Unlocking Versatility in Power Converter Prototyping with Typhoon HIL

Developing Power Converter Systems (PCS) involves significant challenges when transitioning from simplified simulations to complex real-world systems. Control algorithms developed and tested purely in offline simulation may not perform as expected when implemented on physical hardware. Additionally, code changes from development to real-time deployment can lead to instability, delays, or inaccurate responses in the physical prototype. Real-time testing and validation of control strategies before final hardware is available enables early error detection and extensive testing, reducing development time and cost while improving product quality.

This white paper provides a functional overview of the Catalonia Institute for Energy Research(IREC)’s application of Rapid Control Prototyping (RCP) within the H2020 HYBRIS project. In this project, the HIL404 real-time simulator serves as the controller for the power converter system. During the early design phase, Typhoon HIL Control Center is used to model both the power stage and control loops in a Model-in-the-Loop (MIL) configuration, running in real-time on the HIL404. This setup enables pre-prototype validation of hardware and software aspects. Following the RCP methodology, the power converter prototype is developed while the control stage remains implemented on the HIL404 as a prototype controller.

Thanks to the Typhoon HIL simulator’s high-resolution analog inputs and built-in PWM modulation capabilities, sensor measurements are accurately acquired, and MOSFET gate drivers are effectively controlled on the physical PCS prototype. The result is a Rapid Control Prototyping method that significantly reduces development risks and time requirements for testing PCS control strategies.

Unlocking Versatility in Power Converter Prototyping with Typhoon HIL

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