Improved transient performance and converter miniaturization are the major driving factors behind high frequency operation of switching power supplies. However, high speed operation is limited by topology, control, semiconductor, and packaging technologies. The inherent mitigation of switching loss in resonant converters makes them prime candidates for use when the limits of switching frequency are pushed. The goal of this thesis is to address two areas that practically limit the achievable switching frequency of resonant topologies. Traditional control methods based on single cycle response are impractical at high frequency; forcing the use of pulse density modulation (PDM) techniques. However, existing pulse density modulation strategies for resonant converters in dc/dc applications suffer from: • High semiconductor current stress. • Slow response and large filter size determined by the low modulating frequency. • Possibly operating at fractions of resonant cycles leading to switching loss; thereby limiting the modulating frequency. A series resonant converter with variable frequency PDM (VF-PDM) with integral resonant cycle control is presented to overcome the limitations of existing PDM techniques to enable efficient operation with high switching frequency and modulating frequency. The operation of the circuit is presented and analyzed, with a design procedure given to achieve fast transient performance, small filter size, and high efficiency across the load range with current stress comparable to conventional control techniques. It is shown that digital implementation of the controller can achieve favourable results with a clock frequency four times greater than the switching frequency. Driving the synchronous rectifiers is a considerable challenge in high current applications operating at high switching frequency. Resonant gate drivers with continuous inductor current experience excessive conduction loss, while discontinuous current drivers are subject to slow transitions and high peak current. Current source drivers suffer from high component count and increased conduction loss when applied to complementary switches. A dual-channel current source driver is presented as a means of driving two complementary switches. A single coupled inductor with discontinuous current facilitates low conduction loss by transferring charge between the MOSFET gates to reduce the number of semiconductors in the current path, and reducing the number of conduction intervals. The operation of the circuit is analyzed, and a design procedure based on minimization of the total synchronous rectifier loss is presented. Implementation of the digital logic to control the driver is discussed. Experimental results at megahertz operating frequencies are presented for both areas addressed to verify the theoretical results. / Thesis (Ph.D, Electrical & Computer Engineering) -- Queen's University, 2012-09-09 20:43:56.997

In the context of modern aircraft systems, a major challenge is power conversion to supply the aircraft's electrical nstruments. These instruments are energized through a fixed-frequency internal power grid. In an aircraft, the available sources of energy are a set of variable-speed generators which provide variable-frequency ac voltages. Therefore, to energize the internal power grid of an aircraft, the variable-frequency ac voltages should be converted to a fixed-frequency ac voltage. As a result, an ac to ac power conversion is required within an aircraft's power system. This thesis develops a Matrix Converter to energize the aircraft's internal power grid. The Matrix Converter provides a direct ac to ac power conversion. A major challenge of designing Matrix Converters for aerospace applications is to minimize the volume and weight of the converter. These parameters are minimized by increasing the switching frequency of the converter. To design a Matrix Converter operating at a high switching frequency, this thesis (i) develops a scheme to integrate fast semiconductor switches within the current available Matrix Converter topologies, i.e., MOSFET-based Matrix Converter, and (ii) develops a new modulation strategy for the Matrix Converter. This Matrix Converter and the new modulation strategy enables the operation of the converter at a switching-frequency of 40kHz. To provide a reliable source of energy, this thesis also develops a new methodology for robust control of Matrix Converter. To verify the performance of the proposed MOSFET-based Matrix Converter, modulation strategy, and control design methodology, various simulation and experimental results are presented. The experimental results are obtained under operating condition present in an aircraft. The experimental results verify the proposed Matrix Converter provides a reliable power conversion in an aircraft under extreme operating conditions. The results prove the superiority of the proposed Matrix Converter technology for ac to ac power conversion regarding the existing technologies of Matrix Converters.

In the context of modern aircraft systems, a major challenge is power conversion to supply the aircraft's electrical nstruments. These instruments are energized through a fixed-frequency internal power grid. In an aircraft, the available sources of energy are a set of variable-speed generators which provide variable-frequency ac voltages. Therefore, to energize the internal power grid of an aircraft, the variable-frequency ac voltages should be converted to a fixed-frequency ac voltage. As a result, an ac to ac power conversion is required within an aircraft's power system. This thesis develops a Matrix Converter to energize the aircraft's internal power grid. The Matrix Converter provides a direct ac to ac power conversion. A major challenge of designing Matrix Converters for aerospace applications is to minimize the volume and weight of the converter. These parameters are minimized by increasing the switching frequency of the converter. To design a Matrix Converter operating at a high switching frequency, this thesis (i) develops a scheme to integrate fast semiconductor switches within the current available Matrix Converter topologies, i.e., MOSFET-based Matrix Converter, and (ii) develops a new modulation strategy for the Matrix Converter. This Matrix Converter and the new modulation strategy enables the operation of the converter at a switching-frequency of 40kHz. To provide a reliable source of energy, this thesis also develops a new methodology for robust control of Matrix Converter. To verify the performance of the proposed MOSFET-based Matrix Converter, modulation strategy, and control design methodology, various simulation and experimental results are presented. The experimental results are obtained under operating condition present in an aircraft. The experimental results verify the proposed Matrix Converter provides a reliable power conversion in an aircraft under extreme operating conditions. The results prove the superiority of the proposed Matrix Converter technology for ac to ac power conversion regarding the existing technologies of Matrix Converters.

