Woodward Kempen GmbH, Germany | Aiko Sven Classe

Background

Aiko Classe graduated in electrical engineering from the University of Applied Sciences Düsseldorf. He then expanded his expertise and know-how by working as a research assistant at the university and later as an R&D engineer in the field of automotive technologies. Before Woodward, he worked for several OEMs: initially in the field of machine development for hybrid vehicles, and later in the field of simulation of electromagnetic fields for EMC. At Woodward, he is focused on electric energy systems, and is working on converter development, converter control software programming, simulation of power electronics systems, control software tests, and on general design of power electronics devices.

Challenges

Over the years, Mr. Classe has been involved in diverse activities in the domain of converter development. During this time, he identified two main challenges that he wanted to overcome: one related to simulation models and the other to how these models can be used in the workflow. The first challenge was the reliability of the models used in simulation. More precisely, intensive comparisons between field measurements and simulation data proved that it was not possible to have simulation models that correspond to reality. The second the biggest challenge was test automation and finding an efficient way to do requirements engineering for various customers and for different grid codes, standards, and regulations.

Solution

Wooward Kempen created a controller hardware in the loop (CHIL) laboratory with several CHIL-based test cabinets. Woodward simulates several converter generations for DFIG, SM and ASM. Smaller systems with one power cabinet are simulated with one Typhoon HIL 602 and additional SPS modules and relay cards. Converters with multiple power cabinets are simulated with one additional Typhoon HIL device. Moreover, through corporate intranet, developers can access CHIL test cabinets from their offices. Thanks to high-fidelity real-time models and full test automation provided by Typhoon HIL’s integrated software-hardware CHIL testbeds, Mr. Classe, his colleagues and Woodward overcame all their modeling and test automation challenges. They can now test more and there is significantly less work that is required both in the field and on the test stands. This has brought significant advantages in safety, cost savings, and improved cost of quality.