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RESEARCH ARTICLE

Ali HMIDET, Rachid DHIFAOUI, Driss SAIDANI, Othman HASNAOUI

Development of an experimental platform for research inenergy and electrical machine control

© Higher Education Press and Springer-Verlag Berlin Heidelberg 2010

Abstract This paper presents the development of a testbench dedicated for electrical machines and energycontrol, as realized by the research team of the PowerSystems and Electrical Machines Laboratory (RME) of theNational Institute of Applied Sciences and Technology(INSAT) in Tunisia. The principal components of theproposed test bench are explained, and the respectivecharacteristics are given. This paper focuses on mountinglow-cost sensors and developing reliable scientific results.The relevant obtained results in photovoltaic (PV) andwind energy fields, power measurement and control, aswell as alternating current (AC) machine drives arelikewise presented. These are supported by two signalprocessing controller boards based on TechnosoftMCK240 and dSPACE DS1104 kits. In the wind energyfield, some results relative to Self Excited InductionGenerator dedicated to supplying isolated sites arediscussed; in addition, water pumping is discussed forPV energy. In the AC drives area, the results of a closedloop control are presented using a developed direct voltagecontrol (DVC) scheme implemented on dSPACE DS1104.Maps and interesting details of some realized sensors arealso presented.

Keywords test bench, induction motor, solar energy,wind energy, AC/DC/AC converter, sensors and powermeasurements

1 Introduction

The technology of digital signal processors (DSP) hasrapidly evolved, revolutionizing the field of motor controland enabling more sophisticated and efficient controlalgorithms. Static power inverters with various configura-tions play a crucial role in the practical materialization ofthe proposed digital control schemes. Power electronics isthe principal key for flexible energy modulation, voltage,current, and frequency adjustment. On the other hand,energy optimization, saving, and production is a strategictopic that takes into account the energy crisis and possiblestressed future international relations in petroleum and gasresources markets and exchange. Developments in solarand wind energy, for example, are high priorities for theinternational community. These cited factors are linkedclosely and are highly dependent on measuring, visualiz-ing, and checking installed equipments. Systems efficiencyand reliability likewise result from good sensing.Scientific research and development teams and labora-

tories around the world recognize that investigated subjectsshould be considered in the general concept previouslyoutlined. The proposed themes are constrained by practicalconsiderations that should be treated in a global environ-ment, including at least three fundamental components: theindustrial processes, the control unit, and the measurementand acquisition circuits. An immediate benefit of takinginto account these components in the same investigatedsubject is the ability to build an adequate knowledgeprofile for future researchers; in turn, this could lead to theacquisition of more powerful scientific and technologicalcapabilities. For example, power electronics is a complexsubject requiring students to grasp knowledge from a widenumber of areas, including solid state power devices,converter topologies, power systems, electrical machines,control theory, digital signal processing, instrumentation,analog to digital and digital to analog conversion, and soon.The power systems and electrical machines (RME)

research group at the National Institute of Applied Science

Received March 15, 2010; accepted April 22, 2010

Ali HMIDET (✉), Rachid DHIFAOUI, Driss SAIDANIRME Research Group, National Institute of Applied Sciences andTechnology (INSAT), Rue de la terre BP676, 1080 Tunis, TunisiaE-mail: [email protected]

Othman HASNAOUIHigh School of Sciences and Techniques of Tunis, 5 Avenue TahaHussein 1008 Tunis, Tunisia

Front. Energy Power Eng. China 2010, 4(3): 366–375DOI 10.1007/s11708-010-0106-x

and Technology (INSAT) of Tunisia was established sixyears ago, and its main domain of interest lies in powersystems and electrical machines. Various studies and drivesimulation programs have been developed, covering directtorque control (DTC) [1] and field-oriented control (FOC)[2] of induction machine, wind energy conversion systems(WECS) [3–4], unified power flow controller (UPFC) [5]of conventional power systems, and so on. However, themost important part of the realized studies is yet to bevalidated experimentally. This is because the proposedsubjects are closely defined around specific problems andare not considered in a conceptual and practical manner. Ifevery single research team starts from scratch, builds itsown power electronics system, and utilizes its owninstrumentation, signal processing, and control systems,no enduring practical results could be obtained within areasonable period.To overcome these problems and to orient the future

