Amplifier Selction Guide - Opal RT
Amplifier Selction Guide - Opal RT
Amplifier Selction Guide - Opal RT
CONTENTS
INTRODUCTION : PHIL AT A GLANCE 3
Motor Emulators 10
Contact Us 16
Key Considerations When Choosing your PHIL (Power Hardware-in-the-Loop) Solution for your Test/Simulation Application
OPAL-RT TECHNOLOGIES 3
Introduction
PHIL at a Glance
OPAL-RT is at the vanguard of power electronics applications in the areas of industrial development,
power distribution, aerospace, military and electric transportation systems. At the forefront, the
trend towards increasingly rapid innovation involves application-oriented R&D used in system
modularization, analysis, modeling, real-time simulation, design and experimental evaluation. By
connecting a simulator to a Device Under Test (DuT) with low power capability I/Os, and by subjecting
it to rigorous testing as Controller Hardware-in-the-Loop (CHIL), OPAL-RT can help substantially
reduce time to market.
Key Considerations When Choosing your PHIL (Power Hardware-in-the-Loop) Solution for your Test/Simulation Application
4 OPAL-RT TECHNOLOGIES
Introduction
PHIL at a Glance
There are many power amplifier suppliers and each of them has their own range of products, many
specializing in specific market segments. The figure below shows some suppliers, sorted into three such
segments:
Amplifier manufacturers
Key Considerations When Choosing your PHIL (Power Hardware-in-the-Loop) Solution for your Test/Simulation Application
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1| First Consideration
The Amplifier's Operating Range
(Voltage, Current & Power)
The first consideration in designing a PHIL testbed is to evaluate the operating range of the devices that will interface
with it. One common error is to select an amplifier based solely on its generating power capabilities without considering
its capability to absorb power, or its bandwidth. Further, design must be done to test requirements, which can exceed
the device’s nominal quantities during transient tests forcing overcurrent, overvoltage or temporary overload.
The following aspects need consideration in the selection of the amplifier:
• Nominal/steady-state specifications:
• Number of phases
• Nominal Power at nominal frequency (kVA for AC, kW for DC)
• Power factor and rating in sourcing and sinking modes for each quadrant
(if four-quadrant operation is required)
• Nominal AC and DC voltage
• Nominal operating frequency
• Frequency bandwith
• Power and current rating as function of voltage and frequency
Key Considerations When Choosing your PHIL (Power Hardware-in-the-Loop) Solution for your Test/Simulation Application
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Also, many amplifiers can hold a higher current and power than their advertised limit for a short period of time.
Additional information may be provided by the manufacturer for special applications where corner conditions must
be met.
For certain applications it may be necessary to use a step-up transformer to meet the nominal or maximum voltage
rating of the DuT, and users should select the transformer power rating and capability according to the overload
capability of the power amplifier, with a 10% to 20% margin. Note that adding a transformer can alter the frequency
response of the testbed interface, and this requires specific attention regarding DC response simulation.
Additionally, transformers may easily saturate depending on their saturation characteristics and operating conditions.
High transformer-saturation induced by DC voltages or transient conditions such as a fault clearing may be seen by
the amplifier as a quasi short-circuit, which may trip the amplifier. Therefore, it is very important to understand the
application’s needs before designing a PHIL setup. Some transformer designs allow a larger range of linear operation,
but they require core oversizing, and the cost and weight can increase considerably.
In the end, the design of a PHIL testbed always involves compromise with regards to cost and operating conditions.
Key Considerations When Choosing your PHIL (Power Hardware-in-the-Loop) Solution for your Test/Simulation Application
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2| Second Consideration
The second consideration is related to the amplifier price versus the available budget. The amplifier power rating,
voltage range and frequency bandwidth can greatly influence its price, and this factor must always be part of the
selection process. As given in Fig. 5: Ballpark estimates of amplifier cost sorted by power rating, prices range from 1k$/
kW to 2k$/kW for 4Q—low bandwidth—amplifiers and can exceed 12k$/kW for high-frequency linear 4Q amplifiers.
These ranges are rough estimations of the current market prices, and other factors may influence these further.
These are: the chosen bandwidth of the amplifier, the source and sink options, and the type of instrumentation and
control used in the final system.
Selecting the right operating range can be a daunting task since so much depends on the intended purpose, as well as
interactions between the many variables at play in the final system. Also, not all amplifiers have internal measurement
feedback fast enough for a PHIL closed loop. In this case, additional external sensors for high voltage and high current
measurement should be added to the integration cost of your amplifier.
