The company

ABB is a global leader in power and automation technologies that enable utility and industry customers to improve performance while lowering environmental impact. The ABB Group of companies operates in around 100 countries and employs about 135,000 people. The company designs large electric conversion systems that enable the transformation of electric power into controlled power.

The challenges

ACS 6000 medium voltage drives from ABB deliver cutting-edge solutions for critical industrial applications (transportation, metals, etc.) that have to deal with high power and stability related problems. To reach their objective, ABB needed tools sophisticated enough to design and perform highly detailed real-time simulation of power converters and to emulate their behaviors under critical and extreme conditions.

The challenge was to offer a testing tool to assure that all converters were properly functioning and safe. ABB had very high expectations for the results.

The OPAL-RT solution

OPAL-RT provided a customized real-time Hardware-in-the-Loop (HIL) simulation platform, powered by our eDRIVEsim™ and ARTEMiS solver technologies. This solution enabled ABB to emulate full converter systems and electric drives—supporting detailed, high-speed testing of control strategies, torque performance, and fault conditions, all within a digital environment.

The results

• Increased testing speed: more tests conducted in less time

• Daily use by control engineers: testing algorithms and strategies continuously

• Shortened development cycles: faster validation means faster time-to-market

• Improved precision: higher accuracy than traditional test benches

• Reduced risk and cost: safer, more flexible virtual testing environment

• High return on investment: solution adopted for future projects company-wide

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