Drazen Dujic

ABB Corporate Research, Baden-Dttwil, Switzerland

Power Electronic Transformer for railway

on-board applications an overview
ABB Group
April 5, 2013 | Slide 1
PET Power Electronic Transformer
Overview
Why Power Electronic Transformer?
What is Power Electronic Transformer?
PET Topologies
Medium Frequency Transformer
ABB work on PET

AC Catenary AC Catenary
15 KV, 16.7 Hz / 25 KV, 50 Hz 15 KV, 16.7 Hz / 25 KV, 50 Hz

Medium
Low frequency Main Converter frequency
Traction Motor Traction Motor
main transformer transformer
LFT MFT
HV LV
DC link DC link DC link
= 1~ = =
1~ M M
3~ 3~
= 3~ = = 3~

Rail (ground) Rail (ground)

ABB Group
April 5, 2013 | Slide 2
PET - Power Electronic Transformer
Classical Transformer

Line Frequency Transformer LFT

Provides galvanic isolation
Adapts the voltage levels
Dummy aparatus
Operates with AC quantities

ABB Group
PET - Power Electronic Transformer
What is PET?

Power Electronic Transformer is not a transfomer replacement

a converter
provides galvanic isolation
provides voltage adaptation (both type and level)
works with AC or DC quantities at its input/output
provides additional functionalities (not dummy anymore)
uses Medium Frequency Transformer(s) MFT(s)
has Power Electronics (PE) input/output interface
LFT
~ MFT ~
~ ~ OR OR

= =

ABB Group
PET Power Electronic Transformer
Railway Systems in Europe

ABB Group
April 5, 2013 | Slide 5
PET Power Electronic Transformer
Why PET? Size Power

Pt
Ap
K f K u Bm Jf
Waveform Insulation Material Cooling Frequency

ABB Group
April 5, 2013 | Slide 6
PET Power Electronic Transformer
The Others

Bombardier Alstom/SMA

ABB Group
Siemens EPRI
April 5, 2013 | Slide 7
PET Power Electronic Transformer
Early Works
Cycloconverters (SCR based)
Cascaded Cycloconverters (IGBT based)
Between 200Hz - 400Hz on the MFT

ABB Group
April 5, 2013 | Slide 8
PET Power Electronic Transformer
Early Works ALSTOM (2003) - prototype
Cascaded H-bridges and resonant DC-DC converters
Single multi-winding MFT
5kHz on the MFT (ferrite core)
Not commissioned on train

ABB Group
April 5, 2013 | Slide 9
PET Power Electronic Transformer
Early Works ABB (2006) - prototype
EMU
1.2MVA / 2,15 MVA
peak
15 kV, 16.7 Hz
IGBT: 3.3 kV
16 levels / cells
MFT: 400Hz

ABB Group
April 5, 2013 | Slide 10
PET Power Electronic Transformer
Early Works (more)
Cascaded H-bridges
Resonant DC-DC converters (LC or LLC)
Multiple MFTs
Between 4kHz 10kHz on the MFT
M2LC based (SIEMENS)

ABB Group
April 5, 2013 | Slide 11
PET - Power Electronic Transformer
MFTs for Traction

Challenges: Design Choices:

Insulation requirements Magnetic Materials
PD Nanocrystalline
BIL Amorphous
Aging Ferrites
Thermal Cycling Windings
Cooling effort Copper (Litz)
Skin / proximity effects Aluminium (foil)
Weight and Volume restrictions Insulation
Integration aspects Air / Solid / Oil
Mechanical (shock and vibrations) Cooling
Cost Air / Oil / Water

ABB Group
PET - Power Electronic Transformer
MFTs for Traction some examples

ABB: 350kW, 10kHz BOMBARDIER: 350kW, 8kHz SIEMENS: 450kW, 5.6kHz

ABB: 3 x 150kW, 1.8kHz IKERLAN: 400kW, 1kHz IKERLAN: 400kW, 5kHz

ABB Group
PET Power Electronic Transformer
Recent Work 1.2MVA Prototype
Volume MTBF
A
Weight MTBF MTTR
15kV/16.7Hz
Efficiency
PET
Complexity
1. 2. 4.
Reliability?, Availability?
1~ =
= 3~ Redundancy?, Cost?
5.

AC
1~ = 15 kV / 16.7 Hz
3. Crowbar

= 1~

Control 3. 3. 6.
Cooling Start Up 4. 5.
A System 1~ =
Mechanics
U 1. 2.
X = =
PET 2
1~ = PET 3
PET 4 7.
= 3~
PET 5
PET 6
AC
1~ = PET 7
Crowbar

= 1~ PET 8

Control Control CONTROL

Cooling Cooling COOLING
Mechanics Mechanics MECHANICS

ABB Group
April 5, 2013 | Slide 14
PET Power Electronic Transformer
Where did it go?

