power (not only semiconductor) converters. power semiconductor converters equipment for changing...
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Power (not only semiconductor) converters
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Power semiconductor converters
• Equipment for changing quality of electrical energy
(voltage, current, frequency, no. of phases, impedance, etc
• Conversion of energy „nearly“ without power losses
• The most often converters:
– rectifiers (diodes, not controlled)
– frequency converters (non-direct, with DC link)
• The most often applications:
– Power supply, AC drivers
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History of converters
• electro-mechanical principle– beginning by Tesla and Edison– rotating rectifiers, switching of windings, brushes
• electro-magnetic principle– groups of machines: Ward-Leonardo
AC vers. DC
end of 19th. century
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• Selenium based rectifiers:– end of 19. century, low currents
• Mercury based rectifiers:– current of ions in a steam of Hg
– Cathode – liquid of Hg, Anode – solid
– range of kA, kV, traction power supply
– In Prague from 1929 since 1967
• Thyratrone – units of kV, units of A
History of converters
Siemens 15 kV / 1A
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Semiconductor converters
• In Czech from the end of 50. ČKD Elektrotechnika• In 1964 introduced ČKD Polovodiče – Pankrác
discrete devices
modules
converters
silicon
heat sinks, accessories
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Converters - overviewrectifiers: AC/DC
inverter: DC/AC
Frequency converter:AC/AC
(direct/indirect)
DC converter: DC/DC
AC – effective
DC - average
dtuT
U 21
dtuT
U AV .1
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Most often converters - SMPS
• SMPS – Switch Mode Power Source• all chargers, PC supplies, household
appliances
• Aim – reducing of mass and dimension of transformers in comparison with classic linear power supply
• Product S·B · N stands for a cubic (volume) of transformer
2
1
1
2
1
2
f
f
S
S
N
N
NBSfU i 44,4
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Most often converter- DC supply
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Power supply for industry
• DC sources
Without PFC
Active PFC
Power factor correction – better efficiency
passive – big choke (coil)
active – adapted DC link, better PF, more expensive
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4.1 Charakteristika vysokofrekvenčního rušení
Example of high frequency disturbance - SMPS
0
5
10
15
20
0 30 60 90 120 150
f (kHz)
U (mV)
Basic blocs of SMPS and frequency spectrum
M
Disturbance /noise voltage/ of brush DC driver
1 ms
1 kV
usměrňovač můstkový měnič transformátor usměrňovač stabilizace
síť spotřebič
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4.3 Šíření rušení po vedení
Noise-suppressing filters (EMC) – basic circuit solution• symmetric and asymmetric voltage – more types of L, C• impedance miss-matching = low efficiency• reducing of mass and dimensions of coils• limits for capacitors Cx/Cy = leakage currents• additional functions = surge protections, switches, etc.
FILTR
L
N
PE
1
2
1 – symetrické napětí2 – nesymetrické napětí
Zdroj rušení
Přijímač rušení
L1
L1
CY
CY
CX
L
N
PE
L
N
PE
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4.3 Šíření rušení po vedení
Assembly and mounting of filters
• placing and mounting of filters = influence of efficiency• separating of input/output, no loops, minimizing of lengths/areas• placing directly at input• good connections between chassis and filters (grounding)
dobře špatně
filtr filtr filtr
YES NO NO NO YES
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4.3 Šíření rušení po vedení
EMC chokes – most simple solutions
• connected in series in lines• rated for nominal current• overdosing of cores (not convenient)• compensated chokes
– Subtraction of magnetic fluxes– Not efficient for symmetrical voltage
I,F
I,F I
I
F = 0
not-compensated chokes Current compensated chokes
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Nízkofrekvenční a přechodné rušivé jevy
Harmonic, inter-harmonic currentImmediate power p V·A Product of immediate V and I
Apparent power S V·A Product of effective V and I
Active power P W Average value of immediate power p (for periodical signals)
Non-active power Q~V·A, var Square root of difference between S and P
(just for periodical conditions)
Reactive power Q V·A, var Non active power for linear double-pole device (R, L, C)
Power factor - general definitions: P/S
cos cos - Just for harmonic signals is P/S equal to cos !
