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Typhoon HIL. SWISS

QUALITY

Discover the frontier of Hardware-in-the-Loop testing and quality assurance for power electronics

www.typhoon-hil.com


Introduction Who we are Applications

Hardware HIL400 HIL600 HIL602 HIL DSP Interface HILConnect

Software HIL Schematic Editor HIL Control Center Automatic Testing Center

User experiences


Who we are. Typhoon HIL, Inc. is a technology leader in the ultra-high fidelity Hardware-in-the-Loop (HIL) real-time emulators for power electronics. Our solutions are extensively used for power electronics control system design, development and automated quality assurance (QA).

Applications

Research and Development

Typhoon HIL products are used for the design, development and automated quality assurance (QA) of power electronics control systems. Our systems are used worldwide for a range of applications such as motor drives, PV converters, active filters, traction, telecom, research, and teaching.

As an innovative power electronics company, we not only focus on research and development of new products, but also closely work with our customers to help them solve their unique challenges and to customize our products to their specific needs and requirements.

Products

Contact us

Typhoon HIL offers ultra-high fidelity real-time Hardware-in-the-Loop (HIL) emulation systems (with 1Âľs simulation time step) and industrial controllers for power electronics. Our products are distinguished by leading edge technology, unrivaled performance, ease of use stemming from complete vertical integration of the tool-chain, and affordability. Our application specific digital processor architecture and real-time simulation algorithms have set the standard for ultra-high fidelity power electronics HIL systems.

We are an international company serving customers on three continents, and we are aware that our success depends on our ability to listen and work closely with our customers to help them solve their pressing QA problems. Hence, we take pride in being flexible and providing you the right solution for your particular needs.


The problem we have solved. Typhoon products directly address power electronics control design, testing, and QA with a sophisticated ultra-low latency Hardware-in-the-Loop real-time emulator based on our digital processor and vertically integrated software toolchain.

Relevance of the problem

Solution approach

Testing power electronics controls is an extremely time consuming, expensive, and dangerous process, that has to be done in a high- power laboratory, i.e. next to a spinning machinery and/or with grid connected converters. In addition, this approach to testing can not cover all the operating conditions, operational scenarios, and faults. Hence, test until time or money run out is still prevailing in industry.

Our ultra-low latency Hardware-In-the-Loop (HIL) technology enables automated type and routine tests of power electronics control systems which dramatically improve the bottom line by: • Reducing time to market • Eliminating control system quality cost • Streamlining end of line testing.

Our solution directly reduces quality assurance costs that today amount to 2-4% of overall revenues.

Test automation platform

Hardware in the loop real-time emulator

Controller platform

The four key applications of HIL technology are: • Renewable power generation • Industry automation • Transportation • Research and education.


Typhoon HIL Hardware.


Typhoon HIL400. Cost effective, high fidelity 2-core processor Hardware-in-the-Loop system for testing smaller system power electronics controllers.

Applications

Features and Benefits

Typhoon HIL400 emulator is an embedded HIL system for testing, and rapid prototyping of: PV inverters, active filters, motor drives, wind turbine converters.

• Compact 2-core processor HIL for real-time emulation of two complete converters.

Easy to use software tool-chain User friendly and intuitive software is easy to use and master, even for first time users. Build your models and perform sophisticated test scenarios, in the comfort of your office, in four simple steps: 1. Define converter model in the schematic editor and compile circuit with one click. 2. Run the model from the simulation control center and change sources, toggle contactors, load machines etc. 3. Explore emulated signals with external oscilloscope. Zoom in the waveforms near critical events. 4. Automate steps 1 to 3 via Python test scripts and let the HIL400 test your controller.

• Test your controller with 100 ns PWM resolution. • Emulate your power stage with up to 2 MHz update rate. • Interface your controller via 16 analog outputs, 8 analog inputs, 32 digital inputs, and 32 digital outputs. • Build converter models with our library of power electronics components and examples. • Automate testing with simple Python scripts for quick control software testing. • Connect to host PC via Ethernet or USB2.0 .


HIL400 technical details. Processor

Xilinx Virtex-5 FPGA

2 cores

Analog intputs (Ai)

Channels

8 channels

Resolution

12 bit ADC

Input voltage range

± 5V

Channels

16 channels

Resolution

12 bit DAC

Output voltage range

± 5V

Output resistance

400 Ω

Analog IO connector

Connector

DIN 41612, type C 64 pin male connector

Digital inputs

Channels

32 digital pins (input)

Input voltage range VI [V] Threshold voltages (low, high)

-15<VI<+15 (VIL(max) = 0.8V ; VIH(min) 2V)

Channels

32 digital pins (output)

Output voltage range VO [V]

0<Vo<+5 (VOL(max) = 0.2V ; VOH(min) 4.8V)

Output resistance

2kΩ

Digital IO connector

Connector type

DIN 41612, type C 96 pin male connector

Connectivity

Ethernet link

RJ45

USB2.0

USB standard

Dimensions (width x height x length)

308 x 90 x 255 [mm]

Weight

2.5kg

Input power supply

90-240V (universal) 250W

Analog outputs (AO)

Digital outputs

Housing


Typhoon HIL600. Discover the industrial grade ultra-high fidelity Hardware-in-the-Loop system for the most comprehensive power electronics controls test and quality assurance.

Applications

Features and Benefits

Typhoon HIL600 real-time power electronics emulator is an ideal tool for development, testing, optimization, and quality assurance of grid connected converters (i.e. PV, wind, active filter), automotive converters, electric propulsion drives, micro-grids, and industry automation.

• Unleash the new 6-core processor HIL for real-time emulation of up to 6 converters.

Easy to use software tool-chain User friendly and intuitive software is easy to use and master, even for first time users. Build your models and perform sophisticated test scenarios, in the comfort of your office, in four simple steps: 1. Define converter model in the schematic editor and compile circuit with one click. 2. Run the model from the simulation control center and change sources, toggle contactors, load machines etc. 3. Capture signals, zoom in, and explore the waveforms around critical events. 4. Automate steps 1 to 3 via Python test scripts and let the HIL600 comprehensively test your controller around the clock.