For some applications, it will be necessary to consider additional costs and design aspects on top of the amplifier
and other equipment within the testbed. These are, among other things, the electrical mains and lab infrastructure
properly suited for the amplifier and the interfacing transformer, if needed. Some amplifiers also require an auxiliary
DC power supply which also needs to be selected for the testbed. One may want to look at the standards labeling and
main connector types as well. Some amplifier manufacturers may need to customize the power input connections.
BALLPARK CONSIDERATION
The power rating of an amplifier can greatly influence its price and it must always be part of the amplifier selection
process. The table below shows how much prices can vary depending on three power rating categories. These
ranges are only estimates of the real prices and other factors can influence it. Namely, the chosen bandwidth of the
amplifier, the source and sink options and the type of instrumentation and control used in the final system.
The next sections will go into detail
Price estimation in USD
about how to make the right choice. for 3 Phase
Here is a graphic featuring ballpark Power Rating
Low bandwidth High bandwidth
price estimates based on the power
amplifier (< 3kHz) amplifier (> 5kHz)
of the amplifier. Prices will vary
considerably based on the four criteria 4,000$/kVA to 6,500$/kVA to
< 10 kVA
8,000$/kVA 20,000$/kVA
explained in this document.
1,500$/kVA to 6,000$/kVA to
Selecting the right operating rage can 10 kVA to 100 kVA
4,000$/kVA 12,000$/kVA
be a daunting task since so much
depends on the intended purpose 1,000$/kVA to 2,000$/kVA to
> 100 kVA
and the many variables involved in 3,000$/kVA 7,000$/kVA
the final system. Section 3 on sourcing
and sinking will help clarify another Fig. 5: Ballpark estimates of amplifier cost sorted by power rating
essential part of the selection process.
Key Considerations When Choosing your PHIL (Power Hardware-in-the-Loop) Solution for your Test/Simulation Application
8 OPAL-RT TECHNOLOGIES
3| Third Consideration
Source & Sink Capabilities
(4 Quadrant Capabilities)
The third important element to consider when selecting a configuration is its source and sink capabilities. An amplifier
with a sinking capability may be up to twice the price of a standard sourcing amplifier. Depending on the application, a
simulator is often required to provide power to a load (known as sourcing) and/or to absorb power from a generator
(known as sinking). For example, the energy generated from braking in a motor control application may be recycled to
recharge its battery. Likewise, the excess energy generated by a microgrid application may be sold to the main grid,
which can, in turn, push power back to the microgrid. Hence, if the energy flow of an application is required to go in both
directions, an amplifier that does both sinking and sourcing is needed.
Amplifiers with this bidirectional capability are often referred to as 4Q amplifiers. This is because they can function in all
quadrants of the four-quadrant Power Schematic, as shown below. As Fig. 6: Operating power quadrants (current measured
as flowing out of the amplifier) below shows, an amplifier can act as a load if the current flowing out of the amplifier and
voltage are of opposite signs, and act as a power supply if they are of the same sign. It must be noted here that a 4Q
amplifier is required to feed pure reactive (inductor or capacitor) loads with an equal power rating in each quadrant. The
load power factor will affect the power rating of each quadrant.
POSITIVE VOLTAGE
NEGATIVE POSITIVE
CURRENT CURRENT
QUADRANT THREE (III) QUADRANT FOUR (IV)
Function : Power Supply Function : Load
Voltage : Negative (-) Voltage : Negative (-)
Current : Negative (-) Current : Positive (+)
Power : Providing (→) Power : Absorbing (←)
NEGATIVE VOLTAGE
Fig. 6: Operating power quadrants (current measured as flowing out of the amplifier)
There are two types of amplifiers to choose from in terms of source and sink capabilities: the linear amplifier and the
switching amplifier.
Key Considerations When Choosing your PHIL (Power Hardware-in-the-Loop) Solution for your Test/Simulation Application
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SWITCHING AMPLIFIERS
Switching amplifiers work in the saturation region of the switching element in an AC to DC converter. By their
very nature, they are more efficient (>90%) and better suited for sinking power, and normally have a higher
power rating as compared to linear amplifiers due to their technology. A downside is that they generally have a
lower bandwidth depending on PWM frequency and filtering. New switching amplifier designs can now reach a
bandwidth of 5 kHz and higher using faster switching elements like the newer SiC and GaN transistors.
