67 mH ; Inertia J=0.177 kg m 2 . REFERENCES
Shaotang Chen, Lequesne, B. Henry, R.R, Yanhong Xue and Ronning, J.J, Design and testing of a belt-driven induction starter-generator, IEEE Trans. On Ind. Applicat., Vol. 38, pp. 1525 1533, Nov./Dec. 2002. [2] Soong, W.L., Ertugrul, N., Lovelace, E.C. and Jahns, T.M., Investigation of interior permanent magnet offset-coupled automotive integrated starter/alternator, in Conf. Rec. IEEE-IAS Annu. Meeting, 2001, pp. 429 436. [3] Leonardi, F. and Degner, M., Integrated starter generator based HEVs: a comparison between low and high voltage systems, in Proc. IEEE IEMDC, 2001, pp. 622 628. [4] Kahlon, G.S., Mohan, R., Liu, N. and Rehman, H., A case study of starting power requirement: for Visteon Integrated Starter-Alternator system, in Proc. IEEE Digital Avionics Systems Conference, 1999, pp. 8.B.4-1 - 8.B.4-7. [5] Caricchi, F., Crescimbini, F., Capponi, F.G. and Solero, L., Permanentmagnet, direct-drive, starter/alternator machine with weakened flux linkage for constant-power operation over extremely wide speed range, in Conf. Rec. IEEE-IAS Annu. Meeting,2001, pp. 1626 1633. [6] Belverde, G., Guastella, C., Melito, M.; Musumeci and S.; Raciti, A. A low-voltage MOSFET with small on-resistance: an extended characterization in high-efficiency power converter applications, in Conf. Rec. IEEE-IAS Annu. Meeting, 2001, pp. 635 640. [7] Tuckey, A.M.and Krase, J.N.; A low-cost inverter for domestic fuel cell applications, in Proc. IEEE PESC, 2002, pp. 339 346. [8] Seyoum, D., Rahman, M.F. and Grantham, C., Inverter supplied voltage control system for an isolated induction generator driven by a wind turbine, in Conf. Rec. IEEE-IAS Annu. Meeting, 2003, pp. 568 575. [9] Leidhold, R., Garcia, G. and Valla, M.I., Field-oriented controlled induction generator with loss minimization, IEEE Trans. On Ind. Electron., Vol. 49, pp.147 156, Feb. 2002. [10] Cardenas, R. and Pena, R., Sensorless vector control of induction machines for variable-speed wind energy applications, IEEE Trans. On Energy Conversion, Vol. 19 , pp. 196 205, March 2004. [11] Derdiyok, A., Guven, M.K., Rehman, H., Inanc, N. and Longya Xu, Design and implementation of a new sliding-mode observer for speedsensorless control of induction machine, IEEE Trans. On Ind. Electron., Vol. 49, pp. 1177 1182, Oct. 2002. [1]

Figure 16. Waveform details of Fig. 15 (50A/div, 0.2s/div)

V.

CONCLUSIONS

The design and control of an ISG inverter circuit for kiloamp operation is presented. Various critical issues related to the high current capability, compact package, and reliable operation are discussed and solutions provided. A 10kw prototype is designed and built according to the theoretical assessment. The prototype is tested with a R-L load bank to verify the extremely high starting current capability, compact packaging, and robust thermal management. Both computer simulation and testing results demonstrated the success of the ISG system for starting and continuous generating. The thermal stability is proven and temperature rise leaves sufficient margin to tolerant substantial overload conditions. Furthermore, the DC bus current demonstrates excellent behavior during interval of high starting AC current, providing evidence of much extended battery life. With the newly developed high performance DSP, advanced algorithm of sensorless IFO control of AC machines has been implemented for the ISG system. The testing results show that field orientation control and sensorless algorithms are very suitable approaches for achieving high torque starting, high efficiency, and reliable operation of ISG systems.

IAS 2004

2761

0-7803-8486-5/04/$20.00 2004 IEEE