Phase angle °, rad Angle from voltage to current vector
Definitions according ČSN IEC 60050-131: Basic circuit theory
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-400
-200
0
200
400
0 5 10 15 20
napětí
proud
U (V) I (mA)
(ms)
Nízkofrekvenční a přechodné rušivé jevy
Typical currents - consumption
Harmonic conditions: Non-harmonic conditions:
-400
-200
0
200
400
0 5 10 15 20
napětí
proudU (V) I (mA)
(ms)
voltage
current
voltage
current
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Nízkofrekvenční a přechodné rušivé jevy
Power triangle, power factor
S = UI
P = UI cos f
Q = UI sin f
f
Harmonic conditions:• linear devices (R, L, C)• sinusoidal current
General non harmonic conditions:• nonlinear devices (etc. rectifiers)• general consumption of current
S
P
Q~
cos SP
UI
IU
S
P hhhh
1
cos
1111 cos
cos I
I
UI
UI
S
P
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Nízkofrekvenční a přechodné rušivé jevy
Deformation and displacing of current/voltage waveforms
-400
-200
0
200
400
0 5 10 15 20
napětí
proudU (V) I (mA)
(ms)
-400
-200
0
200
400
0 5 10 15 20
napětí
proud
U (V) I (mA)
(ms)
Deformation only of current waveform Deformities of voltage and current waveforms (simultaneously)
voltage
current
voltage
current
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Nízkofrekvenční a přechodné rušivé jevy
Influence of higher Harmonics components
• creation of non-active power, increase of apparent power
• it makes power factor worse
• it makes bigger power losses
• increase of loading for compensation capacitors
• increase of pulsing moments (AC drivers)
• higher harmonics currents are not compensated (neutral conductor!!!)
• overloading of neutral conductor
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Nízkofrekvenční a přechodné rušivé jevy
Reducing of harmonics currents (components of current)
• PFC – Power Factor Correction (removing of root cause)• compensations (passive/active filters) – removing of consequences• principle of PFC – prolongation of current consumption (chokes)
pasivní PFC aktivní PFCpassive PFC active PFC
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Nízkofrekvenční a přechodné rušivé jevy
Passive PFC
-400
-200
0
200
400
0 5 10 15 20
napětí
proud
U (V) I (mA)
(ms)
Consumption of current – time dependence
Spectrum of harmonics
0
50
100
1 11 21 31 41
voltage
current
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Nízkofrekvenční a přechodné rušivé jevy
Active PFC
Consumption of current – time dependence
Spectrum of harmonics
-400
-200
0
200
400
0 5 10 15 20
napětí
proud
U (V) I (mA)
(ms)
0
50
100
1 11 21 31 41
voltage
current
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Nízkofrekvenční a přechodné rušivé jevy
Filters for compensation
Passive filters:• resonance LC circuits for actual harmonics• short circuit for undesired harmonics• disadvantage – accumulation of harmonics from the nearest networks
Active filters:• transistor based PWM converters• active filter are producing (by means of PWM) higher harmonics (IH) and reactive components (IJ) of the load current (IZ)• more complicated circuit
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Main parts of frequency converters
• Backplain board
• Power modules
• Aluminum body (heat
sink)
• Cooling fan (at the
bottom)
• Cooling from bottom to
the top
• Control circuits,
keyboard at front side • Aluminum and plastics
• Control panel, keyboard
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Cooling of modules
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Typical devices
• Power modules – integrated semicon. devices• cooling – passive/active air-based• Inductance-less housing• Potential-free
copper bases
• DC link (circuit) – battery of electrolytic capacitors• Electrolytic cap. – up to 450/500 V• 102 F / 500 V, endurance up 600 V• outlets – screws or SNAP-IN for
soldering into PCB
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Unconventional converters (I)• for car …. 12/24 VDC• for power supply… 12VDC / 230 VAC• massive outlets (terminals)• heat transfer through whole body• compact design• very expensive
Up/down DC converters:
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Unconventional converters (II)
Traction converter for trains (CZ type 560)
• supply voltage 2x 465 V• output voltage 730 V• output current 630 A (permanently)• output current 1200 A (1 min)• nominal power 420 kW perman.• 465 kW per hour• IGCT thyristors• operating frequency 600 Hz• active cooling 4000 m3 / hour• dimensions 1015 × 930 × 1250 mm• weight 460 kg
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Unconventional converters (III)
Extensible rectifier for underground in Prague
• installed at line C
• three-phase bridge, all diodes made as pairs
• input voltage 660 V AC / 50 Hz
• output voltage 884 V DC
• max. input voltage 2000 V
• output current IDC = 3000 A (permanently)
• IDC = 4500 A (2 hour)
• IDC = 9000 A (1 min.)