work of the RME research group to a general and globalstrategy accounting for the three fundamental components,including practical industrial processes, new digitaltechnology control and data, and measurements analysis,RME has focused its effort in the last two years to alaboratory supporting scientifically treated subjects. Thelaboratory design is then realized in accordance withprincipal domains of interest that emphasize the followingtopics:1) electrical machines and energy sources to illustrate

industrial processes;2) static power inverters to ensure variable alternating

current (AC) and direct current (DC) drives;3) computers and DSPs for optimization and control;

and4) measurement and visualization materials.This paper provides a comprehensive overview of the

developed laboratory and presents some illustrative results.

2 Developments in solar energy domain

The installed system includes a photovoltaic (PV) powersource and related sensors. Figure 1 shows the installed solarpower source with 10 PV panels, each with 50W and 17Vrated power and voltage, respectively. The current-voltagecurves (Fig. 2) are distinguished for various irradiationvalues and open loop typical maximum power detection.An interesting closed loop experience is achieved for

water pumping (Fig. 3). As can be seen, the PV panels areseries connected, and the DC-obtained source is used tosupply a three-phase inverter driving a water pump.In the pump water tests, the inverter was driven by the

DSP Kit MCK240. The kit is a complete standalonesystem proposed by Technosoft based on the 16-bit fixedpoint TMS320F240 (F240) DSP controller. It features amonitor chip evaluation application, graphical DMCenvironment analysis tool, and DMC Developer Pro [6].

In addition, the DSP kit includes the following: an eventmanager, a set of pulse-width modulation (PWM) genera-tion functions with 12 outputs having 0–5 V logic levels, aprogrammable dead-band function, a space vector PWMgenerator for a three-phase inverter, three independent up/down timers, three compare units, and a dual 10-bitanalog-to-digital converter (ADC) with 16 input channelsthat could perform two simultaneous conversions within6.6 ms.

Fig. 1 Installed PV panels

Fig. 2 Current versus voltage curves for different irradiations(a) 977W/m2; (b) 853W/m2; (c) 229W/m2; (d) 155W/m2

Fig. 3 Water pump experience

Ali HMIDET et al. Energy and electrical machines control 367

The written C-language program is capable of generat-ing space vector PWM signals, fundamental frequency,and voltage ratio reference values. The fundamentalfrequency of the three phase voltage supplying the pumpis then linked to the irradiation signal using an establishedoff line curve.The problem of maximum power point tracking (MPPT)

requiring a boost inverter generating a high input/outputDC voltage ratio is currently being addressed, and thisdevice is now in the final stage of validation. Figure 4shows the preliminary obtained results. As can be seen, the10 PV panels are parallel connected, and the duty ratio ofthe boost inverter is manually adjusted to observe themaximum power corresponding to a given irradiationvalue. Curves (a), (b), and (c) in Fig. 4 correspond todifferent resistance load values, and experience is gained atmedium and constant irradiation.

Irradiation and temperature information is useful in solarenergy experimentation. Generally, in order to reduce thecost of the system and to allow students and researchers toacquire adequate technological and scientific backgroundin sensor prototyping, irradiation, and temperature sensorsare designed and realized in the laboratory.Given that the short circuit current of a PV source varies

linearly with irradiation and is not significantly sensitive totemperature, this property is used to build an irradiationsensor that utilizes a small PV panel of 7.5 Vand 1W ratedvoltage and power, respectively. The panel is short-circuited by a resistance of 0.24Ω, and the capturedvoltage signal from this resistance is amplified to 10 Vcorresponding to an irradiation value of 1000W/m2. Figure5 illustrates this sensor.To measure ambient temperature, this study employed

the phenomenon of decreasing voltage diode in relation totemperature increase. If a diode is excited by a constant andstable current, the voltage across the diode will vary

linearly opposite the temperature. This principle wasconsidered in this study because of its ability to look fora simple temperature evaluation and an inexpensive circuit.In realizing the device, the silicon diode 1N5406 was usedin the well-known logarithmic operational amplifier-basedcircuit, as demonstrated in Fig. 6. The circuit was realizedso that the inverter pin of IC1 was practically ground, andthe current through the diode was a constant fixed by thepolarization voltage.