1
AC low/AC
medium frequency AC/DC
Medium
frequency
transformer
2

ABB Group
April 5, 2013 | Slide 15
PET Power Electronic Transformer
Recent Work 1.2MVA Prototype Catenery PETT
15kV 16 2/3 Hz Power Electronics Traction Transformer Legend:
Pantograph
HV PEBBs LV PEBBs 6.5 kV 200 A IGBT
6.5 kV 400 A IGBT
Short LRC 3.3 kV 800 A IGBT
AFE Resonant MRC
U_Line
U
Line side Circuit
IGBTs
(Active Front
End)
(Line side of
Resonant Tank (Motor side of
Resonant Converter)
Motor side i + direction
measurements
Converter)
U

Resonant Converter
1500V DC+ Udc_pos M
AFE9 LRC9 MRC9 D DC Traction
LEVEL9 2
S1 S3 S1 S1 motor
Earth discon.
R1

C1

C1

R1
Idc_pos M
SC9 TR9
MCB Lm M M
S1 S2 Lr
Udc_np_L9 Controlled
Cr
R2

C2

C2

R2
Ir9LV by MICAS
Earth discon. 1500V DC-
Udc_neg M
S2 S4 S2 S2
I_LineHigh

Idc_neg M
LEVEL8
inducatnce

SC8 AFE8 LRC8 TR8 MRC8 Udc_np_8

Input

Ir8LV

LEVEL7
SC7 AFE7 LRC7 TR7 MRC7 Udc_np_7
AUX supply
line connector

Ir7LV
15kVA. 3x400V @ 50HZ
Rprechar.

5kVA 36V dc
LEVEL6
SC6 AFE6 LRC6 TR6 MRC6 Udc_np_L6
Ir6LV

LEVEL5
SC5 AFE5 LRC5 TR5 MRC5 Udc_np_L5

Ir5LV
LEVEL4
SC4 AFE4 LRC4 TR4 MRC4 Udc_np_4

Ir4LV
LEVEL3
SC3 AFE3 LRC3 TR3 MRC3 Udc_np_L3

Ir3LV
LEVEL2
SC2 AFE2 LRC2 TR2 MRC2 Udc_np_L2
Ir2LV
Udc_posHVL1
AFE1 LRC1 MRC1 D
S1 S3 S1 LEVEL1 S1
R1

C1

C1

R1

SC1 TR1

Udc_npHVL1 Lm
S1 S2 Lr
Udc_np_L1
Cr
R2

C2

C2

R2
Ir1HV

Ir1LV
S2 S4 S2 S2
I_LineLow Udc_negHVL1

9 levels (cells) with series input-parallel output connection (redundancy (n+1))

Multilevel active front end with DC-DC LLC resonant converters (3.6kV 1.5kV)
Medium frequency transformers (1.8kHz)
ABB Group
April 5, 2013 | Slide 16
PET Power Electronic Transformer
IGBT Back-To-Back Testing Setup
UCSS

Power RSS CSS

UMRC_1 2GND
Ldc1

FS
isDC+
S11 S13 Upos2GND S15 S17
SS
(50A/25A) DC source

C13
R11

R13
C11

TR1
Lr1

RQDD1 SQDD1

GND S
Unp2GND

Lm1 DS CBS

Cr1 ir1

C14

R14
R12

C12
Lg1

S12 S14 Uneg2GND S16 S18

igrid

isDC-
Power
iGND_1
Ldc2

S21 S23 Upos2GND S25 S27

Lg2

C23
R21

R23
C21

TR2 iGND_2
Lr2

RQDD2 SQDD2
Legend:
Unp2GND

Lm2 6.5 kV IGBT

3.3 kV IGBT
Cr2 ir2 measurements
C24

R24
R22

C22

i + direction
S22 Uneg2GND S28
S24 S26

iDC

Used for IGBT characterization.

2 levels Full power rated (3.6kV 1.5kV).
Circulating power: 225kW (1.8MW/8).
fsw: 350Hz AFE, 1.8kHz Resonant LLC DC-DC.
Oil cooled transformers, water cooled PEBB.
ABB Group
April 5, 2013 | Slide 17
 PET Power Electronic Transformer
IGBT Back-To-Back Testing Setup
Bottom waveforms:
S1 S3

Red Resonant current HV side C1

TR
C3

Lr
Blue Resonant current LV side 3.6kV
Cr Lm
1.5kV

C2 C4
S2 S4

6.5 kV 400 A IGBT 3.3 kV 800 A IGBT

PP= =150
25 kW, fsw = 1.8 kHz P = 150 kW, fsw = 1.8 kHz
400
4000 4000
: S25 & S26 [V]

V : S25 & S26 [V]

3000 3000
300
2000 2000
200
1000 1000
V , V , i : [V]/10;V [A]
ce

ce
1000 0
-0.8 -0.6 -0.4 -0.2 0 0.2 0.4 0.6 0.8 -0.8 -0.6 -0.4 -0.2 0 0.2 0.4 0.6 0.8
t [ms]
dc AFE line

0 t [ms]
[A]

-100
: HV & LV side [A]
50 400
: HV & LV side

300
200
-200 100
0 0
-100
-300 -200
res

-50 -300
res
i

-400
i

-400
-0.8
-80 -0.6
-60 -0.4
-40 -0.2
-20 00 0.2
20 0.4
40 0.6
60 0.8
80 -0.8 -0.6 -0.4 -0.2 0 0.2 0.4 0.6 0.8
tt[ms]
[ms] t [ms]

ABB Group
April 5, 2013 | Slide 18
PET Power Electronic Transformer
Low Voltage PET - Simulator

Very helpful for control HW/SW debugging / commissioning.

