Multi-objective optimization of power electronic converters

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Analysis and Design of High-Frequency Soft-Switching DC-DC Converter for Wireless Power Charging Applications

Wireless power transfer (WPT) technology is becoming attractive in a wide variety of applications such as electric-vehicle charging, induction heating, charging portable applications, industrial robots, and biomedical implants. Recent studies have shown various techniques to implement wireless power transfer and these techniques differ based on the type of applications. For example, for electric vehicle charging, the power levels are in the range 5 kW to 25 kW and the operating frequency is in the range 70 kHz to 110 kHz. On the other hand, for consumer applications, the power levels vary from a few watts to hundreds of watts and operates at frequencies of the order of 5 MHz to 10 MHz. This thesis addresses the analysis, design, implementation, and simulation of a wireless charging system targeted towards a high-frequency, low-power portable application with wide separation between transmitter and receiver. The WPT system is composed of three important blocks: inverter (or transmitter), transformer (or coil), and rectifier (or receiver). Hard-switching inverters and rectifiers have major drawbacks at high frequencies due to large switching power loss. Therefore, soft-switching Class-E topology is chosen. The Class-E dc-ac inverter with CLL resonant tank, also referred to as pi2a impedance matching network is analyzed, designed, and simulated to observe its superior performance over other topologies at varying coupling coefficients and loads. Four soft-switching rectifier topologies are analyzed, designed, and simulated to evaluate their behavior at high frequencies. Their compatibility with Class-E inverters in the presence of loosely-coupled transformers is discussed. The physical and commercial limitations of using transformers with magnetic core is presented. Therefore, the preferred solution, an air-core transformer is designed and integrated with the rectifier to evaluate their characteristics at selected coupling coefficient. The overall system including the inverter, loosely-coupled air-core transformer, and rectifier was designed for the following specifications: operating frequency 6.78 MHz, output power across a single-load 40 W, output voltage 25 V, and target coupling coefficient of 0.5. Simulation results have been provided to validate the theoretical predictions. The major challenges faced during the integration of these building blocks are addressed. Finally, conclusions, contributions, and scope for future work are provided

Analysis and Design of High-Frequency Soft-Switching DC-DC Converter for Wireless Power Charging Applications

Wireless power transfer (WPT) technology is becoming attractive in a wide variety of applications such as electric-vehicle charging, induction heating, charging portable applications, industrial robots, and biomedical implants. Recent studies have shown various techniques to implement wireless power transfer and these techniques differ based on the type of applications. For example, for electric vehicle charging, the power levels are in the range 5 kW to 25 kW and the operating frequency is in the range 70 kHz to 110 kHz. On the other hand, for consumer applications, the power levels vary from a few watts to hundreds of watts and operates at frequencies of the order of 5 MHz to 10 MHz. This thesis addresses the analysis, design, implementation, and simulation of a wireless charging system targeted towards a high-frequency, low-power portable application with wide separation between transmitter and receiver. The WPT system is composed of three important blocks: inverter (or transmitter), transformer (or coil), and rectifier (or receiver). Hard-switching inverters and rectifiers have major drawbacks at high frequencies due to large switching power loss. Therefore, soft-switching Class-E topology is chosen. The Class-E dc-ac inverter with CLL resonant tank, also referred to as pi2a impedance matching network is analyzed, designed, and simulated to observe its superior performance over other topologies at varying coupling coefficients and loads. Four soft-switching rectifier topologies are analyzed, designed, and simulated to evaluate their behavior at high frequencies. Their compatibility with Class-E inverters in the presence of loosely-coupled transformers is discussed. The physical and commercial limitations of using transformers with magnetic core is presented. Therefore, the preferred solution, an air-core transformer is designed and integrated with the rectifier to evaluate their characteristics at selected coupling coefficient. The overall system including the inverter, loosely-coupled air-core transformer, and rectifier was designed for the following specifications: operating frequency 6.78 MHz, output power across a single-load 40 W, output voltage 25 V, and target coupling coefficient of 0.5. Simulation results have been provided to validate the theoretical predictions. The major challenges faced during the integration of these building blocks are addressed. Finally, conclusions, contributions, and scope for future work are provided

