Yes / Extrusion is one of the fundamental production methods in the polymer processing industry and is used in the production of a large number of commodities in a diverse industrial sector. Being an energy intensive production method, process energy efficiency is one of the major concerns and the selection of the most energy efficient processing conditions is a key to reducing operating costs. Usually, extruders consume energy through the drive motor, barrel heaters, cooling fans, cooling water pumps, gear pumps, etc. Typically the drive motor is the largest energy consuming device in an extruder while barrel/die heaters are responsible for the second largest energy demand. This study is focused on investigating the total energy demand of an extrusion plant under various processing conditions while identifying ways to optimise the energy efficiency. Initially, a review was carried out on the monitoring and modelling of the energy consumption in polymer extrusion. Also, the power factor, energy demand and losses of a typical extrusion plant were discussed in detail. The mass throughput, total energy consumption and power factor of an extruder were experimentally observed over different processing conditions and the total extruder energy demand was modelled empirically and also using a commercially available extrusion simulation software. The experimental results show that extruder energy demand is heavily coupled between the machine, material and process parameters. The total power predicted by the simulation software exhibits a lagging offset compared with the experimental measurements. Empirical models are in good agreement with the experimental measurements and hence these can be used in studying process energy behaviour in detail and to identify ways to optimise the process energy efficiency.

De nos jours, les énergies renouvelables remplacent les énergies fossiles. Pour assurer une l’interconnexion entre toutes ces installations électriques, l’électronique de puissance est nécessaire. Les principales spécifications de la prochaine génération de convertisseur de puissances sont un rendement et une densité de puissance élevés, fiabilité et faibles coûts. L’intégration PCB des composants actifs et/ou passifs est perçue comme une approche prometteuse, peu onéreuse et efficace. Les délais ainsi que les coûts de fabrication des convertisseurs de puissance peuvent considérablement réduits. L’intégration permet également d’améliorer les performances des convertisseurs. Dans ce but, un concept original d’inductance 3D pliable utilisant la technologie PCB est présenté. Il permet un coût faible pour une production en série, ainsi qu’une excellente reproductibilité. Un usinage partiel de la carte PCB est utilisé, permettant le pliage et la conception des enroulements de l’inductance. Différents prototypes sont développés par le biais d’une procédure d’optimisation. Des tests électriques et thermiques sont réalisés pour valider l’applicabilité du concept au sein de convertisseurs de puissance.Le développement d’une procédure d’optimisation appliqué aux convertisseurs hautement intégrés utilisant l’enterrement PCB est présenté. Tous les choix importants, facilitant l’intégration PCB, e.g. réduction des composants passifs, sont présentés. Cela inclut la sélection de la topologie adéquate avec la modulation associée. La procédure de design et les modèles analytiques sont introduits. Il en résulte un convertisseur comprenant quatre pont-complet entrelacés avec des bras fonctionnant à basse (50 Hz) et haute (180 kHz) fréquences. Cette configuration autorise une variation de courant importante dans les inductances, assurant ainsi la commutation des semi-conducteurs à zéro de tension (ZVS), et ceux sur une période complète du réseau. L’impact de la forte variation de courant sur le filtre CEM est compensé par l’entrelacement. Deux prototypes d’un convertisseur AC/DC bidirectionnel de 3.3 kW sont présentés, les résultats théorique et pratique sont analysés.Pour augmenter la densité de puissance du system, un filtre actif de type “Buck” est étudié. La procédure d’optimisation est adaptée à partir de la procédure implémentée pour le convertisseur AC/DC. L’approche utilisée, mène à un convertisseur opérant également en ZVS durant une période compète du réseau, et ce, à fréquence de commutation fixe. Les technologies sélectionnées, condensateur céramique et inductance compatible avec la technologie PCB sont favorable à l’intégration et sont implémenté sur le prototype. / Nowadays, the green energy sources are replacing fossil energies. To assure proper interconnections between all these different electrical facilities, power electronics is mandatory. The main requirements of next generation converters are high efficiency, high power density, high reliability and low-cost. The Printed Circuit Board (PCB) integration of dies and/or passives is foreseen as a promising, low-cost and efficient approach. The manufacturing time and cost of power converters can be drastically reduced. Moreover, integration allows the converter performances to be improved. For this purpose, an original 3D folded power inductor concept using PCB technology is introduced. It is low cost for mass production and presents good reproducibility. A partial milling of the PCB is used to allow bending and building the inductor winding. Prototypes are designed through an optimisation procedure. Electrical and thermal tests are performed to validate the applicability in power converters. The development of an optimisation procedure for highly integrated converters, using PCB embedding, is presented. All important choices, facilitating the PCB integration, e.g. reduction of passive components, are presented. It includes the selection of the suitable converter topology with the associated modulation. The design procedure and implemented analytical models are introduced. It results in four interleaved full-bridges operating with low (50 Hz) and high (180 kHz) frequency legs. The configuration allows high current ripple in the input inductors inducing zero voltage switching (ZVS) for all the semiconductors, and for a complete grid period. The impact of high current ripple on the EMI filter is compensated by the interleaving. Two prototypes of a 3.3 kW bidirectional AC/DC converters are presented, theoretical and practical results are discussed. To further increase the power density of the overall system, a Buck power pulsating buffer is investigated. The optimisation procedure is derived from the procedure implemented for the AC/DC converter. The result favours an original approach, where the converter also operates with ZVS along the entire main period at a fixed switching frequency. The selected technologies for prototyping are integration friendly as ceramic capacitors and PCB based inductors are implemented in the final prototype.

