ANALYZING EFFICIENCY OF SWITCH-MODE WELDING POWER SUPPLY

esearches and studies have indicated that many of the welding quality issues are related to the weld schedule or power supply. During a weld, a certain amount of energy is lost which can be reduced to improve the efficiency of the power supply. This thesis presents a DC/DC buck converter power supply for small scale resistance spot welding (SSRSW), which can provide a testing platform for studies of different control modes, and at the end implement the results of the experiments and research done with this power supply. In this thesis, a model of the small scale resistance spot welding power supply has been implemented. The power supply uses pulse width modulation technique with MOSFETs to convert the power of a 12V battery to the weld current up to 1000A. Various measurements of voltage and current were taken at the respective terminals to calculate the energy losses. Capacitances were added with gradually increased values and again measurements were taken to calculate and analyze the energy losses in presence of the capacitances based on their numerical values. It was noted that the energy losses were reduced appreciably by this technique. So, the efficiency of the converters can be improved

Survey on Photo-Voltaic Powered Interleaved Converter System

Renewable energy is the best solution to meet the growing demand for energy in the country. The solar energy is considered as the most promising energy by the researchers due to its abundant availability, eco-friendly nature, long lasting nature, wide range of application and above all it is a maintenance free system. The energy absorbed by the earth can satisfy 15000 times of today’s total energy demand and its hundred times more than that our conventional energy like coal and other fossil fuels. Though, there are overwhelming advantages in solar energy, It has few drawbacks as well such as its low conversion ratio, inconsistent supply of energy due to variation in the sun light, less efficiency due to ripples in the converter, time dependent and, above all, high capitation cost. These aforementioned flaws have been addressed by the researchers in order to extract maximum energy and attain hundred percentage benefits of this heavenly resource. So, this chapter presents a comprehensive investigation based on photo voltaic (PV) system requirements with the following constraints such as system efficiency, system gain, dynamic response, switching losses are investigated. The overview exhibits and identifies the requirements of a best PV power generation system

Development of Efficient Soft Switching Synchronous Buck Converter Topologies for Low Voltage High Current Applications

Switched mode power supplies (SMPS) have emerged as the popular candidate in all the power processing applications. The demand is soaring to design high power density converters. For reducing the size, weight, it is imperative to channelize the power at high switching frequency. High switching frequency converters insist upon soft switching techniques to curtail the switching losses. Several soft switching topologies have been evolved in the recent years. Nowadays, the soft switching converters are vastly applied modules and the demand is increasing for high power density and high efficiency modules by minimizing the conduction and switching losses. These modules are generally observed in many applications such as laptops, desktop processors for the enhancement of the battery life time. Apart from these applications, solar and spacecraft applications demand is increasing progressively for stressless and more efficient modules for maximizing the storage capacity which inturn enhances the power density that improves the battery life to supply in the uneven times. Modern trends in the consumer electronic market focus increases in the demand of lower voltage supplies. Conduction losses are significantly reduced by synchronous rectifiers i.e., MOSFET’s are essentially used in many of the low voltage power supplies. Active and passive auxiliary circuits are used in tandem with synchronous rectifier to diminish the crucial loss i.e., switching loss and also it minimizes the voltage and current stresses of the semiconductor devices. The rapid progress in the technology and emerging portable applications poses serious challenges to power supply design engineers for an efficient power converter design at high power density. The primary aim is to design and develop high efficiency, high power density topologies like: buck, synchronous buck and multiphase buck converters with the integration of soft switching techniques to minimize conduction and switching losses sustaining the voltage and current stresses within the tolerable range. In this work, two ZVT-ZCT PWM synchronous buck converters are introduced, one with active auxiliary circuit and the other one with passive auxiliary circuit. The operating principle and comprehensive steady state analysis of the ZVT-ZCT PWM synchronous buck converters are presented. The converters are designed to have high efficiency and low voltage that is suitable for high power density application. The semiconductor devices used in the topologies in addition to the main switch operate with soft switching conditions. The viii Abstract topologies proposed render a large overall efficiency in contrast to the contemporary topologies. In addition the circuit’s size is less, reliable and have high performance-cost ratio. The new generation microprocessor demands the features such as low voltage, high current, high power density and high efficiency etc., in the design of power supplies. The supply voltage for the future generation microprocessors must be low, in order to decrease the power consumption. The voltage levels are dripping to a level even less than 0.7V, and the power consumption increases as there is an increase in the current requirement for the processor. In order to meet the demands of the new generation microprocessor power supply, a soft switching multiphase PWM synchronous buck converter is proposed. The losses in the proposed topology due to increasing components are pared down by the proposed soft switching technique. The proposed converters in this research work are precisely described by the mathematical modelling and their operational modes. The practicality of the proposed converters for different applications is authenticated by their simulation and experimental results

High power high frequency DC-DC converter topologies for use in off-line power supplies