• Test your controller with 20 ns PWM resolution and ultra-high fidelity. • Emulate your power stage with up to 2 MHz update rate. • Quickly find problems and debug your controller with new Capture Function. • Dive into your signals with 1 Megapoint capture record length for all 16 channels. • Interface your controller via 16 analog outputs, 8 analog inputs, 32 digital inputs, and 32 digital outputs. • Build converter models with our extensive library of power electronics components and examples. • Automate testing with Python scripts for the most comprehensive control software testing. • Connect to host PC via Ethernet or USB2.0 .


HIL600 highlights. Test your controller with high fidelity, 20 ns sampling HIL. 20 ns PWM resolution combined with 1ms latency enables the most realistic power electronics controller test and development. For converter switching frequencies up to 40 kHz emulation error and latency are so small that it is difficult to tell the difference between real converter and HIL emulator measured waveforms.

Ultra-high fidelity: magenta: real boost MPPT converter current; green: HIL boost current; dark blue: real boost inductor voltage; light blue: HIL inductor voltage.

Zoom in voltages and currents with Capture Function’s microsecond “microscope.”

Capture HIL signals to quickly detect, debug, and characterize your controller performance.

Quickly discover problems with your control algorithms, and debug the controller with deep memory capture function. Trigger the capture function based on fault injection events and quantify the converter system response. With 1 Megapoint capture record length, on all 16 analog channels, and 1MHz sample rate even tiny glitches in modulator algorithm are quickly identified.

Automate testing with Python: the ultimate ease of use. Automate controller testing processes with Python scripting and HIL600 platform. Discover the most comprehensive power electronics control software testing environment where fault injection such as grid disturbances, short and open circuits are just one Python command away. Use Python scripting and rich math function library to quantify system performance in spectrum of operating conditions under standard operating conditions and fault conditions (internal and external).

Automate testing with Python scripts to comprehensively and reproducibly test and qualify all your controllers.


HIL600 technical details. Processor

Xilinx Virtex-6 FPGA

4 cores

Analog intputs (Ai)

Channels

8 channels

Resolution

12 bit ADC

Input voltage range

± 5V

Channels

16 channels

Resolution

12 bit DAC

Output voltage range

± 5V

Output resistance

400 Ω

Analog IO connector

Connector

DIN 41612, type C 64 pin male connector

Digital inputs

Channels

32 digital pins (input)

Input voltage range VI [V] Threshold voltages (low, high)

-15<VI<+15 (VIL(max) = 0.8V ; VIH(min) 2V)

Channels

32 digital pins (output)

Output voltage range VO [V]

0<Vo<+5 (VOL(max) = 0.2V ; VOH(min) 4.8V)

Output resistance

2kΩ

Digital IO connector

Connector type

DIN 41612, type C 96 pin male connector

Connectivity

Ethernet link

RJ45

USB2.0

USB standard

Dimensions (width x height x length)

340 x 90 x 285 [mm]

Weight

4kg

Input power supply

90-240V (universal) 250W

Analog outputs (AO)

Digital outputs

Housing


Typhoon HIL602. Deploy industrial grade ultra-high fidelity Hardware-in-the-Loop system for the most comprehensive power electronics controls test, verification, and pre-certification jobs.

Applications

Features and Benefits

Typhoon HIL602 real-time power electronics emulator is an ideal tool for development, testing, optimization, and quality assurance of grid connected converters (i.e. PV, wind, active filter), automotive converters, electric propulsion drives, micro-grids, and industry automation.

• Unleash the new 6-core processor HIL for real-time emulation of up to 6 converters.

Easy to use software tool-chain User friendly and intuitive software is easy to use and master, even for first time users. Build your models and perform sophisticated test scenarios, in the comfort of your office, in four simple steps: 1. Define converter model in the schematic editor and compile circuit with one click. 2. Run the model from the simulation control center and change sources, toggle contactors, load machines etc. 3. Capture signals, zoom in, and explore the waveforms around critical events. 4. Automate steps 1 to 3 via Python test scripts and let the HIL602 comprehensively test your controller around the clock.

• Test your controller with 20 ns PWM resolution and ultra-high fidelity. • Emulate your power stage with up to 2 MHz update rate. • Quickly find problems and debug your controller with new Capture Function. • Dive into your signals with 1 Megapoint capture record length for all 16 channels. • Interface your controller via 32 analog outputs, 8 analog inputs, 32 digital inputs, and 32 digital outputs. • Build converter models with our extensive library of power electronics components and examples. • Automate testing with Python scripts for the most comprehensive control software testing. • Connect to host PC via Ethernet or USB2.0 .


HIL602 highlights. Test your controller with high fidelity, 20 ns sampling HIL. 20 ns PWM resolution combined with 1ms latency enables the most realistic power electronics controller test and development. For converter switching frequencies up to 40 kHz emulation error and latency are so small that it is difficult to tell the difference between real converter and HIL emulator measured waveforms.

Ultra-high fidelity: magenta: real boost MPPT converter current; green: HIL boost current; dark blue: real boost inductor voltage; light blue: HIL inductor voltage.

Zoom in voltages and currents with Scope/Capture Function’s microsecond “microscope.”

Capture HIL signals to quickly detect, debug, and characterize your controller performance.

Quickly debug control code with deep memory scope/capture function. Trigger on fault injection events and quantify the converter system response. With 1 Megapoint capture record length, on all 32 analog channels, and 1MHz sample rate even tiny glitches in modulator algorithm are quickly identified.

Automate testing with Python: the ultimate ease of use. Automate controller testing processes with Python scripting and HIL602 platform. Discover the most comprehensive power electronics control software testing environment where fault injection such as grid disturbances, short and open circuits are just one Python command away. Use Python scripting and rich math function library to quantify system performance in spectrum of operating conditions under standard operating conditions and fault conditions (internal and external).

Automate testing with Python scripts to comprehensively and reproducibly test and qualify all your controllers.