The Anglo American Platinum Converter Plant produces a copper-nickel sulphide converter matte which is slow-cooled in ingots over several days. During the process, the formation of alloy platelets, containing the majority of the PGM’s and Au, occurs. The alloy forms a magnetic fraction in the bulk matte which can be liberated when the matte is crushed and milled. The alloy platelets are then separated via a magnetic separation process in the Magnetic Concentration plant. The quality of the converter matte is dependent on the reaction and cast temperatures, bulk matte composition and cooling rate of each ingot, which define the microstructure of the slow-cooled matte that is produced as the final product of the ACP process. The current mould size used in the ACP slow-cool aisle is ~10 tonnes (maximum 14.84t), designed for 2 full ingots to be poured from every tap from a full ladle with a capacity of ~20t. This is the ideal situation, however, during normal plant operation ladles develop a build-up of material on the inside (or skull) that reduces the ladle active volume. This results in a large number of half ingots being produced, and, given the smaller ingot size, suboptimal cooling conditions arise and subsequently poor quality Waterval Converter Matte (WCM) is produced because of rapid cooling. In an attempt to match the converter blow size, the ladle size and the slow-cool mould size in future, a larger mould size of 15 ton was specifically constructed to determine if the smelter converted matte can be cast into the larger mould size. Therefore a larger size ingot of 15t with a maximum capacity of 20.6t was also used as part of the trials in order to determine if cooling rates in the larger sized ingot necessitated longer cooling times, and would therefore negatively affect the platinum pipeline and working inventory. The data obtained from these trials were then used to develop and validate a CFD model, specifically developed to simulate the cooling process. From the heat loss data it was calculated that the bulk of the heat lost from the ingots is through the top surface. After the first 12 hours of cooling, approximately 89% of the heat lost from the ingot is via the top surface and this increases to 96% after 24 hours. It can therefore be concluded that the cooling rates of the ingots can be easily manipulated by changing the thermal insulation of the lid that is placed over the ingot after casting. / Dissertation (MEng)--University of Pretoria, 2013. / gm2014 / Materials Science and Metallurgical Engineering / unrestricted

DC-DC converters can be separated into two main groups: switching converters and linear regulators. Linear regulators such as Low Dropout Regulators (LDOs) are straightforward to implement and have a very stable output with low voltage ripple. However, the efficiency of an LDO can fluctuate greatly, as the power dissipation is a function of the device’s input and output. On the other hand, a switching regulator uses a switch to regulate energy levels. These types of regulators are more versatile when a larger change of voltage is needed, as efficiency is relatively stable across larger steps of voltages. However, switching regulators tend to have a larger output voltage ripple, which can be an issue for sensitive systems. An approach to utilize both in cascaded configuration while providing a negative output voltage will be presented in this paper. The proposed two-stage conversion system consists of a switching pre-regulator that can track the negative output voltage of the second stage (LDO) such that the difference between input and output voltages is always kept small under varying output voltage while maintaining the high overall conversion efficiency. Computer simulation and hardware results demonstrate that the proposed system can track the negative output voltage well. Additionally, the results show that the proposed system can provide and maintain good overall efficiency, load regulation, and output voltage ripple across a wide range of outputs.

No description available.

