This
paper presents a novel very flexible power supply for
capacitor charging applications for example powering of the
highest power professional amplifiers. The proposed converter
has very wide input AC line range and operational on three or
single phase with high power factor and low current
distortion. Advanced high frequency power conversion lets the
energy transfer and storage passive devices keep small and
losses of active devices reduced by Zero Voltage and Zero
Current (ZVS/ZCS) switching. With integrated magnetics and
passives construction the power density of this converter
exceeds 7500W/l and the power conversion efficiency is better
than 94%.
fig1.
On fig1. the basic
circuitry of the new converter displayed. There are three
sub-converters (cells) in the circuit each represented by a low
frequency bridge rectifier and a full bridge high frequency
inverter made by four power switches. One leg of the bridge has
a pair of GaN FETs while the other leg consists two fast IGBTs.
The inverter drives a transformer across serial-parallel
resonant network which shapes the magnetizing current to the
ideal waveform for maximum power transfer across the transformer
and provides low loss commutation of active switching devices.
Since this resonant LLCC2 converter is a strongly nonlinear
system therefore it is pretty difficult to control and no
control devices available on the market. We have developed a DSP
based digital control for maintain the operational parameters of
the converter and regulating charge characteristics.
Even with the fastest state-of-the-art power semiconductor
devices the losses would be pretty high due to the operational
frequency of the converter. Only in case of full soft ZV/ZC
switching across the whole operational range it can match to the
target conversion efficiency otherwise bulky heatsink would be
required affects the power density. Another advantage of the
soft switching is that the dV/dt stresses of the components
greatly reduced which lowers the electro-magnetic interference
issues. DSP has information about the input Voltages, input
Currents, resonant tank parameters and charging rates as well as
actual load balance of the charging cells. Implemented complex
nonlinear digital control changes the operational frequency,
pulse width with dead-times and phase shift of each individual
cells maintains the best conversion point of the converter.
Three individual cells have interleaved high-frequency operation
by proper timings of switch drive pulses which fact becomes
important when all cells connected in parallel mode (single
phase operation).
A very unique feature of the proposed converter is that
the AC Powering method could be selected easily by changing only
the AC line cable (fig2.).
Actual configuration of individual cells determined by the power
plug arrangement. The input power socket is fixed while two
types of power cables can be used for AC connection, one type
with four wires (L1, L2, L3, PE) for the three phase operation
and another type with three wires (L, N, PE) for the single
phase operation. Probably it is the easiest and most
failure-proof way of 3/1 phase operational selection by the end
user without the risk of misconfiguration risks (fig3.).
fig2.
True
Three Phase powering: 3 X 200V – 3 X 480V (nominal
400V) provided by the proper AC line cable to the L1, L2, L3
inputs. All of three converters work in actively balanced “Y”
configuration. Neutral connector is not used so the “stair point
in the Y circuit” is not exposed outside. The control circuitry
recognizes the actual type of connection (3/1 phase) and
automatically reconfigures the converters for the optimal
operation modes. Separated high-speed current and voltage
feedback loops by individual cells of the control DSP maintain
the best balancing of load between the line conductors. Due to
the high voltage operation a relative small size power cable is
required which
could mean much less copper cross-section area requirement and a
better cost-effective power distribution. Three phase operation
with high power factor and low line current shape distortion has
the advantage of best interfacing to power sources, AC
distribution lines or diesel generators. The converter is able
to handle the worst voltage balance problems across the line
conductors and even remains operational with two phases*.
fig3.
Single
Phase powering: For the greatest flexibility this power
supply can be operated from a single phase line 90V – 250V
(nominal 230V) if required. All three (L1, L2, L3 ) inputs
are connected in parallel by the AC cable as a single
powerful Line conductor while Neutral conductor goes to
the previous star point of Y configuration. The control
circuitry matches the operational
parameters of high
frequency converters for the best charging characteristic.
Although the advantages of true three phase
powering has lost
(high voltage, relative low current skinny line cable and
small low-frequency ripple) however the parallel
configured converters
can pull out three times of the current from the single
phase line. Thanks to the hardware and operational
mode changes the
overall conversion efficiency of power supply is not much
worst than in three phase case. When all of the
converters connected
in parallel it would create huge current ripple on the
line what is difficult to handle (even at so high
frequency
many bulky line
filtering elements would be required). The proposed
solution has a special phase-shifted synchronization
between the
individual converters which dramatically reduces the
current ripple by the number of units connected. Not only
the size and cost of EMI input filter reduced by
interleaving and proper phase-shift control but the output
high frequency ripple too. It
means lower
high-frequency current stresses across the output energy
storage elements. Overvoltage events (like accidental 400V
fig3. connection in
single phase mode) are not problematic unlike most of the
single line power supplies on the market now.
The three phase
operation is far better than single in the light of
low-frequency output ripple conditions of the converter.
This fact is even more important when the converter act as
a power supply of low-frequency amplifier. However in
certain applications issues of this elevated ripple can be
compensated by the proper sizing and number of the output
energy storage capacitors.
Very high operational
frequency is required to keep the passive energy transfer
elements small, especially the size of power transformers
and inductors depend on the frequency of magnetizing
current. Above ~250KHz the Skin-effect becomes significant
part of contributing
the overall power losses of conductors so the layout is
critical. Most of the conventional wire-connected devices
would not work very well so We have integrated most power
semiconductors and passive devices in the same structure.
This way
the length of high-frequency interconnections could be
reduced and it greatly helps to improve the power density.
When lots of heat sources (power coils, semiconductors)
placed in pretty close proximity each other most of the
conventional air-convection based cooling concepts
would not be so effective since there is just limited
surface area or even no room for the airflow.
fig4.
We have developed a
novel but simple cooling concept for the converter (fig4.). Lossy
power semiconductors and passives which carry high
currents integrated into the same planar structure and
mounted onto a flat coolplate which is represented by
a thick copper baseplate of the heatsink. Most of the
moisture sensitive electrical components located
outside of the cooling airflow, the separation barrier
is the copper baseplate of the heatsink. All of the
waste heat produced by the power semiconductors and
passive devices transferred to the baseplate which
works as a heat spreader too. There should not be any
air-gaps between the different layers of power devices
in the 3D structuretherefore voids are filled with
special heat-interfacing but electrically insulator
materials. Dimensioning and placement of interface
materials designed to carry most of the heat flux out
with minimum temperature drop so it helps to maintain
the optimal operational temperature range of
individual components and prevents dangerous
overheating. Unlike conventional discrete power device
based solutions Our integrated planar cooling
structure gives well predictable “hot point” maximum
temperatures which is consistent with temperature of
baseplate and independent from local airflow issues.
Tightly controlled temperatures improve the
reliability of power supply.
Waste heat removed from the heatsink via forced
air cooling by regulated speed DC fans. Actual speed of
fans depends on the momentary load and charging
conditions. The whole 15KJ/s peak charging capability
power supply includes heatsink, connectors, input filter
and fuses consumes just less than 2Liters in volume so
the actual power density of converter is more than
7500W/l. A prototype of the proposed converter is shown
bellow. It includes a 50W universal-line auxiliary
housekeeping power supply too. The dispayed view is from
the heatsink side and does not contain the heat
transfering elements. One of the proposed converter
powers a
PKN 3PHASE-20K while two of them is
the heart of the
PKN 3PHASE-40K professional
amplifiers.