HIL602 technical details. Processor

Xilinx Virtex-6 FPGA

up to 6 cores

Analog intputs (Ai)

Channels

16 channels

Resolution

12 bit ADC

Input voltage range

± 5V

Channels

32 channels

Resolution

12 bit DAC

Output voltage range

± 5V

Output resistance

Analog IO connector

Connector

DIN 41612, type C 96 pin male connector

Digital inputs

Channels

32 digital pins (input)

Input voltage range VI [V] Threshold voltages (low, high)

-15<VI<+15 (VIL(max) = 1.5V ; VIH(min) 3.5V)

Channels

32 digital pins (output)

Output voltage range VO [V]

0<Vo<+5 (VOL(max) = 0.2V ; VOH(min) 4.8V)

Output resistance

1.4 kΩ

Digital IO connector

Connector type

DIN 41612, type C 96 pin male connector

Connectivity

Ethernet link

RJ45

USB2.0

USB standard

High speed serial link

SMA standard

Dimensions (width x height x length)

340 x 90 x 285 [mm]

Weight

4kg

Input power supply

90-240V (universal) 250W

Analog outputs (AO)

Digital outputs

Housing


Typhoon HIL MicroGrid Solution. Complete HIL solution for micro-grid control system development, testing, and pre-certification. TyphoonLink (Gb/s serial link)

signal conditioning

Control System Under Test

signal conditioning

signal conditioning

Control System Under Test

Control System Under Test

signal conditioning

Control System Under Test

MicroGrid HIL solution.

Features and Benefits

HIL602 provides a comprehensive environment for design and testing of control systems for micro-grid power electronics converters. TyphoonLink-Gigabit per second serial link-enables seamless connection of multiple HIL602 units into one unified HIL system that can simulate 16 or more converters. Whether you are testing a single converter control or multiple converter control (centralized or decentralized) HIL602 in the cluster configuration provides a unified environment that is as easy to use as if you were working with single HIL unit. Compile schematic diagram from the Schematic Editor; control the real-time emulation process via HIL Control Panel; quickly access all simulated signals via the Scope/Capture function-the same way as if you were using a single HIL. Finaly, automate testing with Python scripts via Typhoon API.

• Connect 4 or more HIL602 units in HILCluster configuration. • Deploy 24 real-time computational cores as one unified HIL real-time emulation fabric. • Test one or multiple controllers in micro-grid environment for both centralized and decentralized micro-grid control configurations. • Test both lower level and application/micro-grid level control layers. • Interface seamlessly your industrial controllers to multiple HIL units via HILConnect. • Automate test and pre-certification processes with Python scripts via Typhoon API.


MicroGrid Energy storage converter. Develop Micro-Grid energy storage converter control system.

Grid

Diesel powered synchronous generator

Energy storage grid-tie inverter

PV inverter

PMSM wind generator

Loads

Energy storage inverter.

Test, optimize, pre-certify.

In this case, a complete control software for a battery energy storage inverter system is developed using HIL. Complete micro-grid is simulated with the HIL602 Cluster. Micro-grid model implemented provides the most realistic environment for development and testing of micro-grid power electronics systems. In this system micro-grid model comprises intermittent photovoltaic power source, permanent magnet synchronous machine wind turbine generator, diesel powered synchronous generator, variable speed motor drive, resistive load, nonlinear current load, utility grid and main contactor that emulates both grid-connected and off-grid operational regimes. A truly flexible and easy to use ultra-high fidelity real-time simulation environment.

Control loops design and optimization for the energy storage inverter is done on an industrial controller platform directly interfaced with the HIL602 Cluster via HILConnect. All controller functionsâ&#x20AC;&#x201D;i.e. PWM modulator, PLL, current and voltage control loops etc.â&#x20AC;&#x201D;as well as protection and high-level control functions (i.e. dynamic grid support) are tested for different operating conditions. Indeed, HILCluster is ideal for test and pre-certification of micro-grid power electronics converter controllers. Automated test scripts cover a spectrum of test cases (including fault conditions and system unbalance) that provide a cost effective solution for compete test and verification of control system performance. In addition, HILCluster provides easy to use development and test environment for system level micro-grid controller.


HIL602 use case. Controller for centralized PV inverter with MPPT.

Typhoon HIL600 real-time emulator

Controller platform

PV inverter controller development. In this case, complete control software for centralized PV inverter system, including four parallel MPPT converters is developed, tested and qualified using HIL. All the fast controller functionsâ&#x20AC;&#x201D;such as PWM modulation, current and voltage control loops, maximum power point tracking etc.â&#x20AC;&#x201D;as well as protection functions and high-level control functions (i.e. dynamic grid support) were tested and characterized using HIL. Control loop tuning and optimization was done on real controller platform interfaced with HIL602. MPPT code was tested and verified using various illumination profiles (including partial shading) to confirm convergence to global maximum power point of PV panel. In addition current harmonic content was measured to verify filter parameters.

Testing and qualification HIL602, with its deep memory 1Msample/sec/ channel and 1MHz sample rate scope/capture function, up to 6 parallel computation cores, and 20ns sampling resolution, provides the most comprehensive, high-fidelity HIL emulation environment. It is tailored for test and qualification of grid connected converter systems grid compliance including dynamic grid support. Automated test scripts cover test cases required for obtaining grid compliance certificates, i.e. BDEW. Automated fault injection provides comprehensive environment for test and verification of control performance under grid faults (sags, dips, frequency disturbances, over voltages), component failures, and environmental conditions (i.e. solar illumination). Capture function enables detailed analysis of converter dynamics and analytical verification of grid code compliance.


HIL DSP Interface Plug in a TI DSP DIM100 controller card and start controlling your power converter via pin-to-pin compatible Typhoon HIL connection.

Applications

Features and Benefits

Typhoon HIL DSP Interface built for a family of Texas Instruments DIM100 DSP cards (F280x and F2833x) is the way to go if you want to accelerate the development of power electronics applications. Plug-and-play, pinto-pin compatible interface with Typhoon HIL family of real-time HIL emulators eliminates setup time and enables developers to focus on control code development in the comfort of their office.

• Directly connect HIL DSP Interface to any Typhoon HIL emulator (no cables or external power supplies needed).

