Product Evaluation 3-Phase to 9-Phase Transformer,

Application Note 18-Pulse Converter, and Adjustable

Speed Drive, Including Novel Third
Harmonic Calculations

April 2007 Abstract

In the past 14 years, several patented 18-pulse converter methods have been
accepted in the marketplace and successfully applied in various practical
applications. In this paper, a widely used 18-pulse clean power converter, with
Kevin Lee “windmill” transformer topology is presented and analyzed. It provides a more
KevinLee@eaton.com economical solution to achieve harmonic mitigation in electric power systems as
compared to some of the earlier methods. A complete adjustable speed drive
Eaton Innovation Center (ASD) system model including “windmill” transformer, 9-phase diode bridge, DC
4201 North 27th St. link capacitors, inverter with SVPWM (space vector pulse width modulation), and
Milwaukee, WI 53216 induction machine, has been modeled and built for analysis. Features addressed
are, input current harmonic mitigation, DC bus capacitor ripple current and life
span, and motor ripple torque. In addition, the DC link dynamics under a motor
James E. Armes step load change, as well as input voltage unbalance effects on the 18-pulse
converter have been evaluated. Quantification of many of these issues is not
JamesEArmes@eaton.com found in present literature. Experimental tests with a 75 hp “windmill” 18-pulse
Eaton Electrical clean power ASD system, verify the accuracy and effectiveness of the analysis.
4201 North 27th St.
Milwaukee, WI 53216
Introduction
Derek A. Paice With the advent of IEEE 519-1992 [1], 40° phase shift between the output
the increasing demand by utilities for voltages are discussed in [5] – [11].
DAPaice@aol.com power factor improvement, and the The winding current looping and
Paice & Associates, Inc. proliferation of non-linear loads in sharing problems in early days have
114 Rosewood Court industrial power distribution systems, already been solved [12]; the
Palm Harbor, Florida 34685 specification of harmonic mitigation challenging design problem becomes
has become common [2], [3]. In the one of economics [13].
past 14 years, several patented 18-
pulse converter methods have been As illustrated in Figures 1 and 2, the
accepted in the marketplace and are cost of copper has greatly increased in
successfully applied in a variety of recent years as compared to the cost
practical applications such as water of aluminum. It is critical to evaluate
management, oil field installations, new designs and methods for
etc. where adjustable speed drive reducing the overall product cost and
(ASD) and harmonic mitigation are maintain high performance. The focus
required. A 3-phase to 9-phase unity- has been to utilize the copper
gain autotransformer topology with transformer windings more efficiently
± 20° phase shift between output so as to reduce the product cost.
voltages is first proposed in [4]. The However, reduced product cost must
step-up and step-down 18-pulse not compromise performance.
autotransformer topologies with

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The new contributions of this paper are three-fold:

4
1. Present the improved cost-effective “windmill” [16]
3.5 18-pulse clean power ASD system.

3
2. Introduce a novel third harmonic calculation method to
Copper Cost ($/lb)

evaluate 3-phase to 9-phase 18-pulse converter

2.5 transformers.
3. Evaluate the overall system steady state and dynamic
2
performances, which are not found in published
1.5
literatures.
An efficient autotransformer for 18-pulse converters must
1
ensure that all windings contribute to the output power and
circulating third harmonic circulating currents are minimized.
0.5
In the cost effective “windmill” design the autotransformer
0 kVA rating is shown to be about 55% of the DC load power.
1998 1999 2000 2001 2002 2003 2004 2005 2006 The complete system model including the 3-phase to
Year 9-phase transformer, 18-pulse converter with 9-phase
rectifier that can be conveniently constructed using three
Figure 1. Copper Cost Increase vs. Time [23] diode bridges, DC link capacitors, inverter with SVPWM
(space vector pulse width modulation) implementation, and
the induction machine with load is simulated. We not only
4 analyze the input current harmonic mitigation, but evaluate
the DC link capacitor life span [17], [18], and the motor ripple
3.5 torque as compared to a traditional 6-pulse ASD. In addition,
the DC link dynamics under the motor step load change, and
Aluminum Cost ($/lb)

3
the input voltage unbalance effects [19], [20] have been
2.5
evaluated. Quantification of many of these parameters is not
found in present literature. Simulations and experimental
2 tests are used to verify the accuracy and effectiveness of the
analysis using a 75 hp “windmill” 18-pulse clean power ASD
1.5 system.