ABB Group
April 5, 2013 | Slide 19
PET Power Electronic Transformer
Modularity 1.2MVA Prototype
HV PEBB LV PEBB

~ = ~
= ~ =

HV PEBB MFTs LV PEBB

ABB Group
April 5, 2013 | Slide 20
PET - Power Electronic Transformer
Complexity 1.2MVA Prototype
Catenery PETT

P = 1.2MVA, 1.8MVA peak Pantograph

15kV 16 2/3 Hz Power Electronics Traction Transformer
HV PEBBs LV PEBBs
Legend:
6.5 kV 200 A IGBT
6.5 kV 400 A IGBT
Short LRC 3.3 kV 800 A IGBT
AFE Resonant MRC
Line side Circuit (Line side of
Motor side i + direction

9 cells (modular) U_Line

U
U
IGBTs
(Active Front
End)
Resonant
Converter)
Tank (Motor side of
Resonant Converter) measurements

Resonant Converter
1500V DC+ Udc_pos M
AFE9 LRC9 MRC9 D DC Traction
LEVEL9 2

54 x (6.5kV, 400A IGBTs)

motor

S1 S3 S1 S1
Earth discon.

R1

C1

C1

R1
Idc_pos M
SC9 TR9
MCB Lm M M
S1 S2 Lr
Udc_np_L9 Controlled
Cr

18 x (6.5kV, 200A IGBTs)

R2

C2

C2

R2
by MICAS

Earth discon. Ir9LV 1500V DC-

Udc_neg M
S2 S4 S2 S2

I_LineHigh
Idc_neg M
LEVEL8

inducatnce
SC8 AFE8 LRC8 TR8 MRC8 Udc_np_8

18 x (3.3kV, 800A IGBTs) Input

line connector

SC7 AFE7 LRC7

LEVEL7
TR7
Ir8LV

MRC7 Udc_np_7
AUX supply
Ir7LV
15kVA. 3x400V @ 50HZ
Rprechar. LEVEL6
5kVA 36V dc

9 x MFT (150KVA, 1.8kHz) SC6 AFE6 LRC6 TR6

Ir6LV
MRC6 Udc_np_L6

LEVEL5
SC5 AFE5 LRC5 TR5 MRC5 Udc_np_L5

1 x Input Choke SC4 AFE4 LRC4

LEVEL4
TR4
Ir5LV

MRC4 Udc_np_4

Ir4LV
LEVEL3
Mechanics SC3 AFE3 LRC3 TR3
Ir3LV
MRC3 Udc_np_L3

LEVEL2
SC2 AFE2 LRC2 TR2 MRC2 Udc_np_L2

Control Udc_posHVL1

S1
AFE1
S3
R1
LRC1
S1 LEVEL1
Ir2LV

S1
MRC1 D

C1

C1

R1
SC1 TR1

Udc_npHVL1 Lm
S1 S2 Lr
Udc_np_L1
Cr
R2

C2

C2

R2
Ir1HV
Ir1LV
S2 S4 S2 S2
I_LineLow Udc_negHVL1

ABB Group
PET Power Electronic Transformer
It Starts charging from 15kV line

ABB Group
April 5, 2013 | Slide 22
PET Power Electronic Transformer
It Runs 500kW load at the output

ABB Group
April 5, 2013 | Slide 23
PET Power Electronic Transformer
It Stops 500kW down to 10kW

ABB Group
April 5, 2013 | Slide 24
PET Power Electronic Transformer
It is Efficient

ABB Group
April 5, 2013 | Slide 25
PET Power Electronic Transformer
It Looks

ABB Group
April 5, 2013 | Slide 26
PET Power Electronic Transformer
It is in the Locomotive more than 10000 km so far

ABB Group
April 5, 2013 | Slide 27
PET - Power Electronic Transformer
Summary (Sustainability)

Roughly defined, a successful (PET) business is a repeatable process that:

Technology
1. Creates and delivers something of value
Market(ing)?
2. That other people want or need
Cost?
3. At a price theyre willing to pay
Requirements?
4. In a way that satisfies the customers needs and expectations
?
5. So that the business brings in enough profit to make it worthwhile to continue

ABB Group
 ABB Group
April 5, 2013 | Slide 29