Medium Voltage (MV) power conversion systems are essential in high power applications to address the increasing demand of energy and the increasing penetration of renewable energy sources. MV power electronics converters are the key elements for power conversion in MV systems and are the focus of this study. Multilevel converter topologies are promising topologies in MV applications because of their reduced voltage stress on devices, excellent output quality, reduced semiconductor losses, lower common mode voltage among other advantages. However, they may suffer from the large number of switching devices and capacitors, as well as the need to regulate capacitor voltages. SiC MOSFETs can achieve higher switching speeds, higher switching frequencies, higher voltage ratings, higher operation temperatures compared to traditional Si devices. They have shown promise to increase the efficiency and power density of the converters, but may suffer from higher voltage overshoots, increased Electromagnetic Interference (EMI) emission and so on. In SiC-based multilevel converters, the features of multilevel topologies, and the features of SiC MOSFETs are coupled together. The benefits, challenges, and solutions of using SiC MOSFETs in multilevel converters are studied explicitly in this work. With the high switching speeds and high switching frequencies of SiC MOSFETs, and the large number of switches and capacitors in multilevel topologies, SiC-based multilevel converters need to be studied while considering high-frequency voltage and current behaviors and the interactions among them at different locations. Firstly, the use of SiC-based multilevel converter in the high-speed motor drive application is explored. A three-phase inverter is designed and built employing five-level Stacked Multicell Converter topology and SiC MOSFETs. The benefits and challenges of using multilevel converter topology and using SiC MOSFETs for this application are explored. A fitting topology is selected, and a prototype is designed, both with attentions paid to deal with the high switching speeds of SiC MOSFETs. The inverter is verified through experiments to meet all specifications with a high efficiency. Then a unique type of converter, converters with Integrated Capacitor Blocked Transistor (ICBT) cells are studied. Unlike the traditional methods, there are no fast-developing voltage unbalances, or high cell capacitor voltage ripples in ICBT-based converters. The ideal operation principle is analyzed and verified by the simulation results. Then the impacts of non-idealities on the operation are analyzed, and a control method is proposed for this type of converter. The operation and control of ICBT-based converters are verified by experimental results to achieve low cell capacitor voltage ripples and excellent voltage balance in Medium Voltage high power applications. Lastly, the conducted EMI emission in SiC-based multilevel converters are studied. Four SiC-based multilevel converters are studied, with the focus on the power circuit in one converter and the auxiliary circuits in the other three converters. The complexity of noise generation and propagation in multilevel converters is presented. The conducted EMI disturbances are experimentally evaluated, analyzed, and effectively mitigated in all four cases. / Doctor of Philosophy / Medium Voltage (MV) power conversion systems are essential in high power applications to address the increasing demand of energy and the increasing penetration of renewable energy sources. MV power electronics converters are the key elements for power conversion in MV systems and are the focus of this study. Multilevel converter topologies are promising topologies in MV applications because of their reduced voltage stress on devices, excellent output quality, reduced semiconductor losses, lower common mode voltage among other advantages. However, they may suffer from the large number of switching devices and capacitors, as well as the need to regulate capacitor voltages. SiC MOSFETs can achieve higher switching speeds, higher switching frequencies, higher voltage ratings, higher operation temperatures compared to traditional Si devices. They have shown promise to increase the efficiency and power density of the converters, but may suffer from higher voltage overshoots, increased Electromagnetic Interference (EMI) emission and so on. In SiC-based multilevel converters, the features of multilevel topologies, and the features of SiC MOSFETs are coupled together. The benefits, challenges, and solutions of using SiC MOSFETs in multilevel converters are studied explicitly in this work. With the high switching speeds and high switching frequencies of SiC MOSFETs, and the large number of switches and capacitors in multilevel topologies, SiC-based multilevel converters need to be studied while considering high-frequency voltage and current behaviors and the interactions among them at different locations. Firstly, the use of SiC-based multilevel converter in the high-speed motor drive application is explored. A three-phase inverter is designed and built employing five-level Stacked Multicell Converter topology and SiC MOSFETs. The benefits and challenges of using multilevel converter topology and using SiC MOSFETs for this application are explored. A fitting topology is selected, and a prototype is designed, both with attentions paid to deal with the high switching speeds of SiC MOSFETs. The inverter is verified through experiments to meet all specifications with a high efficiency. Then a unique type of converter, converters with Integrated Capacitor Blocked Transistor (ICBT) cells are studied. Unlike the traditional methods, there are no fast-developing voltage unbalances, or high cell capacitor voltage ripples in ICBT-based converters. The ideal operation principle is analyzed and verified by the simulation results. Then the impacts of non-idealities on the operation are analyzed, and a control method is proposed for this type of converter. The operation and control of ICBT-based converters are verified by experimental results to achieve low cell capacitor voltage ripples and excellent voltage balance in Medium Voltage high power applications. Lastly, the conducted EMI emission in SiC-based multilevel converters are studied. Four SiC-based multilevel converters are studied, with the focus on the power circuit in one converter and the auxiliary circuits in the other three converters. The complexity of noise generation and propagation in multilevel converters is presented. The conducted EMI disturbances are experimentally evaluated, analyzed, and effectively mitigated in all four cases.