Plug-and-play HIL interface Plug HIL DSP Interface with TI DSP card directly into your HIL emulator and start running your power electronics application from get go. Easily port a any of Typhoon’s and TI packaged control code examples directly into the DSP without worrying about interfaces (i.e. voltage levels and interface compatibility). All digital and analog signals from/to HIL DSP Interface are routed directly to HIL analog and digital IO pins. to TI controller side for any TI DSP from F280x or F2833x family.

• Plug in TI DSP DIMM100 control card via DIM100 connector. • Compatible with: F2808; F28044; Delfino F28335; Piccolo F2803x and F2806x; Concerto F28M35xx TI DSP DIM100 cards. • On-board peripherals and external connectors for monitoring and debugging • All HIL analog/digital I/O pins physically accessible via headers. Measurement terminals for digital and analog grounds. • Onboard JTAG connector with voltage level selection (5V or 3.3V). • RS-232 serial communication with host PC. • 5 LEDs and 4 slide switches connected to HIL digital outputs. 4 LEDs and 4 slide switches connected to TI DSP digital outputs.


HIL DSP Interface technical details. TI DSP C2000 Control card compatible Analog Inputs (AI), (DSP AI pins connected HIL AO pins)

F2808, F28044, F28335 (Delfino), F2803x (Piccolo), F2806x (Piccolo), F28M35xx (Concerto) Channels

16

Voltage range

±5V (0-3V on DSP)

Channels

3

Voltage range

±5V external (0-3V on DSP)

Channels

11

Voltage range

0-5V (0-3V on DSP)

Digital Output (DO) PWM & GPIO (DSP DO pins connected to HIL DI pins)

Channels

12 PWM + 9 GPIO

Voltage range

0-5V (0-3V on DSP)

Host interface

UART (RS232)

DB9 connector

JTAG

14pin Header for XDS class emulators

User (direct link) to HIL DI

4 switches

direct link to DSP DI

3 push buttons

DO (HIL DO pins driving LEDs)

5 LEDs

DO (DSP DO pins driving LEDs)

4 LEDs

HIL AI pins to external connector

8 channels, ±5V

HIL DI pins to external connector

6 channels, 0-5V

HIL DO pins to external connector

6 channels, 0-5V

HIL AO monitoring

4 BNC connectors

DSP DO monitoring

12 PWM channels

External Analog Inputs (AI), (DSP pins to external connector) Digital Inputs (DI), (DSP DI pins connected to HIL DO pins)

Additional on-board peripherals


HIL DSP Interface use case. Control code development for grid-tie inverter.

Control system development. Grid-tie inverter is an essential part of distributed generation units like wind turbines, photovoltaics, fuel cells, etc. They can control active and reactive power flow, inject current harmonics etc. Additionally, ancillary control services like local voltage and frequency regulation, voltage harmonic compensation, or active filtering can also be obtained.

Test without limits In HIL grid voltage sources can be specified with arbitrary magnitude, frequency and phase shift values just in few steps. Additionally, one can program and reload in runtime grid voltage waveforms defined in order to emulate utility grid disturbances such as: • • • • • •

voltage sags, spikes, phase angle jumps, magnitude ramp, frequency change harmonic distortion

Indeed, HIL approach enables user to build and deploy completely safe “Megawatt” (MW) grid-connected inverter test installation at office desk, without the need for expensive hardware test equipment and high-power laboratory, simultaneously eliminating all safety and cost issues of laboratory setup. Developer can easily conduct standard controller tests required for grid connected power electronics applications (i.e. BDEW, such as the National Electric Code, IEEE 1547) and also not-standard test scenarios that might arise in real-life deployment . Typhoon HIL environment is distinguished from traditional approach where expensive hardware test equipment like AC power sources for grid simulation are used. In addition, it allows engineers to focus on the evaluation of the software-based functionalities which are provided by inverter’s controller, in order to satisfy most of the technical specifications for grid-connected converter systems.


TI Control Panel. Dynamically reconfigurable GUI interface for TI DSP control applications.

Simple graphical user interface. The TI Control Panel provides a dynamically configurable (depending on the control application) and easy to use graphical user interface (GUI) enabling run-time interaction with control application running on HIL DSP Interface with TI DIMM100 control cards. TI Control Panel communicates through RS232 serial link with DSP controller code implemented on a specific TI DIMM100 control card. User can quickly evaluate the corresponding (Typhoon HIL demo or any TI free example C2000 code) power electronics application emulated on the HIL system.

TI Control panel features • Model Control - interact with control code on the TI DIMM100 Control Card. • Model Preview – see the control algorithm implemented on the TI DIMM100 Control Card which is used with selected project. • Model Commands – gives ability to run/stop some parts of the control algorithm or to set/ clear some of the control flags. • Model References – allows user to give input reference values for the control algorithm. • Model Parameters – ability to Read/Modify different parameters in the control code. • Model Analog Meters – monitor control system variables. • Flag Indicators – monitor the operating mode and status of the control code. • Console – gives user feedback information on the action taken.

TI Control Panel GUI layout (dynamically configured for grid-tie inverter application)


HIL Connect Interface System. Directly interface your production grade control system to Typhoon HIL real-time emulators without any modifications to your controls hardware.

Applications

Typhoon HIL Connect interface system enables direct and seamless interfacing of any power electronics controller system to the HIL family of real-time emulator products. It is specifically designed for power electronics industry, by power electronics specialists, to support all industry standard controller I/O interfaces, such as: current sensors, voltage sensors, fiber optic transceivers, contactors, and temperature sensors.

• Current output transducers provide up to 500 mA to emulate power stage’s current sensors: i.e. LEM sensors or current transformers.

Ease of interfacing with HIL Ultra-high fidelity real-time emulator enables comprehensive test and verification of control system in Hardware-in-the-Loop configuration where real controller is “in the loop” with the emulator. To conclusively test, verify, and finaly certify power electronics controller system in HIL configuration it is critical that controller DUT is not modified in any way. Our HIL Connect interface system is designed to support all the true power electronics controller I/O interfaces such that no modifications are needed on the controller. In addition, we offer customization services to modify HIL connect connectors such that our users can use the exact same cables, from controller to HIL Connect, as they use for connecting real power stage to the controller.

