Photovoltaic PPC HiL Testing for Weak-Grid and Extreme Conditions

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Solution Overview

Problem

Conventional PPC performance testing methods pose risks to power grid safety, are difficult to time effectively, and require high simulation costs, especially in simulating extreme weather conditions.

Innovation Solution

A HiL testing platform for photovoltaic power plants, comprising a PPC, inverter controller, and HiL real-time simulator, allows digital simulation of photovoltaic systems without physical connection, using communication protocols and synchronized components to test various conditions in real-time.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If the PPC is connected to a real power station for testing, then the testing results reflect actual performance, but the power quality of the power station is affected and power grid safety is endangered

Engineering Contradiction:
Improvetesting accuracyVSAvoidpower grid safety
Core Design Contradiction:
Measurement precisionVSReliability

Solution Approach 1:

The patent creates a virtual copy of the photovoltaic power station system including PV arrays, inverters, transformers, transmission lines, and power grids. This digital model replicates the electrical characteristics and operational behavior of the actual system, allowing realistic testing without connecting to real equipment. The virtual system responds to controller commands as the physical system would, providing accurate performance measurement while eliminating safety risks.

Inventive Principle:
Principle #26Copying

Solution Approach 2:

The patent introduces a HiL real-time simulator as an intermediary between the PPC (power plant controller) and the virtual power station system. This simulator acts as a bridge that translates controller outputs into virtual system responses and feeds back virtual sensor measurements to the controller. The intermediary enables realistic closed-loop testing while isolating the actual power station and grid from testing activities.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Device complexity

If conventional physical testing is used, then the testing setup is simple, but it is difficult to simulate extreme operation conditions like weak power grid conditions and frequency crossings

Engineering Contradiction:
Improvetesting setup simplicityVSAvoidsimulation capability
Core Design Contradiction:
Device complexityVSAdaptability or versatility

Solution Approach 1:

The patent implements dynamic simulation capabilities in the virtual power station system, allowing real-time modification of system parameters and operating conditions. The virtual model can dynamically transition between different operational states including normal operation, weak grid conditions, frequency deviations, and extreme events. This dynamic adaptability enables comprehensive testing of controller performance across the full range of possible operating conditions without requiring physical reconfiguration.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The patent utilizes parameter changes to simulate various operating conditions by modifying the virtual system's electrical parameters. The simulator can adjust grid impedance, voltage levels, frequency, and power flow characteristics to create scenarios such as weak grid conditions, voltage sags, frequency crossings, and other extreme conditions. These parameter modifications are performed in real-time during testing, enabling versatile scenario generation with simple software control.

Inventive Principle:
Principle #35Parameter changes

3Measurement precision

If extreme operation conditions are tested in real power stations, then comprehensive performance evaluation is achieved, but weather conditions limit test timing and extreme conditions are rare

Engineering Contradiction:
Improveperformance evaluation completenessVSAvoidtest timing flexibility
Core Design Contradiction:
Measurement precisionVSLoss of time

Solution Approach 1:

The patent enables preliminary testing of extreme and abnormal operating conditions before they occur in the actual power station. The virtual system can be configured to simulate rare weather events, grid failures, and extreme operational scenarios at any time, allowing comprehensive controller validation without waiting for real-world occurrences. This preliminary action ensures the controller is thoroughly tested and validated before deployment or before actual extreme conditions arise.

Inventive Principle:
Principle #10Preliminary action

Data Source

PatentUS12615015B2HIL testing platform for photovoltaic power plant, and PPC performance testing method
Publication Date: 2026.04.28 SUNGROW POWER SUPPLY CO LTD
  • US12615015B2 patent drawing
  • US12615015B2 patent drawing
  • US12615015B2 patent drawing

AI summary

A HiL testing platform for a photovoltaic power station and a PPC performance testing method are provided. The HiL testing platform includes: a PPC, an inverter controller, and a HiL real-time simulator. Each of the PPC, the inverter controller, and the HiL real-time simulator is arranged with an upper computer. The PPC is configured to communicate with the inverter controller according to a predetermined communication protocol. The HiL real-time simulator is connected to the PPC and the inverter controller through a digital input interface and/or an analog output interface, and is configured to simulate a testing device in the photovoltaic power station in a digital model form.