Generic functional modelling of multi-pulse auto-transformer rectifier units for more-electric aircraft applications

The Auto-Transformer Rectifier Unit (ATRU) is one preferred solution for high-power AC/DC power conversion in aircraft. This is mainly due to its simple structure, high reliability and reduced kVA ratings. Indeed, the ATRU has become a preferred AC/DC solution to supply power to the electric environment control system on-board future aircraft. In this paper, a general modelling method for ATRUs is introduced. The developed model is based on the fact that the DC voltage and current are strongly related to the voltage and current vectors at the AC terminals of ATRUs. In this paper, we carry on our research in modelling symmetric 18-pulse ATRUs and develop a generic modelling technique. The developed generic model can study not only symmetric but also asymmetric ATRUs. An 18-pulse asymmetric ATRU is used to demonstrate the accuracy and efficiency of the developed model by comparing with corresponding detailed switching SABER models provided by our industrial partner. The functional models also allow accelerated and accurate simulations and thus enable whole-scale more-electric aircraft electrical power system studies in the future

Design Evaluation of a High Voltage High Frequency Pulse Transformer

Unlike commonly used regular transformers, high voltage, high frequency, pulsed transformers are generally represented in special purpose applications. This often means that these electrical devices must be tailored in accordance with the specic requirements of the project. The pulse transformer under analysis in this thesis is a prototype machine variation of which will serve as an essential part of klystron feeder system at the European Spallation Source. In the given application hundreds of pulse transformers will be required in order to supply power for the particle accelerator. The devices will be be integrated into high voltage, high frequency, pulsed power modules. The importance of careful analysis of the prototype system can therefore not be stressed enough. Throughout this thesis work the reliability and functionality of the prototype pulse transformer are examined closely with help of analytic methods, computer aided simulation and laboratory analysis. The design is evaluated in terms of several important qualities such as low voltage drop, sucient rise times and ability to operate without occurrence of unwanted high voltage phenomena. Both electromagnetic and mechanic aspects are included into the study. As the result of the performed work, an evaluation conclusion is presented together with possible improvements of the current design. Aim of the study is to provide a verication as well as present possible alternatives for the transformer system design

High-power converters for space applications

Phase 1 was a concept definition effort to extend space-type dc/dc converter technology to the megawatt level with a weight of less than 0.1 kg/kW (220 lb./MW). Two system designs were evaluated in Phase 1. Each design operates from a 5 kV stacked fuel cell source and provides a voltage step-up to 100 kV at 10 A for charging capacitors (100 pps at a duty cycle of 17 min on, 17 min off). Both designs use an MCT-based, full-bridge inverter, gaseous hydrogen cooling, and crowbar fault protection. The GE-CRD system uses an advanced high-voltage transformer/rectifier filter is series with a resonant tank circuit, driven by an inverter operating at 20 to 50 kHz. Output voltage is controlled through frequency and phase shift control. Fast transient response and stability is ensured via optimal control. Super-resonant operation employing MCTs provides the advantages of lossless snubbing, no turn-on switching loss, use of medium-speed diodes, and intrinsic current limiting under load-fault conditions. Estimated weight of the GE-CRD system is 88 kg (1.5 cu ft.). Efficiency of 94.4 percent and total system loss is 55.711 kW operating at 1 MW load power. The Maxwell system is based on a resonance transformer approach using a cascade of five LC resonant sections at 100 kHz. The 5 kV bus is converted to a square wave, stepped-up to a 100 kV sine wave by the LC sections, rectified, and filtered. Output voltage is controlled with a special series regulator circuit. Estimated weight of the Maxwell system is 83.8 kg (4.0 cu ft.). Efficiency is 87.2 percent and total system loss is 146.411 kW operating at 1 MW load power