Not all amplifiers are made equally; some are not symmetrical in the way they are built to handle sinking and
sourcing modes. Consequently, their safe operating area can be quite different depending on the operating
quadrant, especially when dealing with power overload. Some amplifiers, mostly linear ones, consume extra
power and output it in thermal energy. Others can offload extra power to the supply grid. These high-end
regenerative amplifiers are much more efficient, since less power is lost to heat.
Selecting the source and sink capabilities of an amplifier depends mostly on the application. Once these are
chosen, the next logical step is to select the right bandwidth.
Key Considerations When Choosing your PHIL (Power Hardware-in-the-Loop) Solution for your Test/Simulation Application
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4| Fourth Consideration
Selecting the PHIL Bandwith Depending on
the Application
It is very important to determine the main objectives of the tests to be performed with the PHIL system. These test
objectives will determine the real-time simulator time step and amplifier bandwidth, which are important factors
determining the total PHIL system cost. In fact, the total system cost can double if high-frequency amplifiers are
needed as compared to a normal low-frequency amplifier.
Motor Emulators
For example, a motor emulator intended to test the thermal capability of the inverter design would require
emulating a simple motor model capable of reproducing the RMS value of the motor current under different
steady-state and overload conditions. A low-frequency amplifier, capable of generating voltages and currents
only at the fundamental frequency expected at the motor terminal is enough. However, high-speed motors
with a small number of poles may required frequency capability up to 1000 Hz. A simple motor model
capable of computing the motor speed and its back EMF behind the stator inductor is sufficient. In fact, some
manufacturers will simply connect the inverter under test in connected back-to-back mode with a second
inverter through a series inductor. The required current and voltages for the test are controlled by adjusting
the back EMF amplitude and angles of both inverters.
On the other hand, the analysis of the capability of the inverter controller to suppress torque ripple requires
accurate simulation of high-frequency harmonics, which can reach 5kHz or more depending on motor
rotation speed and number of poles. Such torque ripple can be caused by the cogging torque, also known
as detent or 'no-current' torque, produced by the interaction between the permanent magnets of the rotor
and the stator slots of a Permanent Magnet (PM) machine. The inverter’s dead time produces also harmonic
currents which in turn induce torque ripple that must be cancelled by special controller algorithms.
“Cogging torque of electrical motors is the torque due to the interaction between the permanent
magnets of the rotor and the stator slots of a Permanent Magnet (PM) machine. It is also known
as detent or 'no-current' torque. This torque is position dependent and its periodicity per revolution
depends on the number of magnetic poles and the number of teeth on the stator. Cogging torque is an
undesirable component for the operation of such a motor. It is especially prominent at lower speeds,
with the symptom of jerkiness. Cogging torque results in torque as well as speed ripple; however, at
high speed the motor moment of inertia filters out the effect of cogging torque.”
Source: https://en.wikipedia.org/wiki/Cogging_torque
Key Considerations When Choosing your PHIL (Power Hardware-in-the-Loop) Solution for your Test/Simulation Application
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Such high-fidelity PHIL motor emulators require a high-bandwidth amplifier controlled by a fast-real-time
simulator capable of simulating a detailed model computed by finite element analysis. A simulation time
step below 1 or 2 microseconds and an amplifier with a bandwidth above 5 kHz to 10 kHz may be required
to simulate harmonic current and torque ripple caused by these harmonics depending on motor speed and
number of poles. Motor start-up and faults also generate fast current transients in inverter components
which must be detected by protection systems embedded in the controller hardware. Testing such high-
speed protection may also dictate the response time and bandwidth required by the amplifier, as well as
the simulator time step. In practice, real-time high-fidelity motor models require control of high-bandwidth
amplifiers to simulate motor harmonics, and transients are implemented in FPGA chips to achieve a time
step below one microsecond.
The same analysis must be performed to implement distribution and microgrid PHIL emulators in order to
determine the frequency contents of the steady-state and transient waveforms to emulate in order to meet
test objectives. For example, the testing of a slow global microgrid controller with an update time of 50 to
100 milliseconds would require power amplifiers rated for nominal power grid frequency plus or minus
1 to 5 Hz to emulate power swings. A simulator with a time step of 100 micros would be good enough to
control the amplifier voltage amplitude and phase. A real-time electromechnical transient simulator such
as ePHASORSIM, with a time step of 10 milliseconds using phasor mode (rms), could also be used if it is
necessary to emulate very large power grids to test slow controllers.
Similarly, simulating transient overvoltage and overcurrent induced by fault, transformer saturation and
power electronic based systems will require amplifiers with higher bandwidth controlled by real-time
simulators capable of achieving a small time step.