1
Overall Practical System Model
0.5
In this 18-pulse converter system, a 3-phase input to 9-phase
0 output autotransformer with 6 coils per phase is used to
1998 1999 2000 2001 2002 2003 2004 2005 2006 power a 9-phase AC to DC converter as shown in Figure 3.
Year The 3-phase input voltages feed through input line
impedances (La and Ra) and source inductance (Lsa). It is
Figure 2. Aluminum Cost Increase vs. Time [23] assumed that the 3-phase input impedances are balanced,
i.e., La = Lb = Lc, Ra = Rb = Rc and Lsa = Lsb = Lsc. The
9-phase AC output voltages are fed to a 9-phase rectifier
Most modern adjustable-speed drives (ASDs) use bridge comprising diodes (D1 – D18). The DC link voltage is
electrolytic capacitors to provide ride-through energy smoothed by DC link capacitor (C). The inverter IGBTs
storage capacity on the DC bus. They provide a low (SW11 – SW16) deliver 3-phase PWM voltage waveforms
impedance path for ripple currents generated by the rectifier with variable frequency and amplitude to the motor load.
and PWM inverter stages [14]. It is important to limit DC link
voltage ripple to prevent generation of pulsating torque in
the induction machine, which could produce undesirable
mechanical vibration and acoustic noise [15]. These aspects
will be analyzed to maintain high product performance
integrity. Both rectifier and inverter ripple currents
contribute to the capacitor temperature rise and life span.

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1 2 3 4 5 6 7 8 9
Id IL

ea SW11 SW13 SW15

Lsa La Ra 1 D1 D3 D5 D7 D9 D11 D13 D15 D17 Ic
2 Ian
2C Van
3
eb Lsb Lb Rb 4 Ibn
18-Pulse n Vdc Vbn
r 5
Autotransformer
6 Icn
2C Vcn
ec 7 D4 D6 D2 D10 D12 D8 D16 D18 D14
Lsc Lc Rc 8
9
SW14 SW16 SW12

Figure 3. Overall Circuit Diagram of the “Windmill” 18-Pulse Clean Power Adjustable Speed Drive System

Transformer Design Issues

Design of 3-Phase to 9-Phase Autotransformers
Many autotransformer topologies can transform 3-phase to
9-phase, but when used to power 9-phase 18-pulse
converters that require significant third harmonic currents,
some topologies are more favorable than others. The design
goal is to obtain the required fundamental output voltage
amplitude and phase shift by means of appropriate
windings on each phase. At the same time it is desirable to
use a topology that restricts third harmonic currents. These
harmonics affect conductor rating and can cause fluxes
external to the transformer core. Such fluxes can cause
extraneous heating in adjacent metal structures. Designs
that result in substantial third harmonic flux exiting the core
are usually not tolerated [25].
A new approach is presented in which third harmonic
currents are addressed separately from fundamental
currents, in order to highlight their effect. Specifically, the
sum of the third harmonic ampere-turns due to third
harmonic currents are considered to be zero when a direct
delta connection is available. If such a path does not exist
third harmonic flux is more likely to exit from the three-limb
core. In so doing it creates the effect of a tertiary winding
[26]. Here, we refer to this as a hidden delta. Further
discussion of zero-sequence effects are given in [13] where
an equivalent hidden delta circuit is presented for the simple
case of one winding per phase. The third harmonic is the
major harmonic current of interest.
Since the hidden delta reduces third harmonic current in the
autotransformer windings, the novel analysis presented
here is conservative as well as simple.
The “windmill” topology shown in Figure 4 has three
physical delta paths, and the assumption of zero net
ampere-turns on each phase gives good results in the
design and simulation of this topology.
A 0.653
1
0.121
9 2
0.532
8 0.653 0.347
3
N
0.653 0.653
4
C 7 B
0.653
6 5
Figure 4. Basic Configuration of the “Windmill” Connection
Fractional turns are given relative to 1.0 turns that support the AC
source line to neutral voltage, e.g., VAN
Other topologies, including some polygon connections, are
more likely to require fluxes to emanate from the core. An
example is given in Figure 7. Winding currents in this type of
circuit may be greatly affected by the hidden delta, but
detailed calculations for multiple winding arrangements are
not within the scope of this paper. If the external third
harmonic flux is substantial, any stray losses need to be
determined by experiment.
The proposed simplified analysis is here applied to three
different 3-phase to 9-phase autotransformers, starting with
the “windmill” topology. The same method has been
applied to analyze numerous 3-phase to 9-phase
autotransformer connections. It helps identify topologies
that may create undesirable external third harmonic flux.