Content of this master`s thesis is theoretical introduction of the power factor, reactive power and voltage control of decentralised sources of the high voltage in the E.ON distribution network. Furthermore, the thesis deals with possibilities of regulating the power factor and reactive power, carried on above-mentioned resources, in other to stabilize the voltage and overflow control of the reactive power to higher voltage level. The practical part describes how the automatic power factor and voltage control had been put into action by central management control within the headquaters dispatching systém of the company. Following chapter acquaints a reader with information of how the automatic power factor and voltage control had been tested and how it is utilized in practice. In the conclusion the work summarizes results and effects of the power factor regulation and voltage control to stabilize the voltage and the overflow of the reactive power in the E.ON network.

Orientador: Paulo José Amaral Serni / Coorientador: Eduardo Paciência Godoy / Banca: Everson Martins / Banca: Atila Madureira Bueno / Resumo: A preocupação com a qualidade da energia elétrica, seu uso e técnicas para redução de perdas elétrica não é mais uma tendência e sim uma necessidade, pois, tem se entendido que a energia elétrica é um bem comum e não deve ser desperdiçada. Nesse contexto, estratégias para controlar o nível de tensão e o fator de potência vêm sendo tratadas, com o objetivo de aprimorar o controle dessas variáveis. Este trabalho apresenta uma estratégia de controle integrado de regulação de tensão e do fator de potência para um sistema de distribuição de energia elétrica usando uma rede de comunicação sem fio. A estratégia de controle proposta consiste em uma rede de comunicação entre os dispositivos designados para operarem reguladores de tensão, transformadores com comutadores sob carga e banco de capacitores, concentrando as informações em um único dispositivo capaz de definir a operação dos demais dispositivos alocados no sistema, sendo a concentração das informações feita localmente, sem a necessidade de um sistema de controle centralizado, permitindo uma simplificação e uma redução significativa de custo para implementação de uma solução de controle integrado de tensão e do fator de potência. A estratégia de controle proposta foi modelada no ambiente Matlab®/Simulink® e a rede de comunicação na ferramenta TrueTime. O estudo apresenta uma comparação entre a estratégia proposta e o método de controle tradicional, abordando aspectos relacionados a qualidade de energia elétrica entregue, dema... (Resumo completo, clicar acesso eletrônico abaixo) / Abstract: The issue about power quality, its rational use, and techniques to reduce electrical losses in the distribution systems is not anymore a trend but a necessity, due to, a understanding that the electricity is a common good, then, should not be wasted. Based on this context, strategies have been studying to control the voltage and power factor with the objective to improve the control of this variables. This work presents an integrated control for voltage and power factor strategy to distribution systems using a wireless network. The purposed strategy allows a communication between the devices designed to operate voltage regulators, on load transformers tap changers, and capacitors bank, concentrating all information in only one device, which is able to define the operation of others, being the concentration information made locally, without a necessity of the a centralize system, simplifying and reducing costs related the implementation of an integrated control for voltage and power factor. The strategy presented was modeled in the Matlab®/Simulink® and the communication network using the TrueTime toolbox. The study presents a comparison between the traditional strategy and the purposed, analyzing the power quality delivered, power demand in peak time, and electrical losses in the system. The results shows that the integrated control for voltage and power factor strategy allows the use of capacitors bank downstream of voltage regulators without any impact in the power quality ... (Complete abstract click electronic access below) / Mestre