Key Considerations When Choosing your PHIL (Power Hardware-in-the-Loop) Solution for your Test/Simulation Application
12 OPAL-RT TECHNOLOGIES
Additionally, it is vital to analyze the stability of the closed-loop system formed by the amplifier, the load
and the real-time simulator (model) as well as all sensors and communication links required to interconnect
all these components. The goal is to achieve stability in closed loop operation considering all the delays
and transfer functions of all components forming the closed-loop system including model calculation. The
classical control theory must be applied to design the compensation function in order to keep the open loop
gain smaller than 1, when the phase is 180 degrees.
Several papers listed at the end of this document deal with this subject and propose methods to i) optimize
accuracy and stability, as well as ii) overall safe operation of the PHIL system.
In fact, tuning a PHIL system is the same as optimizing a control system! The main conclusion is that stability
issues must be analyzed carefully and that all delays induced by the real-time simulator, the amplifiers and
interfacing devices must be reduced to the absolute minimum to increase the accuracy and stability limits
of high-fidelity PHIL systems. Amplifiers with bandwidth above 5 to 10 kHz as well as FPGA-based simulators
with time steps below one microsecond are often required.
The maximum bandwidth of a PHIL application is equivalent to the maximum frequency capabilities required
to simulate the specified transients during the test. In motor-based applications, the maximum bandwidth
defines the maximum motor speed. But in most other applications, it defines the maximum harmonic that
the system can produce. Choosing enough bandwidth is important to ensure closed-loop stability and the
capability to meet the test specification, which depends on the application.
The main items and specifications related to the amplifier speed and bandwidth are the following:
• Bandwidth: bode plots with gain and phase as function of frequency in current and voltage mode and at
different power level and type of load.
• Maximum slew-rate and initial delay
• Communication delays from and to the model executed by the real-time simulator
• Interfacing inductance/transformer/impedance
• Sensor accuracy and delay
• Anti-aliasing filters (for instance if the DuT is an inverter)
The above specification is very important to determine the accuracy and PHIL system stability.
Key Considerations When Choosing your PHIL (Power Hardware-in-the-Loop) Solution for your Test/Simulation Application
13 OPAL-RT TECHNOLOGIES
5| Fifth Consideration
Choosing the Right Instrumentation and Control
For PHIL applications, fast control signals and rapid feedback on currents and voltages are required in order
to close the loop. If the feedback is too slow, the model won't measure the updated currents and voltages,
resulting in an unstable configuration. Since real-time platforms may be interfaced with a wide variety of
amplifiers and controllers, choosing the right instrumentation is crucial. In fact, the right equipment can
stabilize a model by reducing the feedback time by considerable amounts. With PHIL, we encounter two
ways to return current and voltage feedback to the simulator: with digital communications or with analog
communications.
Some amplifiers include embedded sensors to measure current and voltage waveforms. Such signals are
available to users to interface with the model either via SFP optical fibers or on analog ports. However,
users must verify that these sensors are fast enough (i.e., signal filtering must be optimized to induce
minimum delays) for the application. OPAL-RT provides a variety of voltage and current sensors if sensors
supplied by amplifier manufactures exhibit too much delay for PHIL applications.
Key Considerations When Choosing your PHIL (Power Hardware-in-the-Loop) Solution for your Test/Simulation Application
OPAL-RT TECHNOLOGIES 14
Conversely, several system-level tests would be too expensive to perform with a PHIL setup and other
tests may be too dangerous to perform in PHIL mode. Also, Controller HIL enables design and test of the
controller when the power devices are not available to reduce the total time-to-market and development
cost. Consequently, one must select the use of either PHIL or CHIL depending on both the study objectives
and project stage to optimize the total project cost and to decrease project delay and security risks.
When PHIL is needed, responsiveness in PHIL testing comes down to this: fast and dynamic feedback.
Without this, real-time simulation of PHIL systems is not possible, and results may not represent their
physical live counterparts. Choosing the right solution comes down to five major concepts, as we’ve
discussed: the amplifier’s operating range, its cost, its source and sink capabilities, its bandwidth, and finally
its instrumentation and control.
This article has simply scratched the surface of the possible configurations and capabilities of such systems—
though we hope our experience has started to clarify the way forward for you.