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Basic Performance Features of 18-Pulse Converters
The small amount of AC line input harmonic currents drawn
by 9-phase, 18-pulse converters is well known and described
in various books and papers [13]. In a pioneering
application, a 3-phase to 9-phase autotransformer described
in [6] was used to supply power for a 500 hp AC to DC
converter feeding a variable frequency drive. Since that
time, numerous alternative means of transformer design
have been proposed and implemented. The practical
“windmill” method discussed here has found widespread
application. Typical system results are given.
9-phase 18-pulse converters not only have low harmonic
distortion in the AC input current, but they also provide a
smoother, higher average value of DC output. Without some
small reduction in the amplitude of the 9-phase output
voltage, the DC voltage associated with 480V systems would
be too high.
Practical transformer designs address this by slightly
reducing the 9-phase output voltage. The “windmill” design
shown in Figure 4 is a particularly efficient configuration and
will be used to establish basic parameters.
Unlike a 3-phase system in which line-to-line voltage is √ 3
times the line-to-neutral voltage, the 9-phase output voltage
has several possibilities. The line-to-line voltage of most
interest is the largest one. For example, this is the voltage
between terminals such as 1 and 5. Its value is: V1-N 0° –
V1-N -160°. The resulting amplitude is 1.969 V1-N. When the
9-phase output voltage is rectified, the DC output voltage is
further increased because there is less DC ripple voltage.
To prevent excessive DC output voltage, the 9-phase output
voltage in the “windmill” connection is reduced to 0.879
times the source line-to-neutral voltage.
The resulting DC output voltage parameters are summarized
below in terms of the source line-to-neutral voltage V1-N. For
comparison the same parameters are given for a standard
3-phase bridge rectifier.
(1) V DC , 3ø = 3 √ 6 V L-N = 2.34 V L-N
π number of turns on each phase of the delta to prevent
(2) V DC , “windmill” = 18 √ 2 sin π •
sin60°
V = 2.44 V L-N
π 9 sin80° L-N
(3) V DC, peak = 2.45 V L-N
The average DC output voltage of a 9-phase bridge rectifier
fed by the “windmill” transformer is observed to be about
4.2% higher than that of a 3-phase bridge. This somewhat
greater average DC voltage is especially useful for PWM
inverter systems where it facilitates obtaining an AC output
voltage equal to the AC input voltage. The peak DC output
voltage is the same, as defined in Equation (3).
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Source of 3rd Harmonic Currents in 9-Phase Converter
The ideal current wave drawn from each of the nine trans-
former outputs is shown in Figure 5.
Idc
wt
0
-Φ Φ
2 2
Figure 5. Basic Current Waveform Drawn by 9-Phase Converter
Using Fourier analysis it can be shown that the output
current wave is described by the following expression:
i( t) = IDC ∑
4 sin (n ø ) cos (n t)
(4)
πn 2
where n is any odd positive integer such as 1, 3, 5, 7 … and ø
= conduction period = 2π/9.
The total rms value of current in each transformer output
lead is 0.471 IDC. Recognition of this relationship is
especially important if the transformer output leads are
fused to protect the rectifiers.
Applying n = 3, we find that the rms value of the third
harmonic in the 9-phase load current is 0.26 IDC .
Third harmonic currents in the transformer output leads are
of particular concern in the transformer design. This current
flows within the transformer windings, and the transformer
design must allow for it. In the “windmill” design three delta
circuits provide paths for these currents.
The “Windmill” Connection
Figure 6 shows the “windmill” topology. As in all 3-phase
transformers with delta connections, there must be an equal
circulating fundamental current. Turns are shown for the
A phase, phases B and C have identical turns.
For ensuing analyses, several assumptions are made,
namely,
1. Magnetizing current is neglected.
2. Coil leakage and resistance are neglected.
3. The sum of ampere-turns on each limb is assumed to
equate to zero at all instants. As noted previously this is
not true for all topologies, but is a reasonable,
conservative assumption for connections like those in
the “windmill” that include direct delta paths.
4. The 3-wire power source is balanced in voltage.
5. The fundamental currents in each output phase are
shifted by 40°. Third harmonic currents are shifted by
three times this amount, namely, 120°.
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Table 1. Calculated Currents in “Windmill” Connection