First, the output voltage diode VD was amplified, withGD as the gain. Then, at a reference temperature T0, theobtained voltage was compared to an alternative andsymmetric saw tooth signal oscillating at �VST andsuperimposed on a DC voltage component equal toGDVD0

. The comparator is a simple operational amplifieroscillating at �VCC and gives at T0 a duty ratio of 50%.The comparator output oscillating signal supplies a seriesresistor-capacitor (RC) load. The capacitor voltage outputV0 at any temperature T is proportional to the differencetemperature ðT – T0Þ as indicated by

V0 ¼ SDGDGVðT – T0Þ: (1)

In the above, SD is the ðV=°CÞ temperature sensitivitycoefficient of the diode, and GV is the ratio between thepolarization voltage VCC and the saw tooth signalmagnitude VST. Here, GD ¼ 20:5 and GV ¼ 7:5.

Fig. 4 MP detection for various load values(a) 43W; (b) 60W; (c) 103W

Fig. 5 Realized irradiation sensor

Fig. 6 Principal elements of realized temperature sensor

368 Front. Energy Power Eng. China 2010, 4(3): 366–375

The calibration procedure was such that the outputvoltage V0 varied in the same manner as the temperature.The VM132 sensor of Velleman Supplier served as thethermometer used as reference in this calibration. Figure 7summarizes the result, and as can be seen, the slope of thiscalibration curve is 361 mV/°C. Taking into account thevalues of GD and GV, the temperature sensitivitycoefficient of the diode could be deduced as SD =2.3 mV/°C, which is a reasonable value. The final establishedtemperature sensor has the following characteristic:

T ¼ 2:78V0 þ 34:5: (2)

3 Developments in wind energy domain

The RME research group has been participating in anational program (federate program for wind energydevelopment) aiming to develop the field of wind energy.A recommended subject is the investigation of small windturbines dedicated to the study of isolated sites. This kindof turbine uses an asynchronous motor working as a self-excited induction generator (SEIG). This means that thereactive energy of the motor is supplied by a shuntcapacitor.A DC motor mechanically coupled to a classical

wounded rotor asynchronous motor shunted by a capacitorwas installed. The DC motor emulating the wind turbine isvoltage- or current controlled. The capacitor is adequatelydimensioned such that sufficient output voltage levels fordifferent speed values could be obtained. The obtainedSEIG could be used in an autonomous mode (passive load)or coupled to an available three-phase alternative energysource by an AC/DC/AC static inverter. Figure 8 presentsthe installed system. Figure 9 shows the temporalevolution during the start-up operation of the DC motorvoltage and current, as well as the current of the loadsupplied by the SEIG. The DC motor current is regulated bya hysteresis analog command loop that has also been realizedin the laboratory. Figure 10 summarizes the simulated

(dashed line) and experimental (continuous line with a star)voltage-current curve of a passive load supplied by the SEIG.The most important problem of the SEIG is the

occurrence of voltage collapse when highly loaded. This

Fig. 7 Calibration curve of the realized temperature sensor

Fig. 8 Isolated wind turbine emulator

Fig. 9 Evolution of DC motor voltage and current and SEGcurrent during start-up operation

Fig. 10 Load voltage-current curve


phenomenon could be monitored through total SEIGdemagnetization. To establish a magnetic field capable ofexciting voltage increase, a small dynamo to inject a DCcurrent into the rotor was installed on the shaft.

