Hong-Je Ryoo

Development and Optimization of High-Voltage Power Supply System for Industrial Magnetron

This paper describes the design and analysis of a 42-kW (14 kV, 3 A) high-voltage power supply for a 30-kW industrial magnetron drive. The design is based on a series resonant converter in discontinuous conduction mode (DCM) to take advantage of both the superior arc protection stemming from the current source characteristics and the high power density owing to the use of parasitic elements such as the leakage inductance in the high-voltage transformer. The detailed design procedure for the resonant tank and high-voltage transformer with respect to the input and output specifications is described on the basis of a simplified analysis of the DCM series resonant converter. Special considerations for designing high-power high-voltage power supplies are provided, such as series stacking of diodes for a voltage doubling rectifier and insulation between each winding of the high-voltage transformer. In addition, a comparative study using theoretical equations, simulation, and experimental results was carried out. This study yielded the output voltage and current characteristics at different switching frequencies and verified the advantages of this topology, such as arc protection without an additional protection circuit and high efficiency due to zero-current or zero-voltage switching. Moreover, the parallel operation of two converters with phase shifted gating signal is proposed to reduce the output current ripple and increase power capability for higher power magnetron drive. Additionally, the design considerations of two auxiliary power supplies (a filament power supply: 15 V, 150 A and a magnet power supply: 50 V, 5 A) are also provided and optimized for effective driving industrial magnetron. Finally, the developed power supply was tested with a 30-kW industrial magnetron, and the results prove the reliability and robustness of the proposed scheme.

Development of Rectangle-Pulse Marx Generator Based on PFN

In this paper, two designs of the rectangle-pulse Marx generator based on pulse-forming network (PFN) for pulse-power application are reported. The PFN is composed of inductors and capacitors. Proposed schemes consist of several identical PFNs that are connected according to Marx generator scheme. PFN Marx generators can output rectangle pulse several hundreds of nanoseconds in duration and several tens of nanoseconds in rising time. The effect of component parameter to the waveform is studied. Prototypes made of four PFNs have been tested. One of the prototypes is designed according to classical Marx mode, while another is designed as an L-C Marx generator in which only one command switch and one isolating switch is needed. In a 500-ns duration, 65-ns rising-time rectangle pulse has been achieved on the matching load.

Design of high voltage capacitor charger with improved efficiency, power density and reliability

This paper describes the design of a 48 kJ/s high-voltage capacitor charging power supply (CCPS), focusing on its efficiency, power density, and reliability. On the basis of a series-parallel resonant converter (SPRC) that provides high efficiency and high power density owing to its soft-switching, the design of the CCPS is explained in detail, including its input filter, resonant tank parameters, high-voltage transformer and rectifier, as well as its protection circuit. By using two resonances per switching cycle, which provides a trapezoidal instead of a sinusoidal waveform of the resonant current, the proposed CCPS can take advantage of the lower conduction loss and reduced switching loss by improving the crest factor and allowing a higher value of the snubber capacitor, respectively. In addition, the compact design of an input filter without bulky components such as a DC reactor and an electrolytic capacitor allows for high power density, a high power factor, and low cost. In addition, the control loops for the voltage and current were optimized with a fast response time in order to compensate for the low frequency ripple of the input voltage, which results from the reduced filter component. Experiments on the developed charger were carried out with both resistor and capacitor loads in order to measure not only its efficiency and power factor with respect to the output power but also its charging time, in order to estimate the average charging current. The experimental results obtained with a resistor load showed a maximum efficiency of 96% and a power factor of 0.96 for a full-load condition. For the measured charging time of a 4 mF capacitor, with 9.68 s for 10 kV charging, the average charging current was estimated as 4.13 A. Moreover, to verify the reliability of the developed CCPS, a variety of tests, including opening and shorting of the output terminal as well as misfiring of the discharge switch during the charging operation, were performed with a 200 kJ pulsed power system. Finally, it was experimentally confirmed that the developed CCPS shows high performance in terms of efficiency (96 %), power factor (0.96), and reliability with a high power density (820 W/L).

Design of a High-Efficiency 40-kV, 150-A, 3-kHz Solid-State Pulsed Power Modulator

This paper deals with the detailed design of a pulsed power modulator using insulated gate bipolar transistor (IGBT) switches for industrial applications. Output specifications of the proposed modulator are as follows: variable output pulse voltage 1~40 kV; pulse width 0.5~5 μs ; maximum pulse repetition rates 3 kHz, and average output power of 13 kW. The proposed pulsed power modulator consists of a high-voltage capacitor charger based on a high-efficiency resonant inverter and pulse generator part including a series of connected 24 pieces power cells. To verify the proposed design, PSpice modeling was performed. Finally, experimental results proved the reliability and robustness of the proposed solid-state pulsed power modulator.

Unit power factor operation of parallel operated AC to DC PWM converter for high power traction application

This paper deals with the parallel operation of several numbers of PWM converters for a high power traction application. Several considerations are made to reduce the transformer interaction which can cause a current control problem in a severe case. Also, in this paper, a novel control strategy is proposed to achieve a harmonic free primary-side current control under a light load condition using one current sensor independent of the number of converters. In addition, the modified predictive current controller, which is suitable for a digital current controller with a relatively large sampling period, is used. Finally, to verify the system validity, a digital control system with a TMS320C44 microprocessor and a small scale simulator are made and tested.

