Power Factor Correction Input Circuit Kevin Wong, Paul Glaze, Ethan Hotchkiss, Jethro Baliao Advisor: Prof. Ali Bazzi Sponsored by: Lenze Americas 3/7/2017 1
Outline Background Power Factor (PF) Power Factor Correction (PFC) Block Diagram Specifications Approach DC/DC Design Topologies Pros/Cons Design simulations Workbench First Prototype PCB Design Testing Results Timeline moving forward 2
What is Power Factor? True PF: the product of displacement and distortion power factor. Displacement PF: the ratio of real and apparent power Distortion PF: the deviation of the current waveform from a sinusoid. Our goal is to make the current waveform match the shape and phase angle of the voltage. 3
Block Diagram 4
Specifications Input Requirements Voltage Input: 90Vac-132Vac Power Factor: >0.95 Frequency: 48-62Hz Inrush Current: <40A Output Requirements Voltage Output: 325Vdc Max Continuous Power: 1472W Voltage Ripple: 20Vpk-pk System Requirements Operating Temperature: -10 to 55 C Switching Frequency: >20KHz 5
Possible DC/DC Topologies Boost Flyback SEPIC Buck Boost 6
DC/DC Converter Pros & Cons Topologies Pros/Cons Factors Boost Buck-Boost Flyback SEPIC Simplicity 1st 4th 2nd 3rd Size 1st 2nd 3rd 4th Cost 1st 4th 2nd 3rd Power Level 1st 3rd 4th 2nd Voltage Regulation 4th 2nd 3rd 1st 7
Boost Converter Diagram 8
Ideal Boost Waveforms 9
Control Options DSP Infineon ICE3PCS01G Adjustability Expansion No reliance on a 3rd party chip Existing control chip Greater stability Lower production costs 10
Workbench 11
First Prototype 12
Schematic 13
PCB Design 14
Testing Results First tested at 130 Vac input with the physical prototype Current Sense Resistors failed from the inrush Infineon Chip, MOSFET, and Pre-Charge Circuit Failed As a result: Rebuilt with a better MOSFET, 700V 46A and manual control of precharge. Tested with a DC input in an Open Loop Circuit With an input voltage from 5V to 75V Thermals were significantly better with the replacement MOSFET Unfortunately, MOSFET failed as well reaching a 75V DC input due to improper gate driving. 15
Testing Results Rebuilt again with 650V IGBT and observed current waveforms closely. Found issues with the inductor current waveform. After replacing the inductor, the waveforms and results are much better. We suspect that this high current may have been an influence on the conditions that lead to previous failures 16
IGBT Testing Results 17
18 IGBT Test Waveform V in =130VDC D=0.5 F sw =40kHz V out =257V ΔV out = 16V I Lavg =5.4A ΔI Lripple =5.6A pk-pk
IGBT Testing Results After MOSFET Shorted, tested with an IGBT Inductor saturation current was probably the cause for our MOSFETS shorting IGBT proved successful at various DC voltages from 30V-130V using a 100ohm Load The efficiency was very consistent Thermals were not much of an issue 19
What s next? Full Power Tests in DC before AC tests AC input tests Contact Lenze to have new VFD shipped with inputs for 325VDC Completion of PCB design and Order placed Have complete working design at Full Power by early April 20
Spring Timeline 21
Resources H. Wei, and I. Batarseh. (1998) Comparison of Basic Converter Topologies For Power Factor Correction. [September 20, 2016] J.W. Kolar and T. Friedli. The Essence of Three-Phase PFC Rectifier Systems-Part I. IEEE Transactions on Power Electronics, Vol. 28, No.1,pp176-198, [ September 20, 2016]. J. Betten. (2011, Q2) Benefits of a coupled-inductor SEPIC converter Analog Applications Journal [Online] Available: http://www.ti.com/lit/an/slyt411/slyt411.pdf [October 14 2016]. G. Sharp. Sepic Converter Design and Operation. BS, WPI, Worcester, MA, 2014. ST. TM sepic converter in PFC pre-regulator. Internet: http://www.st.com/content/ccc/resource/technical/document/application_note/48/9d/ 34/73/b9/27/48/65/CD00134778.pdf/files/CD00134778.pdf/jcr:content/translations/en.C D00134778.pdf, March 2007[October 10, 2016]. "The Flyback Converter," in University of Colorado. [Online]. Available: http://ecee.colorado.edu/~ecen4517/materials/flyback.pdf. [Oct. 27, 2016]. De Nardo et al, Power Stage Design of Fourth-Order DC-DC Converters by Means of Principal Components Analysis. IEEE Transactions on power Electronics, Vol. 23 No. 6,pp2867-2877 22
Questions? Additional information can be found on our website: http://ecesd.engr.uconn.edu/ecesd1703/ 23
MOSFET Testing Results 24
MOSFET Testing Results Testing at various duty cycles and frequencies with a 100ohm load we concluded: As frequency increases the input current decreases At 60kHz the efficiency peaks Decreasing gate voltage decreased the current Lower Duty Cycles exhibited greater efficiency 25
Active vs Passive Rectification Active: Pros: Lower voltage drop Bi-directional current Higher efficiency Cons: Requires control More expensive More complex Passive: Pros: No external control Simple Inexpensive Cons: Uni-directional current Higher voltage drop Lower efficiency 26
Semiconductor Options IGBT Voltage Rating: >1kv Current Rating: >500A Slower switching More expensive MOSFET Voltage Rating: <1kV Current Rating: <200A Faster switching Less expensive 27
Which methods fit our needs? DC/DC Converter Topology We presented the pros and cons of each topology along with preliminary simulations to Lenze on Monday and they have decided that they want us to move forward with the boost converter. Active vs. Passive Rectification Lenze has also stated that they would like us to start with passive rectification in order to simplify the design. 28