4 Developments in static inverters domain

The AC/DC part of the system is a three-phase diodebridge rectifier SKD 25/08 with 800 V rated voltage. Theobtained DC voltage was filtered by two capacitors(470 mF, 350 V) that were series connected. This ensuresan adequate DC bus for the second part, which is the DC/AC inverter. The legs of this inverter are six N-channelPower MOSFETs IRFP460 of 500 Vand 20A rated voltageand current, respectively. These power components wereplaced on accumulations to ensure sufficient cooling.The control circuit consisted of three blocks: a PWM

signal generator, an insulation circuit, and a driver. ThePWM signal generator was ensured by the DSP kit, and thegalvanic insulation block used high-speed HCPL2531 optocouplers. This circuit protected the DSP against highvoltage due to possible faults at the power side. Only threehigher or lower gate drive signals from the DSP Kit wereused. Complement signals were obtained using theintegrated circuits HEF4069. The driver block used theInternational Rectifier IR2130 chip, a high voltage, high-speed power MOSFET, and IGBT driver with threeindependent high and low side referenced output channels.The gate drive IR2130 works with 2.5 ms dead time andcould protect the bridge transistors from over currentconditions.The biggest problem during realization concerns the

bootstrap supply. Three adequate bootstrap capacitors arerequired to supply power for the floating outputs of thedriver. The values of these capacitors are a function of thegate charge requirements of the power switch and themaximum power switch “ON” times. The internal floatingdriver current must thus be supplied from the bootstrapcapacitors. Aside from these energy requirements, thecapacitor should have enough remaining charge to avoidunder voltage shutdown (8.3 V nominal) [7]. In therealization, three identical capacitors of 1.2 mF wereselected. Between these capacitors and the Vdd pin of thedriver, a fast-response diode should be connected, which,in this case, refers to diode BY229. The basic structure ofthe realized inverter is given in Fig. 11, and the detailedcircuit is illustrated in Fig. 12.

5 Developments in power measurementdomain

Instantaneous information of active and reactive powers isimportant in achieving high performance in real-timecontrol. An analog sensor to measure instantaneous activeand reactive powers of a three phase power system wasthus designed and realized in this study. This sensor iscomposed of three blocks, as shown in Fig. 13. The firstconcerns voltage and current measurement, the secondrealizes the Concordia direct and quadrature components,and the third deals with active and reactive powerdetermination.The circuit to be sensed is considered delta connected;

therefore, line voltages are linked to the phase to groundvoltages as presented by

Fig. 11 Block diagram for the AC-DC-AC converter


Vna ¼ ðUca –UabÞ=3,Vnb ¼ ðUab –UbcÞ=3 ¼ ð2Uab þ UcaÞ=3,Vnc ¼ ðUbc –UcaÞ=3 ¼ – ð2Uca þ UabÞ=3:

8><

>:(3)

The studied system is assumed to be balanced; therefore,Concordia transformation leads to the following voltage

and current d-q components:

Vd ¼ffiffiffi3

2

r

Vna ¼ –Uab þ Uacffiffiffi

6p ,

Vq ¼Vna þ 2Vnb

ffiffiffi2

p ¼ Uab –Uacffiffiffi2

p ,

8>><

>>:

(4)

Fig. 13 Structure of the P and Q sensor


Id ¼ffiffiffi3

2

r

Ia,

Iq ¼Ia þ 2Ib

ffiffiffi2

p :

8>><

>>:

(5)

This transformation reduces the number of current andvoltage sensors and reduces consequent cost and dimen-sions of the electronic circuit to be implemented. Only fourHall effect sensors (LEM) are required to obtain low-levelvoltage and current signals. The LEMs used for voltageand current are LV25P and LA25P, respectively. Analogsignals representing the direct and quadrature voltagecomponents of Eq. (4) are generated by an operationalamplifier-based circuit, which implements gains and sumoperations. This circuit is presented in Fig. 14, wherein IC1and IC3 are summing and inverting amplifiers whose gainsare ð1= ffiffiffi

6p Þ and ð1= ffiffiffi

2p Þ for Vd and Vq, respectively. IC2 is

an inverting amplifier with unitary gain used only to obtain( –Uab).To avoid using additional gains, the implementation of

direct and quadrature current components given by Eq. (5)is simplified to Id ¼ Ia and Iq ¼ ðIa þ 2IbÞ=

ffiffiffi3

p. Therefore,

the realized circuit is limited to the Iq component.Direct and quadrature voltage and current components

define active and reactive powers as

P ¼ VdId þ VqIq, Q ¼ VdIq –VqId: (6)

According to these equations, measuring active andreactive powers requires four multiplications and twosums. Integrated circuit AD632 is used to achievemultiplications, while the operational amplifier is used torealize sums.The built watt-var sensor is used in laboratories for

various applications. For example, Figure 15 shows theevolution of active and reactive powers for a practical stepchange of load.