Features and Benefits

• Voltage output transducer provide +/-10V voltage output signals with 10 mA current capability. They can be upgraded to provide up to 650V to emulate certain types of voltage sensors. • Output voltage transducers are also tailored to provide voltages that emulate temperature sensors i.e. thermistors, PTC etc. • Fiber optic receivers enable direct interface for optical signals from your controller system; i.e. gate drive signals • Fiber optic transmitters enable direct interface for optical signals to your controller system; i.e. IGBT desaturation signals. • Digital input voltage transducers that take from -15V to 24V are perfectly suited for contactor and relay control voltage levels. • Digital output voltage transducers that can configured for 3.3V / 5V /15V / 24V operation. • HIL connect is directly interfaced to HIL400/600/800 emulators via two flat cables and DIN41612 connectors.


HIL Connect technical details. User defined connectivity. Scalable I/O voltage and current ranges, channels volume, additional built -in power supply, and more. Voltage Analog Inputs (AI)

Channels

16

Input voltage range

+/- 5V

Channels

16

Input current range

0 - 20mA

Channels

32

Output voltage range

+/- 10 V (or +/- 5 V set by resistors)

Channels

32

Current output range

500 mA per channel

Voltage levels

V(min) = -15V ;

Channels

32

Current range

0 - 20mA

Channels

32

Channels

16 optical transceivers

Speed

5 MBd

Voltage levels

3.3V / 5V /15V / 24V

Channels

32

Current range

0 - 20mA

Channels

32

Channels

32 optical transceivers

Speed

5 MBd

HIL Connectivity

HIL Analog I/O / Digital I/O Connector

DIN 41612, type C (96 pin male)

Housing

Dimensions (width x height x length)

343 x 274 x 347 [mm]

Weight

5kg

Input power supply

90-240V (universal) 250W

Current Analog Inputs (AI)

Voltage Analog Outputs (AO)

Current Analog Outputs (AO)

Voltage Digital Input (DI)

Current Digital Input (DI)

Fiber Optic Digital Input (DI)

Voltage Digital Output (DO)

Current Digital Output (DO)

Fiber Optic Digital Output (DO)

V(max)=24V


Typhoon HIL Software.


HIL software tool-chain. Experience integrated HIL software with automated testing. Intuitive and easy to master, our software provides a unified environment for power electronics design, test automation and quality assurance.

Unified experience.

Discover simplicity.

Model power electronics converters in our simple power electronics editor using a library of passive elements, converters, sources and machines. With only one click, rapidly compile the circuit into machine code that is executable on our HIL hardware. Open the HIL control panel to load the compiled model onto the hardware and launch the real-time simulation. Select signals you want to see on the scope and change sources and parameters for a fully interactive experience. With python script editor, automate your test processes and generate test reports, hands-off.

• • • • • • • • •

Vector graphics circuit editor with examples. Library of power electronics circuit elements. One click circuit compilation. Interactive control of real-time emulation. Dynamic routing of all signals. Waveform editor for source definition. Software control of digital inputs. Automatic testing via Python Scripts. Library of test scripts for testing grid compliance, protection etc. • Python API. • Automatically generate HTML test reports.

circuit compiler

*.py *.py *.py

waveform generator capture function

*.csv *.csv

*.csv *.csv

*.csv

*.html

Typhoon HIL Hardware


HIL Schematic Editor. Schematic editor is designed specially for power electronics engineers. Extensive library of elements and vector graphics provide streamlined yet elegant canvas for rapid building if converter models.

Build the model.

Compile the model.

Schematic editor provides a set of predefined circuit elements, converter switching blocks, machines etc. that enables rapid assembly of power electronics converter models. You build the model by simply dragging blocks from the library and connecting the wires. Double clicking on the circuit elements opens the dialog that lets you easily specify parameters of the selected block. The main library comprises sub-libraries that include:

Compiling the model is done with one click on the compile button. Our real-time simulation is based on piecewise linear state space model with ideal switches that is executed with a fixed time step. Before compiling the model you select the target hardware platform (i.e. HIL400 or HIL600), simulation method, and the simulation time step. Compiler offers: exact simulation that calculates the exact discretized state space model; trapezoidal; and Euler discretization which are approximate discretization methods yet have a smaller HIL memory footprint. Simulation step selected to “auto” enables the compiler to search for minimum feasible simulation time step-given the hardware platform. Preselecting specific time step (i.e. 500ns, 1us, or 2us) selects the initial parameter for compiler, that will incrementally increases if timing constraints are not met.

• passive elements, • power electronics switching blocks (with different switch configurations), • electric machines, • contactors, • measurements, • coupling blocks (for circuit partition).


HIL Control Panel. Be the pilot in the “cockpit” of Typhoon HIL power electronics “flight simulator” via HIL Control Panel user interface.

Interact with simulation.

Dicover the flexibility.

HIL Control Panel enables interactive real-time interfacing with your Hardware in the Loop emulator. Route any of your system variables to any of the analog output channels and adjust the gain and offset. Program your voltage and current sources, visualize waveforms, and load them “on the fly” to emulate grid and inject disturbances. Program your PV panel IV characteristics and illumination levels. Interactively load your machine and change mechanical loading parameters. Directly control all your digital inputs and set their values with a simple drop down menu. Choose software or hardware control for your contactors. In software mode, all the contactor states are directly set in Control Panel, while in hardware mode they are controlled by an assigned digital input pin.

HIL Control Panel is divided in two main tabs: Simulation Control and Capture Signals. Simulation Control Tab features: • Analog output channel configuration: pin address, gain, offset • Digital output configuration: invert signal, software control enable • Source settings: define waveform (arbitraryload from text file, sinusoidal, constant) • Contactor settings: software control enable and state definition (open/close) • Machine settings: mechanical load setting, • Switching block settings: set switch to open or closed state Capture Signals Tab features: • Set number of samples and channels • Trigger settings: channel, input (analog, digital,forced), edge (rising falling) • Channel settings: select capture signal


HIL Automatic Testing. Test your power electronics controls until you run out of ideas, not time and money. With Python and API write test script libraries to test your designs under all operating conditions, faults, and corner casses.

Automate testing with ease.

The power of API.