Este trabalho apresenta o estudo de um carregador de baterias monofÃsico aplicado a veÃculos elÃtricos. Este carregador à composto por dois estÃgios de processamento de energia e um circuito digital de supervisÃo para controlar a tensÃo sobre o banco de baterias e a corrente de recarga das mesmas. O primeiro estÃgio consiste de um conversor CA-CC bridgeless com caracterÃstica de alto fator de potÃncia, e o segundo estÃgio à representado por um conversor CC-CC fullbridge com isolamento em alta frequÃncia e comutaÃÃo sob tensÃo nula (Zero Voltage Switching â ZVS). Para ambos os conversores, foi realizada uma anÃlise qualitativa e quantitativa, bem como apresentados exemplos de projeto para facilitar o dimensionamento dos componentes. Finalmente, com os componentes escolhidos, foi montado um protÃtipo que permite carregar de uma atà oito baterias de 12 V conectadas em sÃrie. O sistema apresenta como especificaÃÃes: tensÃo de entrada alternada de 220 VÂ15%; tensÃo de saÃda contÃnua de 120 V; corrente de saÃda contÃnua de 20 A; e potÃncia mÃdia de saÃda de 2,4 kW. / This work presents a single-phase battery charger for electric vehicles. This converter is composed by two energy processing stages and a digital circuit to control the voltage across the batteries and their respective charging current. The first stage is a high power factor ACDC bridgeless converter, while the second one consists on a ZVS (Zero Voltage Switching) high frequency isolated DC-DC full-bridge converter. For both converters, the qualitative and quantitative analyses have been performed, as well as design examples have been presented in order to ease the components calculation. Finally, a prototype that allows charging up to eight series-connected 12 V batteries has been built. The system specifications are: AC input voltage of 220 V Â15%; DC output voltage of 120 V; DC output current of 20 A; and average output power of 2.4 kW.