The development of a DC-DC converter for use in a proposed range of one to ten kilowatt off-line power supplies is presented. The converter makes good use of established design practices and recent technical advances. The thesis begins with a review of traditional design practices, which are used in the design of a 3kW, 48V output DC-DC converter, as a bench-mark for evaluation of recent technical advances. Advances evaluated include new converter circuits, control techniques, components, and magnetic component designs. Converter circuits using zero voltage switching (ZVS) transitions offer significant advantages for this application. Of the published converters which have ZVS transitions the phase shift controlled full bridge converter is the most suitable, and assessments of variations on this circuit are presented. During the course of the research it was realised that the ZVS range of one leg of the phase shift controlled full bridge converter could be extended by altering the switching pattern, and this new switching pattern is proposed. A detailed analysis of phase shift controlled full bridge converter operation uncovers a number of operational findings which give a better and more complete understanding of converter operation than hitherto published. Converter design equations and guidelines are presented and the effects of the new improvement are investigated by an approximate analysis. Computer simulations using PSPICE2 are carried out to predict converter performance. A prototype converter design, construction details and test results are given. The results obtained compare well to the predicted performance and confirm the advantages of the new switching pattern

Control And Topology Improvements In Half-bridge Dc-dc Converters

Efficiency and transient response are two key requirements for DC-DC converters. Topology and control are two key topics in this dissertation. A variety of techniques for DC-DC converter performance improvement are presented in this work. Focusing on the efficiency issue, a variety of clamping techniques including both active and passive methods are presented after the ringing issues in DC-DC converters are investigated. By presenting the clamping techniques, a big variety of energy management concepts are introduced. The active bridge-capacitor tank clamping and FET-diode-capacitor tank clamping are close ideas, which transfer the leakage inductor energy to clamping capacitor to prevent oscillation between leakage inductor and junction capacitor of MOSFETs. The two-FET-clamping tank employs two MOSFETs to freewheeling the leakage current when the main MOSFETs of the half-bridge are both off. Driving voltage variation on the secondary side Synchronous Rectifier (SR) MOSFETs in self-driven circuit due to input voltage variation in bus converter applications is also investigated. One solution with a variety of derivations is proposed using zerner-capacitor combination to clamping the voltage while maintaining reasonable power losses. Another efficiency improvement idea comes from phase-shift concept in DC-DC converters. By employing phase-shift scheme, the primary side and the secondary side two MOSFETs have complementary driving signals respectively, which allow the MOSFET to be turned on with Zero Voltage Switching (ZVS). Simulation verified the feasibility of the proposed phase-shifted DC-DC converter. From the control scheme point of view, a novel peak current mode control concept for half-bridge topologies is presented. Aiming at compensating the imbalanced voltage due to peak current mode control in symmetric half-bridge topologies, an additional voltage compensation loop is used to bring the half-bridge capacitor voltage back to balance. In the proposed solutions, one scheme is applied on symmetric half-bridge topology and the other one is applied on Duty-cycle-shifted (DCS) half-bridge topology. Both schemes employ simple circuitry and are suitable for integration. Loop stability issues are also investigated in this work. Modeling work shows the uncompensated half-bridge topology cannot be stabilized under all conditions and the additional compensation loop helps to prevent the voltage imbalance effectively

Resonance mode power supplies with power factor correction

There is an increasing need for AC-DC converters to draw a pure sinusoidal current at near unity power factor from the AC mains. Most conventional power factor correcting systems employ PWM techniques to overcome the poor power factor being presented to the mains. However, the need for smaller and lighter power processing equipment has motivated the use of higher internal conversion frequencies in the past. In this context, resonant converters are becoming a viable alternative to the conventional PWM controlled power supplies. The thesis presents the implementation of active power factor correction in power supplies, using resonance mode techniques. It reviews the PWM power factor correction circuit topologies previously used. The possibility of converting these PWM topologies to resonant mode versions is discussed with a critical assessment as to the suitability of the semiconductor switching devices available today for deployment in these resonant mode supplies. The thesis also provides an overview of the methods used to model active semiconductor devices. The computer modelling is done using the PSpice microcomputer simulation program. The modifications that are needed to the built in MOSFET model in PSpice, when modeling high frequency circuits is discussed. A new two transistor model which replicates the action of a OTO thyristor is also presented. The new model enables the designer to estimate the device parameters with ease by adopting a short calculation and graphical design procedure, based on the manufacturer's data sheets. The need for a converter with a high efficiency, larger power/weight ratio, high input power factor with reduced line current distortion and reduced cost has led to the development of a new resonant mode converter topology, for power processing. The converter presents a near resistive load to the mains thus ensuring a high input power factor, while providing a stabilised de voltage at the output with a small lOOHz ripple. The supply is therefore ideal for preregulation applications. A description of the modes of operation and the analysis of the power circuit are included in the thesis. The possibility of using the converter for low output voltage applications is also discussed. The design of a 300W, 80kHz prototype model of this circuit is presented in the thesis. The design of the isolation transformer and other magnetic components are described in detail. The selection of circuit components and the design and implementation of the variable frequency control loop are also discussed. An evaluation of the experimental and computer simulated results obtained from the prototype model are included in the presentation. The thesis further presents a zero-current switching quasi-resonant flyback circuit topology with power factor correction. The reasons for using this topology for off-line power conversion applications are discussed. The use of a cascoded combination of a bipolar power transistor and two power MOSFETs i~ the configuration has enabled the circuit to process moderate levels of power while simultaneously switching at high frequencies. This fulfils the fundamental precondition for miniaturisation. It also provides a well regulated DC output voltage with a very small ripple while maintaining a high input power factor. The circuit is therefore ideal for use in mobile applications. A preliminary design of the above circuit, its analysis using PSpice, the design of the control circuit, current limiting and overcurrent protection circuitry and the implementation of closed-loop control are all included in the thesis. The experimental results obtained from a bread board model is also presented with an evaluation of the circuit performance. The power factor correction circuit is finally installed in this supply and the overall converter performance is assessed

