Power Electronics Control Platform
Embedded control platform for industrial AC/DC rectifiers and DC/DC converters at KraftPowercon. ARM Cortex-M4 with FreeRTOS running 20kHz control loops for voltage regulation and power factor correction. Features comprehensive Hardware-in-the-Loop testing with Speedgoat simulation. Linux HMI dashboard via Modbus for real-time monitoring.
⚡ Challenges
- •20kHz control loop determinism
- •HIL model fidelity
- •Field-safe firmware updates
✓ Outcomes
- ✓Deployed in 10+ converter models
- ✓Zero field failures from control code
- ✓HIL catches 90% of bugs pre-commission
📖 Full Details
This embedded control platform at KraftPowercon AB provides the firmware foundation for industrial power conversion equipment—AC/DC rectifiers and DC/DC converters used in demanding applications including railway systems, renewable energy installations, and industrial processes.
The firmware architecture runs on ARM Cortex-M4 microcontrollers using FreeRTOS for deterministic real-time behavior. Control loops execute at 20kHz, implementing sophisticated algorithms for voltage regulation, current limiting, and power factor correction. The modular code structure separates converter topologies from control strategies, enabling rapid adaptation to new product variants.
Development included building a comprehensive Hardware-in-the-Loop (HIL) test infrastructure. A real-time simulation of power stage dynamics, implemented on a Speedgoat target, connects to actual controller hardware. This enables validation of control algorithms, protection sequences, and fault responses without risking expensive power stage hardware.
A Linux-based HMI dashboard provides operator interface for system monitoring and configuration. The single-board computer communicates with controllers via Modbus RTU, displaying real-time waveforms, alarm states, and operating statistics. Historical data logging supports performance analysis and predictive maintenance.
The data logging system captures millisecond-resolution recordings of voltage, current, and controller states, enabling post-incident analysis that would be impossible with standard SCADA historians.
Commissioning tools enable field engineers to configure controller parameters, perform calibration routines, and validate protection trip points. Over-the-air firmware updates allow deployment of improvements without site visits.
This work represented a significant deepening of embedded systems expertise, demonstrating ability to deliver safety-critical firmware for power electronics applications.