6 Examples of developments inasynchronous machine control

An important part of work dealing with electrical machine

control concerns induction motor. Figure 16 gives anoverview of the benchmark.The focus is on real-time applications, and efforts are

centered on using the dSpace DS1104 R&D ControllerBoard. This device is specifically designed to develophigh-speed multivariable digital controllers and real-timesimulations in various fields. It is a complete real-timecontrol system based on a 603 PowerPC floating-pointprocessor running at 250MHz. For advanced input/output(I/O) purposes, the board includes a slave-DSP subsystembased on the TMS320F240 DSP microcontroller. Forpurposes of rapid control prototyping (RCP), specificinterface connectors and connector panels provide easyaccess to all I/O signals of the board. The DS1104 R&DController Board is equipped with the following periph-erals:1) a set of four multiplexed channels, 16-bit sample and

hold ADC, four parallel channels, 12 bit sample and holdADC;2) dual 10-bit Analog to Digital conversion Module;3) a PWM generation block that could generate six

PWM pulses to fire the switches of a three-phase inverter;4) a 24-bit digital incremental encoders interface;5) 20-bit digital I/O channels; and6) serial interfaces RS232/RS485/RS422.The I/O ports of CP1104 are accessible from inside the

Simulink Library browser. The process of creating aprogram in Simulink and the procedure to use the I/O portof CP 1104 are detailed in the experiments. When theSimulink model is built in real-time, the model is thenconverted into a real-time system on hardware (DS1104).Simulink generates an *.sdf file when the model isconverted into real time. This file provides access to thevariables of the Simulink model in the Control Desksoftware. In this software, a control panel could be created,which allows changing the variables of the Simulink modelin real time to communicate with DS1104; hence, it couldchange the reference quantities, such as speed or torque ofthe motor [8].One aspect of implemented control schemes is the scalar

constant voltage-frequency ratio (CVFR) technique. Awell-known version of the CVFR technique uses themeasured machine speed signal and a PI controller to

Fig. 14 Practical circuit of voltage components


define the electrical frequency reference, and the voltagereference is considered proportional to this frequency [9,10]. To keep the voltage reference in the permittedpractical limit, a saturation block is added, as indicatedin Fig. 17, which sketches this implemented controlstructure. In this structure, the presence of the referenceblock (voltage and frequency commands) is defined byCVFR as well as by the DVC block which generates the

power inverter command signals. The DVC approach ispresented in detail in [11,12]. This approach uses aconstant switching time interval as in the standard DTCscheme. It is based on a very strong min (max) criteriondedicated to selecting an inverter voltage vector.In practical implementation, the main drawback of the

CVFR procedure lies in the effect of the stator-voltagedrop at low-speed operation. The voltage drop at lowfrequencies has the same order of magnitude as thecomputed voltage and makes the method inadequate forlow-speed regions. This problem could be partiallycompensated by applying the following relation, whereinV0 is the boost voltage, and Kv is the slope that correspondsto the nominal stator flux value:

Vs ¼ V0 þ Kvωs: (7)

This control structure could be enhanced by introducingan improvement upon the classical PI. In severe transientregimes, such as in an induction machine start-up, thesaturation of the manipulated variable could involve aphenomenon of racing the integral action, which is likelyto deteriorate the performances of the system or evendestabilize it completely. To overcome this phenomenon,an internal anti-wind-up loop has been added andimplemented in the digital PI controller [13]. A Simulinkmodel implementing the PI controller with the anti-wind-up scheme is demonstrated in Fig. 18. The source of thefeedback to the integrator is the difference between theinput (upstream value) and the output (downstream value)of the saturation block. If “windup occurs” and the controlsignal becomes larger than the saturation limit, thedifference becomes negative. This negative value is passedthrough a gain block (tracking time constant) beforearriving as feedback to the integrator.