Key Considerations When Choosing your PHIL (Power Hardware-in-the-Loop) Solution for your Test/Simulation Application
15 OPAL-RT TECHNOLOGIES
1: Stability and Accuracy Considerations of Power Hardware- in-the-Loop Test Benches for Wind Turbines, Antonino
Riccobono, Alexander Helmedag, Anica Berthold, Nurhan Rizqy Averous, Rik W. De Doncker, Antonello Monti,
https://www.sciencedirect.com/science/article/pii/S240589631733344X
2: Safety Issues for Power-Hardware-in-the-Loop Simulations, Georg Lauss, AIT Austrian Institute of Technology
;Felix Lehfuß, AIT Austrian Institute of Technology Vienna, Austria, http://pubdb.ait.ac.at/files/PubDat_
AIT_133989.pdf
3: PHIL simulation for DER and smart grids: best practices and experiences from the ERIGrid project,
ERIGrid Webinar: 5 December 2017, https://erigrid.eu/wp-content/uploads/2017/12/ERIGrid-PHIL-Webinar-
Presentations.pdf
4: Power Hardware-in-the-Loop Conception: How to Design a Field-Test Environment for Large-Scale Smart Grid
Integration Studies, October 2018, Conference: International Conference on the Integration of Renewable
and Distributed Energy Resources Project: European Research Infrastructure supporting Smart Grid Systems
Technology Development, Validation and Roll Out (ERIGrid), https://www.researchgate.net/project/European-
Research-Infrastructure-supporting-Smart-Grid-Systems-Technology-Development-Validation-and-Roll-Out-
ERIGrid
Authors
Key Considerations When Choosing your PHIL (Power Hardware-in-the-Loop) Solution for your Test/Simulation Application
OPAL-RT TECHNOLOGIES 16
Contact Us
Learn about the benefits and challenges of PHIL simulation, its applications, case studies and much
more on OPAL-RT's website or by contacting one of our PHIL specialists.
Key Considerations When Choosing your PHIL (Power Hardware-in-the-Loop) Solution for your Test/Simulation Application
17 OPAL-RT TECHNOLOGIES
Grid Emulator (50, 60 Hz) 120 to 208 Vrms, 10 A Sink and source 5
Grid Load 120 to 208 Vrms, 10 A Sink and source 5 Sourcing is needed for power absorption
Wind_generator Emulation -
120 to 208 Vrms, 0.2 to 20 kW Source 5
Small Lab Scale
Wind_generator Emulation -
120 to 208 Vrms, 0.2 to 200 kW Source 5
Medium Lab Scale
Grid Inverter Emulation 120 to 208 Vrms, 10 A Sink and source 10
Frequency Emulator 120 to 208 Vrms, 10 A Sink and source 5 Application mainly used for active filters
Photo Voltaic Emulation 200 to 400 Vdc, 200 W to 20 kW Source 1
Automotive Applications
Everything but the battery is simulated. DC
Electrical Power Train Emulation 500 to 1000 kW Sink and source 15
output.
Battery Emulator 20 to 100 kW, 200 to 600 Vdc Sink and source 1 Only the battery is simulated
Drive Inverter Emulator 500 to 1000 kW Sink and source 15 DC with inverter simulated. AC output.
Motor Emulator 500 to 1000 kW Sink and source 15 Only the motor is simulated.
Sink for vehicle to grid applications.
eVehicle Charging Station
3 to 250 kW, 200 to 600 Vdc Sink and source 1 Smaller charging times for higher power out-
Emulator
puts.
Aerospace / Military
400 Hz Supply Grid Emulator 115 Vrms Sink and source 50
Actuator Emulator Up to 1kW Sink and source 20
Key Considerations When Choosing your PHIL (Power Hardware-in-the-Loop) Solution for your Test/Simulation Application
Founded in 1997, OPAL-RT TECHNOLOGIES is The company’s core software, RT-LAB, enables
the leading developer of open real-time digital users to rapidly develop models suitable for
simulators and Hardware-In-the-Loop testing real-time simulation, while minimizing initial
equipment for electrical, electro-mechanical
investment and their cost of ownership. OPAL-
and power electronic systems.
RT also develops mathematical solvers and
OPAL-RT simulators are used by engineers and models specialized for accurate simulation
researchers at leading manufacturers, utilities, of power electronic systems and electrical
universities and research centres around the grids. RT-LAB and OPAL-RT solvers and models
world. are integrated with advanced field programmable
OPAL-RT’s unique technological approach gate array (FPGA) I/O and processing boards
integrates parallel, distributed computing with to create complete solutions for RCP and HIL
commercial-off-the-shelf technologies. testing.
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