N1A=0.121 Turns Idealized Third Harmonic Typical Total RMS
A i30° Current Current /IDC
i3120°
i3-120°+id N1 (0.121) id – i3 0° 0.52
1
i.e., 0.6049 i3 180°
i3-120°
N2 (0.532) 0.3951 i3 0° 0.21
9 N2A=
0.532 2 N3 (0.347) zero 0.19
id
N4 (0.653) i3 120° 0.44
id N5 (0.653) i3 120° + id 0.32
i.e., 0.8724 i3 96.9°
i3120°
8 N3A=0.347 N6 (0.653) 0.3951 i3 0° 0.21
3
id For the purposes of comparing third harmonic effects
N
N5A=
amongst various designs, a factor VA3 is defined to
N4A= represent the total third harmonic VA in each phase of the
0.653 i3-120°+id 0.653
transformer. VA3 is the summation of fundamental voltage
times third harmonic current in each winding. For the
N6A=
4 “windmill” design:
7 0.653 id
C B
VA3 (0.0121  0.6049) + (0.532  0.3951) +
(8) (0.653)  1) + (0.653  0.8724) + (0.653  0.3951) = 1.764
The factor VA3 does not represent the total transformer kVA
but it gives insight into the magnitude of the third harmonic
6 5
effect. It helps identify topologies that, due to unfavorable
connections, may require large amounts of circulating third
Figure 6. Third Harmonic Current Distribution in the “Windmill” harmonic current. Topologies with obvious delta paths, as in
Topology the “windmill” arrangement, are generally advantageous.
Typical fractional turns are based on total 1.0 turn from apex to They obtain efficient utilization of the copper and steel in the
neutral. transformer.
Using the above assumptions and referring to Figure 6, let Total transformer kVA is obtained from closed form or
the third harmonic current drawn from terminal 1 be i3 0° computer solutions. In the “windmill” design the
then that from terminal 2 is i3 -120°, and from terminal 9 is transformer kVA rating is about 55% of the DC load kW.
i3 120°. This sequence is repeated in terminals 4, 5, 3, and
7, 8, 6 of the transformer. In topologies like the “windmill”, full input line current does
not flow through any winding. In this case, closed form
The analysis is described here. Applying the ampere-turn solutions for idealized operation are greatly simplified by
balance law to Figure 6, we get: using current equations that do not include the input line
(5) 0.532 id + 0.121 (id - i3 0°) + 0.653 i3-120° current. The input currents can be readily defined when
+ 0.653 id + 0.653 (i3 -120° + id) = 0 transformer-winding currents have been calculated.
Thus, From closed form solutions, current waveforms can be
id (0.532 + 0.121 + 0.653 + 0.653) = graphed and the total kVA rating calculated, but the practical
(6) 0.121 i3 0° -0.653 i3120° -0.653 i3-120° effects of transformer leakage and source voltage unbalance
from which, are best obtained from computer simulations. To facilitate
simulation, coupling factors for all windings are measured
(7) id = 0.3951 i3 0° on every prototype unit. Production testing includes low
voltage short circuit tests to validate impedance values.

This current flows in N6A (0.653 turns) and N2A (0.532
turns). Distribution of the third harmonic currents is shown
in Table 1; also the total rms current is given relative to IDC.
The current id is about 10% of the DC load current and
extraneous third harmonic flux is not an issue with these
designs.
Other Topologies
Figure 7 shows another 3-phase to 9-phase autotransformer
connection. It is given here as another example to use the
simple analysis method for defining third harmonic currents.
This and modified versions of the topology are further
described in US patent 5,124,904 [6]. As in the “windmill”
design, the hidden delta path is not shown because there is
an obvious delta path to carry third harmonic current.

