CHIL Interface for Power Converter Controller Testing
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Solution Overview
Problem
Current methods for testing power electronics converter controllers require disconnection from the converter and use of custom signal conditioning, leading to errors and inability to accommodate hardware variations, making it difficult to develop and test controllers throughout the lifecycle of power conversion systems.
Innovation Solution
A Controller Hardware-in-the-Loop (CHIL) interface that integrates with the power electronics converter controller, allowing direct digital signal exchange between the controller and a simulator, eliminating the need for custom signal conditioning and enabling continuous testing and development without altering the connection between the controller and converter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If custom signal conditioning circuitry is used to connect controller to PEC simulator, then testing can be performed, but errors are introduced and adaptability to hardware variations is lost
Solution Approach 1:
The patent creates a digital copy of the power electronics converter behavior through software simulation, replacing physical signal conditioning circuitry. The PEC simulator replicates converter characteristics in software, allowing direct digital connection between controller and simulator without analog signal path, thereby eliminating errors from custom circuitry while maintaining adaptability through software configuration
Solution Approach 2:
The patent replaces the mechanical/electrical signal conditioning system with a digital software-based system. Instead of using physical analog signal paths and custom circuitry, the solution uses digital signal exchange and software simulation models, eliminating the need for custom analog signal processing while improving reliability and adaptability
2Ease of operation
If controller is disconnected from PEC for testing, then simulation testing can be performed, but connection alterations are required
Solution Approach 1:
The patent introduces a CHIL interface as an intermediary component that remains permanently connected to the controller. This interface serves as a mediator between the controller and the PEC simulator, allowing the controller to be disconnected from the actual PEC while maintaining a stable connection path through the CHIL interface to the simulator, thereby simplifying testing operations without requiring connection alterations
Solution Approach 2:
The patent establishes a pre-configured CHIL interface and communication path before testing begins. The interface is permanently integrated with the controller and pre-wired to accommodate simulator connections, so that when testing is needed, the system is already prepared and no connection alterations are required during the testing process
3Loss of information
If analog signal processing is used for controller-simulator interface, then signal exchange is possible, but artifacts are unintentionally introduced
Solution Approach 1:
The patent replaces the analog signal processing system with a digital communication system. Instead of using analog voltage signals and signal conditioning circuitry that introduce artifacts, the solution uses digital signal exchange between the controller and simulator, eliminating analog-to-digital conversion artifacts and signal conditioning complexities while maintaining full signal fidelity
Data Source
AI summary
A controller hardware in the loop (CHIL) interface is disclosed. The CHIL interface comprises software and hardware that redirects a signal flow, including modulation signals and measurements exchanged between controller logic and a power electronics converter (PEC), to a CHIL port. Accordingly, the CHIL port provides access to the controller logic, at a digital level, throughout phases of the controller's lifetime (i.e., design, installation, maintenance, upgrade). Thus, the CHIL interface facilitates the use of PEC simulators for testing. The CHIL interface can detach the actual PEC from the control logic so testing can be performed with or without an operating PEC and can avoid the need for dedicated and error prone signal conditioning circuitry that is external to the controller.