Recent research and industrial accomplishment has revealed the advantages of cascaded smart converter PV system over traditional centralized and string PV system. However, even by adopting the cascaded smart converter, it is not always possible to track maximum power point (MPP) for all the panels under heavy shading condition, and a central converter is still required to track the peak power point of PV array. Based on the analysis of system configurations for smart converter PV system, an alternative PV system configuration is introduced which can extract peak power from all the panels under different mismatch condition and connect PV array to 380V DC bus without central converter. Based on this alternative PV system configuration, a multi-phase smart converter with single controller is proposed as a low cost panel-level MPPT solution. This proposal can largely reduce cost by saving MPPT controllers, current and voltage sensors without sacrificing energy production. The effectiveness of the proposal has been verified by both simulation and experiment results. / Master of Science

Galvanic isolation between the grid and energy storage unit is typically required for bidirectional power distribution systems. Due to the recent advancement in wide-bandgap semiconductor devices, it has become feasible to achieve the galvanic isolation using bidirectional isolated DC/DC converters instead of line-frequency transformers. A survey of the latest generation SiC MOSFET is performed. The devices were compared against each other based on their key parameters. It was determined that under the given specifications, the most suitable devices are X3M0016120K 1.2 kV 16 mohm and C3M0010090K 900 V 10 mohm SiC MOSFETs from Wolfspeed. Two of the most commonly utilized bidirectional isolated DC/DC converter topologies, dual active bridge and CLLC resonant converter are introduced. The operating principle of these converter topologies are explained. A comparative analysis between the two converter topologies, focusing on total device loss, has been performed. It was found that the CLLC converter has lower total device loss compared to the dual active bridge converter under the given specifications. Loss analysis for the isolation transformer in the CLLC resonant converter was also performed at different switching frequencies. It was determined that the total converter loss was lowest at a switching frequency of 250 kHz A prototype for the CLLC resonant converter switching at 250 kHz was then designed and built. Bidirectional power delivery for the converter was verified for power levels up to 25 kW. The converter waveforms and efficiency data were captured at different power levels. Under forward mode operation, a peak efficiency of 98.3% at 15 kW was recorded, along with a full load efficiency value of 98.1% at 25 kW. Under reverse mode operation, a peak efficiency of 98.8% was measured at 17.8 kW. The full load efficiency at 25 kW under reverse mode operation is 98.5%. / Master of Science

The intermediate bus architecture employing the 48V bus converter is one of the most popular power architecture. 48V to 12V bus converter has wide applications in telecommunications, networks, aerospace, and military, etc. However, today's state of the art products has low power rating or power density and becomes difficult to satisfy the demand of increasing power of the loads. To improve the current design, a GaN (Gallium Nitride) based two-stage solution is proposed for the bus converter. The first stage Buck converter regulates the 40V to 60V variable input to a fixed 36V bus voltage. The second stage LLC converter convert the 36V to 12V by a 3:1 transformer. The whole solution achieves the fixed frequency control. The thesis focus on the detail design and optimization of LLC converter, especially its transformer. To have high density and high efficiency, the transformer design becomes critical at MHz frequency. The matrix transformer concept is applied and a merged winding structure is used for flux cancellation, which effectively reduces the AC winding losses. A new fully interleaved termination and via design is proposed. It achieves significant reduction in loss and leakage flux. In addition, to study the current sharing of parallel winding layers, a 1-D analytic model is proposed and a symmetrical winding layer scheme is used to balance the current distribution. The hardware is built and tested. The proposed two-stage converter achieves the best performance compared to the current market. / Master of Science / Intermediate bus architecture (IBA) has wide applications in telecommunication, server and computing, and military power supplies. The intermediate bus converter (IBC) is the key stage in the IBA, where the DC bus voltage from the front-end power supply is converted to a lower intermediate bus voltage. Traditional IBC suffers from bulky magnetic components including inductors and transformers. This work illustrates the design and implementation of a two-stage IBC, where the first-stage Buck converter will provide regulation and the second stage LLC converter will provide isolation. Thanks to the soft-switching capability of LLC, the magnetic volume can be significantly reduced by raising the switching frequency of the converter. Therefore, planar magnetics can be used and placed directly inside of the printing circuit board (PCB), which allows for higher power densities and easy manufacturing of the magnetics and overall converter. However, as the frequency goes higher, the AC losses of the transformer caused by the eddy current, skin effect, and proximity effect become dominant. As a result, high-frequency transformer design becomes the key for the converter design. First, matrix transformer concept is applied to distribute the high current and reduce the conduction loss. Second, a novel merged winding structure is proposed for better transformer winding interleaving. Third, a new terminal structure of the transformer is proposed. Finally, the current sharing between parallel windings are modeled and studied. All the efforts result in great loss reduction. The prototype were verified and compared to the current converters that are on the market in the 48V – 12V area of IBCs.