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Finally, we consider a scheme without an obvious delta

i30° winding. If the turns on the long winding shown in Figure 7
are reduced and the resulting winding is connected to the
0.27
A end of the stub windings, a polygon connection is obtained.
0.5077 i3-120° This is shown in Figure 8. As before, since the fundamental
currents in each of the three transformer phases are at 120°,
2 the third harmonic currents, ib, in each phase of the
transformer are in time phase. This rearrangement provides
a satisfactory 9-phase output and the transformer
fundamental kVA is little different from that in Figure 7.
ia However, if we neglect the hidden delta effect, the VA3 factor
i3-120° i3120°
is about three times that for Figure 7. In practice, the hidden
N delta must be considered.
virtual
neutral Calculation of third harmonic currents requires estimates of
1.192 coil resistance, winding coupling factors, and parameters of
the hidden delta circuit. At the design stage the
characteristics of the latter are not easily predicted, also
factors such as external fluxes, heat generation, and
C B
acoustic noise are best left for experimentation.

i30°
0.27
i3120° A 0.5077
i3-120°
Figure 7. Basic 18-Pulse Configuration Using a Delta with Stub
Windings 0.684
ib +i3-120°
Typical fractional turns are based on 1.0 turn to support voltage
from apex to virtual neutral. ib
i3-120° ib i3120°
As in the “windmill” analysis, assume the amplitude of the
third harmonic component of current in each output lead is
i3. Relative phase positions are shown in the figure.
Assuming a vertical reference vector position of 0°, the
fundamental output voltage V2 at terminal 2 is given by:
Hidden Delta
(9) V2 = (1 – 0.2730° + 0.5077 -90°) = 1-40°
C B
The total 3rd harmonic turns acting on any phase coil are
assumed to be zero, thus: ib
0.27 ( ia + i3 -120°) + 1.192 ia + 0.27 ( ia – i3 -120°) +
(10)
0.5077 i3120° – 0.5077 i3 -120° = 0 i3120°
From which we get, third harmonic ia = 0.238 i3 -90°. In the
upper 0.27 turns, the third harmonic of current is (ia + i3 Figure 8. Original Delta Connection with Long Side Moved to Connect
-120°), namely 1.212 i3 -114.36°. In the lower 0.27 turns, with Windings so as to Form a Polygon Connection
the third harmonic of current is (ia -i3 -120°), namely 1.212 Typical fractional turns are based on 1.0 turn to support voltage
i3 -65.64°. Each stub winding with 0.5077 turns carries third from apex to virtual neutral.
harmonic current of magnitude i3. Thus, for the transformer
in Figure 7, we obtain: The apparently harmless rearranging of one winding makes
little difference to the 9-phase output, but greatly impacts
VA3 = (1.192  0.238) + (2  0.27  1.212) + the paths for third harmonic current flow. But if the same
(11)
(2  0.5077  1) = 1.953 topology is used for the secondary of a double-wound
It is noted that the output voltage in the Figure 7 schematic transformer with primary connected in delta, as in [12], the
is somewhat greater than that in Figure 6. If a correction is primary winding provides a low impedance path for third
made to compare identical power loading, the VA3s of the harmonic currents.
schemes shown in Figures 6 and 7 are very similar. Both
topologies are effective and efficient.
For 480V systems, the topology of Figure 7 usually requires
an extender winding to reduce the DC output voltage by
about 11.4%. In contrast, the reduced voltage is an inherent
feature of the “windmill” topology.