Orientador: Luis Carlos Origa de Oliveira / Banca: José Carlos Rossi / Banca: Olivio Carlos Nascimento Souto / Resumo: O presente trabalho avalia a viabilidade técnica da aplicação de compensação reativa em circuitos secundários aéreos de baixa tensão, através da aplicação de capacitores e / ou filtros para aplicação em Baixa Tensão, buscando assim uma otimização dos reativos presentes nas redes secundárias. Considerando-se as constantes mudanças que vêm ocorrendo no cenário de distribuição de energia elétrica, devido ao grande avanço da eletrônica de potência e de cargas não lineares cada vez mais presentes no sistema elétrico, fazem-se necessários estudos para diagnosticar como e em que níveis tais mudanças podem estar afetando as características das redes de distribuição. Verifica-se que tais cargas, possuem um baixo fator de potência, e podem aumentar significativamente o nível de correntes harmônicas devido às técnicas de chaveamento utilizadas nestes dispositivos. Com isto, acentuam-se os problemas da propagação das distorções de forma de onda das correntes às tensões da rede, além de aumentar consideravelmente as perdas de energia elétrica ao longo de seus condutores e transformadores. Há necessidade de se conhecer as características dessas cargas de forma a permitir a correta modelagem das mesmas. O objetivo deste trabalho é identificar o perfil da rede secundária frente aos níveis de harmônicos e fator de potência, permitindo a adequada aplicação de filtros e capacitores para instalação no secundário dos transformadores de distribuição, visando a correção do fator de potência nos circuitos, redução do reativo circulante, das perdas elétricas e eventualmente dos níveis de distorção harmônica. Avaliando-se as interferências no carregamento dos transformadores de distribuição e melhoria do perfil da tensão de alimentação. Neste sentido, foi feita uma campanha de monitoramento em alguns circuitos selecionados... (Resumo completo, clicar acesso eletrônico abaixo) / Abstract: This paper seeks to evaluate the technical feasibility of applying for compensation reactive side air circuits in low-voltage, by the application of capacitors and / or filters for use in the Low Voltage, thereby seeking an optimization of reactive present in the secondary networks. Analysis with a focus on secondary distribution network should consider a new factor, which is the proliferation of non-linear loads. Considering the constant changes that are occurring in the scenario of distribution of electric energy, due to the general advancement of power electronics and nonlinear loads increasingly present in the electrical system, are made necessary studies to diagnose how and to what levels such changes may be affecting the characteristics of distribution networks. It appears that such loads, have a low power factor, and can significantly increase the level of harmonic currents because of the techniques used in these switching devices. With this, stressing the problems of the spread of distortions of waveform of the current tensions to the network, in addition to considerably increase the loss of power over their drivers and processors. Thus, the objective of this study is to identify the profile of the network front secondary levels of harmonics and power factor, allowing the proper implementation of filters and capacitors for installation of transformers in the secondary distribution, aiming to correct the power factor in circuits, Reducing the reactive stock, loss of electrical and possibly the levels of harmonic distortion. Judging is interference in the shipment of processors for distribution and improving the profile of the supply voltage. In this sense, there was a campaign tracking in some selected circuits, computer simulations were also conducted, equipment developed and deployed pilot projects. / Mestre

Ce travail vise une exploration et une évaluation de nouvelles variantes de topologies multiniveaux AC/DC non réversibles (PFC) du point de vue de leur sûreté de fonctionnement : recherche d'une grande sécurité électrique sur destruction interne et maintien d'une continuité de fonctionnement. Elles sont caractérisées par une connexion AC non différentielle, un partitionnement cellulaire en série et symétrique autour d'un point milieu. Cette organisation permet d'exploiter la redondance active série entre les cellules d'un même groupe et l'effet de ségrégation topologique qui apparaît entre les deux groupes de cellules. Les structures étudiées sont modulaires et peuvent être parallélisées et étendues à un nombre quelconque de phases. Elles ne possèdent que des cellules mono-transistors basse-tension (Si et SiC 600V max) performantes et intrinsèquement tolérantes aux imperfections de la commande et aux parasites donc naturellement sécurisées. Les comparaisons prenant en compte les pertes, la répartition des pertes, le dimensionnement et le report de contraintes sur défaut interne mettent en avant la structure PFC Double- Boost Flying Cap. à 5 Niveaux, brevetée en début de thèse, comme une solution ayant le meilleur compromis. Sur le plan théorique nous montrons que le seul calcul de la fiabilité basé uniquement sur un critère d'occurrence au premier défaut est inadapté pour décrire ce type de topologie. La prise en compte de la tolérance de panne est nécessaire et permet d'évaluer la fiabilité globalement sur une panne effective (i.e. au second défaut). L'adaptation de modèles théoriques de fiabilité à taux de défaillance constant mais prenant en compte, au niveau de leurs paramètres, le report de contrainte en tension et l'augmentation de température qui résulte d'un premier défaut, permet de chiffrer par intégration et en valeur relative, le gain obtenu sur un temps court. Ce résultat est compatible avec les systèmes embarqués et la maintenance conditionnelle. Un prototype monophasé à 5 niveaux, à commande entièrement numérique et à MLI optimisée reconfigurable en temps réel a été réalisé afin de valider l'étude. Il permet une adaptation automatique de la topologie de 5 à 4 puis à 3 niveaux par exemple. Ce prototype a également servi de banc de test d'endurance du mode de défaillance sur claquage - avalanche de transistors CoolMos™ et diodes SiC, volontairement détruits individuellement dans des conditions d'énergie maîtrisée et reproductibles, afin de prouver expérimentalement le maintien du service sur plusieurs centaines d'heures au prix d'un derating de 30% maximum en puissance seulement. La détection et le diagnostic rapide de défauts internes ont également été traités dans ce travail. D'une part, par la surveillance directe et le seuillage des tensions internes (tensions flottantes) et d'autre part, par une détection harmonique de la fréquence de base (amplitude et phase) en temps réel. Ces deux techniques ont été intégrées numériquement et évaluées sur le prototype, en particulier la seconde qui ne requiert qu'un seul capteur. VI Enfin, nous proposons dans ce travail une nouvelle variante PFC Vienna multicellulaire expérimentée en fin de mémoire, utilisant deux fois moins de transistors et de drivers pour les mêmes performances fréquentielles au prix d'un rendement et d'une répartition des pertes légèrement moins favorables que la structure brevetée.

