Converters Design for

RES

Prof. H. M. Suryawanshi, FNAE

M.E.(IISc), PhD, FNAE, SMIEEE, FIE, FIETE
Dean (R&C)
Associate Editor of IEEE Trans. On Industrial Electronics
Department of Electrical Engineering
Visvesvaraya National Institute of Technology, Nagpur – 10
1. Specifications of Converter
2. Selection of Power semiconductor switches
3. Selection of Magnetic material
a. Selection of core
b. Design of inductor
c. Design of transformer
d. Selection of Litz wire
e. Selection of Capacitor
4. Design of Snubber circuit
5. Design of Heat sink
6. Design of Gate Drive circuit
7. Design of filter
8. Closed loop control
Device selection
 Power Electronics

is the technology
associated with
efficient conversion, control and conditioning
of electrical power
by
Static means
 The goal of Power Electronics

is to control the flow of energy from

electrical source to electrical load

• Thermal with the help of • Industry

• Hydro • Domestic
• Nuclear • Public Utility
• Wind • Transport
• Solar
• Tidal
CONVERTERS • Others

• Others
 Converters

Rectifier
AC DC

Chopper
AC DC
Inverter
 Converters - applications

Domestic : Fan,Television, Washing Machine, Micro-oven,

Computer, Air conditioner, Emergency Lamp, UPS, Door bell,
Eliminator, Clock, Lift, toys, Lighting, Air Cooler, sewing
machine, refrigerator

Transport : locomotive, Rope way, conveyor belt, hoist,

crane, electric car, hybrid car, aeroplane, two wheeler

Communication : Telephone, mobile charger, PA system,

satellite, antenna
 contd….

Drives : AC / DC motors, SRM, PMSM, BLDC, Stepper Motor

FACTS Devices : SVC, Statcom, SSSC, UPFC, UPQC,IPFC,

TCSC, PAR, Active filter, HVDC, HVDC Light, asynchronous
link, solar interface

and many more

Specifications of Converters

¾Power rating
¾Voltage rating
¾Current rating
¾Switching frequency
¾Applications
 Selection of Power
Semiconductor Switches
 MOSFETs: IRFP450 (1), IRFB13N50A (2),
IRFP448 (3), IRFB11N50A (4)
IGBTs: SGP23N60UFD (5), FB15R06KL4 (6),
FB10R06KL4 (7), IRG4BC15UD (8)
Device losses Vs frequency for different switching devices (Load current 5A)
 C
G

Photograph circuit symbol

(a) Output characteristics (b) Transfer Characteristics

• MOSFET – preferred • IGBT – preferred
upto 2.0 kW of power above 2.0 kW power
SPW35N60C3 IRGP50B60PD

VCES = 600V, IC = 33A

Vds=650V, Rds(on)=0.1 Ω, ID = 35A, TO-247 VCE(on) typ. = 2.5V
MOSFET – SPW35N60C3 IGBT – IRGP50B60PD

Typical Parameters Typical Parameters

• td(on) = 10 nsec. • td(on) = 33 nsec.
• tr = 5 nsec • tr = 26 nsec
• td(off) = 70 nsec • td(off) = 140 nsec
• tf = 10 nsec • tf = 50 nsec
Conduction loss (at 50% of Irated = 10 A) Conduction loss (at Irated= Ic= 10 A)

case - 1 case - 1
10amp 10amp

I2Rds = 102 x 0.1 = 10 w VceIc = 2.5 x 10 = 25 w

case - 2 case - 2

5amp 5amp (1) I2Rds = 52 x 0.1 = 2.5 w 5amp 5amp (1) VceIc = 2.5 x 5 = 12.5 w
(2) I2Rds = 52 x 0.1 = 2.5 w (2) VceIc = 2.5 x 5 = 12.5 w
Total loss = 1 + 2 Total loss = 1 + 2

M1 M2
= 2.5 + 2.5 I1 I2
= 12.5 + 12.5
=5w = 25 w
Magnetic Materials for Power
Electronics

Dr. H. M. Suryawanshi, FNAE

Dean R&C, Professor
Electrical Engineering Department
VNIT-Nagpur

17
 Introduction
Desired characteristic of magnetic materials are:

9 High relative permeability μr

9 High saturation magnetic flux density Bsat
9 Low coercivity Hc
9 High electrical resistivity ρc
9 High Curie temperature (Tc), low hysteresis and eddy-current
losses per unit volume

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19
¾ Ferromagnetic materials are thus selected for inductors and
transformers in power electronic circuits
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21
Ferrite Cores

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 Ferrite

¾ Widely used material for inductors and transformers in power electronics.

¾ They are made up of iron oxide (Fe2O3), combine with other metals such
as cobalt (Co), copper (Cu), magnesium (Mg), manganese (Mn), nickel
(Ni), silicon (Si) and zinc (Zn).