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General Design Considerations capacitor ripple current profiles of a 6-pulse ASD and the
“windmill” 18-pulse ASD at the same power level. The
In all practical transformer designs the actual currents are current ripple components of the 18-pulse system are
modified by the various winding-to-winding coupling factors greatly reduced, particularly in the low frequency range.
and coil winding resistance. As noted previously, computer
simulations of the “windmill” topology incorporate these From the time-series representation of the dc capacitor
factors. Calculated results in conjunction with 18-pulse ripple currents, the rms value of a particular ripple current
converters agree very satisfactorily with complete systems harmonic component can be calculated using Fourier
tests. transform functions of any numerical mathematical analysis
tool such as Matlab:
All phase-shifting autotransformers should include thermal
overload trips in each phase. These provide protection in the
Icaph =
|fft(Icaph)|
event of a partial loss of load, for example if any of the 18 (12)
√ 2 • N/2
converter devices become inoperative.
where N is the number of time series points in the ripple
Phase-shifting autotransformers can provide substantial size current time series. The total capacitor power loss is
and weight savings compared with double-wound designs. calculated using the capacitor ripple current harmonic
Typically, a 3-phase to 9-phase transformer for converter spectrum as:
operation requires only about 45% as much kVA as a double-
Nh
wound transformer. Also, it is more efficient. 2
(13) Ploss = ∑Icaph, n • ESR(fn)
n=1
Summary of 9-Phase Autotransformer Design Issues
where ESR (fn) is the value of the equivalent series resistance
Idealized performance factors of a 9-phase, 18-pulse at a particular frequency fn.
converter fed by a “windmill” transformer configuration are
defined. The value of the total rms ripple current can be determined
from the harmonic spectrum as:
A simplified analytical method is described that gives insight
into third harmonic circulating currents. If not adequately Nh
controlled these currents can create additional extraneous
losses. The method enables topologies to be selected that
offer high efficiency and good utilization of iron and copper.
(14) Icaph, rms =

The capacitor hot spot temperature Th [°C] and lifetime Lop

√ n=1
2
∑Icaph, n

The procedure has been found of considerable value in [hours] are calculated as follows [24]:
evaluating efficient phase-shifting autotransformer designs,
(15) Th = Ta + Ploss • Rth
such as the “windmill” connection.
85 – Th
Simulation and Experimental Evaluation (16) Lop = A • 2 c

where Ta is the capacitor ambient temperature and Rth is the

Input Current Harmonics capacitor thermal resistance. The coefficients for the life
Simulations of the system in Figure 3 using Simpler, PSIM span are A and C.
and Matlab have been conducted to evaluate the overall
system performance. A comparison on input current
Bus Capacitor Current (A)

harmonics has been made between the 6-pulse ASD system 150
and the “windmill” 18-pulse topology [21]. The operating Conditions: 6-Pulse 75 hp ASD with Lin = 525 uH
100 C = 2800 uF, Full Load
point parameters consist of La = 525uH, C = 2800uF, 75 hp
inverter driven induction machine load. The simulated input 50
current waveforms are depicted in Figure 14 for both steady 0
state and step load operating conditions. A typical 75 hp, -50
6-pulse ASD with 450uH line inductor has input current total
-100
harmonic distortion (THD) of ~33%, while the “windmill”
0.584 0.586 0.588 0.59 0.592 0.594 0.596 0.598 0.6
18-pulse has ~5% input current THD. The 18-pulse solution
Time (Sec)
is clearly more suitable for applications where meeting IEEE-
519 is required. 40
Conditions: 6-Pulse 75 hp ASD with Lin = 525 uH
Harmonics (A)

DC Link Capacitor Lifetime 30 C = 2800 uF, Full Load

The “windmill” topology determines the input current 20

profile, which contributes to the low frequency DC link
capacitor ripple. The space vector pulse width modulation 10
(SVPWM) implemented in the inverter control has been
0
modeled in order to quantify the inverter’s contribution to 0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10,000
the DC link capacitor ripple currents. Frequency (Hz)
Evox Rifa electrolytic capacitor: PEH200V433CMB2 is used in
the capacitor loss and lifetime evaluations. The ESR (effective Figure 9. Simulated DC Link Capacitor Ripple Current Profile of the
series resistance) of the capacitors rises significantly at low 75 hp System Including Inverter SVPWM Effect
frequencies. Thus, capacitor losses are particularly sensitive
to the low-order rectifier ripple current frequency components
(e.g., 360 Hz, 720 Hz). Figures 9 and 10 illustrate the DC link

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The estimated DC link capacitor life span of the 18-pulse

solution is about 150,000 hours as compared to 63,000 for rs Lls jωλqds j(ω-ωr)λqdr
Llr rr
the 6-pulse system. + – – +

+ +
150 iqds iqdr
Bus Capacitor Current (A)