To evaluate the performance of the implemented controlstructure, a series of measurements was accomplished.These measurements correspond to a perturbation scenarioconsisting of two cases.Case 1 The induction machine initially runs at a

constant speed reference of 157 rad/s and at no loadregime. A load torque of 3 N$m is applied at a time intervalFig. 17 Block diagram of closed loop scalar control approach

Fig. 18 Reference frequency generator with the anti-wind-up PIcontroller

Fig. 16 A test bench for AC machines

Fig. 15 P,Q evolution for a step change of load


of 10 s, and then, the load is removed. This casecorresponds to a step-up and a step-down torque perturba-tion. The motor load is a magnetic powder brake,generating a torque proportional to its DC excitationcurrent. Figure 19 corresponds to this case and presentstime responses in accordance with� stator reference pulsation ωs at the output of the anti-

wind-up PI controller (curve a: red color);� electrical rotor speed ωr captured by the speed sensor

using an incremental encoder having 360 pulses perrevolution (curve b: green color); and� voltage duty ratio defining the reference value for

stator voltage magnitude (curve c: blue color).This torque perturbation has a small effect on machine

speed and has practically the same value in steady state.Only a small and dumped variation occurs as the torqueincreases and decreases, implying that the anti-wind-up PIcontroller has successfully worked and machine speedconverged to its reference value. In Fig. 19, the machinespeed deviation could be evaluated in percent with respectto the reference value. This deviation is negligible since itremains at less than 5%.

The most important effect resulting from torqueperturbation appears at stator pulsation and voltagemagnitude. Based on the classical theory of inductionmachine and on the practical operating area of speed-torquecurve, torque is considered proportional to both frequencyand the square of voltage. These properties explain whystator voltage and pulsation trajectories have the same shapeas the torque command. Finally, in Fig. 19, it can be seenthat system dynamics corresponds to a settling time of aboutone second and a maximum overshoot of less than 5%.Case 2 The induction machine initially runs under a

load torque producing a rotor speed of 94.2 rad/s. Thetorque of the load is kept constant, resulting in therealization of a positive and a negative step change of thespeed reference. Speed command is suddenly increasedfrom 94.2 rad/s to 188.5 rad/s, before decreasing to theinitial value 94.2 rad/s. Figure 20 corresponds to this caseand shows the following:� machine speed reference ωref (curve a: red color);� electrical rotor speed ωr (curve b: green color);� stator reference pulsation ωs (curve c: blue color); and� voltage duty ratio (curve d: light blue color).

Fig. 20 System response for Case 2

Fig. 19 System response for Case 1


These results prove the good performance of theproposed control structure. The machine speed reachesits command without undesirable lag or overshoot; there-fore, a stable steady-state point is obtained. The voltageduty ratio trajectory is highly similar to that of statorfrequency. The control structure is built on a constantvoltage-frequency ratio principle. Dynamic behavior ischaracterized by a rise time of about 0.4 s, a peak time of0.6 s, and a settling time, which practically corresponds to2 s. Maximum overshoot is estimated at 4.5% for the noload regime.

7 Conclusion

An experimental platform realized by the research team ofRME of INSAT in Tunisia is presented in this paper, andthe topics and relevant results obtained by the variouscomponents of this test bench are explained. Energygeneration and control as PV and wind energy, ACmachine drive, and the development of a variety of low-cost and reliable sensors are also discussed. A particularinterest is attributed to the use of new technology controlcomponents and software as DSPs. Noteworthy observa-tions resulting from the use of DSP and dSPACE Kits forwater pumping and induction machine control arepresented. The realized experimental platform is nowcurrently used by the research team to improve its scientificworks. This practical experience has effectively enhancedthe scientific knowledge profiles and technological cap-abilities of the team in various subjects, including solidstate power devices, converter topologies, power systems,electrical machines, control theory, digital signal proces-sing, instrumentation, analog to digital and digital toanalog conversion, and so on.

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