Development of a multilevel converter topology for transformer-less connection of renewable energy systems

The global need to reduce dependence on fossil fuels for electricity production has become an ongoing research theme in the last decade. Clean energy sources (such as wind energy and solar energy) have considerable potential to reduce reliance on fossil fuels and mitigate climate change. However, wind energy is going to become more mainstream due to technological advancement and geographical availability. Therefore, various technologies exist to maximize the inherent advantages of using wind energy conversion systems (WECSs) to generate electrical power. One important technology is the power electronics interface that enables the transfer and effective control of electrical power from the renewable energy source to the grid through the filter and isolation transformer. However, the transformer is bulky, generates losses, and is also very costly. Therefore, the term "transformer-less connection" refers to eliminating a step-up transformer from the WECS, while the power conversion stage performs the conventional functions of a transformer. Existing power converter configurations for transformer-less connection of a WECS are either based on the generator-converter configuration or three-stage power converter configuration. These configurations consist of conventional multilevel converter topologies and two-stage power conversion between the generator-side converter topology and the high-order filter connected to the collection point of the wind power plant (WPP). Thus, the complexity and cost of these existing configurations are significant at higher voltage and power ratings. Therefore, a single-stage multilevel converter topology is proposed to simplify the power conversion stage of a transformer-less WECS. Furthermore, the primary design challenges – such as multiple clamping devices, multiple dc-link capacitors, and series-connected power semiconductor devices – have been mitigated by the proposed converter topology. The proposed converter topology, known as the "tapped inductor quasi-Z-source nested neutral-point-clamped (NNPC) converter," has been analyzed, and designed, and a prototype of the topology developed for experimental verification. A field-programmable gate array (FPGA)-based modulation technique and voltage balancing control technique for maintaining the clamping capacitor voltages was developed. Hence, the proposed converter topology presents a single-stage power conversion configuration. Efficiency analysis of the proposed converter topology has been studied and compared to the intermediate and grid-side converter topology of a three-stage power converter configuration. A direct current (DC) component minimization technique to minimize the dc component generated by the proposed converter topology was investigated, developed, and verified experimentally. The proposed dc component minimization technique consists of a sensing and measurement circuitry with a digital notch filter. This thesis presents a detailed and comprehensive overview of the existing power converter configurations developed for transformer-less WECS applications. Based on the developed 2 comparative benchmark factor (CBF), the merits and demerits of each power converter configuration in terms of the component counts and grid compliance have been presented. In terms of cost comparison, the three-stage power converter configuration is more cost-effective than the generatorconverter configuration. Furthermore, the cost-benefit analysis of deploying a transformer-less WECSs in a WPP is evaluated and compared with conventional WECS in a WPP based on power converter configurations and collection system. Overall, the total cost of the collection system of WPP with transformer-less WECSs is about 23% less than the total cost of WPP with conventional WECs. The derivation and theoretical analysis of the proposed five-level tapped inductor quasi-Z-source NNPC converter topology have been presented, emphasizing its operating principles, steady-state analysis, and deriving equations to calculate its inductance and capacitance values. Furthermore, the FPGA implementation of the proposed converter topology was verified experimentally with a developed prototype of the topology. The efficiency of the proposed converter topology has been evaluated by varying the switching frequency and loads. Furthermore, the proposed converter topology is more efficient than the five-level DC-DC converter with a five-level diode-clamped converter (DCC) topology under the three-stage power converter configuration. Also, the cost analysis of the proposed converter topology and the conventional converter topology shows that it is more economical to deploy the proposed converter topology at the grid side of a transformer-less WECS

Modeling and Analysis of Power Processing Systems

The feasibility of formulating a methodology for the modeling and analysis of aerospace electrical power processing systems is investigated. It is shown that a digital computer may be used in an interactive mode for the design, modeling, analysis, and comparison of power processing systems