PWM Load Simulation for Inductive Control Device Testing
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Solution Overview
Problem
Current simulation devices for peripheral circuit arrangements, such as electric motors, lack sufficient scalability and adaptability, leading to inadequate simulation of dynamic behavior and requiring extensive hardware changes for different inductive loads, which complicates testing and validation of control devices.
Innovation Solution
A simulation device with a multi-stage converter and semiconductor switches, controlled by a computing unit executing a model code, generates pulse-width modulated gate-source voltages to simulate currents and voltages that closely match real-world conditions, allowing for precise and flexible simulation of peripheral circuit arrangements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a simulation device uses a simple voltage source to simulate electrical loads, then the device complexity is reduced, but the simulation precision and ability to replicate dynamic behavior deteriorate
Solution Approach 1:
The simulation device is segmented into multiple functional modules: a multi-stage converter with separate control circuits for each stage, a computing unit for model code execution, and semiconductor switch control devices. This modular segmentation allows the system to achieve high simulation precision through coordinated operation of specialized subsystems while keeping the overall architecture manageable.
Solution Approach 2:
The simulation device employs dynamic control through pulse-width modulation (PWM) of semiconductor switches in the multi-stage converter. The control signals dynamically adjust the switching states based on real-time calculations from model code, enabling the device to accurately replicate the dynamic behavior of inductive loads such as electric motors during various operating conditions.
2Manufacturing precision
If a simulation device is designed for a specific inductive load, then the manufacturing precision for that load is improved, but the adaptability to different peripheral circuit arrangements deteriorates
Solution Approach 1:
The simulation device achieves universality through its multi-stage converter architecture with independent control circuits for each stage. By executing different model codes on the computing unit, the same hardware platform can accurately simulate various inductive loads including electric motors with different characteristics, thereby providing both high precision for specific loads and broad adaptability to different peripheral circuit arrangements.
Solution Approach 2:
The device utilizes parameter changes in the form of different model codes that define electrical characteristics such as inductance, resistance, and back-EMF constants. By changing the mathematical models executed on the computing unit rather than hardware components, the simulation device maintains manufacturing precision for specific loads while achieving versatility across different peripheral circuit arrangements.
3Measurement precision
If extensive hardware modifications are made to adapt the simulation device to different inductive loads, then the simulation accuracy for new loads is improved, but the loss of time for reconfiguration increases
Solution Approach 1:
The simulation device replaces mechanical hardware reconfiguration with software-based adaptation. Instead of physically modifying the circuitry to accommodate different inductive loads, the system loads and executes different model codes on the computing unit. This substitution of mechanical reconfiguration with software programming dramatically reduces adaptation time while maintaining high simulation accuracy for various loads.
4Speed
If a simulation device uses high-frequency switching to improve dynamic response, then the speed of simulation is improved, but harmful factors such as ripple currents and electromagnetic interference increase
Solution Approach 1:
The multi-stage converter maintains continuous useful action by coordinating the switching of semiconductor devices across multiple stages. This continuous operation smooths out ripple currents that would otherwise be generated by high-frequency switching, while still achieving fast dynamic response through the combined effect of staged conversion and PWM control.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a more realistic simulation of electrical behavior, enabling more accurate testing and optimization of control devices by closely mimicking the dynamic behavior of real inductive loads, thus improving the scalability and adaptability of simulation devices.
Implementation Method 1
a comparison of the first modulation signal with the first carrier signal is performed by means of the first comparator, in the course of which comparison a pulse-width modulated first gate-source voltage is generated
Data Source
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AI summary
The invention relates to a method for simulating a peripheral circuit arrangement connectable to a control device (DUT), wherein a simulation device (Hx) is electrically connected or electrically connectable to the control device (DUT), and wherein the simulation device (Hx) comprises a first actuator (S1) with which a first simulation current (Is1) which can be transmitted from a first load terminal (D1) of the control device (DUT) to a first actuator output (Out1) of the first actuator (S1) can be influenced, and wherein the first actuator (S1) comprises a first multi-stage converter, and wherein the simulation device (Hx) further comprises a first semiconductor switch control device (Tc1) and a computing unit (Cx), and the computing unit (Cx) executes a model code.wherein a first switch control signal (Ts1) is calculated and provided by means of the computing unit (Cx) and the model code for transmission to the first semiconductor switch control device (Tc1), and wherein the first semiconductor switch control device (Tc1) has at least one first comparator (Co1), wherein a pulse-width modulated first gate-source voltage (Ts11) is generated at a first comparator output (X1) and applied to a first control terminal (G11), and the first simulation current (Is1) is influenced by means of the first gate-source voltage (Ts11).