AC/DC adapters mostly employ two-stage topology: Power Factor Correction (PFC) pre-regulation stage followed by an isolated DC/DC converter stage. Low power AC/DC adapters require a small size to be competitive. Among their components, the bulk DC-link capacitor is one of the largest because it should keep the output voltage with low ripple. Also, the size of this capacitor is penalized due to the universal line voltage application. Synchronization through employing leading edge modulation for the first PFC stage and trailing edge modulation for the second DC/DC converter stage can significantly reduce the ripple current and ripple voltage of the DC-link capacitor. Thus, a smaller DC-link capacitance can be used, lowering the cost and size of the AC/DC adapter. Benefits of the synchronous switching scheme were already demonstrated experimentally. However, no mathematical analysis was presented. In this thesis, detailed mathematical analyses in per-unit quantity are given to facilitate the calculation of the DC-link capacitor ripple current reduction with Leading/Trailing Edge Modulation strategies. One of the limitations of leading/trailing edge modulation is that the switching frequencies of the two stages need to be equal to achieve the best reduction of the DC-link capacitor ripple current. The DC-link capacitor ripple current will become larger if the switching frequency of the DC/DC converter is larger than that of the PFC pre-regulator, which blocks us to employ higher frequency for isolated DC/DC converter to reduce its transformer size. This thesis proposed a new Leading/Trailing Edge Modulation strategy to further reduce the DC-link bulk capacitor ripple current when switching frequency of DC/DC converter stage is twice the switching frequency of PFC stage. This proposed pulse width modulation scheme was verified by simulation. Experimental results obtained through digital control based on FPGA are also presented in this thesis.

In this work, single stage power factor corrected AC/DC converters for LEDs / single stage Flyback converter having different configuration from the traditional Flyback and single stage SEPIC converter is investigated. The study involves analysis, circuit design, performance comparisons and implementation. The study covers LEDs / their developments, characteristics and state-of-art in this new technology. The circuits are investigated by means of computer simulations. Operating principles and operating modes are studied along with design calculations. After applying prototypes in laboratory, the simulation results and theoretical analyses are confirmed. The single stage Flyback converter has high voltage input (220-240 Vac), and the output feeds up to 216 HB-LEDs, with the ratings of 24 V, 3.25 A with 90 W. The single stage SEPIC converter with universal input (80-265 Vac) has an output that feeds 21 power LEDs, with 67 V, 0.30 and 20 W ratings.

In this thesis an educational test bench for studying the power quality attributes of the commonly used single-phase full-bridge diode rectifiers with power factor correction (PFC) circuits is designed and tested. This thesis covers the active and passive power factor correction methods for single-phase bridge rectifier. Passive filtering approach with dc side inductor and tuned filter along with active filtering approach via singleswitch boost converter is considered. Analysis, simulation, and design of a single phase rectifier and PFC circuits is followed by hardware implementation and tests. In the active PFC approach, various control methods is applied and compared. The educational bench is aimed to useful for undergraduate and graduate power electronics course, power quality related laboratory studies.