Conditions: W
ì i ndmill”18-Pulse 75 hp ASD with Lm
100 Vqds Vqdr
Lin = 525 uH, C = 2800 uF, Full Load
50
0 – –

-50
-100
Figure 11. Complex dq Equivalent Circuit of a Three-Phase Induction
0.584 0.586 0.588 0.59 0.592 0.594 0.596 0.598 0.6
Machine in a Rotating Reference Frame ( ).
Time (Sec)
40
Conditions: “Windmill”18-Pulse 75 hp ASD with The definitions of the complex variables include [22]:
Harmonics (A)

30 Lin = 525 uH, C = 2800 uF, Full Load

vqds: complex stator voltage iqds: complex stator current
20 vqdr: complex rotor voltage iqdr: complex rotor current
10 rs: stator resistance rr: rotor resistance
qds: stator flux linkage qdr: rotor flux linkage
0 Ls: total stator inductance Lls: stator leakage inductance
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10,000
Frequency (Hz)
Lr: total rotor inductance Llr: rotor leakage inductance
Lm: magnetizing inductance
Figure 10. Simulated DC Link Capacitor Ripple Current Profile of the
75 hp 18-pulse System Including Inverter SVPWM Effect The electromagnetic torque impressed on the shaft of the
induction machine can be expressed as [22]:
3 P e e*
(17) Te =   Lm  Im [ iqds  iqdr ]
Induction Machine Torque Ripple 2 2
The induction machine model employed is a d-q motor Where P is the number of poles and the last term represents
representation [22]. Additionally, the rotational inertia of the the imaginary part of the product of the complex stator
rotor and all rigidly connected rotating masses must be current and the complex conjugate of the rotor current.
included in the analysis. The motor pulsating torque is
principally produced by interactions between the
fundamental electromagnetic flux and the 5th and 7th motor
harmonic currents. The resulting pulsating torque can have 60 Conditions: 6-Pulse 75 hp ASD with Lin = 525 uH
Torque (Nm)

C = 2800 uF, Full Load

undesirable effects including vibration and audible noise.
40
Figures 9 and 10 show the torque comparison results
between the 6-pulse and 18-pulse configuration. The 20
“windmill” 18-pulse system has a torque ripple reduction
of ~30% at 6th harmonics (360 Hz in the U.S.). 00
0.57 0.575 0.58 0.585 0.59 0.595 0.6
In order to calculate the phase currents for unbalanced Time (Sec)
Torque Spectrum (Nm)

excitation, the three phase voltages can be transformed 10

into a complex dq voltage space vector in a rotating Conditions: 6-Pulse 75 hp ASD with Lin = 525 uH
reference frame and then applied to the appropriate C = 2800 uF, Full Load
complex dq equivalent circuit for the induction machine 5
shown in Figure 11 [22].

0
0 200 400 600 800 1000 1200 1400 1600 1800 2000
Frequency (Hz)

Figure 12. Simulated Induction Machine Torque Profile of the 75 hp

System Including Inverter SVPWM Effect

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800

DC Link Voltage (V)

260 Conditions: “Windmill”18-Pulse 75 hp ASD with
Torque (Nm)

Lin = 525 uH, C = 2800 uF, Full Load 600

240
400
220 200 Conditions: “Windmill” 18-Pulse ASD with Lin = 525 uH

200 0
0.57 0.575 0.58 0.585 0.59 0.595 0.6 0.04 0.045 0.05 0.055 0.06 0.065 0.07 0.075 0.08 0.085 0.09
Time (Sec) Time (Sec)
Torque Spectrum (Nm)

20

Input Currents (A)

Conditions: “Windmill”18-Pulse 75 hp ASD with Conditions: “Windmill” 18-Pulse ASD with Lin = 525 uH
15 100
Lin = 525 uH, C = 2800 uF, Full Load
10
0
5
-100
0
0 200 400 600 800 1000 1200 1400 1600 1800 2000
0.04 0.045 0.05 0.055 0.06 0.065 0.07 0.075 0.08 0.085 0.09
Frequency (Hz)
Time (Sec)