¾ Typical saturation flux density is in the range 0.25–0.45 T for the different
material grades.

¾ High resistivity so lower eddy current loss.

¾ Low curie temperature. This must be taken into account while designing.

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¾ Most commonly used types are Mn-Zn and Ni-Zn ferrites.

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Different shapes of ferrite core

Pot core
PQ Core EE Core

ETD Core U/C Core Toroid Core

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¾ Saturation flux density of ferrite core decreases with temperature

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Powder Core

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 Powder Core
¾ Iron or iron alloy powder is compressed with insulation materials

¾ Insulating material provide distributed air gap, so low value of

effective relative permeability.

¾ The distributed gap helps to tolerate high DC current before the

iron saturates

¾ Have high resistivity, low hysteresis and eddy current losses, and
excellent inductance stability under both DC and AC conditions

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¾ Effective inductance value is stable over a wide temperature
range

¾ Have high saturation flux density

¾ The lack of localized air gap eliminates a fringing effect

¾ Curie temperature is about Tc= 450◦C

¾ Effective permeability is in the range of 15-550

¾ Basically available in toroidal shape. Sendust and MPP are

available in both toroidal and E cores
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30
 Comparison of Bsat , Max.operating
frequency and Curi temperature of ferrite
and powder core

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DC bias performance comparison

If Inductor current have large DC component, then

performance of Ferrite core is poor

32
Core Loss Comparison

33
Relative Cost comparison of Powder
core and Ferrite

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Temperature Stability Comparison

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 Performance comparison of Ferrite
and Powder cores

Material Core DC Relative Saturation Curie Operating Tempe-

Loss Bias Cost Flux Tempe- frequency rature
Density rature stability
(Tesla)

AmoFlux Low Better Medium 1.5 400° C 2 MHz Better

High Flux Moderate Best Medium 1.5 500° C 1 MHz Better
Sendust Low Good Low 1.0 500° C 2 MHz Good
Very Low Better High 0.75 460° C 2 MHz Best
MPP
XFlux High Best Low 1.6 700° C 500 kHz Good
Iron Highest Good Lowest 1.2 - 1.5 770° C 200 kHz Poor
Powder
Ferrite Lowest Poor Lowest 0.45 100 - 250° 2MHz Poor
C

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Carbonyl Iron powder core

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 Carbonyl Iron powder core
¾ It is another type of powdered iron core. Carbonyl iron cores are
obtained by heating carbonyl iron Fe(CO)5

¾ Has a relatively low permeability, in the range (1–50).

¾ Have low hysteresis losses up to very high frequencies (10MHz)

and can be used in high frequency applications.

¾ The quality factor Q, (Q = jwL/R) is very high even for

frequencies above 150 MHz.

¾ Main applications are in EMI/RFI devices and in high linearity RF

current sensing
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Amorphous Alloys

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 Amorphous Alloys
¾ Made up of ferromagnetic and metallic elements like Si, B ,
Carbon etc.

¾ They have glass like structure so also known as metallic glass.

¾ The relative permeability μr is very high, more than 150 000.

¾ saturation flux density is in the range from 0.7 to 1.8 T

¾ As temperature goes from 25oC to 250oC, the saturation flux

density reduced by 30% or more.

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¾ POWERLITE®, Metglas®, VITROVAC® etc are some of
the commercially available amorphous high frequency core.

¾ Maximum operating frequency is about 250KHz.

¾ Usually available in U and Toridal shape.

¾ Used in pulse transformer, current transformer, SMPS

power factor correction choke etc.

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Nano crystalline Cores

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 Nano crystalline Cores
¾ Made up crystals with a typical size of 7–20 nm that are iron (Fe)
based . In addition there are traces of Si, B, Cu, molybdenum
(Mo) and niobium (Nb)

¾ They combine the high saturation magnetic flux density of silicon

steels with the low loss of ferrites at high frequencies.

¾ saturation flux density is about 1.2T- 1.5 T.

¾ The nanocrystalline cores are used up to 150 kHz.

¾ High relative permeability μr.
¾ applications in current transformers, pulse transformers and
common-mode EMI filters
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 Refernces
1. Data sheet of Magnetics®, http://www.mag-inc.com/

2. Data sheets from Metglas®, http://www.metglas.com/

3. Valchev, Vencislav Cekov, and Alex Van den Bossche. Inductors and
transformers for power electronics. CRC press, 2011.

4. Kazimierczuk, Marian K. High-frequency magnetic components. John

Wiley & Sons, 2013.

5. McLyman, Colonel Wm T. Transformer and inductor design handbook.

Vol. 121. CRC press, 2004.

6. Hurley, William G., and Werner H. Wölfle. Transformers and Inductors

for Power Electronics: Theory, Design and Applications. John Wiley &
Sons, 2013. 44
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