Typhoon Script Editor enables you to build and execute test libraries to exhaustively test all aspects of a controller. Program test sequences under a spectrum of operating conditions, including faults. For grid connected converters test dynamic grid support, i.e. low voltage ride through, active and reactive power injection, protection etc. Use the library of test scripts to test against dynamic grid support standards such as German BDEW. In drives applications, program various drive cycles and test fault responses under both internal and external faults. For example, inject short and open circuit faults, switch faults, and test against parameter variations. Define performance envelopes and verify the system compliance.

Typhoon API comprises: HIL Control Panel API, Schematic Editor API, Texas Instruments DSP Control Panel API, and Test Executor. HIL Control Panel API provides an interface with the target HIL and enables control of the simulation process and all functions available through Control Panel. Schematic Editor API provides programmatic interface to manipulate existing schematic diagrams. It enables changing circuit parameters, compiling a circuit, setting target hardware platform, time step, simulation method etc. Texas Instruments DSP Control Panel API provides programmatic interface to control HIL DSP Interface and change controller parameters. Test Executor Test enables running one or more python scripts and generates html report files with test results.


WebLab. Full HIL experience in the Cloud.

HIL in the cloud.

Benefits of the WebLab.

Share your internal HIL resources without organizational or physical limitations.

Universal world wide access to the HIL resources in the Cloud enables your organization to

WebLab technology helps you better share your HIL resources and experiences within your organization. It is ideal for the companies that already have considerable HIL experience and HIL infrastructure and are looking for the efficient ways to propagate the best practices throughout their organizations.

• Collaborate between teams with various domain expertise

Access Typhoon HIL internal HIL resources without initial investment and risk-free. WebLab technology gives you the access to HIL technology without making a capital expenditure. It is ideal for SME that have only limited HIL needs or are looking for the way to evaluate the HIL technology against the needs of their organizations.

• Involve your customers from specification, over type testing to commissioning and project evolution • Provide hands on instruction to your customers, and employees on various aspects of your product’s design and operation • Provide the remote assistance and problem solving to your customers • Control the progress of the outsourced design work more effectively • Centralize and automate the quality assurance and quality validation of your products control software


User experience


Woodward IDS uses HIL400 to develop new PV inverter controller. Woodward IDS develops new controller for PV inverters with the HIL400 “HIL400 has greatly enhanced the efficiency of our development process and will contribute greatly to Quality Assurance as the new controller covers an ever wider range of applications”. Dr. Andreas Dittrich

Introduction Since 1870 Woodward has been controlling speed and power and is today a world leader in turbine controls, motor drives and power management systems which includes the CONCYCLE family of Wind Turbine Converters from 1.25 to 6MW and the SOLO family of solar inverters from 100kW to 1MW.

The Project A new controller, the IPC50, was needed to achieve a more compact, more flexible and lower cost design which would be suitable for both renewable energy applications. The design teams were located in Switzerland for the design and in Bulgaria for testing.

Challenge The challenge was one of design co-ordination (different product families and power ranges), disparate locations (Switzerland, Bulgaria ...) and the rapid prototyping of a radically new and cost-reduced controller. A key to controller design is the validation of performance over a wide range of operating conditions, all the more so when the converters have different applications (Solar and Wind) and a wide power range (100kW to 6MW).

Design and testing can be a lengthy process especially where different design and test teams in geographically distant locations are simultaneously involved. Clearly, a lengthy process is not compatible with keeping costs in check.

The Solution Woodward IDS decided at the start of the project that their development would rely on an advanced design and test tool: the Typhoon HIL400 Power Electronics emulator. This real-time hardware-in-the-loop tester is a desktop box to which a developmental controller is connected in order to test control algorithms. The HIL400 thus replaces the power laboratory and allows the controls to be tested under all foreseeable operating conditions, eliminating 99% of all bugs and problems before the final, costly lab tests take place at full power. The test “bench” is shown in the following picture taken in the Woodward design office in Zürich. In the foreground can be seen the IPC232 controller with its UFI2IO and CTR651 cards connected to the HIL400 emulator just behind it. The Tektronix oscilloscope to the left displays the analogue output signals from the HIL400 emulating the inverter while the screen to the right displays the HIL400 Control Interface from a PC (not shown). The HIL400 has a


“Parts of the controller design and development could be entrusted to an engineering student, since testing was at desktop level with no high voltages” says Martin Vinzens, Engineering Director at Woodward IDS, Zürich. “We had our international experts and consultants around for the 20 weeks of the project and our engineering student, Alexandre Cavalier from Paris was able to work on the design of the controller and put it through extensive tests with minimal supervision”.

simple graphic user interface (GUI) as shown below, reminiscent of standard simulation software packages. The GUI below is for the initial solar application for which different types of panel with varying degrees of insolation could be emulated, along with different filters, line impedances and grid voltages (sag, flicker, surge, harmonic content etc.). In the case of a wind turbine, different machine characteristics can be programmed (reactances, mechanical inertia etc.) which would be difficult if not impossible to replicate in a lab at rated power. “The HIL400 allows the emulation of up to two converters with unlimited passive components around them” says Alexandre Cavalier. “If the screen gets too busy because the circuit is complex, you can split it with convenient ‘coupling elements’. Also, the library is really comprehensive with passives, converters, motors, sources, switches, meters etc.”

The Results The development of the new Woodward controller was sped up with a minimum of involved resources. “Having the flexibility of a real-time simulator in the office meant that all those involved could test and modify algorithms without continually scheduling cumbersome tests in the Power Lab. By the time when we would be ready to go to the lab for final tests, the job then is practically done” says Martin Vinzens.

Conclusions The traditional approach of testing power electronics controls, solely in a power lab, is too costly and incomplete to meet the quality and reliability requirements of continually evolving controller functionality. The Typhoon family of emulators addresses this paradigm and offers a revolutionary way of reducing development and QA costs in a world where power management and renewable energy production have become the Leitmotif of our age.