Figure 13. Simulated Induction Machine Torque Profile of the 75 hp Figure 14. Simulated 75 hp 18-Pulse System Load Step Response
18-Pulse System Including Inverter SVPWM Effect
800
Dynamic Load Step Change Response DC Link Voltage (V) 600
As seen in Figure 3, the DC link voltage is supplied by the
400
uncontrolled rectifier bridge(s) (D1 – D18). It is important to
maintain the DC link voltage as steady as possible to prevent 200 Conditions: “Windmill” 18-Pulse ASD with Lin = 525 uH
any disturbance to the ASD inverter and load operation.
Figure 14 shows the effect of a step increase in load from 0
0.12 0.125 0.13 0.135 0.14 0.145 0.15
40A output to 80A. The DC link voltage drops from 665V to Time (Sec)
639V and reaches a new steady state value of 655V within
one cycle of 60 Hz. This rapid response decreases capacitor
Input Currents (A)

Conditions: “Windmill” 18-Pulse ASD with Lin = 525 uH

ripple current on the “windmill” 18-pulse system as 100
compared with a 6-pulse system. It leads to an increased
capacitor life. 0

Input Voltage Unbalance Effects -100

In power distribution systems, the utility input voltage
unbalance is a common occurrence [17]. An operating point 0.12 0.125 0.13 0.135 0.14 0.145 0.15
for the 75 hp ASD has been investigated consisting of the Time (Sec)
following parameters: La = 525uH, C = 2800uF, 100% load,
and 0.5% input voltage unbalance. Figure 15 demonstrates Figure 15. Simulated 75 hp 18-Pulse System Input Voltage Unbalance
the results. The simulated DC link voltage is at ~670V and Performance
the input currents are at 82A, 76A, and 82A respectively. The
input phase A current THD from simulation is 5.4%.
The “windmill” 18-pulse system is put into test for its
performance under the practical input voltage unbalanced
conditions. The experimental setup is shown in Figure 16.
The input line-line voltages are measured to be 490V, 495V
and 492V at the testing facility, a 0.6% unbalance with a DC
link voltage of 667V and a motor speed at 1748 RPM. The
measured three-phase input currents are 79A, 78A, and 81A.
The waveforms and the phase A current THD of ~5.9% are
illustrated in Figure 17. The simulation and the initial
experimental results agree quite well.

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Conclusions
75 hp ASD
In this paper, an improved 3-phase to 9-phase “windmill”
18-pulse clean power ASD system is presented. A novel third
harmonic circulating current calculation method is introduced
and used to investigate different topologies. A system
evaluation demonstrates the steady state and dynamic
performance of a complete rectifier and PWM motor drive. It
is shown through modeling, analysis, simulation, and
experimentation that the “windmill” topology improves the
input current THD, increases the DC link capacitor life span,
reduces the induction machine torque ripple, and provides
good step load response. Further, the arrangement performs
well under moderate input voltage unbalance conditions
encountered in practical power distribution systems. The
state-of-the-art simulation is built on the complete system
consisting of the utility source, “windmill” 9-phase auto-
Input “Windmill” transformer, 9-phase rectifier bridge, DC link capacitor,
Inductors 18-Pulse inverter with space vector pulse width modulation (SVPWM)
Autotransformer and induction machine with load. A complete 75 hp ASD
system has been manufactured and used to verify the
accuracy and effectiveness of the analysis. Predictions from
the analysis compare favorably with experimental results. The
thorough evaluation presented in this paper will be useful to
guide the 18-pulse ASD selection in applications where
excellent input power quality, long life, and reliable ASD load
performance are essential.

Figure 16. Experimental “Windmill” 18-Pulse System Setup

Dranetz 8000 Dranetz Model 8000 17:22:28 Dec-05-05

C
A
V m
o p
t s
s D
A

B
1.00 V/Div 2.1 msec/Div 30.0 A/Div
Dranetz 8000 Dranetz Model 8000 Dec-05-05 17:23:02
Harmonics:CH A Ref 80.12 A. 60.0Hz
%Fund Ithd 5.949 %
3.33
2.67

2.00

1.33

0.57

0.00
5 10 15 20 25 30 35 40 45 50

Figure 17. Experimental Input Phase A Current Profile

Note: Third harmonics in the AC line input current are due to
unbalance in the AC supply voltage [21].

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References
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