Compact and high repetitive pulsed power modulator based on semiconductor switches

This paper describes the design of a compact and highly repetitive pulsed power modulator based on semiconductor switches. Output specifications of the proposed modulator are as follows: variable output pulse voltage, 1-10 kV; width, 1-10 μs; pulse repetition rate (PRR), 1-50,000 pps; and average output power, 10 kW. The proposed solid-state pulsed power modulator has two main parts: an IGBT stack that hasa gate drive circuit for the pulse output with a variable pulse width and repetition rate, and a capacitor charger that has a controllable output voltage. To connect all the storage capacitors in a series for high voltage pulses, a simple and reliable IGBT stack structure was proposed based on the Marx generator. In addition, the gate driver circuit, which supplies power and signals to all the IGBTs simultaneously, was introduced. This providesa superior protection function against the arc and the short. To charge the storage capacitors, a novel 10 kW (10 kV, 1 A) high voltage capacitor charger with the combined advantage of a series-loaded resonant converter and a ZVS (zero-voltage-switching) full-bridge pulse width modulation (PWM) converter was proposed and designed especially for the solid-state pulsed power modulator. Theexperiment results verified that the proposed scheme and structure can be used effectively for a high voltage pulsed power modulator that requires variable voltage, repetition rate, and pulse width, depending on the process of the applications.

Design and Implementation of Enhanced Resonant Converter for EV Fast Charger

This paper presents a novel application of LCC resonant converter for 60kW EV fast charger and describes development of the high efficiency 60kW EV fast charger. The proposed converter has the advantage of improving the system efficiency especially at the rated load condition because it can reduce the conduction loss by improving the resonance current shape as well as the switching loss by increasing lossless snubber capacitance. Additionally, the simple gate driver circuit suitable for proposed topology is designed. Distinctive features of the proposed converter were analyzed depending on the operation modes and detail design procedure of the 10kW EV fast charger converter module using proposed converter topology were described. The proposed converter and the gate driver were identified through PSpice simulation. The 60kW EV fast charger which generates output voltage ranges from 50V to 500V and maximum 150A of output currents using six parallel operated 10kW converter modules were designed and implemented. Using 60kW fast charger, the charging experiments for three types of high-capacity batteries were performed which have a different charging voltage and current. From the simulation and experimental results, it is verified that the proposed converter topology can be effectively used as main converter topology for EV fast charger.

Semiconductor switch-based fast high-voltage pulse generators

Very fast high voltage unipolar and bi-polar pulse generators using semiconductor switches are proposed in this study. They are able to generate pulse voltages of which rising time, pulse width, and magnitude can be controllable with the following parameters: 1) polarity: unipolar or bi-polar 2) pulse voltage: up to 15[kV] 3) rising time: less than 500[ns] 4) pulse width: up to 1200[ns] 5) pulse repetition rate (PRR): 200 /spl sim/ 2000[pps] . They consist of a thyristor based-rectifier, a DC link, a forward or push-pull resonant inverter, a high voltage IGBT stack, diode stacks (optional for bi-polar), and a variable capacitor. The developed system has the superior advantages on compactness and high efficiency and it can be effectively applied to the various industry applications, including flue gas treatments and plasma generation equipments.

Design and analysis of an eddy current brake for a high-speed railway train with constant torque control

The introduction of the eddy current brake (ECB) system in high-speed railway train (HSRT) is known to be advantageous, in that the system is independent of wheel-rail adhesion coefficient which is greatly affected by weather condition. It also minimizes the maintenance of the brake system and does not require any additional electric energy because it is powered from the regenerated power at the time of the braking. In this study, a downscaled ECB magnet is designed and the braking and attraction forces of the ECB are simulated by 2-D FEM. The simulation results are experimentally verified on a downscaled prototype. A control algorithm of the ECB is proposed to generate constant braking torque using linear variation of the reference current according to speed. Experimental results show that the constant torque is generated all over the operating speed-range by the developed control algorithm.

Low-Ripple and High-Precision High-Voltage DC Power Supply for Pulsed Power Applications

This paper describes the design and implementation of a three-phase resonant converter with low ripple and high control accuracy. Based on a three-phase LCC-type resonant converter-which has advantages of low ripple, highefficiency, and high-power density compared with a single-phase converter-a high-voltage power supply with low ripple (<;0.1%) was designed. In addition to the general merits of an LCC-type resonant converter operating at continuous conduction mode- including soft switching, low conduction loss, and current source characteristics-the proposed scheme uses only one phase under a light-load condition by having different leg designs of the gate drive circuit and snubber parameters. This allows the design to overcome the operational constraints of the general LCC-type resonant converter. The distinctive design of the three-phase converter structure provides high efficiency and low ripple not only during rated operation, but also under light-load conditions. In order to analyze the high performance of the proposed scheme from no load to rated load, a PSPICE simulation was carried out. Comparison results with a conventional LCC-type resonant converter based on a single-phase structure are analyzed from the viewpoints of output ripple, losses, and operable load range. Using the proposed converter, a 20-kV, 20-kW high-voltage dc power supply design and implementation was presented with a superior gate drive circuit. Finally, the superiority of the proposed converter was verified through a simulation and experimental results. It was experimentally confirmed that the developed power supply achieves high performance in terms of efficiency (98%), operable load range (0.5-20 kV), and low ripple (0.05%), with a high power density.