Power Factor Correction Input Circuit · Power Factor Correction.” [September 20, 2016] •J.W. Kolar and T. Friedli. “The Essence of Three-Phase PFC Rectifier Systems-Part I.”

Power Factor Correction Input

Circuit

Kevin Wong, Paul Glaze,

Ethan Hotchkiss, Jethro Baliao

Advisor: Prof. Ali Bazzi

Sponsored by: Lenze Americas

3/7/2017

1Copyright © 2016 – Advanced Power Electronics & Electric Drives Lab (APEDL)

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


▪ True PF: the product of displacement and distortion power factor.


What is Power Factor?

▪ Distortion PF: the deviation of

the current waveform from a

sinusoid.

▪ Displacement PF: the ratio

of real and apparent power

▪ Our goal is to make the current waveform match

the shape and phase angle of the voltage.

Block Diagram


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



Possible DC/DC Topologies

▪ Boost

▪ Flyback

▪ SEPIC

▪ Buck Boost

DC/DC Converter Pros & Cons

7

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

Copyright © 2016 – Advanced Power Electronics & Electric Drives Lab (APEDL)

Boost Converter Diagram


Ideal Boost Waveforms


Control Options

10

Infineon ICE3PCS01G

● Existing control chip

● Greater stability

● Lower production costs

DSP

● Adjustability

● Expansion

● No reliance on a 3rd

party chip


Workbench


First Prototype


Schematic


PCB Design


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.


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

IGBT Testing Results

17

IGBT Test Waveform

Vin=130VDC • D=0.5 • Fsw=40kHz • Vout=257V

ΔVout = 16V • ILavg=5.4A • ΔILripple=5.6Apk-pk

18

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


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


Spring Timeline


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


23

Questions?

Additional information can be found on

our website:

http://ecesd.engr.uconn.edu/ecesd1703/


http://ecesd.engr.uconn.edu/ecesd1703/

MOSFET Testing Results


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


Active vs Passive Rectification

Active:

Pros:

• Lower voltage drop

• Bi-directional current

• Higher efficiency

Cons:

• Requires control

• More expensive

• More complex

26

Passive:

Pros:

• No external control

• Simple

• Inexpensive

Cons:

• Uni-directional current

• Higher voltage drop

• Lower efficiency


Semiconductor Options

27

MOSFET

● Voltage Rating: <1kV

● Current Rating: <200A

● Faster switching

● Less expensive

IGBT

● Voltage Rating: >1kv

● Current Rating: >500A

● Slower switching

● More expensive


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.


Documents

Power Factor Correction Input Circuit · Power Factor Correction.” [September 20, 2016] •J.W. Kolar and T. Friedli. “The Essence of Three-Phase PFC Rectifier Systems-Part I.”