Assessment of novel power electronic converters for drives applications

Phd ThesisIn the last twenty years, industrial and academic research has produced over one hundred new converter topologies for drives applications. Regrettably, most of the published work has been directed towards a single topology, giving an overall impression of a large number of unconnected, competing techniques. To provide insight into this wide ranging subject area, an overview of converter topologies is presented. Each topology is classified according to its mode of operation and a family tree is derived encompassing all converter types. Selected converters in each class are analysed, simulated and key operational characteristics identified. Issues associated with the practical implementation of analysed topologies are discussed in detail. Of all AC-AC conversion techniques, it is concluded that softswitching converter topologies offer the most attractive alternative to the standard hard switched converter in the power range up to 100kW because of their high performance to cost ratio. Of the softswitching converters, resonant dc-link topologies are shown to produce the poorest output performance although they offer the cheapest solution. Auxiliary pole commutated inverters, on the other hand, can achieve levels of performance approaching those of the hard switched topology while retaining the benefits of softswitching. It is concluded that the auxiliary commutated resonant pole inverter (ACPI) topology offers the greatest potential for exploitation in spite of its relatively high capital cost. Experimental results are presented for a 20kW hard switched inverter and an equivalent 20kW ACPI. In each case the converter controller is implanted using a digital signal processor. For the ACPI, a new control scheme, which eliminates the need for switch current and voltage sensors, is implemented. Results show that the ACPI produces lower overall losses when compared to its hardswitching counterpart. In addition, device voltage stress, output dv/dt and levels of high frequency output harmonics are all reduced. Finally, it is concluded that modularisation of the active devices, optimisation of semiconductor design and a reduction in the number of additional sensors through the use of novel control methods, such as those presented, will all play a part in the realisation of an economically viable system.Research Committee of the University of Newcastle upon Tyn

Soft-Switched Step-Up Medium Voltage Power Converters

With a ten-year average annual growth rate of 19 percent, wind energy has been the largest source of new electricity generation for the past decade. Typically, an offshore wind farm has a medium voltage ac (MVac) grid that collects power from individual wind turbines. Since the output voltage of a wind turbine is too low (i.e., typically 400 690 V) to be connected to the MVac grid (i.e., 20 40 kV), a heavy line-frequency transformer is used to step up the individual turbines output voltage to the MV level. To eliminate the need for bulky MVac transformers, researchers are gravitating towards the idea of replacing the MVac grid with a medium voltage dc (MVdc) grid, so that MV step-up transformers are replaced by MV step-up power electronic converters that operate at the medium frequency range with much lower size and weight. This dissertation proposes a class of modular step-up transformerless MV SiC-based power converters with soft-switching capability for wind energy conversion systems with MVdc grid. This dissertation consists of two parts: the first part focuses on the development of two novel groups of step-up isolated dc-dc MV converters that utilize various step-up resonant circuits and soft-switched high voltage gain rectifier modules. An integrated magnetic design approach is also presented to combine several magnetic components together in the modular high voltage gain rectifiers. The second part of this dissertation focuses on the development of several three-phase ac-dc step-up converters with integrated active power factor correction. In particular, a bridgeless input ac-dc rectifier is also proposed to combine with the devised step-up transformerless dc-dc converters (presented in the first part) to form the three-phase soft-switched ac-dc step-up voltage conversion unit. In each of the presented modular step-up converter configurations, variable frequency control is used to regulate the output dc voltage of each converter module. The operating principles and characteristics of each presented converter are provided in detail. The feasibility and performance of all the power converter concepts presented in this dissertation are verified through simulation results on megawatts (MW) design examples, as well as experimental results on SiC-based laboratory-scale proof-of-concept prototypes