Turbo Power Systems uses Typhoon HIL emulator to advance its development of Power Inverters for Microgrids. TPS develops the efficient, reliable and compact power inverters with the ability to produce good quality 3 phase mains electricity, using HIL400. â&#x20AC;&#x153;The Typhoon HIL400 has been a very useful tool, I have been able to test my controller in a safe manner and as a consequence it has given me much more confidence in my p.c.b. and firmware designâ&#x20AC;? says Mr. Steve Mitchell, embedded systems engineer at Turbo Power Systems.â&#x20AC;?

Introduction Turbo Power Systems designs and manufactures high performance electric motors, generators, and power electronic systems and provides custom solutions to Energy Conversion, Industrial, Transport and Defense markets. TPS provides solutions to difficult and challenging requirements. The engineering innovation was tested over years and allowed the company to undertake challenging designs either from the environmental requirement stand point or performance to volume stand point. The Power Electronics Division specializes in the design and manufacture of a wide range of power electronics products for several different applications in our chosen markets including variable frequency drives for industrial and aerospace applications, specialist high voltage power supplies and auxiliary power converters and battery chargers for the rail industry.

Challenge The power generation market is changing. With the proliferation of micro-grids utilizing smaller generators it is becoming more localized, with power being generated closer to the consumer. Power inverters have their place in this market acting as an interface between generators (electrical machines) and the electricity grids.

These can be more compact than traditional gearbox based systems, eliminating many problems seen in installation of the generator set. To service this growing market, efficient, reliable and compact power inverters need to be developed with the ability to produce good quality 3 phase mains electricity.

Typhoon HIL400 Experience Both a control circuit board and control architecture have been developed for a grid level voltage source inverter. After simulating the controller for several months, the stage was approached where the controller needed to be applied to the physical hardware. This step is always problematic, especially when dealing with a newly designed and fully tested control platform. Even with good engineering practices in place, it is not possible to foresee every issue. Mistakes can be very costly and even dangerous when dealing with power electronics. Failed components are expensive to replace and take several man hours to replace. As a consequence an engineer can become bogged down with providing protection for the power electronics at a stage when one wishes to concentrate on the control architecture and associated algorithms. Once running, the Typhoon HIL400 (Figure be-


With the HIL400 it was possible to remove the offending controller behavior without significant cost to the company.

low) was able to accept the switching waveforms from the control p.c.b and generate both current and the voltage waveforms. This allowed the real controller to be run as a closed loop system. The results captured by oscilloscope are illustrated in figure below, where the top three traces represent the current waveform in the output inductors. The 6 digital waveforms are the switching patterns sent to the top and bottom IGBTs of the three limb inverter. The figure illustrates that the switching patterns generated by the controller produce the correct three phase output. A particularly useful feature of the monitoring software was the dead time violation alert. In a real situation a dead time violation would lead to a short on the DC Link of the inverter and the flow of potentially damaging currents in the switching

hardware. However, as this was real time emulation, no components were damaged during the control platforms development period.

Conclusion Typhoon HIL400 emulator provided the opportunity to utilize the real control platform instead of simulation and to iron out the hardware and software bugs on the line. The emulated signals allowed for the observation of the signal conditioning and protection hardware during operation. From voltage transducer to micro-controller input, it was easily confirmed that they work as they were designed to. In that way P.C.B controller design was effectively verified.


Enerdrive uses HIL400 for distribution transformers testing. Enerdrive developed closed loop control software with optimization of the filtering components of a 700kVA VSI to replace a traditional MG set for distribution transformers testing. “A setup comprising the Typhoon HIL400 and an OEM controller makes an ideal development environment which combines: real control signals, in real time, with “real hardware” which is as easy to operate as a software simulation package.” “HIL400 is must have for every Power Electronics Engineer”, Dr. Andreas Dittrich, Enerdrive CEO

Introduction

Solution

Enerdrive is a Power Electronics control software Company founded in 2005 which offers services in the areas of power electronics and energy conversion systems. Its expertise is in applications for wind and solar power conversion, industrial drives, active filter technology and static power supplies with focus on control system design and software development.

Simultaneous optimization of the differential mode filter, common mode filter, the modulation algorithm and the closed-loop control is a challenging task. When an OEM controller is connected to the HIL400, the simultaneous optimization of power electronics software and power electronics hardware is greatly simplified because the power hardware in the HIL400 becomes as easy to handle as the control software. Typhoon HIL software tools provide an intuitive way to describe the power electronics hardware and to operate it inside the HIL400. With HIL400 it is now possible to operate an OEM power electronics controller in the comfort of the office.

Challenge Distribution transformers are one of the most important and widest spread components of the power grid. To determine the state of health of distribution transformers typically, a series of tests comprising open-circuit tests, short-circuit tests, and partial discharge tests are required. Traditional test setups—comprising rotating motor-generator (MG) sets—have a number of drawbacks and are slowly being replaced with voltage source inverter (VSI) technology. The key challenge was to reach very low levels of voltage THD and common mode currents with the smallest size filtering components. The VSI control has to be optimized to provide high quality waveforms to the device under test for: • open-circuit test under nominal voltage, • short-circuit test under nominal current, and • partial discharge measurements with minimal interference from common mode currents.

Results Measurements of inverter phase current and line voltage in the laboratory match almost perfectly with the measurements from the setup with HIL400 in the office. In both cases exactly the same OEM control software and hardware were used.

Conclusion HIL400 enables both physical and temporal decoupling of the power electronic software and hardware development. With Typhoon HIL400 is now possible to test the operating conditions that would be too time consuming, too expensive, or simply impractical to do in the laboratory.


Laboratory setup

HIL400 based setup

Laboratory setup results

HIL400 setup results


Induction motor drives Variable speed drives are becoming ubiquitous. However, design and testing control systems next to a spinning machinery is neither safe nor pleasant experience. HIL400 system with Texas Instruments family of DSP controllers integrated in Typhoon HIL DSP Interface provides safe yet high-fidelity environment that can be used by novice students as well as experienced engineers.

Control algorithms Our platform is geared for design and testing of different control layers, ranging from modulators, PLL, current and voltage loops, to torque and speed loops and estimators, all the way to slower protection functions i.e. contractors, pre-charging, temperature protection etc.

