EnvSimRT: Fully automated real-time testing of power electronic systems under multimodal loads

At a glance

• Power electronic components are essential for ensuring a stable power supply from renewable energy sources, and their reliability is therefore of corresponding importance.
• In the EnvSimRT joint project, the project partners are expanding the HiPE-LAB test laboratory so that power electronic systems can be subjected to dynamic and multimodal loads already during the development phase.
• Among other tasks, Fraunhofer IWES is responsible for developing models for aeroelastic and drive train simulation, as well as for simulating hygrothermal effects in the converter.

The challenge

With the transition to renewable energy generation, power electronic components have become a central element of the energy supply. As the availability of sunlight and wind varies significantly, the available energy is also not constant. Power electronic components in frequency converters ensure that a voltage with fluctuating frequency and amplitude is converted into a voltage with constant frequency and amplitude, thus creating a stable power supply system. As such, their reliability is of key importance.

However, testing currently takes place only once the system has already been installed and commissioned in the field. By that point, it is already too late to prevent the frequently occurring early failures of components. Pre-deployment testing, however, poses particular challenges for test laboratories, as, among other things, the climatic and electrical conditions under which power electronic systems must operate reliably can vary considerably.

The solution

This is where the EnvSimRT research project comes in. The aim is to expand the HiPE-LAB test laboratory set up by Fraunhofer IWES and IALB by adding a real-time simulation system in order  to be able to simulate the complex climatic and electronic operating conditions even more accurately using models developed in advance. This will make it possible to expose power electronic systems to application-specific, dynamic, and multimodal loads already during the development phase.

Among other tasks, Fraunhofer IWES is responsible for developing the models for the aeroelastics and the drive train as well as for modelling the hygrothermal effects in the converter. In a further work package, the institute is responsible for the creation of test profiles for an application-specific test of the system as well as evaluation of the measurement data.

The added value

EnvSimRT will produce a new test system enabling industry to test their systems under real-life environmental conditions already in the development phase and to identify and rectify any remaining weaknesses. This not only translates to time and cost savings for industry but will also result in more reliable power electronic systems that, in turn, will ensure a stable energy supply for all areas of daily life. The results will be demonstrated in the project using the example of wind energy applications but can also be applied to other areas of application of power electronics.