Hardware in the loop real-time emulator

Controller platform

A range of induction machine control algorithms can easily be designed, optimized and tested, i.e.: • V/f controls, • Vector control, and • Sensor-less control. In addition, we enable testing against different operating conditions, faults, and parameter variations, such as: • • • •

Sensor faults Machine faults (open and short circuit) Converter switch faults Machine parameter variations.


Permanent magnet motor drives

Permanent magnet machines are widely deployed in high-power variable speed wind turbine systems, due to their high power density and performance. In addition, PM machines are used in automotive and industry automation applications. HIL400 system with Texas Instruments family of DSP controllers integrated in Typhoon HIL DSP Interface provides comprehensive and completely safe, yet high-fidelity environment that can be used by novice students as well as experienced engineers to develop, optimize, and test variety of control strategies.

Our platform is well suited for both high speed control tasks as well as slower ones. Testing application level control tasks is also straightforward. In addition, we enable testing against a spectrum of realistic operating conditions, faults, and parameter variations, often encountered in real life situations. These operating scenarios include: • Sensor faults • Machine faults (open and short circuit) • Converter switch faults • Machine parameter variations • Dynamic load torque specification, via drive cycle specification.

Hardware in the loop real-time emulator

Controller platform


PV Inverter systems Photovoltaic Converters In photo-voltaic systems, power electronics converter are one of the key components, as they directly interface one or multiple PV panels with the electrical utility grid. Design and testing of control SW/FW/HW for these converters is expensive and time consuming due to: â&#x20AC;˘ direct power connection to the grid (high- voltage, high power ) ; â&#x20AC;˘ difficulty of emulating PV panels ( including dynamic solar irradiation shading effects, PV faults etc. )

Typhoon HIL provides high-fidelity emulator system for design, testing, and test automation of PV converter control systems, that takes power hardware out of the picture for control designers. HIL enables fault injection including grid disturbances, islanding modes, and dynamically controllable solar illumination. HIL400 system provides integrated, completely safe, and comfortable environment for students and engineers to learn, experiment and implement solar PV control and protection algorithms, no matter the power ratings; from kW to MW.


Testing made Simple.

Test rate [test points/(month*setup)]

At 80 times higher control system Test rate and 8 times lower Burn rate Typhoon HIL technology will make a large positive impact on your Quality Assurance and Quality Validation efforts.

100,000

With HIL Without HIL

10,000

1,000

100 0

5,000

10,000

15,000

20,000

25,000

30,000

Burn rate [EUR/(month*setup)]

With 640 times lower cost per tested point, 24h of testing per day and a minimum need of human supervisionduring testing (automatic testing) you can finally afford to exhaustively test your control system.

with HIL

without HIL

3,000.00

Burn rate [EUR/(month*setup)]

55,000.00

Test rate [test points/(month*setup)]

25,000.00 650.00


15,000.00 13,000.00

Laboratory setup material cost Laboratory setup development time 200 h 65,00

65,00 3,500.00

65,000.00 10,500.00

800 h 200 h 10 tp/h 2,000 tp

Test reports and laboratory maintenance* Effective test time* Test rate Number of testpoints covered*

* estimate for 3 calendar months of test time

37.75

Varaible cost of a test point [EUR]

With an optimistic assumption of the full presence of an experienced test team and no major setbacks we reach the cost of 37.75 EUR for each test point.

Total 103,500.00

3 calendar month testing with 2 engineers 1000 h Laboratory infrastructure 3 months

75,500.00

28,000.00

Non recuring test setup cost

Variable cost of testing

Total EUR

Quantity

Unit cost EUR

Control system testing without HIL

Testing control system in a laboratory requires laboratory setup and the safety regulations require presence of at least two persons. The table below illustrates the key financial and technical parameters of a 3-calendar month type testing of a controller for the new power electronics product.

Control system testing without HIL

Quantity

Unit cost EUR

1 200 h

11,200.00 65,00

65,00 940,00

33,520.00

6,500.00 2,820.00

9,320.00

11,200.00 13,000.00

24,200.00

Total EUR

400 h 1,600 h 100 tp/h 160,000 tp

0.06

* estimate for 3 calendar months of test time

Test reports and laboratory maintenance* Effective test time* Test rate Number of testpoints covered*

Varaible cost of a test point [EUR]

Testing with HIL assumes 24h working days for the HIL, a minimum of maintenance activities, and a possibility to scale without limits by purchasing additional HIL equipment.

Total

3 calendar month testing with 0,2 engineers 100 h HIL600 license 3 months

Variable cost of testing

HIL 600 hardware price HIL setup development time

Non recuring test setup cost

Control system testing with HIL

With only one HIL600 setup, within the 3 calendar months time frame and with only 10% of the man hours it is now possible to increase the test coverage by factor 80 (eighty) and save 70,000.00 EUR.

Control system testing with HIL


How we support you. Comprehensive on-line documentation, extensive examples, user forums, on-line videos, and highly technical support teams with local sales and distributor offices across Europe, North America, and Asia guarantee highest quality support.

International network of Typhoon HIL offices, broad distributor base, and number of value added resellers guarantee quick turnaround time and responsiveness to your specific needs and requirements. Our industrial customers and partners constantly drive our product development and customization providing constant feedback and product enhancement vectors.

Furthermore, Typhoonâ&#x20AC;&#x2122; s strong ties with academic research and teaching laboratories enable constant knowledge flow between teaching and research. As a company, we believe in building and supporting strong international power electronics innovation ecosystem that will benefit our societyâ&#x20AC;&#x2122; s quest for green and sustainable energy future.


Typhoon HIL, Inc. 339 Hurley St. #1 Cambridge, MA 02141 USA

Typhoon HIL GmbH Wettingerstrasse 21 CH-5400 Baden Switzerland

Tajfun HIL d.o.o. Miloša Bajica 3 21000 Novi Sad Republic of Serbia

Phone: +1 617 909 0087

Phone: +41 (0)56 209 1519 Fax: +41 (0)56 200 5001

Phone: +381 (0)21 421 617 Fax: +381 (0)21 472 2584

www.typhoon-hil.com e-mail: info@typhoon-hil.ch

2013 Typhoon HIL Company Catalog  

Overview of Typhoon HIL products, applications, use cases and services

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